VOL 07 | DEC 2015

www.efficientmanufacturing.in

EFFICIENT MANUFACTURING

Asset performance management Driving maximum value from assets Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong Malaysia, Singapore, Taiwan, Also available in China,

EM - Interview (p. 28) FOCUS Medical machining P. 30 Gaur Dattatreya VP & Head of Business Unit Robert Bosch Engg & Business Solutions EVENT REPORT Solid Edge University 2015 P. 60

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Responding quickly & effectively “While the future may not Here we are, the last month of the year. There were some ups and downs in the industrial look so promising with a growth in this year. But India still remains as a new growth leader in Asia-Pacific, having very volatile global economy, overtaken China. With the Prime Minister’s ‘Make in India’ initiative to place India on the it’s always worth taking world map as a manufacturing hub and give global recognition to the Indian economy, India’s advantage of every manufacturing sector could touch US$ 1 trillion by 2025. There is potential for the sector to opportunity you have account for 25-30% of the country’s GDP and create up to 90 million domestic jobs by 2025. Instead of being a dumping ground for the companies across the world, India could attain to try new things” a unique position of manufacturing excellence by this programme, for building worldclass products for our own consumption as well as for export. This calls for acquiring an ability to respond quickly and effectively to the changing demand conditions of the domestic as well as international markets. The zero defect mindset is the necessity to ensure the success of `Make in India’ programme, besides fostering technical excellence, with skill enhancement in our workers. Moreover, there is an acute need to improve India’s ailing infrastructure scenario and defunct logistics facilities. In short, it is a long road ahead! As we approach the end of the year, it is always a good time to regroup, reexamine and revisit your strategies and tactics—both from a business as well as an operational perspective. While the future may not look so promising with a very volatile global economy, it’s always worth taking advantage of every opportunity you have to try new things. Finally, with all the unrest and intolerance in the world, we hope you find the success! Best wishes!

Shekhar Jitkar Publisher & Chief Editor [email protected]

EDITORIAL ADVISORY BOARD Sonali Kulkarni N K Dhand Raghavendra Rao Satish Godbole President & CEO CMD Vice President Vice President, Motion Control Div Fanuc India Micromatic Grinding Technologies Manufacturing & Process Consulting Siemens Ltd Frost & Sullivan Dr Wilfried Aulbur Dr K Subramanian Vineet Seth Managing Partner President, STIMS Institute, USA Dr P N Rao Managing Director Roland Berger Strategy Consultant Training Advisor, IMTMA Professor of Manufacturing India & Middle East Technology Delcam Plc Vivek Sharma S Ravishankar Department of Technology Managing Director Managing Director University of Northern Iowa, USA Yamazaki Mazak India DMG MORI India

Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

EM | Dec 2015 7 CONTENTS

Market Management Focus

10 NEWS INTERVIEW MEDICAL MACHINING 28 “Getting smarter for the best 30 Challenges in the healthcare 16 “Physics for simulation” IoT infrastructure” industry Interview with Nicolas Huc, Interview with Gaur Dattatreya, The article briefs on the developments VP, Development & Product VP & Head of Business Unit, with which manufacturers can cater Manager, COMSOL Robert Bosch Engineering & to any form of medical device or Business Solutions equipment manufacture without 20 “There is a shift in the switching between different quality trend” CAD/CAM providers Interview with Ravindra SD, FACTORY TOUR REPORT Managing Director, 64 Building strong export market Vollmer Technologies A factory tour report on the recent visit of Taiwan machine tool EVENT REPORT industrial facilities 58 Strengthening Indo-German relations A post-event report on the recently held 4th VDMA Mechanical Engineering Summit at New Delhi

60 Designing without COVER STORY Boundaries… 22 Asset performance management A post-event report on the recently A read on how organisations with technology and held Solid Edge University 2015 know-how available today, can drive profitability by Siemens PLM Software in from all industrial assets by creating a cooperative Cincinnati, Ohio, USA & collaborative environment enabled by real time technology

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 CONTENTS

Technology

Cover image courtesy: Shutterstock

SUPPLY CHAIN MANAGEMENT CUTTING TOOLS New Products 36 Lean guiding principles for 48 Taking hole deburring the supply chain to new depths 69 Drilling tools; Flexible clamp This article talks on Built-in Quality, A read on how the new Mechanical cables; Smart 3D sensors; one of the lean guiding principles to Edge Profiting process keeps exit burrs Tribological filaments; develop a lean culture in a from negatively impacting tool rigidity, 70 Centring points for drill bits; supply chain operation machining accuracy and tool life in Shoulder milling tools; deep, small-diameter through holes CAD/CAM sheet metal GEAR MANUFACTURING software; Compact 42 Ready for large tasks MANUFACTURING IT mechatronic module; The article discusses the large industrial 52 Achieving program excellence 71 Face milling cutter; Laser measuring centres for gears adapting to A read on how aerospace & defense processing machine; the current market needs firms achieve program excellence with Pneumatic drive machine; Siemens integrated verification Precision hardened & management system ground flanges

Columns

07 Editorial 08 Contents 72 Highlights – Next issue 72 Company index

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 MARKET | NEWS

BFW launches tech centre at Kolhapur EDM summit organised by EDM Productivity Forum

BFW recently inaugurated a tech centre at Kolhapur to meet the growing EDM Productivity Forum (EPF) recently held its EDM summit across Mumbai, needs of customers. It will showcase cutting edge new products for the Pune, Nasik & Aurangabad. customers’ next-gen requirements. The 4-day event witnessed The company will position dedicated over 250 people from over service engineers and stocking of the 150 tool rooms visiting the spares closer to customers and, forum. The event was jointly thereby, provide effective after-sales supported by Makino India and service. In terms of application, and GF Machining Solutions engineers stationed at the tech centre and provided a platform for will provide solutions to challenging sharing best practices in problems faced by customers. For The summit provided a platform to award best EDM machining. Industry According to Raghavan, the centre trainings, company officials will practices in EDM machining experts like Stephen Harris will strengthen the company’s conduct customised & comprehensive from MWI, USA & N Konishi presence in Kolhapur to meet the training programs for production from TOKAI Carbon made technical presentations on the EDM process. customers’ next-gen requirements processes, engineering applications, Sadananda Koppalkar, Head - Business Development, Makino, used the maintenance, etc. Ganesh Technologies platform to share inputs on how to improve the productivity on EDM is the channel partner for Kolhapur. With market knowledge, sales expertise machines. It also featured some of the best tool rooms in this region, where and customer relationships developed over two decades, this association there were insights on the best practices & improvements in the EDM section. will further strengthen the Kolhapur centre. According to Ravi Raghavan, Also, there was the first ever benchmarking study done by Prime Industries CEO, BFW, “To meet the needs of customers in Kolhapur like sound amongst its clients across 4 cities. Over 35 clients participated in this study castings, Mahabal metals, Mourya Industries, Caspro Metals, General and winners were chosen in areas of best MRR, lowest wear and best Machine Tools, etc, we have decided to strengthen our presence here.” surface finish achieved on EDM.

COMSOL releases Multiphysics® 5.2 Fair Friend Group acquires MAG Group

COMSOL has recently released COMSOL Multiphysics® 5.2 that provides Fair Friend Group (FFG) has recently acquired MAG Group, a leading simulation community the only fully integrated environment for creating machine tool manufacturer for the automotive industry, which simulation apps. It delivers new features, improved stability & robustness strengthens it position as and faster execution. Major upgrades to the application builder available in one of the world’s leading COMSOL Multiphysics include the new editor tools for easy creation of user machine tool suppliers. interface components, commands Speaking on the occasion, Dr for dynamic updates of graphics, Reiner Beutel, CEO, MAG, and more control over the said, “MAG will benefit from deployment of simulation apps. the global footprint and Running simulation apps using financial strength of FFG, COMSOL server in a corporate while our customers will network or in the cloud is now up to benefit from the sharing of five times faster. Many updates, new know-how and technology The software delivers new features, improved features and simulation application between our companies, increased production capabilities as well as stability, robustness & faster execution examples are also available for the local service wherever they are”. With MAG’s seven production facilities, add-on electrical, mechanical, fluid, FFG increases the number of machine tool factories to 51 across the and chemical products. “We leveraged the Application Builder to more globe, now covering Taiwan, Germany, Italy, Hungary, Japan, South efficiently communicate complex design ideas across multiple simulation Korea, China, Switzerland, India and USA, with a total of 32 brands. and process departments, which has allowed app users to easily explore According to Jimmy Chu, Founder & Chairman, FFG, “I am happy to the outcome of proposed designs,” said Borja Lazaro Toralles, Research welcome MAG and its employees to our large family. I am confident that Engineer on the Manufacturing Technology Centre (MTC) simulation team. the integration of MAG into FFG will be beneficial for all of us, and for Its features include ability to update graphics while running an app. our customers and suppliers.”

10 EM | Dec 2015 Multitasking Production mill-turn Milling machining

5-axis Machining

High Speed Machining

DP Technology Corp.

Catch us on MARKET | NEWS

Frost & Sullivan announces Sustainability 4.0 Awards HaasTec to be held at Pune

Frost & Sullivan has recently announced the launch of its Sustainability The HaasTec will soon take place in Pune, where innovative & affordable 4.0 Awards 2016, which will take place on May 27, 2016 at Mumbai. The Haas CNC machine tools will be on view. Machines like UMC-750 five- erstwhile Green Manufacturing Excellence Awards is a prestigious awards axis universal machining centre and ST-35 big bore CNC lathe will be on banquet that has become a premier platform acknowledging companies display. All machine tools on display will be powered and performing for their work in sustainability requirements across their value chains. demonstrations, cutting metal. Haas specialists from the HFO will be The impact of transformational changes, unexpected disruptions in available to guide visitors through the demonstrations. The machines to technologies and established operating systems has shifted the focus be displayed at the event include UMC-750 five-axis vertical machining of industries toward sustainable practices. With an increasing number centre offering a capacity of 762 x 508 x 508 mm in the X, Y and Z-axis respectively; ST-35 big bore CNC lathe that can accommodate bars up to 102 mm in diameter and of enterprises embracing approaches to sustainable development, the offers a capacity of 533 need to support these businesses and recognise their efforts has become (dia) x 660 mm (length) paramount. Announcing the launch of the 7th edition of the awards with 806 mm of swing; banquet, Nitin Kalothia, Director—Manufacturing & Process Consulting, ST-10Y turning centre Frost & Sullivan, said, “The parameters of perpetuity of a business with Y-axis; DT-1 drill tap has moved beyond revenue generation and management’s innovative machine with new 30 thinking. To survive and thrive in today’s volatile ecosystem, corporates taper 15,000 rpm spindle, in India are imbibing sustainable development as part of their long-term All machine tools on display will be powered and VF-2 VMC, VF-2SS, mini strategy.” The sustainability program was instituted in 2009. performing demonstrations mill and VF-7/50 VMC.

Grind Master bags the SME Business Excellence Award Milacron India launches extrusion capabilities

Grind Master has recently received the SME Business Excellence Award in Milacron India inaugurated its Extrusion Open House at the Ahmedabad the mid-corporate segment under Engineering & Machinery sector organised facility recently. It included the demonstration of an extrusion line in live by Karur Vysya Bank and Dun & production of cPVC pipes. At the event, Milacron received two orders for Bradstreet (D&B) at New Delhi. The India-built pipe extrusion systems from local customers. The orders were event, attended by eminent for complete systems and business leaders and senior included extruder, controller, die/ government officials, also included head, cooling/sizing tank, puller, the release of the publication cutting/saw and accumulation “Leading SMEs of India 2015”. “It table. The first system will ship gives me great satisfaction that we before the end of 2015 and the are emerging on a national and second system is scheduled to Sameer Kelkar felicitated with international stage as a trustworthy ship in Q1 2016. Speaking at the the award & passionate machine builder,” said Milacron India inaugurated its Extrusion event, Brian Marston, VP & GM, Sameer Kelkar, Executive Director, Open House at Ahmedabad Global Extrusion Business, stated, Grind Master, while receiving the award. Grind Master has been growing at “The conical twin screw counter a phenomenal rate in the past few years, closing FY14-15 with a turnover rotating extruder producing cPVC pipe is one of our most popular extrusion of more than `120 crores. As one of the large machine tool builders in India, technologies and we anticipate a strong demand for these machines in it qualified in the “mid-corporate” category, thus, reflecting the India and surrounding regions”. The three-day event catered to the needs transformation into a professionally managed business. Recently completing of India’s growing construction industry. The extruder produced ¾ inch the 50th machine in China, the company has created a brand known for cPVC pipes and an injection moulding machine cPVC line Servo 150 was expertise & innovation in metal finishing internationally. engaged in the production of cPVC fittings.

12 EM | Dec 2015

MARKET | NEWS

National Productivity Summit 2015

Indian Machine Tool Manufacturers’ Association firmly believes that it is Transforming India (NITI) Aayog, briefed on the current Indian economic necessary to recognise those scenario, the challenges and opportunities who have contributed to lying ahead. He then impressed upon the productivity improvement in importance of productivity and manufacturing Indian industries and to to the growth of the nation, in conjunction encourage more to emulate with the drive of the government on the ‘Make these pioneers. With this in India’ campaign, to equip the Indian objective, IMTMA hosts the manufacturing fraternity and scale them to National Productivity Summit greater heights in the global arena. every year. The summit this year Leading firms such as Ashok Leyland, was recently organised at Bajaj Auto, Bosch, Keihinfie, Lucas TVS, Gurgaon. Mahindra & Mahindra, Maruti Suzuki, Tata The event showcased the Motors, TVS Motor and Wabco India presented best productivity improvement The event showcased the best productivity improvement projects in their case studies on productivity practices, projects in metal working metal working industries all of which contested for IMTMA – ACE industries, which have excelled Micromatic Productivity Championship in achieving superior performance through sustained productivity Awards 2015 that gave away cash awards of ` 10 Lakhs. improvements. The two-day event witnessed around 300 participants from Wabco India, TVS Motors, Bajaj Auto, Keihinfie, Lucas TVS and SKF India 102 companies. L Krishnan, President, IMTMA, presented the welcome were adjudged the winners of the IMTMA - ACE Micromatic Productivity address, where he spoke on innovative approaches to address productivity Championship 2015 Awards. Further, a Vox Populi award was given to challenges, new ideas and concepts. Presentations were put up by teams TVS Motors. Also, plant visits to Hero Motocorp, Sona BLW Forging, from Maruti Suzuki, Honda Cars, Hitech Gears and Sartorius India Group. Hitech Gears and Honda Motorcycles & Scooters India were arranged a day During the event, Dr Saraswat, Hon’ble Member, National Institution of prior to the event.

Mikrosa wins i-NOVO Award German machine tool industry performing valiantly

During EMO 2015 in Milan, Mikrosa rceieved the i-NOVO Award from the In the third quarter of 2015, order bookings in the German machine tool online industrial fair DirectIndustry for its centreless external cylindrical industry fell by 1%, compared

German Machine Tool Industry grinding machine KRONOS S 250. The machine is designed for high- Order bookings and turnover remain at a high level to the preceding year’s

volume production in the high-precision segment and for the plunge and Order Intake [Index, nominal] equivalent period. Domestic 240 original values

12-months moving throughfeed grinding of workpieces in average orders rose by 9%, while 200

the diameter range of 1.5 to 35 mm, 160 demand from abroad was and is constructed with a plunge grind 120 down by 7%. In the first nine 80

Order Intake, %-change to previous year 3Q 2015 1-3Q 2015 width of up to 245 mm. Its new design 40 Total -1 0 months of 2015, order Dome stic +9 -3 Foreign -7 +1 0 is geared systematically towards 1996 1997 1998 1999 20002001 20022003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20132014 2015 bookings stagnated compared

Note: Index basis shipments 2010=100, data until September 2015 Sources: VDW, VDMA ergonomy and user-friendliness. The 02.11.2015 Verein Deutscher Werkzeugmaschinenfabriken e.V. (VDW) to the previous year. Domestic control panel, for example, has quick orders fell by 3%, with demand and simple height adjustment. So, the Order bookings and turnover remain at from abroad up by 1%. KRONOS S 250’s new design is operator can adapt it to his own needs a higher level According to Dr Wilfried geared systematically towards and avert potential postural defects. Schäfer, Executive Director— ergonomy and user-friendliness The machine’s sliding doors, which VDW, Frankfurt, “In the year’s third quarter, our sector was boosted by can be opened wide, are equipped orders from Germany itself and from the Eurozone. Western Europe proved with ergonomic door handles featuring an adjusted grip profile. To simplify to be the motor for demand in the German machine tool industry. The the cleaning process, the machine’s surface structures were improved Americas, by contrast, were disappointing, with orders down across the and the materials used were optimised. The centreless external cylindrical board. Asia, as a whole, scored with modest growth. Good business with grinding machine is fitted with a multi-coloured signal light with an South Korea & Japan, however, was offset by a substantial minus in integrated flash function, thereby, providing optimum status visibility. orders from China, the biggest market.”

14 EM | Dec 2015

MARKET | INTERVIEW “Physics for simulation”

Nicolas Huc, VP of Development & Product Manager, COMSOL, briefs on combining many areas of physics for simulation purposes and features of the new version of COMSOL Multiphysics®, and shares his views on challenges in scientific modelling, in an interview with Shekhar Jitkar. Excerpts…

Tell us more about the simulation software models that can be What is new in COMSOL Multiphysics® version 5.2? used to predict effects of heat transfer and thermal stress and to A lot of efforts has been put to implement hundreds of improve thermal performances of a given application? enhancements on existing capabilities. This makes COMSOL Heat transfer modeling in COMSOL Multiphysics® covers Multiphysics® 5.2 the most stable and finished product we the 3 means of heat transfer: conduction, convection and ever released. Of course, there are new functionalities, but radiation. Heat transfer by conduction handles non-linear it is important to stress that great attention was paid to material properties which can be, for example, temperature details and feedbacks to improve the software in all aspects dependent. It also supports anisotropic material properties (accuracy, performance, usability). The version 5.2 provides which is often needed for composite material modelling. It can simulations experts the Application Builder, a mature be combined with the “Curvilinear Coordinates” interface to simulation app design. It is a highly productive interface define the orientation of anisotropic material for app design that makes it possible that have complex geometry configurations. for experts to embed their expertise in Heat transfer by convection is supported for COMSOL Apps. COMSOL Server™ allows laminar and turbulent flow regimes, it can to deploy their simulation applications and be combined with phase change to achieve have them used by users everywhere. high cooling performances. Heat transfer by radiation is implemented for surface- Which are the industry segments that to-surface radiation and radiation semi- COMSOL is targeting globally and in transparent media. All the heat transfer India for the latest version of Multiphysics capabilities can be freely combined with all software? our structural mechanics capabilities for One strength of COMSOL is that COMSOL thermal stress modeling. Multiphysics® is used for a wide range of applications in several different industries. The ability to combine many areas of physics It is used in automotive industry, for MEMS for simulation purposes is the latest innovation design, for defense and electronic industry of COMSOL. Can you elaborate more on it? as well as in food industry, medical applications, etc. COMSOL Multiphysics® has been designed to combine multiple physics from the beginning. This is not something How challenging it is to make the industry receptive to that has been introduced recently, it is a pillar of the scientific modelling? software. We are using a patented method for assembling My experience is that every industrial player has a number the finite element discretisation of arbitrary equations. It of challenges to address and that in some cases modelling offers an optimal framework for the numerical treatment of and simulation provides a solution. In this case, scientific multiphysics problems. modeling is easily adopted. When scientific modeling With this method, COMSOL Multiphysics® is able to treat doesn’t provide a satisfactory solution or when there is no all the physics (and the corresponding equations) in a coupled identified challenge for it, then it’s almost impossible to manner. For strongly coupled physics, this is the key to have convince someone to invest in something that does bring high convergence rates and high accuracy. Models with any identified benefit. I would say that the industry is strongly coupled physics correspond to configurations where already rather receptive to scientific modelling. The fact two or more physics interact which each other and none of that simulation market is continuously growing tends to them is leading the other ones. For example, models with Joule confirm that. I believe that the challenge is on our side. The heating where the electric properties are greatly influenced by more industrial challenges we address the more the industry the temperature. Natural convection is another example when will use scientific modelling and simulation. ☐ the flow and the temperature are strongly coupled.

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MARKET | INTERVIEW

“There is a shift in the quality trend”

Ravindra SD, Managing Director, Vollmer Technologies (a subsidiary of VOLLMER Werke Germany), believes that the trend today is shifting from the use of labour-intensive applications to automation. In his interview with Megha Roy, he discusses the latest innovations and trends in the industry. Excerpts…

Can you brief us on the latest developments happening at your We saw a tough year in 2014. But towards the end of the end when it comes to handling sharp tools, saw blades, tooth year, our business picked up, and since then we have seen a shapes or tool geometries? good inflow of orders and the turnover has been good too. For sharp tools, the machines are nearly stabilised to the However, price is a major challenge in our industry. So, we saturation level, although there is still room for improving have produced low cost machines with a reasonably good machine speed. The machines are stabilised in terms of quality. Also, what customers are looking at and how many technology. For rotary tools, Vollmer had saw blades do they want to process in a day launched a new concept for tool & cutter helps us to recommend machines according grinder at the GrindTec 2014, where Vgrind to the technology level. 160 was introduced. In the existing product portfolio for the circular saw blade grinding, Can you elaborate on the demand & we have also introduced new models to technological trends in your sector? How are streamline the existing portfolio into the latest developments helping in creating modular machines, so that all machines look new value for customers? identical and have standardised parts & easy In the rotary tool business, there are new inter-changeability between machines. technologies coming up like laser machining. For saw blades, we have a range of Also, in medium to high-tech machines, machines. We make from the simplest of there are some developments happening. hydraulic machines to sophisticated 8-9 Since price is a major influencing factor, axis machines that can be automatically specially in Asian markets, we keep end operated. We have also developed band saw products in mind and develop our products blade grinding machines. In the area of tool geometries for accordingly. saw blades, we always strive to improve on the hardware & We are serving customers in different sectors. Vollmer software on our machines, so that the tools are processed in machines are known for quality and ease of operation. The faster & simple manner. The new tooth shapes are derived customers have to only change the parameters based on the by our customers based on the applications in question & we individual saw blades and start the machine. The machines develop the machines to handle these tooth geometries. are pre-loaded with the required software & the programs according to the customer needs, which helps them to work How does R&D work in your domain? with our machines at ease. We have an R&D team of 70 people working in Germany. They work towards product development—both on existing Can you brief us on your global as well as Indian market trends & new products depending on the market requirements. in the near future? CNC tool and cutting grinders are the new introductions India is facing a crunch of reasonably skilled manpower today. from the company. Besides, we are working towards a few So, the mindset of customers is also changing. The market new technology innovations. is moving from labour-intensive applications to automation and, thereby, trying to minimise labour-dependency & How do you look at the current scenario in the manufacturing also ensuring consistent quality. Hence, there is a shift in industry in India? What are the major challenges in the quality trend as well due to automation, and Vollmer the industry? has a wide product range to address this demand from the In general, the market is witnessing many ups and downs. markets worldwide. ☐

20 EM | Dec 2015

COVER STORY | MANAGEMENT

ASSET PERFORMANCE MANAGEMENT

Shutterstock Driving maximum value from assets Image courtesy:

It is becoming more important than ever for all industrial operations to drive maximum value from all assets, due to increasing financial and competitive pressures. With the technology and know-how available today, organisations can drive profitability from all industrial assets by creating a cooperative and collaborative Dr Peter Martin environment, underpinned by the appropriate measures of VP, Business Value Consulting Schneider Electric performance and enabled by real-time technology. [email protected]

22 EM | Dec 2015 MANAGEMENT COVER STORY

With the rapid rise in industrialisation came a corresponding Root of the conflict rise in the complexity of industrial operations. Prior to the industrial revolution, most people involved in the production The conflict between maintenance and operations teams of goods were generalists. They had skills and abilities that in industrial operations is not very surprising, once it becomes crossed multiple disciplines. But with the rise of highly complex apparent how the performance of each team is measured. industrial operations, leaders of these companies quickly In industrial operations in which operations and learned that the best way to manage the complexity was to maintenance performance are measured, the most common train specialists in key areas of the operation. No longer was measure for maintenance is asset availability, while the most the operator of a piece of equipment responsible for the common measure for operations is asset utilisation. A cursory maintenance of the equipment. Rather, separate maintenance analysis of these two measures clearly shows that they tend to and operations departments were established. The same was be inverse functions. That is, when the assets are running in true for accounting, engineering, production planning and a reasonable manner, increasing asset availability typically scheduling, and a number of other disciplines. requires the reduction of asset utilisation and vice versa. This Even within the field of engineering, multiple specialists presents a real conundrum to industrial plants as illustrated areas were established, such as mechanical engineers, in Figure 1. The problem this creates is that the maintenance chemical engineers, electronic engineers and industrial department and operations department have to be in conflict engineers. Although creating these areas of specialty was with each other almost by definition. And the better each initially critically important to getting these complex team is, the greater the level of conflict. operations working effectively, it also led to today’s often It is difficult to identify an industrial factory or plant disjointed industrial organisations. today in which the operations and maintenance teams really With time, each of these specialised disciplines developed work cooperatively. This conundrum has become a major their own vernacular and working practices, and subsequently barrier to the performance improvement of many became islands of specialty within the overall industrial industrial operations. operation. And it became more and more difficult for the specialists in one island to understand and communicate with Asset performance measures those in other islands. Perhaps the largest impact of this “island of organisation” phenomenon has been right at the Before moving to approaches for resolving the conflict, it operational levels in a plant. In most industrial plants, the may be helpful to evaluate asset availability and asset maintenance teams and the operations teams do not cooperate utilisation with respect to their appropriateness for industrial very well. In many plants, they actually seem to conflict with assets. One issue with these two terms is that they are not one another as they each try to carry out their responsibilities. very well defined. Also, asset availability typically is measured Since these two teams work on the same asset base in the as the percentage of time an asset is available to the operation. operation, this conflict may result in suboptimal operations This is an extremely limited view. An asset may be available, and reduced profitability. Many industrial operations are but in such poor repair that it can only output a small feeling financial and competitive pressure as never before, percentage of its designed capability. Although the asset may and it is becoming more important than ever to drive be available it is certainly not maintained to be in the maximum value from all assets. condition that it should be.

EM | Dec 2015 23 COVER STORY MANAGEMENT

Maintained State vs Effective Utilisation Optical Economic Asset Performance

Perhaps a better measure of performance is the current the primary objective nor is it the primary measure of success. maintained state of the asset. That is: But industrial operations can learn from performance-based Maintained State = Actual Full Asset Output / Designed sports teams by trying to identify what the common objective Maximum Asset Output is across industrial maintenance and operations teams. If And, perhaps the best measure of operations is a measure such a common objective and resulting performance measure called effective utilisation defined as follows: can be identified, the results in terms of both cooperation Effective Utilisation = Asset Output / (Maintained State * and performance improvement may be astounding. Designed Maximum Output) The difficulty is in defining the equivalent of the “win” in Using these two measures would at least provide well industrial operations. In other words, what is the overriding defined metrics that relate to operations and maintenance objective for both the operations and maintenance that while helping to reveal the true value of an effective plant should take precedence over the individual operating and maintenance program. The problem with these measures is maintenance KPIs? The effective answer to this question may they still do not solve the conflict since these new measures be much simpler than it initially appears to be. The reason for are still inverse functions (Figure 2). the operations and maintenance teams in industrial It is sometimes helpful to draw analogies from other organisations is directly tied to the overall objective for the performance driven operations to identify a solution. In car organisation to begin with— to make money. Since real world racing, which is an extremely well defined, performance- constraints limit the ability to continually operate any asset at based sport, a similar relationship exists between the 100% maintained state and 100% effective utilisation, there operations team (drivers) and maintenance team (pit crew). must be some ideal position at which the performance of the In discussing this with one of the most successful asset is optimal from a financial perspective (Figure 3). automobile racing organisations in the world, Hendrick If this point can be determined, it may be the equivalent Motorsports, the key to success was revealed. Rather than of the “win” for that asset. The recent invention by Invensys having the primary measures of maintained state or effective of sensor-based, real-time accounting and operational utilisation, the primary measure is winning the race. The measures provides the basis for effectively measuring the other two are relegated to secondary measures. financial asset performance vector. By building a software By defining a primary measure that both the pit crew and model of the ideal operation of the asset, the current the drivers can effectively strive to meet they have managed operational output of the asset at any point in time can be to create an incredibly cooperative relationship across their divided by the modeled ideal operational output, to provide race teams. And the results are phenomenal. an operational asset performance measure that can be trended Clearly, in industrial operations “winning the race” is not in any historian.

24 EM | Dec 2015 High Performance Cutting Tools

INDIA’S LARGEST BURR MANUFACTURER SINCE 1968

Forbes & Company Limited [email protected] l www.totem-forbes.com COVER STORY MANAGEMENT

Asset Modeling Analysis Asset Performance Management

This can in turn be compared with the financial asset first step in the process of optimising the profitability from performance trend to provide the critical information the assets. Figure 5 shows a simplified view of the traditional required for profit-based asset performance management. improvement progression from operations and maintenance Decisions on how long to operate assets between preventive teams. The right side of the model shows the operational maintenance activities, whether to extend asset operation to progression from basic control, to advanced control, all the meet critical production schedules and when to consider way to process optimisation. The success of these programs asset upgrade or replacement can be made from both an was typically measured by operational KPIs. operational and financial perspective. Likewise, the left side of the model shows the traditional The asset performance information can be provided to asset management progression from reactive, through both operational and maintenance teams in simple preventive and all the way to predictive maintenance. contextualized dashboards or scorecards to provide guidance The key step forward is when these two perspectives join and feedback to those employees on how their activities together to provide a combined performance view and when favourably or adversely impact the operation. Since both the real-time financial and operational metrics provide the teams are primarily measured to the same objective, the convergence mechanism. With the measures in place, degree of cooperation and collaboration naturally increases. industrial organisations can undertake a continuous profit This new level of collaboration can produce impressive results improvement approach by identifying specific improvement in the form of increased profitability. projects and executing them. The key advantage provided by Although this real-time perspective is a step forward on the asset performance system is that each improvement will traditional asset-centric performance measures in industrial be clearly measureable from both operational and financial operations, it is limited because it only considers the perspective. This enables industrial operations to effectively instantaneous asset performance at any point in time, but understand what truly drives value and what doesn’t. With does not take into consideration the lifecycle performance time, organisations learn to focus on those activities and degradation as assets are utilised and either soil or wear actions that drive the most value. The result is unprecedented down. This can be effectively accomplished by evaluating the improvement in the profitability of the industrial operations. asset performance from both an operational and financial perspective over time (Figure 4). Conclusion

Asset performance improvement The technology and know-how is available today to help industrial operations better drive profitability from all Once the appropriate performance measures are installed, industrial assets. Success in this area requires that companies and the operations, maintenance, engineering, supervision break from traditional perspectives and create a cooperative and management teams are empowered with the information and collaborative environment, underpinned by the required to make better, collaborative and timelier decisions, appropriate measures of performance and enabled by real- the performance and profitability of the operation will start time technology. ☐ to significantly improve. But this should be viewed only as a

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Blaser Swisslube India Pvt. Ltd. Gurgaon, Pin – 122002 Phone 0124 – 4994000, [email protected] MANAGEMENT | INTERVIEW

“Getting smarter for the best IoT infrastructure”

…says Gaur Dattatreya, Vice President and Head of Business Unit, Robert Bosch Engineering and Business Solutions, in this interaction with Maria Jerin, while highlighting the company’s endeavour on capitalising technology enablers for smart manufacturing. He also details about the manufacturing ecosystem that is prevailing in India as well as the roadmap for smart manufacturers. Excerpts…

What was the outcome of the recent visits of the Indian Smart manufacturing means increasing the use of IT in Prime Minister Narendra Modi and the German Federal manufacturing areas. It helps the companies get more flexible, Chancellor Angela Merkel to Bosch facilities in Bangalore? increase speed and improve quality. It goes beyond electronic Prime Minister Narendra Modi and German Federal control of machines and integrates digitally, the entire value Chancellor Angela Merkel took a tour of the facility at Bosch stream of production – logistics, procurement, material flow, to get a very good view of how successfully and consistently managing inventories and so on. For example, the RFID chip German technology is supporting products in India. We on the part that is being produced, will help identify itself showcased our state-of-the-art automotive products as well to the machine, which will in turn, know which tools and as our foray in the healthcare domain with the new India process to be applied. This takes flexibility to a new level specific product for eye care. We also demonstrated our world where potentially every part that is being produced on a line class manufacturing capabilities and most importantly - our could be different. trainee development program. is is denitely relevant in today’s digital and connected We emphasised the significant contribution that Indian era. Over the past few decades, manufacturing has evolved engineers have made to Bosch’s success story in India, as well from being labour-intensive (traditional manufacturing) to a as to their current importance for the company’s worldwide sophisticated set of information technology based processes activities in many strategic areas such as data mining and (advanced smart manufacturing). Manufacturers are being smart manufacturing. propelled to a new age—the next and the fourth industrial revolution. is digital transformation in manufacturing will What is smart manufacturing? Is it the next wave of industrial have huge impacts on both low-cost & high-cost countries and revolution? How does it link with smart city concept? ultimately aect the local & global manufacturing value chain.

28 EM | Dec 2015 INTERVIEW | MANAGEMENT

“One has to develop a holistic plan for systematic investment in upgradation of material and human resources” Gaur Dattatreya

According to you, what are the technology enablers for that will require different skills. Skill development and smart manufacturing? How Robert Bosch capitalises on retraining is a necessary part of smart manufacturing. It will such technologies as a strategic asset for growth? not mean reduced number of jobs; on the contrary there will Industry 4.0 combined with traditional manufacturing along be more demand for skilled people. with IT and the Internet of Things (IoT) are the key enablers At Bosch, we are devising and deploying programs to for the transformation in the manufacturing sector. Global train our staff on the new requirements. This is also true for companies are introducing pilot projects in India on Industry white collar jobs as well as leaders. 4.0. Initial results show up to 30% productivity increase, significant cost reduction and reduction of stock. At Bosch Your company recently announced ` 650 crore of investment in India, we are investing in all of our 14 manufacturing in Indian operations to implement connected production plants to make them smart manufacturing locations in a in all 14 manufacturing plants across the country. Is it a time bound fashion. Additionally, we are offering services to part of your strategy to align your plans with “Make in Indian industry to help them in their transformation towards India” initiative by the Govt of India? smart manufacturing. Adaptation to latest IoT technology and As a part of the ‘Make in India’ business initiative, the Indian upgrading our existing machinery is a continuous process for government aims to advance industrialisation and modernise us striving to achieve the best results in the world. We want production in the country. Connected manufacturing offers to set an example of the best IoT infrastructure in the country great opportunities to faster react to market requirements, and continue to churn out leading quality products. reduce manufacturing downtimes, improve efficiency of supply chains and increase productivity factors, which all What do you think on the network of suppliers and vendors can contribute to increase the competitiveness of the Indian called as manufacturing ecosystem that is prevailing in industry over the long-term. India? Is the country ready to leverage smart manufacturing We are committed to the ‘Make in India’ campaign, hence, concept? our focus is towards producing worldclass products using the All the technology pieces for smart manufacturing are best infrastructure, not only for consumption in India, but available. Manufacturing ecosystem has to gear up and get also for exports. The total investment that Bosch has made in into the digitally integrated environment. Each member of our manufacturing plants spanning over more than 60 years the ecosystem is required to develop their respective roadmap will run in phenomenally large numbers which will surely for transformation. The good news is that for integration you humble the recent announcement of ` 650 crore. require additional joining pieces, you don’t have to throw away your existing lines. Can you comment on the roadmap for smart manufacturers? Roadmap is required for every manufacturer to transform How Robert Bosch is keeping up pace on skill development to act and become smart manufacturer. Depending on the state as a knowledge provider for next generation manufacturing? of current automation and the desired position, one has Skill development is an important part of the new system. to develop a holistic plan for systematic investment in When automation increases, we will require less number of upgradation of material and human resources. If improving people (but highly trained ones) to operate lines than we flexibility, speed, quality or productivity is on your agenda, require now. At the same time, additional roles will emerge start your transformational journey now. ☐

EM | Dec 2015 29 MEDICAL MACHINING | FOCUS

Challenges in the healthcare industry

Healthcare companies are under pressure to provide this higher quality at lower cost and to increase their productivity to meet the growing demand. In order to meet these Vineet Seth requirements, it is important to use advanced CAD/CAM MD – India & Middle East, Delcam Ltd, UK software and CNC machines for machining of medical devices. [email protected]

As per a recent market report, India imports nearly 75% Driving factors of all medical devices. The medical devices market in India, according to a leading analyst company, is over 3 billion US Companies in the healthcare industry face the same dollars annually, currently. This number will grow higher in demands from their patients that traditional engineering the coming years. The reason for such massive imports is clients see from their customers for faster delivery of better largely due to archaic standards, very little or no and cheaper products. Patients want to receive higher quality encouragement for indigenisation and improper application products and services, and they want to complete their of said devices – to name a few. Adding to this, the comparative treatment in the shortest-possible time. At the same time, availability of trained professionals in the medical device healthcare companies are under pressure to provide this domain – particularly in machining, to that of other higher quality at lower cost and to increase their productivity engineering or medical fields adds to the challenges faced by to meet the growing demand. These requirements can only be the healthcare industry in our country. About 20% of these met through the application of more advanced and more imported devices are made through direct high-end automated technology. Multi-tasking machines are being used manufacturing / machining processes. This in itself is close increasingly in the medical and dental industries, applications to over 600 million US dollars a year. include the manufacture of all types of medical and dental

30 EM | Dec 2015 FOCUS | MEDICAL MACHINING

For specialist bone screws and smaller implants, it is very important to simulate machining beforehand

screw, prosthetics, and components for medical equipment. be ready in time for the surgery and also that these implants In order to drive these complex and multi-tasking are accurate in every aspect. machines, it is always important to use a CAM software that The process used by customer begins when patient data in complements these machines in every way. The primary either a CT or MRI scan is received. This data is converted reason for using advanced CAD/CAM software and CNC into STL format to produce prototype models of the skull and machines, is to reduce the overall time and cost for creating the implant. This enables the operation procedure to be the medical component. The benefits of medical machining practised in advance and ensures that there are no surprises may offer opportunities for reduced waiting times for the in the operating theatre. The same technology is also used to patient, avoiding unnecessary surgery, compress process produce drilling jigs and/or cutting jigs needed by the times, reduce patient trauma, speed up patient recovery time surgeon. The next decision concerns the manufacturing and finally reduce medical costs – both for individuals and method for the implant. The more straightforward examples insurance companies. can be machined directly from medical-grade titanium using five-axis machining; but the more complex implants require a Design & manufacture combination of additive manufacturing and machining. As far as bone screws and smaller dental implants are For example, Delcam’s healthcare solutions help design concerned, these are manufactured using a special type of and manufacture custom-made maxillofacial implants for machine called a Swiss-lathe. The Swiss-lathe is a multi- patients suffering with tumours or major bone loss. Typically, tasking machine that performs multiple operations the reconstructive surgery carried out at the time involved a simultaneously. Typically, the medical parts machined on bone graft using a shaped portion of patient’s fibula. Aesthetic Swiss-lathe are less than 25 mm in diameter. One can only outcomes were often poor and the patient had to endure a imagine how critical and complicated it is to sequence the lengthy period in a leg plaster cast while the fibula healed. many moving parts and axes of a Swiss-type machine. Using Ideally, the surgeons would like to operate well beyond the a patented approach called divide-and-conquer, the margins of the tumour and insert the custom-made implant programmer is able to view the part the same way the multi- in the same procedure. Therefore, surgeons want implants to axis lathe on which it is being machined sees it. The software

EM | Dec 2015 31 MEDICAL MACHINING | FOCUS

With a computer-generated simulation of the machining process, the user can see in exacting detail what the part will look like after it’s been programmed, no matter how small it is

does so by breaking down a part into a series of machining materials used in medical machining are aerospace grades of tasks for different part faces programmed in ‘Face Windows.’ aluminium and titanium that the engineer was familiar with It lets the user see a multi-axis turn-mill for what it really is, from his earlier career and helped him reduce the machining which is to say, not just a mill and a lathe, but really a lathe time by half in a particularly important project. with up to nine different types of milling capabilities, It may not always be possible to invest in skilled depending on the capabilities of the machine and the manufacturing workforce. There are tools like the Delcam 
  engineering requirements of the part at hand. Thus, this Custom Software Core, which is a library of middleware    approach lets a user quickly program a part in the exact way software that allows one to interface their .NET applications his machine will cut the component. to PowerMILL (CAM) and PowerSHAPE (CAD) software. For specialist bone screws and smaller implants, it is very This allows development professionals to streamline processes  
 
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32 EM | Dec 2015 FOCUS | MEDICAL MACHINING

save material wastage as the raw material is typically in powder included structural ribs for strength, high resolution 3D relief form, fused by a variety of techniques – usually depending on for aesthetics and textures/aeration holes for potential the material and the 3D printing machine, to form the 3D part, clinical benefits. which is input as a triangulated mesh CAD model. While 3D Additive manufactured custom orthotic insoles process printing allows for complex shapes to be created that is does not replace the faster and more economical subtractive otherwise not possible with subtractive machining, it is a much milling method but it does open some new and interesting slower process and often quite expensive. Having said this, the doors. For example, by 3D printing an orthotic, the cost of 3D printers are now coming down and there are also practitioner is able to design the ideal custom insole more material that are available for 3D printing. unhindered by the restrictions of conventional manufacturing. 3D printing is not limited to metal implants and generic For the immediate and present future, it is best to combine medical devices alone. Even in the field of mass customisation, the strengths of additive and subtractive manufacturing – by combining the functionality of different software modules, where possible, to derive the best value out of the process. Delcam has been able to generate and print a series of concept With all of the above developments, manufacturers now designs which demonstrate some of the possibilities for have the opportunity to cater to any form of medical device devices such as custom foot orthotics to be created by 3D or equipment manufacture without the need to change or printing. The process comprised of creating the orthotic switch between different CAD/CAM providers. This in itself designs where additional product features were added. These will reduce half the complexities. ☐

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EM | Dec 2015 33

SUPPLY CHAIN MANAGEMENT | TECHNOLOGY

Lean guiding principles for the supply chain

This article talks on Built-in Quality - one of the lean guiding principles, to develop a lean culture in a supply chain operation. With processes designed to make work flow correctly, and tools available to eliminate small problems before they grow large, employees can focus on delivering excellent products and services that increase overall customer satisfaction.

In the supply chain arena, a lean culture offers tremendous time because there’s no need to correct mistakes, and you save rewards, but pursuing a lean strategy also requires a significant money because your product is never damaged and retailers commitment. Luckily, becoming lean doesn’t mean you have don’t experience stock-outs. Your efficiency often allows you to re-engineer your operation. You can work with a logistics to take advantage of lower-cost transportation options. partner to make continuous, incremental gains in quality and You can’t enjoy these advantages by inspecting for quality efficiency. after the fact. The way to ensure quality is to perform work correctly the first time. That means building quality into Built-in Quality: Get it right the first time every process.

High quality in the production and distribution of products Mistake-proofing to eliminate rework improves your bottomline. If employees always know where to find the product they need, goods flow smoothly from one A company should engineer its supply chain processes with section of the facility to the next. Orders can be filled correctly, its workers in mind. Any worker should be able to perform completely and on-time, satisfying customer demand. You save processes perfectly to meet the requirements of customers and

36 EM | Dec 2015

SUPPLY CHAIN MANAGEMENT | TECHNOLOGY

Using tools like these, employee teams and their manager can stop fighting fires—rushing to correct problems after they occur—and concentrate on fire prevention

other stakeholders, such as regulatory agencies. Once the the right slots. The scanner display then tells the workers how engineering team designs a process, they conduct a failure many boxes to pick. As they carry out their instructions, they mode and effects analysis (FMEA)—a trial run in which scan the labels on each box, and the system confirms that they someone tries on purpose to “break” the process. By locating have chosen the right products. These multiple checks help to weak points where mistakes might occur, the engineers are ensure that pickers fill their orders correctly. Subsequent scans able to bring the process even closer to perfection. as boxes are loaded onto pallets or into a trailer further Next, the design team decides which metrics it will use to reinforce the quality chain. determine whether the process is meeting its requirements. Then it documents the standards for performing the work. The Understanding root causes team describes the process in text and also creates simple how- to instructions using photographs to illustrate each step for Even the most carefully-crafted processes, and the most employees. reliable in-process controls, won’t eliminate errors completely. When a lean business opens a new supply chain facility, it When a mistake slips past the safeguards, you need to dig down follows the procedures described above to create and document to get at the root of the problem. The goal is to further mistake- each process that workers in the facility will perform. It then proof the process by ensuring that the error never has a chance monitors work in the facility for 90 days to make sure that all to recur. the processes are working as expected. Once those processes Consider a series of orders that include a certain model of are validated, the facility is certified to be fully operational. graphics cards for a desktop computer. Before these orders are Over time, as customers’ needs change and the facility starts to loaded onto a truck, an audit finds that they all contain the handle different products, the engineering team creates, wrong card. As soon as the auditor uncovers the mistake, it’s documents and certifies new processes, always aiming to time to stop work and walk back through the process to ensure that anyone can perform the work without error. discover what went wrong. It’s not enough to replace the wrong cards with the right ones for today’s shipment. The team needs In-process controls to discover the cause of the error and correct it, so the process is performed perfectly in the future. Along with designing error-proof tasks, a company can A tool called the “Five Whys” helps employees step back implement safeguards that prevent mistakes while work is in through the process, discovering, for example, why the pickers process. Some of these in-process controls may be simple visual picked the wrong card (because the bins were mislabeled) and reminders. Technology also helps. For instance, an employee why the bins were mislabeled (because the database contained who is packing a box with ten items might use a scale to check an error), and so on. the weight of that box. If each item weighs one pound, the A tool called a fishbone diagram also helps employees employee cannot accidentally pack the box with eleven items. analyse the causes of an error by: The ten-pound reading on the scale signals that the packing a) Drawing a central line labeled with the name of the defect job is complete. This safeguard ensures that the employee (the fish’s spine) sends only correctly-packed boxes to the next station. b) Drawing the “bones” that radiate from the spine to represent Bar code scanning systems help to maintain quality at many categories of problems that might cause the defect points along the supply chain. In a warehouse, pickers working c) Brainstorming about possible causes within each category. along a row will scan location codes to ensure that they are in Using tools like these, employee teams and their manager the right aisle. When they start picking, they scan the locations can stop fighting fires—rushing to correct problems after they where product is stored to confirm that they have arrived at occur—and concentrate on fire prevention.

38 EM | Dec 2015

SUPPLY CHAIN MANAGEMENT | TECHNOLOGY

Figure 1: Benefits of Built-In Quality Lean Guiding Principles for the supply chain principle 2: Built-In Quality

Instant feedback responsibility for quality control. A lean operation empowers employees to spot problems and fix them. But more than that, In the quest for quality, there’s no room for delay. You can’t it empowers them to investigate why the problems occurred in wait for a Friday meeting to tell a supply chain team that in the first place, in order to eliminate those ultimate causes and filling an order for side view mirrors on Monday, it shipped make sure the mistakes never happen again. rear view mirrors instead. Workers will be hard-pressed to To transform employees into quality experts, it’s essential recall who picked that order, which aisles they worked, what to eliminate fear from the equation. Employees should feel free instructions they received and what exactly they did. to voice concerns, and to stop the flow of work to correct an Part of a team leader or supervisor’s responsibility is to error. When someone spots a mistake, that should never help employees do their work according to established become an occasion for blame. The goal is not to point fingers, standards. When one of those leaders finds that a process is but to set things right so the team can continue to do the best not working up to par, it presents an opportunity for coaching. job possible for its customers. Then the team should celebrate The leader should take the employee aside immediately, explain the improvement. what isn’t going right and provide instruction on how to do the work better. Leaders should also provide instant feedback Conclusion when they observe employees performing their work remarkably well. A lean culture builds quality into every facet of its operation. With processes designed to make work flow correctly, and Get everyone involved tools available to eliminate small problems before they grow large, employees can focus on delivering excellent products In a lean culture, it is every employee’s job to perform work and services that increase overall customer satisfaction. ☐ according to the documented standards and to take Courtesy: Ryder Supply Chain Solutions

40 EM | Dec 2015 High precision blank preparation, shank diameter up to Ø 20.0 mm, runout tolerance within 0.002 mm, and simultaneous grinding of roughing and fi nishing operations. Ground with the NEW ShapeSmart®NP3 The smart choice.

www.rollomaticsa.com [email protected] GEAR MANUFACTURING | TECHNOLOGY

Ready for large tasks Where large powers and high torque are required, large gears are the answer: in marine drives, cement & coal mills, wind turbines & Dipl-Ing Günter Mikoleizig Product Management hydroelectric power plant. e article talks on large industrial Gear Inspection Machinery Klingelnberg GmbH measuring centres for gears adapting to the current market needs. [email protected]

In manufacturing, precise measurements are the societies need complete documentation, and this can be cornerstone for complying with very tight tolerances and assured only by regular measurement and testing. The high ensuring the efficiency of the entire operation. Large requirements for process reliability and the associated quality measuring centres have to be fast and easy to operate in order documentation call for robust metrology near to the to determine the current quality of the workpiece and decide production line. Manufacturers of large gears consequently on any necessary corrections in the process chain. need high-precision measuring devices which can be operated The inner life of gear trains for wind turbines is especially as easily as possible. quality-sensitive. These include cylindrical gears, cylindrical The new ranges of model from Klingelnberg in the P series gear shafts, rings with internal gearings and planetary gears. meet this need. The company now offers continuous Safe, reliable operation – even in heavy weather conditions – measuring technology in the applications sector up to is absolutely essential, as the only way to safeguard a long and 3,800 mm. This satisfies maximum quality requirements and economic operating lifetime. the standards of the classification societies. The new machine The increasing size of parts is leading to ever greater versions combine demanding geometry measuring tasks with challenges for production quality. Customers or classification high-precision gear measurement.

42 EM | Dec 2015

GEAR MANUFACTURING | TECHNOLOGY

Mounting table with support and centering element

Shorter floor-to-floor measuring times bores. The angled measuring arm can move the 3D stylus head inside the bore close to the measuring point, ensuring Measuring centres for large gears are suitable for high measuring accuracy. measuring workpieces with an outside diameter up to 3,800 Special features are used to facilitate loading prior to a mm and a weight up to 20,000 kg. The machines have a rotary measurement. Shaft-type workpieces can optionally be table and three linear measuring axes for acquiring measuring clamped with a column and tailstock for a fixing range up to data. The new rotary table provides high running accuracy 2,500 mm, so that they can be fixed between centres. Disc- (radial and axial runout < 0.5 μm) – important prerequisites shaped workpieces are placed on the rotary table of the for accurate measurement of size, shape and position measuring machine. Depending on the size of the workpieces, deviations during a single work cycle. A high-precision angle extra fixtures are available for this purpose. To make an measuring system is integrated in the rotary table axis for accurate measurement, the position of the workpiece axis is rotational position acquisition. 3D stylus systems with digital determined in relation to the rotary table axis. data encoders are used for optimum measured data logging on the tooth flanks. The traversing paths of the linear axis Control feature allow inspection of up to 800 mm in the horizontal plane and vertical distances up to 2,000 mm. The rotary table and the The control compensates deviations in a range up to 10 linear measuring axes are powered directly by AC motors for mm. This feature greatly simplifies loading of the measuring greater guiding accuracy. machine, as the operator no longer has the time consuming The rotary table and the linear axis measuring attachment task of aligning the heavy workpieces with the rotary table are supported on a load-bearing machine bed. Combined axis. Centering elements together with an mm scale are quite with a suitable foundation, this provides a geometrically sufficient. As an alternative, the measuring machines can be reliable base for the measuring machine. The machine design aligned mechanically via an air bearing integrated in the enables inspection of various diameters and distances on the rotary table. This can be used to align even heavy workpieces same workpiece in one set-up. The gear measuring centres exactly. are optionally available with a straight horizontal measuring Using the control software, the operator can quickly create axis, including a 3D stylus system or a downward angled a measuring program to define the measurement sequence. measuring arm. The horizontal axis is useful in versatile He enters the test parameters together with the standards or applications for disc-shaped workpieces and shafts and for directives for analysis. The desired and actual form can then gear-cutting tools. The angled variant is particularly suited be compared reliably using the analysis software. This is for testing gears in planetary systems used in the wind power important, as large gears with high profile and tooth trace sector. Here the task of measurement is to test internal gears loads need especially large modifications. Measuring times with large gear widths and to perform high-precision are shortened by programming fixed measurement sequences, dimension, dimensional (MFL) measurements in workpiece and the centre performs the prescribed steps iteratively.

44 EM | Dec 2015 VLC 200 H VERTICAL PICK-UP HOBBING MACHINE

Precision Gear Cutting FOR WORKPIECES Ø 8 IN AND MODULE 4 1 2 3

INTEGRATED AUTOMATION FLEXIBLE SOLUTION VERTICAL CHIP FLOW » Built-in pick-up spindle and » Easy integration into » Well suited for high-performance conveyor belt manufacturing systems dry hobbing

EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91-80-42544400 I Fax: +91-80-42544440 I E-mail: [email protected] I Website: www.emag.com www.emag.com GEAR MANUFACTURING | TECHNOLOGY

Gear measuring centre P 150 W provides accurate and fast measurements of workpieces up to 1,500 mm diameter and a weight of up to 8,000 kilograms

Versatile adaptability procedure is simple to adapt and functions on the skid plate principle. The parameters it provides a single run, together In addition to the standard equipment, users can opt for with other measurements, are the centre line average (Ra), additional features to customise a measuring centre. This the average peak-to-valley height (Rz) and the maximum enables them to respond specifically to a measuring situation. peak-to-valley height (Rt). The special stylus system is The resulting centering accuracy in the millimetre range is changed either manually or automatically. Appropriate sufficient to start the measuring run immediately. Additional roughness sensing systems are available for the respective mounting tables with different diameters are available for module sizes. large ring-shaped workpieces. These are designed to be Precise results can be obtained only if the workpiece changed with a short set-up time and effort. The fixtures used temperature at the time of measurement is taken into account. on the rotary table also fit the mounting tables. A difference of a few degrees Celsius from the reference Centres are preferred for fixing shaft-type workpieces. temperature (20 °C) will cause results to deviate by two-figure Tailstocks in different types are available. Detachable columns micrometer amounts when determining test parameters for with a tailstock are used for small workpieces or gear-cutting profile tooth traces and for the base tangent length. To avoid tools. Fixed columns with tailstock are available for testing such inaccuracies, the new P machines provide an optional extremely long and large shafts, enabling measurements on workpiece temperature sensor. This has to be placed manually up to 2,500 mm fixing lengths. The column can be moved on the workpiece prior to the measuring run. The temperature using a wireless remote control to adjust the arm for the measurement takes only a few seconds. All subsequent necessary fixing length or to adapt it for the loading position. measurements are then related to the reference temperature. An optional automatic stylus changer speeds up the process The angled measuring arm of the W version is fitted with if a number of different measurements are made in succession. a monitoring camera. The ultra-compact camera can be fixed The stylus is then changed automatically during the measuring flexibly on the measuring arm according to the intended sequence. Precision is maintained due to the high centering measurement and the required viewing angle. Its primary accuracy of the stylus holder plate. If the stylus still needs to task is to let the operator view the position of the stylus on be calibrated for certain measurements, this is done outside the monitor of the control unit when measuring inside gear the centre of the machine. The operator sees the necessary teeth, and make any necessary corrections. instructions for a manual stylus change on the screen. Feedback from the industry is the basis for developing new gear testing machines and measuring concepts. The main Measuring surface roughness focus is on key market requirements for faster processes with simultaneously high quality standards. The modular design The P series machines also have an optional feature for enables to customise measuring devices for individual measuring surface roughness on the tooth flanks. The demand in the industry. ☐

46 EM | Dec 2015 ADVERTORIAL | MANUFACTURINGADVERTORIAL IT

If productivity matters, choose ESPRIT CAM software

This screw, about 1.5 cm in length, has a tapered core and a triple Stainless steel Harpoon® suture anchors produced in ESPRIT thread with variable pitch. It was produced for orthopedic surgery

DP Technology has come up with one of the most revolutionary modules which is confined and specially customised for medical industry. This gives a chance to all the medical companies to make use of something which is specialised in their sector and kick-start its implementation from day one.

The medical industry now faces challenges met by some of the As a worldwide leader in CAM innovation, it provides other industries in past: the need for sophisticated, robust powerful solution to CNC programmers in all manufacturing computer-aided-manufacturing (CAM) software for complex disciplines. This high-performance CAM software is designed machining. ESPRIT CAM software, by DP Technology Corp, is for ease of use and is compatible with all types of CNC machine the choice of many medical-industry manufacturers like Stryker, tools. ESPRIT covers the spectrum of medical applications: 2-5 Johnson & Johnson, Smith & Nephew Orthopedics, Orchid axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking Orthopedics, Chetan Meditech, Meril Life & many more that seek mill-turn machining and B-axis machine tools. to make high-quality, complex parts and cut programming time. Saves time: ESPRIT maximises the capabilities of mill-turn Performance enhancement is one of the major concerns in machine tools. The software’s functionality includes mill-turn all these companies. Looking at the small sizes of variety of on C and Y axes and it combines turning, milling and drilling products it is very difficult for CAM software to provide operations in one G-code program. Users can perform accurate accurate solution, automation options and reduce cycle time & 5-axis milling machining, whether simultaneous or indexed, programming time. With ESPRIT CAM software, the company and fully exploit the power and flexibility of machines equipped provides training and support for its customers to improve their with a B-axis. production line with a variety of automation options available Accurate simulation: ESPRIT features solid and dynamic inside the software. Any such complex operations like re- simulation that eliminates the risk of collision. Simulation chucking, broaching, thread whirling, applies to the whole spectrum of cycles pinch turning/milling, support axis in mill-turn (2-5 axis) machining, as synchronisation, etc are easily supported well as turning with multiple spindles inside the software. and multiple turrets, up to 22 axes. The programmer verifies a listing combined with all milling and turning operations, plus associated cycle periods. Customers’ quotes Certified post processors: ESPRIT CAM software for sliding “The post processor’s accuracy and the training & support head machines generates quality G-code programs for Swiss has been phenomenal” turning that are highly optimised to minimise cycle times, Chetan Meditech reduce remnant waste, and preserve tool wear while maximising “ESPRIT is one of the few software in the world, which can part quality. It does not provide post processor; it provides support any kind of machine with any controller” machine drives which provides accurate G-codes for any Orchid Orthopedics machine with any controller. ☐

EM | Dec 2015 47 CUTTING TOOLS | TECHNOLOGY

Taking hole deburring to new depths

A read on how the new MEP (mechanised edge profiling) process developed by Seco Tools keeps exit burrs from negatively Teun van Asten impacting tool rigidity, machining accuracy and tool life in deep, Engineer, Marketing Services—Solid Milling small-diameter through-holes Seco Tools

Burr formation creates challenges for part manufacturers to remove burrs quickly and consistently. Hole edges can be across all industry segments, especially when drilling deep finished to high-tolerance specifications on the same machine through-holes in critical components. In these applications, that drilled the hole initially. burrs of excess material form at both the entrance and exit of Seco Tools has developed a new MEP process that the workpiece, with the exit burr posing the most challenge. combines innovative tool design with 5-axis toolpaths to These burrs can lead to poor part quality and production enable fast, repeatable deburring of holes deeper than 10 inconsistencies, which are unacceptable in aerospace and times diameter. other closely regulated industries. Manufacturers traditionally remove burrs with hand End user demands grinders, emery cloth or other manual processes. These methods, however, are slow and require the part to be moved The aerospace industry specifies dimensions for certain and refixured for the deburring process. Even when performed part and hole edge conditions, including chamfer and radii. by skilled personnel, it is impossible to achieve part-to-part These features typically undergo approval and certification consistency in manual deburring operations. Mechanised processes to meet tolerances measured in hundredths of a Edge Profiling (MEP), on the other hand, employs an millimeter as well as ensure consistency from part to part. engineered tool, guided by a machine tool’s CAM program, The deburring process has to achieve a precise balance

48 EM | Dec 2015 TECHNOLOGY | CUTTING TOOLS

As hole depth grows, the tool’s length- to-diameter ratio also increases, making it less resistant to cutting forces and more prone to vibration

between machining away the burr without removing material hole depth grows, the tool’s length-to-diameter ratio also from the part. increases, making it less resistant to cutting forces and more Standard deburring and profiling tools used for MEP prone to vibration, chipping or breakage. Moderation of the processing of part edges and other features include solid- cutting parameters is necessary and deburring may not be carbide chamfering end mills as well as tools that employ fully effective. indexing inserts with complex cutting geometries. Custom MEP tools have specific radii, chamfers, angles and Tool & process development combinations of those cutting edge features. The most sophisticated deburring tools have edge designs that produce Seco has developed an innovative tool concept and a chamfer with a radiused edge preceded by lead-in and combined it with 5-axis toolpath strategies that facilitate lead-out angles designed to prevent formation of effective deburring of the exit area of deep, small-diameter secondary burrs. through-holes. The tool features a tapered shank with a large MEP tools commonly have square cutting edges, but ball neck diameter where the tool enters the part. The design nose and lollipop-style tools are available for profiling edges provides a 0.05-mm clearance between the neck and diameter on contoured components that would otherwise restrict of the hole. Below the entry of the hole the tool tapers to a access of square-edged tools. Applied on a 5-axis machine, a smaller diameter and at its end are cutting edges. ball nose tool can scan the line of a complex part profile and The CAM toolpaths employ 5-axis motion to tilt and create a radius on a long contoured edge. rotate the workpiece so that the centreline of the tool circles Toolmakers also provide tools custom-engineered to around a point and describes a conical form at the hole exit, profile edges and remove burrs at the entry or exit of larger where the tool’s cutting edges remove the burr. At the same through-holes. The custom tools feature complex cutting time, the neck of the tool at the hole entry effectively remains geometries. When cutting conditions are stable and cuts are stationary and does not interfere with the sides of the hole. smooth and uninterrupted, the tools permit use of more A Z-axis movement positions the tool in the hole and then aggressive cutting parameters. Conversely, when features the machine’s 5-axis capability combines X, Y, and Z motion such as access holes interrupt the cutting path, parameters to perform the deburring process. are more conservative to minimise tool wear and failure. Application & testing Deep, small-diameter holes The tools and toolpaths deburring the exit of a 3.2-mm The exit ends of deep, small through-holes are challenging diameter, 36-mm deep through-hole, were initially tested. to deburr because they require small-diameter tools. As The length-to-diameter ratio was greater than 10:1. Initial

EM | Dec 2015 49 CUTTING TOOLS | TECHNOLOGY

The tools and toolpaths deburring the exit of a 3.2-mm diameter, 36-mm deep through-hole, were initially tested

trial-and-error testing arrived at an optimal rotation rate of engineered to remove burrs at the entry of a through-hole 1,200 rpm, a speed that enabled the tool to complete 128 provide longer tool life than those designed for eliminating holes without replacement. burrs at the exit end. Tools for deep-hole exit burrs have a Deburring each hole required no more than three seconds, higher length-to-diameter ratio, making them more prone to compared to manual deburring techniques that could require instability and vibration that, in turn, accelerate wear. a full day or more to deburr an equivalent number of holes. Therefore, a tool engineered to deburr both the entry and exit Because the CAM program and machine control handled the of a deep through-hole would exhibit longer life for the entry tool’s movement, the deburring results matched exactly from feature than for the exit feature, resulting in the need to the first hole to the very last. discard the tool with much of its capability unused. Additionally, MEP tools that deburr the entry area of a Programming details hole can be reground, but the critical relationship between the cutting edge and tool tip in MEP tools for deep, small-diameter To programme tool movement before the MEP process, through-hole deburring precludes regrinding. The reason is the machine operator must enter the exact location and that applying a reground tool would involve changing the definition of the surfaces to be deburred. The tool length offset in the machining program, something prohibited by the must be defined as well. Tools are ground to a tolerance strict protocols of aerospace machining practices. within 0.0375 mm. The front end of the tool is ground in the same operation as the cutting edges, producing a relationship Conclusion between the tip of the tool and the cutting edge within 0.0125 mm. The tool length is specified in the CAM program; the Manufacturers continually respond to customer demands operator can confirm the tool length off the machine with a for increasingly tight part tolerances. The aerospace industry presetter or on the machine via a laser or touch probe. leads the trend, but requirements for precision and consistency are becoming stricter in the medical, energy and other MEP for multitasking? industries as well. Deburring, an essential element of precision part Some MEP tooling combines the machining of a part production has long been carried out through manual feature with a deburring operation. Select end mills, for methods. Unfortunately, these operations can be inconsistent example, locate the MEP machining feature at the top of its from part to part and are expensive in terms of labour, setup cutting zone to machine the hole diameter and then deburr and part handling expense. In fact, some end-users have the entry point in the same operation. banned manual deburring because it cannot be documented Analyses of MEP applications have indicated that tools and certified. ☐

50 EM | Dec 2015 Since1949

ProductionProP duction TooToolol On-On-linelilini e MonitorMonitor management management measuring system

Horizontal Lathe Wheel Turning Lathe Vertical Lathe Horizontal Boring & Multi-Axis Machine series series series Milling machine series series

www.femco.com.tw

FEMCO INDIA Global Raisoni Ind Park, Far East Machinery Co.,Ltd Gat No. 182/183/184 Part, Near Lonikand, Factory Automation Technology CO.,LTD Phulgaon, Alandi-Markal Rd, TEL:886-5-2205295 FAX:886-5-2205293 Pune 412216 E-mail:[email protected] +91-20-66787600 MANUFACTURING IT | TECHNOLOGY

Achieving program excellence

Integrating virtual and physical testing enables delivery of products on schedule and on budget. A read on how aerospace & defense firms achieve program excellence with Siemens integrated verification management system

The complexity of aerospace and defense (A&D) products virtual and physical testing enables delivery of products on and the number of requirements that they must meet to gain schedule and on budget. The benefits include: customer or regulatory acceptance continue to grow. As a t Reduces program risks to schedule, budget & deliverables “system of systems” comprised of software, hardware and t Improves program performance with a single verification electronics, A&D products involve lengthy, multi-disciplinary management system development programs and interrelated verification activities t Increases traceability of requirements from program to gain customer or regulatory agency approval. Whether it’s through design, analysis, and test a commercial airliner, weapons platform or a spacecraft, t Reduces verification costs with improved planning and failure is not an option. execution A&D companies compete in a global market place and t Enables proactive management of requirement compliance execute programs with multiple global partners and suppliers. with real-time reporting To be successful in this environment, A&D companies must t Accelerates program audits with accurate, up-to-date, demonstrate their ability to consistently execute programs documented deliverables and activities across the extended organisation, delivering products that The Siemens PLM Software Verification Management meet requirements on-schedule and on-budget. Integrating solution enables companies to achieve this goal by connecting

52 EM | Dec 2015 TECHNOLOGY | MANUFACTURING IT

requirements to all tasks, analyses, tests and data involved in proving requirements are met. Teamcenter also provides the verification process, providing complete visibility and integration of analysis-to-analysis (an often-overlooked traceability across planning, design, analysis, test and final failure point) by managing the process to take the outputs conformance reporting. from one analysis and them as inputs to the next analysis, as well as all the other artifacts required to conduct the next Providing full lifecycle traceability analysis; other boundary conditions or inputs, models, etc. Only in this way are design analyses and tests truly integrated Programs must meet requirements that are set by their and connected. customers, contained in their contracts, and meet company product standards for design and safety, as well as industry Tracing the test to the physical test article requirements from regulatory authorities such as the Federal Aviation Administration (FAA) and the European Aviation Physical tests are a necessity for aerospace and defense Safety Agency (EASA). Teamcenter software from Siemens products, and it’s imperative that tests prove that requirements PLM Software enables all program activities to be driven by are met. Proving a test valid requires that a sequence be these requirements, from initial program goals to the followed from requirements to be verified to test plans that individual components that will make up the final product. define the verification approach and that test articles and With Teamcenter, full product lifecycle traceability makes it equipment are configured properly. Teamcenter establishes possible to ensure that all requirements have an approved the path from requirements to test plans to test article to verification method, that the method is executed, and that confirm that a test is required, properly planned, and appropriate results are recorded to support achievement of accurately executed. If changes in requirements or the product the requirements. design occur, Teamcenter can be used to immediately provide full visibility of their impact on plans, test articles, and tests Synchronising analysis from design through test including those already run that need to be re-executed. Teamcenter also maintains the complete history of all As a full product lifecycle solution, Teamcenter can be test articles and equipment, enabling full traceability to the used to communicate requirements to all disciplines in the past test article or analytical model configurations. In product development process as well as changes to those addition, Teamcenter provides complete instrumentation requirements. This single collaborative source permits traceability: from measurement requirements defined by design, analysis, and test organisations to work in unison to engineering in the test request; to the instrumentation plan; ensure that analysis and simulation models are synchronised to the physical instrument installed on the test article and its with design models for both production and test articles, calibration data through to the raw data and the reduced and that physical test articles conform to requirements across engineering unit data used for reporting compliance. Full disciplines. By synchronising these models, simulations traceability enables the ability to demonstrate that the test representing the production design - as well as all the article matches the current engineering definition as well as modifications made to the test article - remain valid for the original production design at every stage.

EM | Dec 2015 53 MANUFACTURING IT | TECHNOLOGY

Physical tests are a necessity for aerospace and defense products, and it’s imperative that tests prove that requirements are met

Integrating verification management system Conclusion

Moving from planning what to do to actually doing it The Verification Management solution in Teamcenter requires task definitions, scheduling, and management. empowers A&D companies to successfully execute their Teamcenter provides this functionality for all verification programs on-schedule and on-budget by providing visibility activities to link engineering, manufacturing, procurement, and closed-loop requirement traceability into all activities of and test to support long lead planning, resource utilisation the verification process to confirm requirement compliance. and execution of the verification activities. Verification With efficient planning, simulation, analysis and test requirements are linked to supporting documentation for execution in an integrated environment enabling confirmation virtual and physical test configurations, test plans, test of requirements achievement, Teamcenter supports program procedures and test results to enable complete status reporting audits and reduces the time and cost of verification that of the process. This holistic approach ensures efficient usage ultimately improves program performance. of resources and provides visibility into the process to ensure A simple idea inspired this product. Thousands of that deadlines are met. Requirements can be linked to decisions made it real. Making a great product takes more activities on the verification management schedule as well as than inspiration. It takes thousands of decisions for a good to a Work Breakdown Structure for correlation to financial idea to become real. Not just the big milestone decisions, but reporting systems; integrating cost, schedule, and technical all the small decisions that lead up to them. The fact is anyone requirements in a single system. can make the decision that makes the difference in your Additionally, the verification management solution product’s success. For leading companies throughout the includes a catalyst. This fast track implementation provides world, Siemens PLM Software is an essential environment for best practice models and preconfigured elements for activities immersive product decision-making. The solutions give such as defining data objects and roles that can be used in everyone involved in making your products “high-definition automated workflows. The open and configurable software PLM.” HD-PLM ensures that people get the information they allows you to control the appearance and behaviour of the need, when they need it—with absolute clarity—to make Siemens PLM implementation, whether it is for a more informed decisions faster. No matter what industry comprehensive PLM environment or a standalone verification you’re in—automotive or aerospace, electronics or energy, environment. Deployment accelerators include recommended marine or medical, machinery and more—PLM software product selections, network design decisions, configuration helps you make the smart decisions that go into procedures, deployment best practices and user training. The making great products. ☐ verification management catalyst enables you to accelerate Courtesy: Siemens PLM Software the digital transformation of your enterprise. This allows you to improve productivity and achieve greater availability and reliability while reducing the total ownership cost.

54 EM | Dec 2015 Projekt1 09.09.14 08:41 Seite 1

Toll Free: 1800 233 2065 EVENT | REPORT

Strengthening Indo-German relations

With a participation of around 140 members, e 4th VDMA Mechanical Engineering Summit was recently held at New Delhi. e summit witnessed co-operation from German companies towards ‘Make in India’ campaign, and bestowed their support towards India’s future growth. A post-event report…

With the recent visit of the German Chancellor Angela India, Schwach Bharat and Sagar Mala, a foundation is being Merkel, both Germany and India have stepped up their laid for a multiplier impact on inclusive development. This has bilateral cooperation and agreed upon 18 MOU’s. Today, the emphasised on the 4 Ds - demographic dividend, democracy, world is looking at India as the final destination for demand and the recently added 4th D - deregulation. This investments and growth and Hon’ble Prime Minister has set effort shows to be bearing fruit as India saw the highest foreign clear goals and reforms to help achieve them. The objective direct investment inflow for new projects among all nations in of these engagements are to support and augment the ‘Make the first half of 2015, beating America and China.” He further in India’ programme through increasing the innovation and adds that in January-June 2015, India attracted $31 billion technology prowess of the Indian industry. (` 2.05 lakh crore) in capital expenditure (capex) from foreign companies, China, the largest economy in Asia, attracted $28 Highlights bn and the US got $27 bn in the period. Dr Corinna Fricke, Head Economic Section, Federal The summit started with a welcome note from Rajesh Republic of Germany in New Delhi reiterated the Nath, Managing Director, VDMA India, where he mentioned strengthening bonds between India and Germany and the that the Prime Ministers clarion call to ‘Make in India’ holds increased bilateral trade between the 2 countries which enormous promise to transform the Indian economy. crossed 17 Billion Euros in 2012. Dr. “There is immense “Complemented by initiatives such as “Skill India”, Digital potential for growth in the country but feels that it has been

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TG 165 and C2 AD.indd 1 30/11/15 6:46 pm EVENT | REPORT

Rajesh Nath, MD,VDMA India; Arun Maira, Former Member, Planning Commission; Dr Rajan Katoch, Secretary, Department of Heavy Industry, GOI; Dr Corinna Fricke, Head Economic Section, Federal Republic of Germany in New Delhi; Ulrich Ackermann, MD, Foreign Trade Division within VDMA Frankfurt during the summit

at a growing slowly but steadily specially in the last few implementation of GST, Digital India and third party months,” she said. certification issues. This was followed by an address by Dr Rajan Katoch, The second leg of the technical session began with Secretary, Department of Heavy Industry, GOI. He “Prospects for Indo-German collaboration in high technology enlightened the audience on “Manufacturing in India – Road manufacturing” by Hermann Muehleck, Head—German to Progress”, where he explained the slew of measures taken Business Centre, India, Ernst & Young GmbH. The objective by his department as part of the ‘Make in India’ programme of the study was to identify high-technology sectors that are to increase country’s share of manufacturing in GDP to 25% most suitable for Indo-German collaboration. by 2020 from present 15%.” The session continued with “Application of Industry 4.0 in manufacturing” presented by Volker Schmid, Head—Asia Showcasing Indian relations Pacific, Festo Didactic SE. The concept was to inform & prepare for manufacturing of tomorrow, which is presently Ulrich Ackermann, Managing Director, Foreign Trade led by primarily Europe and other developed countries. Division within VDMA Frankfurt shared insights of the “Gaining importance in high-tech manufacturing, process German engineering industry, which attained a turnover in automation and end-to-end digitisation of business will 2014 of 212 bn Euro, out of which the export share stood at become a key driver for enhancing production and cost 77% with Asia contributing to 27% of this export share. “India efficiencies. The Indian IT sector holds strong know-how on is the 5th most important country for German Machinery software development and on digitisation of business exports, while the top three include USA followed by Italy and processes from which collaboration partners can benefit,” he Mexico. While India on the other hand, imported machinery explained. from China followed by Germany and Japan,” he said. The technical session ended with the insights on “Make in The keynote address on “Overview of the Indian Economy” India Mittelstand” by Satish Sharma, Deputy Secretary (EW), was presented by Arun Maira, Former Member, Planning Ministry of External Affairs. It is a first of its kind business Commission. This was followed by a presentation on “Goods support programme designed to offer services in coordination and Services Tax- Impact on Manufacturing Industry” by with the Indian Government and other entities. It starts with Sandeep Gupta, Partner, ASA & Associates LLP, spoke on the company selection and on-boarding; in the second stage “Goods and Services Tax- Impact on Manufacturing Industry”, market entry support will be facilitated. Also, a panel discussion where he presented various tax models implemented in was held on “Make in India—a slogan or reality” moderated by developed countries and reiterated that Dual GST is to replace Nath. The panelists highlighted the German dual system of different indirect taxes on goods and services by the central & education, which provides theoretical & practical knowledge state governments. to students. The students here are given an opportunity to not Next, Ajay Shankar, Chairman & Expert Committee, just learn, but also work in the industry, thereby, creating Regulatory Approval, organised a session on “Ease of doing technically skilled workforce from the onset.☐ business – approach from Indian government”, where he Courtesy: VDMA touched upon various issues like creating regulatory layovers,

58 EM | Dec 2015

EVENT | REPORT Siemens PLM Software Image courtesy:

Designing without boundaries…

Siemens PLM Software’s recently concluded Solid Edge University 2015 at Cincinnati, Ohio, USA, with the introduction of ST8 that delivers powerful modeling with unparalleled mobile flexibility & real-time access to vibrant global user community. The two-day event witnessed several general and breakout sessions, which

helped users improve productivity, expand skills and Megha Roy Features Writer experience the smart operation platform. A post-event report… [email protected]

There was a time when constraints of traditional 3D & innovative, and helps to bring products faster in the market modeling were difficult to address to. However, things have at a lesser cost. changed now and with the latest version of Solid Edge—ST8, one can leave behind these complexities. ST8 has more Highlights flexibility built in its system, and, as such, is more effective. So much so, that people can come across their mother system Day 1 of the event started with a welcome note by John and be able to be productive right away. It is also synchronous Miller, Senior Vice President & General Manager, Mainstream

60 EM | Dec 2015 REPORT | EVENT

Engineering, Siemens PLM Software. “Solid Edge provides Unfolding ST8: powerful, accessible and user-friendly companies of all sizes apt solutions for business needs. We Uniquely powerful are working towards widening the gap of people who insist t
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&EHF by creating pattern using a table/spreadsheet, making pattern in irregular ways, not just rectangular or circular and linking patterns together for design automation. Besides, it can perform enhanced welding, enriched digital mockup and and 3D feature recognition enable users to focus on designs, enhanced drawings,”showcased Ruchti. rather than design tools, resulting in an accelerated modeling Day 2 witnessed 14 breakout sessions attended by people process. Flexible modeling incorporating synchronous across industries. “Introducing Solid Edge into academic technology frees the user to intuitively produce realistic and institutions” by Mike Brown, Academic Relations, Mainstream accurate designs faster, thus, reducing time-to-market. Engineering Software was one of them. Besides, presentations Highlighting this, John Fox, Vice President—Marketing like “Design Automation Saves Time and Money” was put up for Mainstream Engineering Software, Siemens PLM Software, by Harry Irwin, Project Engineer, Schafer’s Electric Enclosures explained, “This combines parametric & direct modeling. So, and “Design Without Boundaries in a multi-CAD World,” by it has more flexibility & precision and is more accessible to Kevin Grayson, Technical Sales Consultant, Siemens PLM users.” Adding further, Say Tiam Go, Vice President—Mid Software. Market Portfolio, Siemens PLM Software, averred, “Larger organisations like Philips Medicals look for solution, where Accelerated modeling process there is only one platform to design. They check how easy is it to migrate the data across. For them, ST8 provides a In the latest release of Solid Edge, improvements to standard CAD platform. It is also beneficial for customers synchronous design intent management, complex sketching with multiple CADs.”

EM | Dec 2015 61 EVENT | REPORT

“We have design centres in Pune, which are responsible for our products. There is a vast The full version of Solid Edge ST8 can be installed on growth in manufacturing & designing tablets running Microsoft’s Windows® 8.1 operating system, capabilities in India” giving users more freedom to design anytime, anywhere. John Miller, Senior Vice President, Mainstream Speaking on the product development strategies, Staples Engineering Software, Siemens PLM Software shared, “We have a product planning & development team of around 15 people, which includes mechanical engineers, “Our product development strategies are based on psychologists and graphic artists. They take care of the themes like how to take synchronous to new level, product development from the core. These strategies are encouraging drafting, especially for sheet metals & creating a comfortable platform for people based on themes like taking synchronous to new level, coming from other systems like SolidWorks” encouraging drafting, especially for sheet metals & creating a Dan Staples, Director, Solid Edge Product comfortable platform for people coming from other systems Development, Siemens PLM Software like SolidWorks.” “One can import disparate types of CAD files Simplifying 3D modeling with synchronous technology. It’s good in interpreting files and reading them, not as Simplification of large and complex assembly capabilities dumb solids, but as actual models that in Solid Edge ST8, combined with its ability to accurately you can manipulate with” simulate and predict kinematic conditions, greatly accelerates John Fox, Vice President—Marketing for Mainstream Engineering Software, the assembly design process and significantly reduces the Siemens PLM Software need for physical prototypes. Also, it offers multi-CAD designs that design faster and intelligently without the “The Indian market has a large workforce constraints of traditional 3D modeling. As per Fox, “ST8 population. So, the professionals can learn the enhances speed. It helps design from concept to market. technologies much faster. Platforms like ST8 will Today, it is important to have global supply chains, where one not only enhance their learning process, but will needs to work with more suppliers. One can import disparate make things smarter for the Indian market” types of CAD technologies with synchronous technology. It’s Say Tiam Go, Vice President—Mid Market good in interpreting files & reading them, not as dumb solids, Portfolio, Siemens PLM Software but as actual models that you can manipulate with.” “With Solid Edge, it is easy to build & model A way forward… components and analyse its behaviour and interactions. Today, I directly start working Discussing the vision of Solid Edge for next decade, on the Solid Edge platform. Modeling things has become easy,” Staples highlighted that as the industry changes rapidly, we Philip Norman, CEO, Ross Robotics have to be flexible to change with it. “There are many developments happening in areas of cloud and Additive Manufacturing today. For defining our vision, we start from the core basis, i.e. being in sync with mechanical engineers and designers. Synchronous technology came to the picture only when we were done with CAD. However, drawings are scale naturally with display resolution & have an easy access still important. Also, sheet metal will get deeper with time. to Solid Edge UI. For part modeling, it will modify multiple We will respond to Additive Manufacturing and cloud in a bodies using a single feature and have solid sweep, which can customer-oriented way. CAD is ultimately about the sweep a solid along a path to generate cutouts or protrusions. productivity at engineer’s desktop,” he concluded. In addition, for sheet metal modeling, a sheet metal clash in While wrapping up the two-day event, a sneek peek on flat will be available to warn when plates clash in flat pattern. ST9 was presented, which displayed that the next version will There will also be a Teamcenter tab on CommandRibbon to have customisation & preference management and support provide direct & easy access to commands and enhance for high resolution monitors in which Solid Edge UI will learning experience of users.

62 EM | Dec 2015 REPORT | EVENT

Revamping robotic dynamics

Using Solid Edge from Siemens PLM Software has paved the way for many start-ups across the globe. The case study discusses how Ross Robotics has re-invented the way specialised service robots are designed, developed and used.

Powered by new technology, robots are becoming cheaper, Large Hadron Collider, just outside Geneva has a very large smarter and more autonomous. As a result, more robots are amount of sophisticated equipment that needs to be monitored being deployed beyond the automotive factory floor, in diverse & maintained by robots, rather than people. Our robot system market segments like defense, agriculture and logistics. These is largely non-metallic & non-magnetic as it is built using a so-called service robots, often used to tackle dull, dirty, or hybrid plastic, non-magnetic metallisation process and can dangerous jobs, comprise one of the fastest growing segments operate in extremely harsh conditions in the Collider,” explains of the robotics industry. The International Federation of Philip. Robotics reports that technology-driven start-ups are stepping Speaking further on his robots, he says, “One of our robots up to meet the growing demand, representing 15% of the has performed remote monitoring in the CMS experiment – companies in this segment. this is the experiment that captured the Higgs Boson equipped with cameras, LiDAR scanners and a number of other Configuring robots faster specialised sensors. The robot is now autonomous and can, therefore, operate without requiring a human controller.” Philip Norman, CEO, Ross Robotics, has developed what he calls the world’s first and only modular robotic system – a Towards advanced technology platform that enables companies to configure application specific robots faster and more efficiently than traditional In the early days of his business, Philip designed with pen approaches. Ross Robotics’ platform includes numerous and paper, but, now, is a daily user of Siemens Solid Edge patented design elements. One is a coaxial physical/power/ software. He understands the critical role that affordable data connector – just plug and twist to connect both power and engineering software has played in the success of his venture data stream. Another involves bio-mimetic traction devices helping him design products as well as communicate complex that enable robots to scramble through dense brambles, up and ideas to customers. “We use Solid Edge as a rapid development down stairs and even swim. Philip sees potential for their tool to design the visuals and produce the real devices we application in relief work, in the oil & gas industry or in deliver to customers,” he shares. He also recognises the unique security, among other sectors. advantages provided by Solid Edge’s synchronous technology, One of Philip’s robots, heavily modified, is operating at the which he describes as “a curious combination of extreme largest particle physics laboratory in the world for the European accuracy and extreme fluidity.” ☐ Organisation for Nuclear Research, known as CERN. “The Courtesy: Siemens PLM Software

EM | Dec 2015 63 FACTORY TOUR | REPORT

Building strong export market

Taiwan has grown rapidly over the decades by focusing on export- led, higher-end electronics and tech industries. Mechanical industry, the country’s third largest industry segment accounts for more than 80% in the export market. EM was recently invited by TAITRA to have a visit on the Taiwan machine tool industrial facilities to witness the core competence of the industry. Maria Jerin Features Writer A factory tour report… [email protected]

What is impressive about Taiwan is despite being small industry has been identified as Taiwan’s 3rd largest industry (with a population of 23.4 million) and the extent of its after semiconductors and optoelectronics. diplomatic isolation, the country has managed to build a The country is now the world’s fourth largest exporter of strong economy on the back of technology and innovation. It machine tools and it is expected to be ranked third in the has one of the most evolved scientific and technological coming years. Most of the machine tools rolled out in local infrastructures in the world. Taiwan today is the global hub of factories are exported to one of the 138 markets overseas. To the semiconductor and electronics industry. According to the witness the success factors of this machine tool industry, Taiwan government’s plans and forecasts, the mechanical Taiwan External Trade Development Council (TAITRA)

64 EM | Dec 2015 REPORT | FACTORY TOUR

recently organised a week-long factory tour to explore the surface is precision hand scraped to increase the flatness and country’s world-class industry cluster, very well linked supply improve geometric accuracy. “The factory floor is chain, the industry’s stable quality, fast lead time and reasonable incorporated with skilled engineers for scrapping to make price. The visit included eight companies, who are specialised accuracy in the component. The hand-scraping process is in different product categories: SHIEH YIH Machinery (SEYI), labour-intensive and must be performed by skilled craftsman producers of mechanical presses; Taiwan Asahi Diamond who are trained in the technique,” noted Irene Mao, Sales Industrial, manufacturing diamond tools; Kao Fong Machinery Dept, Section Manager, KAO MING Machinery Industrial. (KAFO), specialising in manufacturing various ranges of Further highlighting the challenges on this, Raoul Su, Sales machining centres, gun drilling machine, moving column Manager, Manford Machinery, noted that too much effort is type; Goodway Machine Corp, specialising in manufacturing needed to draw skilled people into their industry as the various ranges of turning centres; Manford Machinery, manufacturing industry is losing its charm. specialising in manufacturing wide range of machining centres, CNC lathes, tapping centre; Accutex Technologies, producing Enabling business competence cutting edge techniques in CNC wire cut EDM; Quaser Machine Tools that include various ranges of machining Apart from the shopfloor factors, the companies have centres, five-axes machining, ATC tool management system, different product strategies that enable them to have business FMC series; KAO MING Machinery, specialising in a wide advantage. For example, SEYI’s product strategy includes range of machining centres and radial drills. servo technology, total solution application (Turnkey) and application of Industry 4.0. Goodway Machine has the Exploring machininig dynamics business advantage of self-owned key component manufacturing. Talking on her company’s core technology; The ability of Taiwan machine tools to compete with other Rebecca Hsieh, Vice President, Sales Dept, Goodway Machine countries without the support of a strong car industry or Corp, said, “Our product focus includes multi-tasking and huge domestic demand depends entirely on Taiwan’s flexibility turn-key solution for Japanese auto-parts industries. We have and adaptability. Taiwan’s machine tool industry supply chain, produced first live tooling turret in the country. We are also from R&D design to component manufacturing, assembly, developing our own intelligent control system, G.LINC.” In testing and marketing, forms a complete system, thus, giving similar way, Accutex Technologies develops its own controller the industry an advantage. The shop floors are clean and well for its wire cut EDM machines. Highlighting his company’s maintained with skilled technicians and contract labourers. vision of to be 3rd largest wire cut EDM supplier in the world, Most of the critical machining components are machined by Ray Liang, Vice President & CEO, Accutex Technologies, said, Japanese machines. “The mother machines are mainly from “Our quality strategy is in ICT technology, circuit test and Japan that includes Mitsubishi, Mazak, etc,” said Jason Yu, PCBA inspection technology. We have also developed our Senior Sales, Operation Director, KAFO. own application, Accutex Remote Monitor, for Industry 4.0. The core components of the machine such as spindle, We are spending 9.6% of our revenue in R&D, which is much machine bed and bearings are assembled with high level of higher than the average global standard.” He also averred that precision and accuracy. Pointing out this, Rock Liao, their competence is in research and not in sales. President, Quaser Machine Tools, said, “All core components Adding his company’s role on R&D, Liao of Quaser said, are precisely assembled in a constant temperature controlled “We have invested in advanced research & development tools room, which possesses higher assembly quality and such as new generation of CAD software and finite element technology integration of machines than general competitors analysis simulation software for machine design. Our in the market.” During the whole assembly, every contacting cooperation with international research partners in the

EM | Dec 2015 65 FACTORY TOUR | REPORT

Kao Ming Machinery professional is explaining about the employee skills matrix

development of advanced motion control, high speed spindle competence factor is in Europe with around 30% market technology and thermal & vibration damping properties share. Manford Machinery has sold over 100 machines to the enables it to create innovative high speed & high performance USA government. machine designs.” The company’s strategy is in incorporating On a highly focused note, Quaser exports 60% of products automation and producing mill-turn combination machines. to the European market. Speaking on the quality factor, Liao It also offers cell automation system for skill engineer said, “Our competency with the German standard is because shortage. In general, the Taiwan machine tool industry is of our machine design and its assembly processes to extend producing matured five axis machining technology with high the life-time of spindle. We have our sales & service subsidiary level and more flexibility. Explaining further, Irene Mao in Switzerland to cater to Western Europe market. Our added, “Taiwan’s greatest novelties are improving the location competitors are mainly from Japan, Europe and North of change head for 5 face machines. It can increase X travel as America.” KAO MING Machinery Industrial’s main market is well as the change speed for head.” in USA, Germany and China with 30% market share each.

Market share – region Market share – user industry

Interestingly, despite the political conflict, Taiwan Machine tools are used by producers of many industries companies are one of the largest investors in Mainland China. to make a virtually endless range of products. Recent Many Taiwan companies have their subsidiaries in China to technological innovations have given rise to many potential meet the huge local market. As for Mainland China and end-user markets, and with it, new opportunities and emerging countries in south-east Asia, central & South challenges for Taiwan’s machine tool industry. Speaking on America, Taiwan’s exports mostly consist of machining the opportunities, Chou said, “We have firmly established centres & metal forming tools. Taiwan Ashai Diamond the position in the global automotive supply chain with the Industrial’s main market is Asian countries with 63% market sale of large tonnage presses in the range of 2400 ton. Leading share. SEYI has established XIE YI TECH MACHINERY automotive OEMs as well as many global tier 1 & tier 2 auto (CHINA) subsidiary company in Dongguan, China. Speaking suppliers are now among the company’s key customers. Our on the global performance of his company, Thomas Chou, products also find applications in metal hardware, home Vice President, Sales & Service Division, SHIEH YIH appliances, 3C components and transportation.” While Machinery Industry, said, “In USA, since past 2 years, the highlighting the challenges, Dr Ming-Shong Lan, Chairman, market is booming. Even some automobile factories from Taiwan Asahi Diamond Industrial, mentioned that they want China & Japan have moved to USA & Mexico. We also have to have more market share in automotive industry because SEYI-America branch office in Tennessee, USA, to serve this the electronic industry fluctuates often depending on demand market. In Europe, we have sold over 300 presses.” In the which is not in the automobile industry. The company’s main exports to more advanced nations in Western Europe and market is in electronics industry with around 80% market USA, lathes comprise a significantly high percentage, whereas share in making of TFT-LCD for Taiwan, Korea and Japan. metal forming tools are considerably lower. Meanwhile, The Taiwan machine tool industry is facing tough machining centres have long established their position as the competition from its Italian and Korean counterparts, market mainstream. KAFO’s global market is mainly in the especially in the mid-end market segment. In an attempt to USA aerospace industry. Goodway Machine’s great gain greater market share, some Taiwanese producers take on

66 EM | Dec 2015 REPORT | FACTORY TOUR

SEYI professionals with TAITRA representatives and journalists during the visit of Taiwan machine tool industrial facilities

niche market through intensive market study and diversified India. But now, we are facing tough competition from India’s strategies. Speaking on this, Liang said, “Few years ago, our local turning centre makers where they have advantage in machines were used only for making parts in moulding terms of price & service.” industry. Now, parts are also made for aerospace & medical Some of the Taiwanese companies have partnered with industry as well.” KAO MING Machinery Industrial’s major Indian distributers to sell their machines. For example, market distribution is in automobile and aerospace industry Accutex partnered with Electronica group to sell their wire with nearly 50% shares each. The company is also supplying cut EDM machines and Manford Machinery has collaborated machines to defence market in China. Goodway Machine’s with S&T Engineers to sell their machining centres. “The products find application in automotive, precision parts, 3C performance in India, through the agent is about 20 machines components and optronic. every month,” added Raoul Su.

Market presence in India The way forward…

Though Taiwan’s machine tools exports to India are According to a trade report by the Department of growing, it is still finding many challenges to increase its Commerce, Ministry of Commerce & Industry of India, market presence in India due to limitations from Indian Taiwan is among India’s top five machine tool suppliers in government in terms of policies & guidelines, Indian rupee 2014. Trade between India and Taiwan is increasing rapidly value depreciation, higher import duties of machine tools with Taiwan’s machine tools exports to India growing by & accessory components and lack of infrastructure. Speaking 11.6% in the first two quarters of 2015 (January to June). on the current situation in India, Jack Chen, Senior Manager, This comes in the wake of the overall Taiwan–India bilateral Sales Department, SHIEH YIH Machinery Industry, was trade touching US$ 2.108 billion in the first five months of optimistic and he further briefed that their automotive tier 2015. Taiwanese exports to India contributed USD 1.28 1 to tier 3 are looking for a boost in manufacturing. “We are billion, while imports from India touched US$ 828 million. expecting good business orders in the upcoming IMTEX Taiwan’s machine tools export to India grew 10% in the first 2016, where we will be exhibiting our innovation in large five months of this year. The country has exported US$10.12 tonnage presses,” he said. Dr Lan opined that India is lacking billion of machinery, including US$1.64 billion of machine when it comes to road and rail network. “It takes a plenty tools in the first six months of this year. The production value of time to transfer goods from one place to other,” of Taiwan’s machine tool industry is expected to increase he emphasised. 1.3 -1.5% by 2017. Most of the Taiwan machines are sold to India by agents India’s huge domestic market is a big attraction. Taiwan’s and dealers. Explaining this, Jason Yu noted, “We have our hardware & technology strengths and India’s software power mould & car industry key customers in India like Motherson, and recent thrust on manufacturing can make them ideal Maruti-Suzuki, to name a few. We are selling an average of 30 partners. Taiwan companies are looking at manufacturing in machines in India every year. In recent months, we have India equally encouraging. It will help India build its received business orders from Honda plant, Mumbai, where manufacturing base in an area that is high-end and has we will be supplying our gear hobbing machines.” While enormous potential. India and Indian companies could learn explaining her company’s performance in India, Hsieh added, a lot about building innovation and technological backbone “Twenty years ago, we found our machines were selling in from Taiwan. ☐

EM | Dec 2015 67 TECH | TALK Vibrations on CNC machines

Vibration problems during machining process generally result in G V Dasarathi noise, bad surface quality and sometimes tool breakage. The column Director – Applications Cadem Technologies talks on what causes these vibrations, and how they affect the part. [email protected]

Machining vibrations, also called chatter, correspond to the relative movement between the workpiece and the cutting tool. As the spindle and axes motors rotate on a CNC machine, there are numerous parts vibrating at the frequencies at which these motors are rotating. These vibrations result in waves on the machined surface and also affect machine bed and spindle housing. The spindle is vibrating in its bearings, the bed is oscillating up and down on the floor to which it is bolted, the turret is making angular movements about its axis of rotation and the various axes are making linear movements. Let us take an example of a small experiment, if one is Cadem Technologies trying to shake his right hand violently, as if shaking off water from it, one can observe the other parts of body shaking too –chest, shoulders, other arm and legs. They will all shake Image courtesy: (vibrate) at the same frequency as the right hand. Because of the damping effect, the farther away a part is from the The vibrations result in waves on the machined surface and also right hand, the less its amplitude, but its frequency will be affect machine bed and spindle housing the same. Damping is the effect of absorbing vibrations, and all the soft flesh and water (75% water) in the body is good The design of the various structures and the material used in for damping. them dampen vibrations. All this leads to reduced amplitude The same phenomenon works in a CNC machine. The of vibrations between the tool & the workpiece. most violent shaking happens close to the sources of vibration In the market, we find same range of CNC machines but (spindle, axes, tool changer, etc) and their amplitude reduces costing between X and 5X depending on the manufacturer. as one goes away. Finally, the tool vibrates against the part, We wonder why there’s so much difference, and often say “Ah, and this causes poor dimensional accuracy, poor surface those guys are just charging for their big brand name”. It’s not finish and poor tool life. that. The price is higher because of better bearings, better On a well-designed machine, the quality of bearings and material, better design, etc. This gives you closer tolerances, various mating parts reduces the amplitude of vibrations. better surface finish, better tool & machine life. ☐

68 EM | Nov 2015 NEWS | TECHNOLOGY

Drilling tools Flexible clamp cables

Dagger Master Tool Industries developed universal drills for reliable Extech Instruments offers two flexible drilling in a variety of materials ranging clamp cables with Model CA3010 — from titanium to copper & steel. Universal 10" (25.4 cm) and Model CA3018 — series lines of the company offers 18" (45.7 cm) that allows meter’s machinists reliable drills that ideally capabilities to measure AC current up cover standard applications at an to 3000 A. The features of the flexible excellent value for money – precise clamp cable include 7.5 mm cable machining and good surface quality diameter that fits into tight spaces and included. The product line provides around large conductors. It measures appropriate universal tools for drilling of AC current in three ranges. It has easy steel, cast iron, stainless and highly twist clamp cable closure to lock or alloyed steel as well as non-ferrous Universal drills open. It is compatible with most metals such as copper, brass, aluminium, multimeters and clamp meters with tungsten copper and titanium. The company also offers suitable drills for standard sized banana plug inputs. It is certified with CAT III-1000 V, the processing of plastics. It is specialised in micro tools. Even the CAT IV-600 V category safety rating (for use only with multimeters that smallest diameters belong to their standard product range. To reduce have equivalent CAT ratings). The flexible clamp cable has battery vibrations and, thus, achieve better machining results especially in small capacity indicator that provides battery condition. Its flexible clamp jaw drilling operations, drills of Series 629, 630, 631 and 639 are equipped easily wraps around bus bars and cable bundles where standard clamp with a reinforced shaft. Polished flutes and chipping spaces also ensure adaptors and meters can’t. The complete pack includes 6.6 ft (2 m) lead a good chip flow. All these features result in a superb surface quality. with banana plugs, and two AAA batteries. Dagger Master Tool Industries | Mumbai FLIR Systems India | New Delhi Email: [email protected] | Tel: +91-22-2494-3840 Email: [email protected] | Tel: +91-11-4560-3555

Smart 3D sensors Tribological filaments ifm electronic introduces the new 3D O3M151 smart sensor that opens igus with a selection of four tribological filaments and the 3D print service, up new possibilities for vehicle automation and new assistance functions offers customers the possibility to print maintenance and lubrication-free for automation tasks. The company’s 3D sensors are based on its patented special parts and small series. For the company, Additive Manufacturing photonic mixer device technology (PMD) for fast distance detection. The is one more step to give the design engineer the greatest possible new 3D O3M151 smart sensor freedom in construction with lubricant- and maintenance-free plastics. was specifically designed for The company has already outdoor use and difficult introduced the world's first ambient light situations, thanks tribological filament for 3D to the protection classes IP 67 printers last year, and has and IP 69K. Big or small now expanded the series to a obstacles, uphill or downhill: it total of four materials. Since always keeps an eye on the Hannover Messe, it has everything. Bright or changing also offered a 3D print service. light is no longer a problem for Customers can turn to igus the 3D sensor. The O3M151 has O3M151 with their 3D data and have Tribological filaments & 3D print some integrated functions that their parts printed quickly and can solve different applications. A highly developed algorithm from the without complications. Delivery times for printed parts depend primarily automotive industry is used ensuring, for example, reliable automatic on the complexity of the components; still, here too the goal is delivery object recognition of up to 20 objects. This function can be used as within 24 hours. With high-performance plastics and additive collision warning, for example. For simple distance tasks typical functions manufacturing, two modern technologies which combined promise such as minimum, maximum and average distance are available. maximum freedom in construction and high abrasion resistance meet. ifm electronic India | Kolhapur igus India | Bengaluru Email: [email protected] | Tel: +91-231-2685920 Email: [email protected] | Tel: +91-80-45127810

EM | Dec 2015 69 TECHNOLOGY | NEWS

Centring points for drill bits Shoulder milling tools

KOMET GROUP has developed a choice of two new centring points for Pramet has expanded its popular shoulder milling range with a new the KOMET KUB Centron® Powerline core bit drill which, with its program of cutters, geometries and inserts. This includes a program of multiple cutting edges, enables helical cutters for roughing high feed rates and, as a result, applications. Offering a depth of short production times. The cut up to 108 mm, the cutters are centring point is a crucial element suitable for use with Pramet’s of the KOMET KUB Centron® versatile ADMX 16 inserts and Powerline. It guides the tool support medium machining of most precisely along the drilling axis, engineering materials including ensuring dimensional accuracy, cast iron, stainless steel and straightness and outstanding Helical milling cutter aluminium alloys. The large KOMET KUB Centron® Powerline process reliability at drilling clearance between the cutting teeth, depths of up to 9xD. The core bit combined with internal coolant delivery, promotes efficient chip has two or, depending on the diameter, more than two quatron indexable evacuation. The axial clamping of inserts on the end teeth increases inserts, which provide a high level of stability and optimal chip milling stability. This creates less noise and vibration which, in turn, also evacuation. The cutting distribution on each side allows short chips to reduces tool wear. For use with shoulder milling inserts ADMX11 and be produced even when using materials that are extremely difficult to ADMX16, as well as the LNGX12 range, the new geometries’ positive rake machine. The four cutting edges per indexable insert, various substrates angle provides low cutting resistance, reduced cutting forces and and coatings and tailoured topographies for excellent chip control, soft less power consumption. As part of the launch, two new positive cutting action, etc. allow for a long tool life. geometries – MF and MM – have also been added for milling. KOMET Precision Tools India | Bengaluru Dormer Pramet | Gurgaon Email: [email protected] | Tel: +91-80-6772-8000 Email: [email protected] | Tel: +91-124-470-3825

CAD/CAM sheet metal software Compact mechatronic module

Radcam Technologies offers the latest version, Radan 2016 sheet metal SCHUNK has developed ERS rotary modules for rotary movements in software solution developed by Vero Software, UK. Radan 2016 provides the medium load range. The currently most compact mechatronic rotary an environment where the module on the market is available in unit size 170 with a height of 66 conversion of 3D assemblies to 2D mm, achieving a nominal CAD drawings can be done with moment of 5 Nm, and a customisable parameters that too maximum moment of up to with a single click of the mouse 17 Nm. It is used for button. The 3D environment implementing flexible and supports all global formats like compact system concepts. STEP, IGES, SAT, Parasolid, etc. and The core piece is a torque also provides a unique feature of motor with a hollow shaft. It fly-through mode that allows the is light-weight and compact, user to see inside an assembly. The ERS rotary modules and is absolutely wear-free, documents that can be generated making it very reliable. It can Radan 2016 in Radan have been revisited and endlessly turn up to 250 rpm to any intermediate position at a repeat they not only include the nest accuracy of 0.01°. In contrast to rotary modules with a conventional reports containing critical information such as part weight, part area, and servo motor, the ERS has no additional interfering contours and no cycle timing but also the bill of materials and now they can be customised elasticity. This long-lasting module from the company convinces with easily. The latest version of Radan provides an update on the auto tooling high acceleration, swiveling speed, and precision. On request, an feature with which the user can now tool specific areas of the part, thus, integrated pneumatic holding brake ensures that individual positions further increasing the tooling efficiency. can be reliably fixed. Radcam Technologies | Bengaluru Schunk Intec India | Bengaluru Email: [email protected] | Tel: +91-080-4200-7936 Email: [email protected] | Tel: +91-080-40538999

70 EM | Dec 2015 NEWS | TECHNOLOGY

Face milling cutter Laser processing machine

Seco Tools offers its general-purpose Quattromill face milling cutter in EWAG introduces a new laser processing machine, the LASER LINE a new close-pitch version. Thanks to a special patented centre-locking PRECISION for modern tool manufacturers to get started in laser technology. insert screw design, the new face mill puts more teeth/inserts in the cut The latest short pulse fibre laser for higher feed rates, improved surface finishes and increased technology used in the green wavelength productivity. Instead of locking from the range (532 nm) offers highly efficient front, the company’s innovative insert machining results for the commercially screw locks/operates from the back of the available diamond cutting materials insert pocket, eliminating the need for such as CBN, PKD and CVC-D. wedges or other extra parts and Rotationally symmetrical tools of up to accommodating more inserts per cutter 200 mm diameter and up to 250 mm diameter. Additionally, the company length as well as indexable inserts from significantly increased the density and 3 mm inscribed diameter and up to 50 strength of the Quattromill close-pitch Quattromill mm circumscribed diameter can be Laser line precision cutter bodies. Quattromill face mills are machined without force with the LASER free cutting, feature positive cutting rake / negative radial rake LINE PRECISION. The unique and patented ‘Laser Touch Machining’ geometries and accommodate a wide range of standard inserts for all machining process offers excellent surface quality, even on tools with workpiece materials. And due to their cutter geometries, the face mills complex or delicate geometries. Any cutting contours, clearances and 3D excel in both stable and unstable machining conditions. With the machining of chip breaker geometries can be performed in one clamping company’s new close-pitch development, Quattromill boosts feed rates operation. The resulting flue gas and the vapourised material are suctioned and overall milling performance. away and carried to a corresponding suction/filter system. Seco Tools India | Pune United Grinding India | Bengaluru Email: [email protected] | Tel: +91-2137-667406 Email: [email protected] | Tel: +91-99-8013-8897

Pneumatic drive machine Precision hardened & ground flanges

Suhner now presents a set of instruments in the form of the new Wendt India has developed new pneumatic drive machine LRC 20 precision hardened & ground and the matching VSC extension flanges that are ideally suited for system to reach the deepest both conventional and super corners. The new system can also abrasive wheels. In the pursuit to grind, mill, and polish places that excel the performance of super previously could be accessed only abrasive wheel it is important that with great difficulty: in the distant the wheel is mounted, trued and Precision hardened & ground flanges corners of impellers or the insides balanced on the flange before of narrow pipes. The new drive LRC 20 mounting on the grinding machine. The company makes customised flanges machine LRC 20 gives you 20,000 to suit various makes/models of grinding machine may it be surface grinder, rpm to work with in your hand. At the same time, it is extremely slender cylindrical grinder, centreless grinder, creep feed grinder and other similar and manoeuvrable, and fulfils all safety, ergonomic, and energy machines. The flanges are manufactured from alloy steel case hardened and efficiency requirements. And it is pleasantly quiet. Even under full load, 58+2 HRC for its longevity and maintaining the precision. The flanges are the sound pressure level is only 69.5 dB. A centrifugal governor made in diameter ranging from 100 mm to 500 mm. Larger diameter is also regulates the speed to such precision that it saves about 20% of the made depending on the customer requirement. In order to ensure accuracy of compressed air needed for conventional technologies. The exhaust air the grinding system from the locating taper of flanges and the flat surfaces, is directed backwards, protecting the work surface from lubricating oil they are precision ground with surface finish of 0.4 μRa. The face and radial and reducing noise levels even further. The system comes with matching run out are maintained within 10μ, generally for precision flanges it will be extensions that can be attached to the machine for each application. within 5μ. The flanges are blackened for corrosion resistance and dynamically Only 13 mm in diameter, the extension elements are very thin. balanced prior to dispatch. Suhner India | Bengaluru Wendt India | Bengaluru Email: [email protected] | Tel: +91-080-2783-1108 Email: [email protected] | Tel: +91-94433-27680

EM | Dec 2015 71 HIGHLIGHTS | COMPANY INDEX | IMPRINT

Highlights - Jan 

IMPRINT

Publisher / Chief Editor Shekhar Jitkar [email protected]

Features Writer Megha Roy [email protected]

Features Writer Maria Jerin [email protected]

» Composite machining » CAD/CAM » Sheet metal working Advertising Sales Composite parts are finish machined by CAD/CAM is used in firms that are Sagar Tamhane Modern sheet metal technology allows for (Regional Head - North & East) way of turning, milling, slitting, drilling, involved in producing consumer pinpoint accuracy and low-cost production Contact: +91 9820692293 routing, etc. However, our knoweldge of electronics, electronic components, of virtually any material in virtually any [email protected] machining conventional materials like moulded plastics and a host of other shape. For all jobs, be it individual parts or aluminium, steel or cast iron cannot products. The next issue highlights new large-size orders, today, state-of-the-art Dhiraj Bhalerao be directly applied since the basics of developments in the CAD/CAM technology, laser technology, high-performance IT (Regional Head - West & South) Contact: +91 9820211816 machining action and machineability of which facilitates communication among control and intelligent logistics are very [email protected] composites completely differ. Associated those involved in design, manufacturing important. This allows mastering even the critical aspects must be carefully and other processes. most complex geometries. In the January Prabhugouda Patil considered for successfully machining issue of EM, we take a look at the best Bengaluru composites and the machine tool employed » Rapid prototyping practices, market trends and technologies Contact: +91 9980432663 should be constructed accordingly. The Rapid prototyping decreases development in the sheet metal working industry. [email protected] upcoming issue highlights these trends. time by allowing corrections to a product Advertising Sales (Germany) to be made early in the process. By giving Caroline Häfner (+49 - 89 - 500 383 - 53) engineering, manufacturing, marketing, Doreen Haugk (+49 - 89 - 500 383 - 27) and purchasing a look at the product [email protected] early in the design process, mistakes Overseas Partner can be corrected and changes can be Ringier Trade Media Ltd made, while they are still inexpensive. China, Taiwan & South-East Asia The next issue looks at advances in rapid Tel: +852 2369 - 8788 prototyping, which will eventually lead to [email protected] improved product development by enabling better communication in a concurrent Design & Layout Jogindar J Dumde (Graphics Designer) engineering environment. [email protected]

Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, COMPANY INDEX Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Name ...... Page Name ...... Page Name ...... Page Tel: + 91 - 20 - 6451 5752 Accutex Technologies ...... 64 Hyundai WIA India ...... Back Inside Cover, Robert Bosch Engg & Business Solutions . 28 Ace Micromatic Group ...... 1 ifm electronic India ...... 55, 69 Rollomatic India ...... 41 Board of Directors Kilian Müller Altair Engineering India ... Front Inside Cover igus ...... 4, 69 Ryder Supply Chain Solutions ...... 38 (CEO - Worldwide) BFW ...... 10 IMTMA ...... 14, 37 Schneider Electric ...... 22 Hanno Hardt (Head - Marketing & Business Development) Blaser Swisslube ...... Cover, 27 India School of Business (ISB) ...... 3 Schunk Intec India...... 70 Frank Wiegand Cadem Technologies ...... 68 Jyoti CNC Automation ...... 5 Seco Tools ...... 39, 48, 71 (COO - Worldwide) Shekhar Jitkar Comsol Technologies ...... 10, 16 Kao Fong Machinery (KAFO) ...... 64 SHIEH YIH Machinery (SEYI) ...... 64 (Publisher / Chief Editor) Dagger Master Tool Industries ...... 69 KAO MING Machinery Industrial ...... 64 Siemens PLM ...... 52, 60 Subscription Delcam ...... 30 Klingelnberg ...... 42 Suhner ...... 71 Cover Price: `100 Dormer Pramet ...... 70 Komet Group ...... 70 TaeguTec India ...... Back Cover, Annual Subscription Price: `1000 [email protected] DP Technology ...... 11, 47 Korloy India ...... 13 TAITRA ...... 64 Tel: +91-20-6451 5754

EDM Productivity Forum (EPF) ...... 10 Manford Machinery ...... 64 Taiwan Asahi Diamond Industrial ...... 64 Printing EMAG ...... 45 Milacron India ...... 12 Tyrolit India Superabrasive Tools ...... 43, Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Fair Friend Group ...... 10 Mitsubishi Heavy Industries ...... 2 United Grinding ...... 14, 71 Femco Machine Tools Manufacturer ..... 51 MMC Hardmetal ...... 21 Vargus India ...... 6 Copyright/Reprinting The publishing company holds all publishing Flir Systems India ...... 57, 69 MotulTech India ...... 33 VDMA ...... 14, 56 and usage rights. The reprinting, duplication Forbes & Company ...... 25 PMT Machines ...... 15, Vollmer ...... 20 and online publication of editorial contributions is only allowed with express Frost & Sullivan ...... 12 Quaker Chemical ...... 17 Wendt India ...... 71 written permission from the publishing Goodway Machine Corp ...... 64 Quaser Machine Tools ...... 64 Yamazaki Mazak India ...... 34, 35, company. The publishing company and editorial staff are not liable for any Grind Master ...... 12 Radcam Technologies ...... 70 YG1 Cutting Tools ...... 18,19 unsolicited manuscripts, photos and Haas Automation India ...... 12 illustrations which have been submitted. Internet http://www.efficientmanufacturing.in

72 EM | Dec 2015 Perfect, Precision, Progressive Machine Technology HYUNDAI WIA Machine Tools pours its whole efforts on every process of production and distribution, covering from self-reliant designing to manufacturing and after sales service.

The next generation affordable The Fastest, the Most Versatile CNC Lathe Vetical Machining Center Highly Efficient Next Generation E Series F Series Horizontal Machining Center HS Series

E160 Series F500D/600D • 45° slanted one-piece high rigidity bed structure • High-precision P4 Angular Contact Bearing main spindle HS Series • Unbeatable rapid travel speed: 30m/min • Dual Tables for high productivity • Heavy Duty Motion Roller Guidways • The most reliable high speed servo turret • Latest Servo ATC for fastest tool exchange in the class • Powerful Dual Wound Spindle Motor is adopted: 0.1sec/step • Latest SIEMENS 828D Controllers for various software • Heaviest Maximum load in its Class support • Compact design, able to install within a • Big Plus Spindle (BBT) narrow space.

Machine Tools Line-Up HYUNDAI WIA India Office • CNC Lathe (Horizontal & Vertical) #4/169, Rajiv Gandhi Salai, (OMR), Kandanchavadi, • Drill Tap Centers Chennai - 600 096, Tamilnadu, India • Vertical Machining Centers Tel. +91 44 3290 1719 • Horizontal Machining Centers • CNC Boring Machines MMMooobbb: +91 9840999094 en.wiamachine.co.kr e-mail. [email protected], [email protected]