Ace micromatic newletter jan 2013

Newsletter

Our Journey with SonaAcemicromatic has started his journey along with Sona in 1987 (Sona Started) with a supply of Hydraulic grinding machines (In name of Parishudh Sadhan Yantra now Micromatic Grinding Technologies) & ACE Auto lathes.

Productivity SummitRecently concluded Productivity Buzz 2012, was a first of its kind event which gave a platform to display productivity solutions in metalworking.

SAAB EngineeringA rising starWhatever is present today in front of our eyes seems simple and easy to operate. How many of us are aware of what all effort and technologies goes into it.

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January 2013

Bangalore is one of thebest cities in India.

PAGE 9 Another feather inMicromatic Grinding hat.

PAGE 17 New website launch for Ace Micromatic

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The largest machine tool group in India

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Ace Micromatic Tech Center at Bangalore

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January 2013

Ace Micromatic Newsletter

CEO SPEAK

SuCCESS StOry: CNC AutOmOtIVE

“The future looks bright. With the advancement of technology, I am sure the Indian machines today, are comparable to the ones manufactured anywhere in the world”, added Mr. Vivek Shah.

SAAB ENgINEErINg: A rISINg StAr

“Man power is the biggest challenge we face today, so we are planning to convert all our units with completely automatic machines so work can be done faster with less workforce”, added Mr. Sanjiv.

CASE Study: tPm-trak®

TPM-trak has advantages like it is a real time data collection leading to online OEE monitoring, it monitors day wise production quantity and downtimes emailed to top management automatically, it increases operator awareness in reducing idle times downtime analysis is done on real-time basis, it analyze the operators wise performance through readily available reports, it also reduces Shop floor supervision.

ANOthEr fEAthEr IN mICrOmAtIC grINdINg tEChNOlOgIES’ hAt

PrOduCtIVIty Buzz 2012

Recently concluded Productivity Buzz 2012, was a first of its kind event which gave a platform to display productivity solutions in metalworking.

thE fAStESt SOlId CArBIdE drIll ON thE mArKEt: COrOdrIll 860

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SONA - BESt mAChINE tOOl SuPPlIEr AwArd

Acemicromatic group has also developed many machines (tooled up for various components) for Sona. Some of the SPM machines are also specially built for Sona (ball burnishing machine from ACE model TNB-45).

COVEr PAgE PICturE

The cover page picture shows a bunch of pressure compensators manufactured at Auto CNC (An Ace Micromatic Group company).

Auto CNC manufactures approx. 7000 pressure compensators per month which are being used for automotive applications. Each pressure compensator is an assembly of 40 smaller components and the entire operation is handled at the plant in Bangalore.

NEw frANChISEE OPENINgS

NEw wEBSItE lAuNCh

A new website has been launched for Ace Micromatic: www.acemicromatic.net

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Editor: Ankur Agarwal

Sub Editor / Correspondent: Ms. Khubi Sharma

design: Studio Xalt, Bangalore

Printed at: Repromen, Bangalore

Contributions: Aravind HV (Pioneer CT), Vijay Nilatkar (Sandvik)

Disclaimer: Edited, designed and printed on behalf of Ace Micromatic Group. The design, pictures and content used in this publication are intellectual property of the group. No part of this publication may be reproduced or transmitted in any form without the prior written consent of the editor.

Efforts have been made to keep the information in this brochure as much correct as possible. However, the editor cannot be held responsible in case of any discrepancies found in the data.

If you have any interesting story/event/contribution to be shared or any questions, please get in touch with the editor at [email protected]

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January 2013


Ace Micromatic - India’s Largest Machine Tools group with a rich heritage of over three decades, twenty three thousand plus machines’ working globally are striving continuously to make a difference to your business and it’s Productivity. Our business revolves around your business to positively impact our mutual growth and success. This revamped newsletter is an initiative to bring to our customers and the metal cutting industry our learning’s and a platform to celebrate customer success stories globally.

The criteria for machine tool selection and application is changing, just adding machines to produce more and increase capacity is not the way, blindly going in for advanced high cost technology that works elsewhere may not be the most effective approach. Also while new machines & technology is important, it must be partnered with strong commitment to customer success from the people supplying the machines. The key is long-term business partnerships where we work together with customers to generate creative solutions for improving productivity, machine utilization, and overall manufacturing capability cost effectively to suit local needs. We see a big role in partnering companies to improve productivity and differentiate from their competition.

In this issue of our newsletter we highlight intelligence that can be added to manufacturing using our TPM-Trak, share a few customer success stories, other customer events and developments that have happened across the group. We hope you find value from this publication and eagerly look forward to your feedback to help us make this effort in true synergy with you. Happy reading.

T.K. Ramesh CEO Micromatic Machine Tools Pvt. Ltd.

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CNC Automotive manufactures variety of parts some of them are assembled here itself and some of the finished parts are delivered directly to the customers.

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January 2013


Today no one likes to waste time in travelling. Engineers are looking for the means of transport through which time and money can be saved. Every month a new car models are being introduced in the market with some new technology that increases competition in the market.

There are many questions which are not answered about the different phases of manufacturing in India. While searching for these answers we came across Mr. Vivek Shah of CNC Automotive, who owns number of manufacturing cells in different parts of Bangalore. It’s interesting to know that Mr. Vivek is the second generation to run CNC Automotive.

Shah family came to Bangalore from Gujarat many years back. Two brothers Mr. Jayant Shah and Mr. Mahesh Shah, who are brothers, started their manufacturing unit in Peenya in the year 1969, in which they started with plating and then added manufacturing components to increase their business. Each unit produces a family of parts. Every unit works individually.

“Bangalore is one of the best cities in India; it welcomes people from every walk of life and opens the gates of opportunities for all. In terms of manufacturing also it has become very advanced and provides good national and international market for sales of the Indian goods. It has lots to discover and we are still in process of discovering it through our manufacturing means”, said Mr. Mahesh Co Founder of CNC Automotive.

Mr. Vivek shared with us “The first machines we used were from Ace Designers, because their machines are affordable, convenient and provides good service. However I would expect them to go into better technology so that we don’t have to depend on the machines which we are importing from other countries.We have the potential to produce advanced machines which can give competition to Chinese machines”.

CNC Automotive have more than 150 Ace designer machines in all their manufacturing cells. The major models

which they use are Cub, Jobber XL, Jobber Jr, Jobber, LT 16, MCV 300 and MCV 400. With these machines they produce around 1.5 million components every month which are delivered to the different parts of the country.

They manufacture variety of parts some of them are assembled here itself and some of the finished parts are delivered directly to the customers. They manufacture Automotive components, Precision Automotive Components, Dia frame, Air Filters, Pump Plungers, Holders, Housing covers, and Valve Holders etc. These parts are used in fuel injection pumps, CNC Automotive’s clients are Hydraulic Companies, Bosch, Delfied, TACO etc.

“The future looks bright. With the advancement of technology, I am sure the Indian machines today, are comparable to the ones manufactured anywhere in the world”, added Mr. Vivek Shah.

- as told to our correspondent Ms. Khubi Sharma.

SuCCESS StOry CNC AutOmOtIVEBeing the second largest populated country and the largest democracy in the world, India stood very firm in the industry of manufacturing. Every day around 10,000 children take birth in India; from this figure we can imagine what will be the demand for all kinds of goods used in everyday life. Ever increasing populations and need of the people have put enormous pressure on the manufacturing industry to meet the increasing demands.

Parts manufactured by CNC Automotive Parts manufactured by CNC Automotive

Ace Machine used by CNC Automotive

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SAAB Engineering manufacture automobiles parts which includes Starters, generators and pulleys.

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January 2013


Each and every tangible thing we need in our daily life is a result of gradual and number of steps which are combined together to make it work. How many of us have given a thought to how do all this comes into being. Every question has an answer. Let’s find out some of them.

SAAB Engineering is a manufacturing unit located in Bangalore Karnataka. They are one of the key customers of Ace Micromatic. SAAB has four units in Bangalore, three in Bommasandra and one in Jigani. These four units have more than 90 turning machines from Ace Micromatic Group.

In a conversation with Mr. Sanjiv Balagopal, founder of SAAB Engineering.He shared his experience working on Ace Micromatic machines. He said “I and my brother Ajay started this business with one machine as a workshop in Frazer Town, then slowly and gradually shifted to Bommasandra. At a time when there were very less opportunities for growth we started with 20 thousand rupees of investment. In 1995 we bought our first CNC turning Machine from Ace Micromatic Group, the LT 16; that was the time we came across the excellent function of these machines and till date we have a preference of turning machines from same

brand. We manufacture only automobiles parts includes Starters, generators and pulleys”.

SAAB Engineering manufacture around 1.2 million parts a month. They not only cater to the Indian market , but also export 25% of their turn over to the Bosch plants located in the countries like South Africa, Brazil, Bulgaria, Germany, Spain Etc. Their key customers are Bosch, Maruti, Hyundai, Valieo, Penso, Suzuki etc.

Other preferred machines by SAAB are milling machines, grinding machines, single milling turning machines, and

SAAB ENgINEErINg A rISINg StArWhatever is present today in front of our eyes seems simple and easy to operate. How many of us are aware of what all effort and technologies goes into it. When we see a car moving on the road we can only see the brand and the model name, there are hundreds of spare parts which contributes in making it run on the road.

SAAB Engineering’s manufacturing unit

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jobbers from Ace Micromatic Group. “To be honest we chose these machines because they are automatic and trouble free. Today the major challenge we face is the skilled man power, Ace machines help us in overcoming this problem as one man can handle multiple machines at the same time”, said by Mr. Sanjiv, Co-founder of SAAB Engineering.

Mr. Sanjiv further added that their business has grown eventually in last ten years, today SAAB Engineering gives competition to the brands which were doing well ten years ago. They have made firm position in the market and also made their mark in the industry. As per their customers demand they have started importing iron as the raw material, established cold forging sections in unit 3, and heat treatment in their plant itself. “Customers want products

on a turnkey basis, so to serve them better we are providing end to end solutions including the finished product under one roof”.

SAAB Engineering is very well organized and focussed about their future plans. They are in market for pretty long time and very well aware of the demand and supply of market, their experience in the market helps them in understanding the market patterns and accordingly the projects are designed.

“As I mentioned before man power is the biggest challenge we face today, so we are planning to convert all our units with completely automatic machines so work can be done faster with less workforce”, added Mr. Sanjiv.

- as told to our correspondent Ms. Khubi Sharma.

Parts manufactured by SAAB Engineering

Parts manufactured by SAAB Engineering

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January 2013


March 1st 2012 saw the launch of CoroDrill 860 the fastest solid carbide drill on the market for steel drilling.

This drill is a top performer for conventional drilling, chamfered holes, inclined surfaces, cross holes, stack drilling and convex/concave surfaces. With excellent chip evacuation control, when using high cutting data in long and short chipping materials, the drill provides consistently problem free drilling at high penetration rates.

The new unique geometry combined with the new flute shape provides a cutting edge shape for effective clearance of the chip, even at increased penetration rates.

Low cutting forces give you fewer problems with weak fixturing, thin walled components and loads on the cutting edge.

The drill comes in lengths 3-8xD as standard.

thE fAStESt SOlId CArBIdE drIll ON thE mArKEt COrOdrIll 860

Sandvik Coromant is a world-leading supplier of cutting tools and tooling systems for the metalworking industry and is represented in 130 countries. 25 state-of-the art Productivity Centers located around the world provide customers and staff with continuous training in tooling solutions and methods to increase productivity. Sandvik Coromant is part of the Tooling business area of the Sandvik Group.

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Established in 1974, SAF is a pioneer and the largest manufacturer and exporter of Cold Forged/Cold Extruded Steel and Aluminium Components in India. SAF has State of the art in-house tool room, has a Self-Developed Forging Technology exporting to NA/EU Tier1 customers since 1998,has its Offices & Warehouses in North America & Europe, funds Debt free – New Projects from internal accruals, Design, Assembly and Testing capacity – Scaled up as Tier1, produces Captive SPM Design & Manufacturing Division, Diversification into Non – Auto Sector. SAF manufactures auto electrics parts, drive line parts, suspension and steering parts, brake parts, and power transmission parts.

AceMicromatic has been a trusted partner for Super Auto Forge for more than 30 years. Hundreds of AceMicromatic machines are in operation at SAF as well as its vendors.

Being able to compete and sustain in face of global competition means strict adherence to on-time delivery, excellent quality and cost-competitiveness. This quest for competitiveness led SAF to focus on improvements in its internal processes at their MEPZ plant.

Flow Chart showing CNC machines usage at MEPZ

This flow chart depicts flow of material through the cell, including final operations such as welding, washing, in addition to standard CNC operations.

It was observed that the output from the CNC machines was low and more shifts were required for these machines compared to the other processes like piercing, welding and assembly in the line. It was thought that productivity was being lost because of offset correction, turret play, down time, idle operator etc.

In 2010, SAF had implemented TPM-Trak on dozens of its stand-alone CNC machines, and seen dramatic improvements in outputs and OEE.

Winner of multiple prestigious awards, TPM-Trak® from PioneerCT (AceMicromatic group) is India’s leading real-time OEE and machine monitoring framework that works with virtually any production machine, or assembly stations. Data for every part produced, stoppage of machines, hourly, shift/day based production data and OEE can be easily accessed automatically by email, SMS, or computers.

In 2012, SAF chose to implement TPM-Trak® on machines at the MEPZ cell, for getting detailed production and downtime information, based on which they would be able to pin-point issues and take up corrective action.

Actionable data and dashboards from TPM-Trak were made available to operating personnel and decision-makers on their computers and laptops over the LAN. It also helped to increase awareness amongst operators and supervisors.

CASE Study tPm-trak®

Every country’s future has significant dependence on its manufacturing industry. A robust manufacturing industry significantly contributes to a country’s import and exports, which in turn expands the growth rates and GDP; hence it is very important for manufacturing industry to be healthy and highly productive to be able to compete in the world market.

Super Auto Forge Limited (SAF) has set such an example by achieving focused productivity improvements in their Chennai Plant in India.

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January 2013


After implementation of this software following were the changes that came into being.

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Some of the key improvements driven lead to:

• Output increased from 350 no. to 410 no. per shift and hence one shift was reduced.

• Cost savings due to man-power reduction of Rs. 6,72,000.00 / annum.

• Cost savings due to energy saving (reduction of one shift) is Rs. 6,48,000.00 / annum.

• Reduced downtimes, and increased output

With these improvements now an integral part of SAF’s operational strategy, SAF is in the process of horizontally deploying TPM-Trak across all its machines, and at its vendors. Real-time TPM-Trak data is also in the process of being integrated to ERP so drive operational poka-yoke in manufacturing execution.

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January 2013


As a part of Kick off ceremony, suppliers identified as major contribution towards project were invited and a trophy was presented to “M/s Micromatic Grinding technologies ltd, for the excellent support and contribution for the successful completion of the EFC project.”

Award was presented by YUJI HIRAOKA San, Managing Director, TKAP, Bangalore.

ANOthEr fEAthEr IN mICrOmAtIC grINdINg tEChNOlOgIES’ hAt

Award presented by YUJI HIRAOKA San, Managing Director, TKAP, Bangalore.

TKAP Project Milestone meeting of Engine (E/G) & Transmission (T/M) was held on 24th April 2012 .

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SOlutIONS ON dISPlAy

1. tPm trak case study with Super Auto forge, from PCt

Why-Why analysis to identify the bottlenecks in production and the analysis and improvement after implementation of TPM-Trak, which resulted in increased operator awareness, downtime analysis in real-time, reduced shop floor supervision and real time data collection.

2. Proposed Vs Achieved cycle time, from AmS

Various fixtures shown for processing hydraulic head on a VMC, along with their proposed v/s achieved cycle time.

3. machining 2 spigot ends in single set-up; loading / unloading of heavy components, from ACE

Maintaining co-axiality/concentricity and machining both spigot ends at the same time. Also, a conveyor line for loading / unloading the heavy motor, thereby reducing the fatigue.

4. grind track case studies, from mgt

Grind-track, a diagnostic tool for in-process monitoring of the grinding process. Grind track is helpful in improving productivity by optimizing the grinding process; and studying the effect of process variables. Case studies included inconsistent component quality, effect of dressing, wheel glazing, burn on component, and benchmark optimization.

PrOduCtIVIty Buzz 2012

Recently concluded Productivity Buzz 2012, was a first of its kind event which gave a platform to display productivity solutions in metalworking.

Below are few glimpses of the Ace Micromatic Group’s participation in the event.

The booth setup showcasing the various innovative productivity solutions from the group

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January 2013


The team members in action on the opening day of the event

Ace Micromatic Group was the Platinum Sponsor for the event

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The team effort got us the “Most Innovative Solution for productivity” award

The team members in action at the event

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January 2013


Best machine tool supplier award

Acemicromatic group has started his journey along with Sona in 1987 (Sona Started) with a supply of Hydraulic grinding machines (In name of ParishudhSadhanYantra now Micromatic Grinding Technologies) & Ace Auto lathes. Ace has supplied his 1st model of LT-2 CNC lathe to Sona in the year 1989. AMS has entered Sona in 2003, MGTL entered with his CNC range in Sona with his model e-Grind 200 in 2003. After that the Journey goes on. Today Sona is using more than 200 No. of our group companies’ machines. (Approx. 150 ACE, 25 AMS, 28 MGTL) in their various plants in India.

Acemicromatic group has also developed many machines (tooled up for various components) for Sona. Some of the SPM machines are also specially built for Sona (ball burnishing machine from ACE model TNB-45).

Apart from direct buying by Sona there are many vendors of Sona who are using our machines based on Sona’s recommendations. Acemicromatic is a 1000 Crore group company today. The Journey will not be completed without the support of Sona Group. We sincerely thank SonaParivar for their recognition & giving us this prestigious award of “Best Machine Tool Supplier”. We assure our best services & support to Sona with the theme “Partnering growth”.

SONABESt mAChINE tOOl SuPPlIEr AwArdOur Journey with Sona

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NEw frANChISEE OPENINgSAcme Machine Tools, Belgaum

Lighting the lamp at the customer meet in Hubli

Lighting the lamp at the customer meet in Belgaum

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January 2013


Gnani Machine Tools, Ranipet

Felicitating the Chief Guest, Mr. S. Doraiswamy (Exec. Director - Real Talent Engg.Ltd.)

The gathering at the Ranipet Customer Meet

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Trichy Machine Tools, Trichy

Lighting the lamp at the customer meet in Trichy

The gathering at the Trichy Customer Meet

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January 2013


NEw wEBSItE lAuNChThe new group website consists of many features including comparison of the products, updated contact addresses, our social networking links and many more.

www.acemicromatic.net

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lISt Of SAlES ANd SErVICE CENtErS

NOrth

delhiT: +91 11 22414232E: [email protected]

faridabadT: +91 129 4047000E: [email protected]

gurgaonT: +91 124 4745500E: [email protected]

ludhianaT: +91 97791 28296E: [email protected]

rohtakT: +91 99966 91055E: [email protected]

rudrapurT: +91 95570 30224E: [email protected]

germanyT: +49 (0) 15237939254E: [email protected]

ShanghaiT: +86 (21) 5866 5031E: [email protected]

SwitzerlandT: +41 (0) 32 652 58 41E: [email protected]

SOuth

BangaloreT: +91 80 40200555E: [email protected]

Bangalore - BommasandraT: +91 80 27834836E: [email protected]

BelgaumT: +91 99800 02597E: [email protected]

CoimbatoreT: +91 422 4506183E: [email protected]

Chennai - AmbatturT: +91 44 40440700E: [email protected]

Chennai - SriperumbudurT: +91 44 40440700E: [email protected]

Chennai - tambaramT: +91 044 22265531E: [email protected]

hyderabadT: +91 40 27750496 E: [email protected]

ranipetT: +91 4172 272732E: [email protected]

trichyT: +91 431 2483066E: [email protected]

wESt

AhmedabadT: +91 99242 89892E: [email protected]

AurangabadT: +91 240 2552309E: [email protected]

IndoreT: +91 73899 39190E: [email protected]

NasikT: +91 253 6610254E: [email protected]

Pune - ChakanT: +91 21 35322002E: [email protected]

Pune - ChinchwadT: +91 20 40712111E: [email protected]

KolhapurT: +91 230 2460444E: [email protected]

mumbaiT: +91 22 26861009E: [email protected]

mumbai - thaneT: +91 22 25889006E: [email protected]

Pune - ShirurT: +91 98906 23217E: [email protected]

rajkotT: +91 281 6548369E: [email protected]

EASt

JamshedpurT: +91 657 6539931E: [email protected]

KolkataT: +91 33 23648781E: [email protected]

INDIA

INTERNATIONAL

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January 2013


For updated list please visit: www.acemicromatic.net

micromatic machine tools Pvt. ltd., #240/241, 11th Main, 3rd Phase, Peenya Industrial Area, Bangalore – 560 058 Tel: +91 80 4020 0505 Email: [email protected]

You can find us here too

/acemicromaticgroup /acemicromatic /user/acemicromaticgroup

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Ace micromatic newletter jan 2013