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Improving product performance & reliabilityEFFECTIVE WARRANTY APPROACH
VOL 11 | FEB 2020 | ` 100
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EFFICIENT MANUFACTURING
EM - InterviewStefan Joksch,Member of the Board & Director Technical, Oemeta Chemische Werke GmbH (p. 24)
EM - InterviewUlf Meyen,Head of Subsidiary Operations, Oemeta Chemische Werke GmbH (p. 24)
FOCUS E-mobility P. 34
SPECIAL FEATURE Composite Machining P. 48
2019
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Tel: +91 90115 [email protected]
Pune - Nasik Highway, Chakan, Pune - 410501
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VARGUSIus
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The biggest challenge for India’s economy today is to raise the GDP growth to a sustainable 6-7% in the coming years. The Union Budget 2020-21 is a mixed bag on this count. Largely, the Budget has addressed the need to fuel growth and development, and corporates have little reason to complain. It aims to holistically build the nation’s economy in the long-term by ensuring a progressive policy framework. The focus is clearly on boosting economic growth, with announcements of several measures for infrastructure, agriculture and rural development, setting up of data centre parks across India, simplification of taxation regime, emphasis on the manufacture of electronic items to harness export potential, easing of taxation on start-ups, rationalisation of personal income taxes, among others. The proposal to set up large solar power capacity alongside rail tracks and enabling farmers to set up solar power generation capacity on their barren lands will open up immense growth opportunity for the renewable energy sector. It’s encouraging to see the importance given to technology adoption, capacity building, higher education and skill development.
Although the industry welcomes this Budget now, the immediate impact on corporate bottomlines is not clear. The picture will only become clear as companies or individuals come to grips with the new systems.
Manoeuvring the policy framework, balancing the needs of economic revival amid very limited fiscal space will be quite a challenging task for the government. It needs an immediate concrete action-plan to determine the way ahead. The outcome will be determined by effective and accurate implementation of the measures announced. Till then, let’s all contribute towards building a globally competitive and innovation-led economy.
Shekhar JitkarPublisher & Chief [email protected]
Determining the way ahead!
ED
ITO
RIA
L A
DV
ISO
RY
BO
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D Raghavendra RaoSenior Vice PresidentManufacturing & Process ConsultingFrost & Sullivan
Dr Ravi M DamodaranChief Technology Officer Greaves Cotton
Dr N RavichandranFormer Executive DirectorLucas-TVSChief Mentor,UCAL Fuel Systems
N K DhandExecutive Chairman, Micromatic GrindingTechnologies
Dr P N RaoProfessor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Vineet SethManaging DirectorMastercam India
Sonali KulkarniPresident & CEOFanuc India
Dr Wilfried AulburManaging PartnerRoland Berger Pvt Ltd
Satish GodboleVice President, Motion Control DivSiemens Ltd
ED I TOR I AL
EM | Fe b 2020
Overseas Partner:
China, Taiwan, Hong Kong & South-East Asia
2nd INTERNATIONAL AUTOMOTIVE MANUFACTURING SUMMIT 2020Manufacturing Excellence with Technology Innovations
23-24 June, 2020 Gurgaon, Haryana, India
For Delegate Registration, Sponsorships, Paper Presentations
& other details, contact:
Dhiraj Bhalerao (West & South)[email protected]+91 9820211816
Sagar Tamhane (North)[email protected]+91 9820692293
Alok Kumar (Bangalore)[email protected]+91 8861009443
3
AUTOMATION & DIGITISATION
ENGINEERING MATERIALSTechnologies for Additive Manufacturing of components from liquid materials
18
40
COVER STORYEffective warranty approach – Improving product performance & reliability
FOCUS GRADUAL EXPANSION OF E-MOBILITY – BENEFITS TO THE ENVIRONMENT
CONTENTSMARKET 08 NEWS
12 “There is increased interest in predicting noise generated from electric machines”Interview with Pawan Soami, Technical Product Manager, COMSOL Multiphysics
13 “Performance is a continuous process”Interview with Nitin Lall, General Manager – Industrial Technique Business Area, Atlas Copco
START-UP
14 “We want to help scientists accelerate their innovation process”Malthe Muff, CEO & Co-founder, Inniti
V IEWPOINT
28 Upgrading & upskilling – Creating enhanced manufacturingHow organisations are creating an ecosystem for skill development to embrace the future technology.
MANAGEMENT INTERVIEW
24 Innovation is one of the main parts in our strategyStefan Joksch, Member of the Board & Director Technical, and Ulf Meyen, Head of Subsidiary Operations, Oemeta Chemische Werke GmbH
LEADERSHIP INSIGHTS
16 “Inspiring customer loyalty”Nirmalya Kumar, Lee Kong Chian Professor of Marketing, Singapore Management University & Distinguished Fellow, INSEAD Emerging Markets Institute
COVER STORY
18 Effective warranty approach – Improving product performance & reliabilityA peek into different generations of warranty analysis,
warranty costs and the challenges of warranty claims.
FOCUSCustomer views, battery technology and key markets in EVs
CAD/CAMDiscussing the advantages of programming strategies like Automatic Feature Recognition (AFR) and feature-based machining
34
38A&D India – the leading industrial magazine in India, on Automation & Digitisation, that offers a three-dimensional perspective on technology, market and management aspects of automation
EM – the leading industrial magazine in India, on Efficient Manufacturing, that offers a three-dimensional perspective on technology, market and management aspects of manufacturing
www.industr.com/[email protected]
AUTOMATION & DRIVES
Jun-Jul 2018 I VOLUME 11
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Advt
VOL 11 | J
UN-JUL 2
018 | ` 100
AUTOMATION & DRIVES
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CULTIVATING GREEN PATCH IN BROWNFIELD
A practica
l way
to get
starte
d in manufac
turing IIo
T
In association with
FOCUS
A&D - Intervi
ew
Rebecca Liebert,
President &
CEO,
Honeywell
UOP
(p.30)
VIEWPOINTCollaborative
Robots P. 32
Power & Energy P. 4
0, 42
AUTO
MATIO
N &
DR
IVES
Aug-Sep 2018 I VOLUM
E 11
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/en
VOL 11 AUG-SEP 2018 ` 100
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Advt
In association with
FOCUS
VIEWPOINT Sensors in
Automation P. 36
Automotive &
Machine Tools P. 42
A&D - Interview
Rolf Najork
President of Executive Board,
Bosch Rexroth AG (p.32)
A&D - Interview
Hans Bangert
Managing Director,
Bosch Rexroth India (p.32)
A&D - Interview
Marc Jarrault
Managing Director,
Lapp India (p.34)
SMART OPERATIONS
Recipe for success AUTOMATION & DIGITISATION
AU
TOM
ATION
& D
RIVES
O
ct-Nov 2018 I VO
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VOL 11 OCT-NOV 2018 ` 100
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Advt
In association with
VIRTUAL COMMISSIONING
Scope in the Manufacturing Industry
AUTOMATION & DIGITISATION
A&D - Interview
Akilur Rahman,Chief Technology Officer,
ABB India (p.28)
FOCUS
VIEWPOINT Technology adoption in the Indian
automotive sector P. 30
Food & Beverage Processing P. 34
AUTO
MATIO
N &
DIG
ITISATION
Dec’18-Jan’19 I VO
LUME 11
ww
w.industr.com
/en
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Advt
In association with
OT & IT COLLABORATIONUshering new business models
AUTOMATION & DIGITISATION
A&D - InterviewIndraneel Chitale,Partner – Chitale Group
(p.22)
FOCUSVIEWPOINT Collaborative approach for success P. 24
Aerospace & Defence P. 28
VOL 10 | DEC’18-JAN’19 | ` 100
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EM - Intervie
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Vijay Kalra
,
Chief of
Manufac
turing
Operatio
ns,
Mahindr
a & Mahi
ndra [A
S] (p.
34)
EFFICIENT MANUFACTURING
VOL 08 | O
CT 2017 | ` 100
FOCUS
SPECIAL FEATURE Industrial M
aintenance P. 58
Cutting To
ols P. 40
Lean in automotive m
anufacturin
g
ROADMAP FOR IMPLEMENTATION
www.industr.c
om/en
VOL 09 | MAY 2018 | ` 100
www.industr.com/en
EM - Interview
Viraj Kalyani,
Founder & Chairman
Kalyani Studio (p. 28)
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FOCUS Automotive Plastics P. 34
SPECIAL FEATURE Shopfloor Management P. 54
PRINCIPLES, APPLICATIONS AND DIRECTIONS
Sustainable Manufacturing
EFFICIENT MANUFACTURING
OPPORTUNITIES & CHALLENGESEV manufacturing in India...
VOL 09 | AUG 2018 | ` 100
www.industr.com/en
EM - Interview
Dr Nagahanumaiah,Director,CMTI (p. 28)
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FOCUS Defence Manufacturing P. 30
SPECIAL FEATURE Industrial Parts Cleaning P. 48
EFFICIENT MANUFACTURING
What drives the sector
MATERIAL HANDLING INDUSTRY IN INDIA
VOL 10 | MAY 2019 | ` 100
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EFFICIENT MANUFACTURINGwww.industr.com/en
EM - InterviewSanjay Chavre,Sr Development Officer, Dept
of Heavy Industry – Ministry
of Heavy Industries & Public
Enterprises, Govt of India (p. 30)
FOCUS Automotive Plastics P. 40
VIEWPOINT Industry Associations – Bringing the sector closer P. 32
FOCUS 34 E-mobility
Customer views, battery technology and key markets in EVs
TECHNOLOGY CAD/CAM
38 Benefits of automatic CAMDiscussing the advantages of programming strategies like Automatic Feature Recognition (AFR) and feature-based machining.
ENGINEERING MATERIALS
40 Additive manufacturing with liquid materialsTechnologies for Additive Manufacturing of components from liquid materials.
TEST & MEASUREMENT
44 Ensuring precision & efficiency through measurement solutionsHow Jendamark Techcellency turned to FARO for its 8 ft Platinum FaroArm.
COMPOSITE MACHINING
48 Enabling accurate machining of composite partsHow Flow International Corporation used Renishaw HS10 & HS20 laser encoders.
New Products
50 Speech software module; Insulation monitors; High speed & feed lines
51 Machinery for vertical farming; Milling assortments; Leak detection camera
Columns03 Editorial 04 Contents 06 Guest Editorial52 Highlights – Next issue52 Company index
6
GUEST | ED I TOR IA L
EM | Fe b 2020
With the fourth generation of the industrial revolution being implemented across the industry, its immediate and long-term future will be defined by the development of cutting-edge technologies. Many of the technologies are poised to significantly impact the way the industry will function. Let’s take a look at a few important trends to watch out for in the manufacturing sector in 2020.
Predictive maintenanceThe ability to predict failures and
effective equipment maintenance will reduce the downtime and ultimately increase the life of the equipment and avoid disruption of operations. However, in order to successfully build a predictive maintenance model, manufacturers have to effectively gain insights on the variables and collect enough data on the behavioural patterns that occur on the shop floor. It is also very important to have a strong data base on previous failures that can be reviewed, and then set out a plan on predictive maintenance of the equipment accordingly.
CybersecurityWith more machines getting connected
& integrated into organisations, it becomes highly important to have a robust cyber security strategy. As the industry becomes more connected, it becomes crucial for manufacturers, as it can impact them in
CO
MM
ENTS
& C
OM
MEN
TAR
Y
a number of ways. Hence, companies have to spend time on educating their employees about the importance and potential consequences of cyber activities. Cyber security becomes more vital as a major concern to companies because of the increase of malware attacks by the day. Therefore, companies cannot afford to overlook this aspect and must put cybersecurity on their top priorities.
Smart manufacturing / 5GSmart factories are becoming the
norm of the day. They rely on connected devices that leverage on technologies like automation, IoT, AI and more. In addition, these connected devices are capable of sensing the environs and also interact. With factories growing towards digitalisation, it’s important to adopt new networks in an efficient and effective manner. The factories of tomorrow will greatly rely on sensor technology and will prominently feature connected tools utilising the data to guide the task force. 5G’s high capacity and wireless
flexibility will make a perfect choice to support modern manufacturing.
Wearable technologyThe rise of IoT in industrial applications
has given rise to wearable technology. Manufacturers are increasingly looking at investing in wearable devices with different applications that the workforce can utilise. The features found in various wearable devices like data collection and transmission, even in some cases to record the actions for further analysing, only increase the workplace productivity, safety and efficiency. The wearables enhance the capacity of employers to effectively collect valuable information, track activities and provide customised experience, depending on the needs and desires.
Virtual Reality (VR) and Augmented Reality (AR)
Whether in helping process development or improvement of products, AR and VR are the real game changers. In the VR world, one can really recreate a situation much better than ever before, thanks to the technological advancement. Whereas in AR, one has limited space, as users need to be in the real location to augment their experience of reality. We will see a lot more manufacturers incorporating these technologies in their organisation to drive the future defined by digital connectivity. ☐
“WITH FACTORIES GROWING TOWARDS DIGITALISATION, IT’S
IMPORTANT TO ADOPT NEW NETWORKS”
Rajesh T GhashiMANAGING DIRECTOR CHIRON INDIA MACHINE TOOLS
8 EM | Fe b 2020
MARK E T | NEWS
ACMA inks MoU with NASSCOM CoEAutomotive Component Manufacturers Association of India (ACMA) recently signed a Memorandum of Understanding (MoU) with the National Association of Software and Services Companies (NASSCOM) through its Centre of Excellence - IoT & AI (CoE), under which both the associations will collaborate on multiple areas related to digital technology adoption in the auto components industry and work on common agenda to foster the innovation ecosystem. The collaboration will focus on three aspects – awareness, education and adoption to enable smooth digital journey of the auto component industry. It will also support the sector to harness digital technologies like AI, ML, Advance Robotics, AR/WR wearables, RFID, IoT and digital payments.
Intech Additive Solutions announces launch of ‘Made in India’ range of metal 3D PrintersIntech Additive Solutions recently announced that they have designed, developed and delivered to the Indian manufacturing industry a ‘Made in India’ technological solution, with the launch of their new range of metal 3D Printers, iFusion series, having the iFusion SF1 and the iFusion LFMulti. Explaining the iFusion series of metal 3D Printers, Sridhar Balaram, MD & CEO, Intech Additive Solutions, expounded, “These cost-effective machines are part of Intech’s 3D ecosystem with software bundled in for machine parameter optimisation and build process being sold as a package. The overall target of Intech is to reduce the cost of acquisition, operations and first time right, with a quick go to market.” Further, he added, “These machines are a culmination of more than 30,000-man hours of research, development and innovation spread over the past 36 months. We have 3D printed more than 800 parts for variety of industries in different materials. Along with our in-house developed software, AMOptoMet, and the upcoming AMBuilder, we aim to create a full-fledged ecosystem for Additive Manufacturing fuelling the industrialisation of AM in India.”
Eaton reaches agreement to sell its hydraulics businessEaton recently announced that it has entered into an agreement to sell its hydraulics business to Danfoss A/S, a Danish industrial company, for $3.3 billion in cash. The company’s hydraulics business had sales of $2.2 billion in 2019 and employs approximately 11,000 people. Speaking about the company’s ongoing transformation, Craig Arnold, Chairman and Chief Executive Officer, Eaton, elucidated, “We believe this transaction will create substantial value for our shareholders and allow our hydraulics employees to be part of a company that has a strong commitment to the hydraulics industry.” Expressing his views on the agreement, Kim Fausing, President and Chief Executive Officer, Danfoss, averred, “Eaton Hydraulics is a highly respected player in the global hydraulics industry, recognised for its dedicated people and strong brands. By combining the knowledge and experience of these two companies, our customers will benefit from unmatched expertise from a single partner.” The transaction is subject to customary closing conditions and regulatory approvals and is expected to close by the end of the year.
Commenting on the association, Vinnie Mehta, Director-General, ACMA, stated, "We are pleased to collaborate with NASSCOM CoE. The partnership will help the auto component industry in its digital transformation and to be future ready. The outcome of this partnership is expected to create advanced skills and development of intellectual property industry wide, in line with the vision of digital India. The Digital Committee of ACMA will also play an important role in this initiative.”
Taking the discussion further, Sanjeev Malhotra, CEO, NASSCOM CoE, asserted, "One of the most important goals of the NASSCOM CoE is to foster innovation in digital transformation and how they can impact outcome, workflow and operations in different industry segments manufacturing, auto, etc. The MoU we have signed with ACMA is important to foster collaboration and innovation for their member companies in building skills essential to remain ahead of the curve & stay globally competitive.”
Both the associations will jointly conduct events and workshops to raise awareness about the existing and new opportunities to drive adoption of deep tech within the industry ecosystem. It will enable the members of ACMA to access the latest innovative products and solutions from the start-ups incubated by CoE and from the extended ecosystem. There will be curated workshops in areas like problem-solving application and innovations for group of members and development of white papers related to deep-tech adoption within the ecosystem.
9EM | Fe b 2020
NEWS | MARKET
ŠKODA AUTO DigiLab India and software development centre supports INDIA 2.0 projectŠKODA AUTO recently founded its fourth DigiLab unit, in Pune, India. This lab will support the core business of ŠKODA AUTO Volkswagen India by developing digital and mobility solutions. In addition, a dedicated software development centre has been established by Volkswagen IT Services India in Gurugam and Pune to support ŠKODA AUTO’s IT requirements globally and develop digital solutions. Speaking about the expansion plans, Bernhard Maier, CEO, ŠKODA AUTO, explained, “With ŠKODA AUTO DigiLab India, we are consistently expanding our global network. Most of our customers in India have grown up with smartphones and expect tailor-made mobility services and seamless connectivity in the car. This is exactly what we are undertaking at our new DigiLab in partnership with local high-tech companies.” Taking the discussion further, Gurpratap Boparai, MD, ŠKODA AUTO Volkswagen India, added, “With the new digital services and mobility solutions provided by ŠKODA AUTO DigiLab India and our dedicated software development centre with offices in Gurugram and Pune, we want to create a diverse digital ecosystem for our customers.”
NEWS MARKET
L&T-MBDA sets up a missile integration facility in Tamil NaduL&T recently announced that it has set up a missile integration facility at a special economic zone in Coimbatore, Tamil Nadu, in collaboration with European defence major MBDA Missile Systems. The L&T-MBDA joint venture, known as LTMMSL, has set up the ‘assembly, inert integration and testing facility for missile sub-systems and missile weapon launch systems’ in a plant spread across 16,000 sqm. It has already received a few export orders and will begin delivering the defence equipment from 2020. The new facility shall start delivering sophisticated weapon systems using state-of-the-art test equipment such as missile launchers and airframe segments, including control actuation units. The statement further added that the LTMMSL will build complete missile systems for the Indian Armed Forces exploring prospects under the Buy (Indian – IDDM), Buy (Indian) and Buy & Make (Indian) categories for defence procurement.
IHS Markit India reports manufacturing PMI at 8-year high in JanuaryIHS Markit India recently reported that despite the downturn in the economy, Manufacturing Purchasing Managers’ Index (PMI) jumped from 52.7 in Dec to 55.3 in Jan, its highest level in just under eight years. The economy seems to be showing signs of a revival with India’s manufacturing sector activity climbing in January, driven by sharp rise in new business orders amid a rebound in demand conditions, leading to a rise in production and hiring activity. Discussing the latest report, Pollyanna de Lima, Principal Economist, IHS Markit, asserted, “The manufacturing sector growth in India continued to strengthen in January, with operating conditions improving at a pace not seen in close to eight years.” The Economic Survey 2019-20 projected India’s economy to grow in the range of 6-6.50% in the 2020-21 financial year.
TaeguTec launches new product lineTaeguTec recently launched its newest product line, SFEEDTEC High Speed & Feed lines. The SFEEDTEC range of products is committed to reducing cycle time and bringing down cost of manufacturing for customers, while setting high standards for innovative engineering and user-friendly designs in the industry. While presenting the new range, Jacob Harpaz, Chairman & President, IMC Group, highlighted, “Today, most CNC machining centres are smart machines. Metal removal today is high tech – and high-tech machining means advanced tools are no more a matter of choice.” Sharing his views on the newest product line, L Krishnan, MD, TaeguTec, said, “On one hand, the digital tools of Industry 4.0 would help one to reduce the unproductive time. But at the same time, there is a significant look out for what is the actual production time. We need to balance our focus between reducing the unproductive time as well as optimising the machining time. SFEEDTEC fulfils these needs.” Krishnan further added that SFEEDTEC has been tested all over the world – in tech centres and customer places – before launching it with patented features.
10 EM | Fe b 2020
MARK E T | NEWS
Great Wall Motor to buy GM's India plantGreat Wall, China, plans to enter India with its Haval, an automotive marque, and electric vehicle brands, and has agreed to buy General Motors' (GM) car plant in India. The deal, which is expected to be completed by the second half of 2020, will jumpstart the company's plans to build and sell cars in India and bring to an end GM's manufacturing operations in the country. The company is expected to upgrade and modify GM's plant to suit its needs and set up a base for its suppliers, said one of the sources, adding that the automaker expects to begin production within a year. Talking about the acquisition, Lui Xianshang, VP, Global Strategy, Great Wall, cited, "The Indian market has great potential, rapid economic growth and a good investment environment. Entering the Indian market is an important step for Great Wall Motors' global strategy."
Nicolás Correa India celebrates 10th anniversaryNicolás Correa India recently celebrated its 10th anniversary, in presence of José Nicolás-Correa, President, the Correa Group; Parag Alekar, CEO, Nicolás Correa India and important customers of the company. The subsidiary offers sales, after-sales service and application engineering in India for Correa milling machines. Talking on the occasion, Nicolás-Correa adhered, “The Indian market is becoming an important one for us, with already 74 machines installed in the country, and the Indian subsidiary contributes around an average of 5-8% to our annual global turnover.” Alekar, while highlighting the important milestones of the last 10 years in India, informed, “We could install first 50 machines in a short span of six years, after starting our office, and the machines supplied to ‘Áakash Missile' was one of the important milestones. We are the preferred suppliers for the global multi-nationals like SMS, GE, JCB, BIESSE in India, besides the Indian Railways.”
HAL and Wipro 3D partner for metal 3D Printing Hindustan Aeronautics Limited (HAL) and Wipro 3D, the metal Additive Manufacturing (AM) business of Wipro Infrastructure Engineering, recently signed a pact to design, develop, prove out, manufacture and repair aerospace components using metal additive technology. The initiative would focus on development, prove out and production of aerospace applications, including MRO, using metal Additive Manufacturing, as per the media release from HAL. It said that prove-outs and certification of components developed using metal 3D Printing was a key element of this co-operation. Talking about this association, Shekhar Shrivastava, CEO, Bangalore Complex, HAL, said, “This collaboration between HAL and Wipro 3D will create a unique synergy of capabilities that can accelerate the adoption of metal Additive Manufacturing in aerospace in India. Qualification of parts for aerospace is challenging as it would require prove out and extensive testing, followed by certification by regulatory authorities which may also include flight testing.” Discussing this further, Ajay Parikh, VP & Business Head, Wipro 3D, expounded, “The MoU will provide significant manufacturing and MRO flexibility and freedom to existing, upcoming and legacy aerospace programmes.”
MARK E T NEWS
Elgi’s metrology department accredited by NABLElgi Equipments’, metrology department plays a crucial role in ensuring enhanced reliability and performance consistency across the company’s product portfolio, which is in line with the company’s focus on high quality, customer-centric compressed air solutions. The metrology department, located at Elgi’s state-of-the-art manufacturing unit, in India, has been accredited by NABL in the field of mechanical–dimension, pressure and torque. The metrology department was set up to ensure every product undergoes the right measurement through the usage of accurate and precise measuring equipment, resulting in a reduction in variation in accordance with the ISO/IEC 17025-2017 norms. Over the years, the laboratory facilities have been upgraded with computerised master equipment and data acquisition systems. Addressing the team at the Metrology Department, Dr Jairam Varadaraj, Managing Director, Elgi Equipments, said, “At Elgi, we are never satisfied with the status quo; we believe in pushing the boundaries, every day, in our quest to be ‘always better’. Across the world, we know our customers deserve the best and appreciate, high reliability, unmatched performance consistency and zero downtime.”
MAKE BETTER PARTS FASTER.www.mastercam.com
Choose the world's #1 CAM solution for the software and support you need to get more chips on the floor and parts out the door.
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12
MARK E T | I N TER V I EW
EM | Fe b 2020
Can you highlight the significance of COMSOL Conference 2019?The COMSOL Conference presents a unique opportunity for attendees to exchange ideas and interact with other users and technical experts of COMSOL. It offers minicourses on over 25 topics, user presentations, panel discussions, keynote talks, and a poster session with over 50 posters encompassing different multiphysics applications.
What are the new trends in Multiphysics and new applications? COMSOL Multiphysics® is a pioneer in multiphysics simulation. Applications such as thermal management of Li-ion batteries and battery packs, and Structural Thermal Optics Performance (STOP) analysis of optical devices can be easily and accurately modeled in the software. As the automotive industry is moving towards the electrification of automobiles, there is increased interest in predicting and mitigating the noise generated from electric machines. Lightweighting is another important aspect in vehicles, which brings modeling of composite materials into focus.
Can you tell us more about modelling composite structures for improved product design? What are the trends in the smart composite materials? What can you model with the Composite Materials Module? Composite modeling is relatively new in COMSOL, and the previous version 5.4 first introduced the Composite Materials Module. The module offers various in-built interfaces, pre-processing and post-processing tools for modeling the laminated structures of fibre composites. Users can model any composite laminates or sandwich panels, analyse them with layer-wise theory or equivalent single layer theory and perform multiphysics problems or multiscale problems with the help of this module.
Can you brief us on the tools for designing and optimising multibody systems?
COMSOL® provides an advanced set of tools for designing and optimising multibody systems. The Multibody Dynamics Module enables users to simulate mixed systems of flexible and rigid bodies, where each body may be subjected to large rotational or translational displacements. Such analyses help users in identifying critical points in multibody systems, thus enabling them to perform more detailed component-level structural analyses. This module also gives you the freedom to analyse forces experienced by segments of the structure, and
stresses generated in flexible components that may lead to failure due to large deformation or fatigue.
Which are the industry segments that COMSOL is targeting globally and in India for the latest version of Multiphysics software? COMSOL being a general-purpose tool, finds use in a wide variety of industries and applications. With the latest version, the software’s reach continues to grow in the automotive, heavy electrical, aerospace and defense, oil and gas, and renewable energy sectors, to name a few, both globally and in India. Another revolutionary functionality that is gaining popularity in India is the
COMSOL Compiler™, which enables users to create standalone executables that can be shared with anyone, without needing access to a COMSOL license.
How challenging is it to make the industry receptive to scientific modeling, especially the manufacturing industry? It can be a challenge for someone habituated with experimentation to adopt simulation techniques. However, most industries have gained confidence in the accuracy and efficacy of simulation tools. Although simulation cannot be looked at as a replacement for experiments, it offers a time- and cost-effective alternative such that the design optimisation can be done with simulation. The manufacturing industry, too is relying more on simulation and then validating the findings with experiments. ☐
“There is increased interest in predicting noise generated from electric machines”
…says Pawan Soami, Technical Product Manager, COMSOL Multiphysics, in this interaction with Alok Kumar. Soami throws light on modeling with the Composite Materials Module, the COMSOL
Compiler™ released by the company and how simulations are getting more popular. Excerpts…
13EM | Fe b 2020
INTERV I EW | MARKET
How is the roadmap to Industry 4.0 and Smart Manufacturing different for your company? Which are the new organisational capabilities that need to be developed?The digitalisation we are experiencing will profoundly change the reality of production. Over many years, our company has built up knowledge in connected assembly processes and has extensive experience in how to architect a connected ecosystem. Our proven solutions are now further integrated horizontally and share data seamlessly between all applications supporting the life cycle of assembly, from applications supporting R&D, through production, to applications used in service and analysis. Our one key objective of the initial phase is the learning of new concepts and to strive for an organisation and culture of collaboration and agility to prepare for the upcoming changes.
What are your current strategies and priorities, considering the current uncertain market conditions?The automotive industry is currently leading the development of manufacturing and assembly concepts and processes. The development is driven by environmental requirements, with the introduction of alternative drivelines and fierce market competition, with an explosion of the number of models and variants. We develop market-leading solutions for multiple joining technologies. Hence, we need to work closely with customers to develop assembly solutions and processes using these joining technologies and supporting control and analysis applications.
In this VUCA world, it becomes imperative for us to work closer with customers, starting from the design conceptualisation stage to the after-sales service. Our solutions need to be incorporated from the early stages to have a significant impact on the total outcome.
What are the main focus areas of your company bringing value to your customers?We have six pillars of value which we provide to our customers
– increased uptime (by having a comprehensive preventive maintenance program), reduction in defects (by providing part verification & documentation), new product introduction (reduce installation costs & quick setup), improved productivity (ensuring first time right), human factors (reduction in training needs for new models or process changes) & reduction in energy use (reduced energy consumption by creating a lean set-up).
What’s your take on the state of the power tools market right now? From low cost tools provider to high-end solution provider, every manufacturer wants to have his share of the available pie. With an increased focus on cost competitiveness, the end-customer is easily drawn to investing ‘as much as needed’ or more focused on ‘time-being’. This presents our company both, a challenge and an opportunity. Our solutions are focused on giving customers tangible & intangible benefits. Tangible benefits include reduced floor space, reduced hardware & reduced power consumption. The intangible benefits include ease of use, operator-friendly and scalability for future expansions.
Which are your target industry sectors currently?The target sectors which look exciting in India would be the energy sector and how the motor vehicle industry would evolve towards electric vehicles.
What has been the performance measurement for your division this year? What is the plan for the company for 2020?Performance is a continuous process. In the present business environment, we are glad that we grew over a year before and the plan for 2020 would be to keep this up. There are many new opportunities available in the market and our endeavour would be to tap into these. The main areas to look into would be providing industry solutions for error-proofing & quality via digitalisation and partnering players for electric vehicles & the energy sector as well. ☐
“Performance is a continuous process”…asserts Nitin Lall, General Manager – Industrial Technique Business Area, Atlas Copco, in this
interview with Juili Eklahare. He stresses on the main focus areas of the company, the industry solutions it provides and its essay in tapping into new opportunities in the market. Excerpts…
14 EM | Fe b 2020
START- UP | I N TER V I EW
Can you elaborate on what is Inniti and the inspiration behind starting it?We saw how much time scientists spend in the laboratory performing manual and repetitive work, and we wanted to change this by enabling scientist to automate their workflow. At Inniti, we connect all their laboratory equipment to our software platform, thereby automating the execution and data gathering of their experiments. Right from the beginning, we have been focused on developing a user-friendly solution. Now, attributing to the software’s user-friendly interface, scientists do not require a lot training to use our solution. Our solution is used by both, the R&D departments and university laboratories within filtration, biotech and pharmaceutical.
How does your company enable faster, better and cheaper laboratory tests with the help of IoT?Our software connects all laboratory equipment to our platform and creates a digital twin of all the equipment. The scientists can then automate the experiments by drawing a flow chart, so that their equipment is operated automatically. We create an inter-connectivity between equipment from different manufacturers to help scientists build and operate complex experiments automatically. We free up their time from the laboratory by automating the execution and data gathering / processing of their results. By automating experiments, we ensure that the experiments are performed with machine pression, and it increases the scientist’s capacity, as each scientist can operate more experiments at once. For example, with one of our customers Aquaporin, we implemented a solution that increased their capacity by 300% and lowered the labour time by 70%.
How do solutions offered by you ensure an easy access, track of each other’s work and easy replication throughout the team?In a laboratory, all experiments done by the team are available for the whole research team on our platform; so, they can keep track of each other’s work, see how their colleagues
have performed an experiment and its results. If they want to replicate an experiment, they simply have to build the setup and press start, and the experiment is then performed in the exact the same way. The scientist has a complete overview of how all the experiments have been performed and its results.
Can you tell us more about the product portfolio offered by your company and its functioning?At Inniti, we sell a combined software and equipment solution.
On the software platform, scientists can control all their laboratory equipment & design and automate experiments. They can plot graphs and have access to all the experiment data. Our Inniti connectors can be inserted into equipment from third party producers, such as ThermoFisher Scientific, so their equipment can be connected to our software platform. We also have our own portfolio of laboratory equipment, such as pumps, flow sensors, pressure senor, pH sensor, etc.
What are your short-term and long-term goals? Any plans of collaboration in the near future? For the short-term, we want to work with
more scientists, and we are right now focusing on companies working with filtration, including micro-filtration, ultra-filtration and forwards osmosis. Going forward, we want to work more with organisations in biotech, food & beverage and the chemical industry. We are also aiming at partnering with laboratory equipment manufacturers, as we connect their equipment to our software platform, which can generate a lot of data about the use of their products available.
The long-term goal is to become the number one research platform globally. We want to help scientists accelerate their innovation process with a complete platform dedicated to them, which covers the whole workflow in the laboratory. From automating the experiments, documentation, report writing and utilisation of data, we want to assist scientists in optimising their experiment based on their data. ☐
“We want to help scientists accelerate their innovation process”
…mentions Malthe Muff, CEO & Co-founder, Inniti, in his discussion with Anvita Pillai. Muff herein discusses the motivation behind starting Inniti, how it helps R&D organisations and laboratories in automating experiments and how it eases out repeated experimentation. Excerpts of the discourse…
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16 EM | Fe b 2020
LEADERSH IP I NS IGHTS
Nirmalya Kumar is one who is transforming the view of the role that marketing is playing worldwide. He is considered one of the world’s leading thinkers on strategy and marketing and has worked with over 50 Fortune 500 companies in 60 different countries as a coach, conference speaker and consultant. Besides this, Kumar also has a great passion for art; he has the biggest known private assemblage of paintings by Jamini Roy, Hemendranath Mazumdar and Rabindranath Tagore.
Kumar did his PhD in marketing from Kellogg Graduate School of Management in Northwestern University. In 1995, he became Professor of Marketing at International Institute for Management Development in Switzerland. Soon, he became Professor of Marketing & Director of Aditya Birla India Centre at London Business School and later in 2013, member-group executive council and head of strategy at Tata Group. It wasn’t until 2017, that he became the Lee Kong Chian Professor of Marketing at Singapore Management University and distinguished fellow at INSEAD Emerging Markets Institute.
Kumar has imparted immense
knowledge, especially leading to leadership, through the methods of teaching to consulting, and by writing some substantial books – some of the most prominent ones being Marketing As Strategy: Understanding the CEO’s Agenda for Driving Growth and Innovation and India Inside: The Emerging Innovation Challenge to the West. One of the important lessons that he has taught is how a business can be a leader in sustainability. He advises that in order to take an approach to sustainability, one vital step would be to be an activist of societal change – the companies that are leaders today have implemented sustainability and distinguished their products in this aspect.
Also, in his blog, a pivotal subject that Kumar throws light upon is branding. He says that the brand’s mission statement helps articulate ‘why the brand exists’. A good mission statement should have five attributes – benevolent (so that the brand
is focused on how it impacts others), energising (so it makes employees, dealers and suppliers involved in making the brand feel inspired), ambitious (so that it stretches the organisation to be at greater heights), discriminating (so that employees are guided to make choices in their daily work) and simple (so that employees can easily recall it as well as clearly understand the purpose of the brand). “Branding is about striking emotional chords with consumers. It is about cultivating identity and trust to inspire customer loyalty,” he says.
Kumar, undoubtedly, is an ardent voice for upcoming and present businesses in India. As business strategy, management and marketing have gotten complexed over the years, Kumar has given out extensive insight, helping create and lead to the origin of exceptional future leaders.
BRANDING IS ABOUT CULTIVATING IDENTITY
Nirmalya KumarLEE KONG CHIAN PROFESSOR OF MARKETING,SINGAPORE MANAGEMENT UNIVERSITY &DISTINGUISHED FELLOW, INSEAD EMERGING MARKETS INSTITUTE
Inspiring customer loyalty
Juili EklahareFEATURES WRITER
Oemeta India Pvt. Ltd . | 710 Indo-German Chamber of Commerce Nucleus Mall, 1 Church Road | Camp, Pune - 411001 | Tel.: +91 204 10 47-112 | [email protected]
Headquarter:Oemeta Chemische Werke GmbH | Tel.: +49 (0) 4122-924-0 | [email protected] www.oemeta.com
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18 EM | Fe b 2020
COVER STO RY T ECHNOLOG Y
– Improving product performance & reliability
EFFECTIVE WARRANTY APPROACH
In today’s world of high-tech industries, everyone relies on growing technology and products, and it is crucial that equipment function with highly efficient performance. When they fail to do so, it can lead to the customer being exasperated. Therefore, while making an excellent product, an important element that helps manufacturers assure profits is warranty. A warranty can save a lot in terms of repair and replacement costs and also assure the customer that they are making the best decision. Warranty, in fact, is an image of the quality of the product itself. The cover story discusses the different generations of warranty analysis, warranty costs and its phases under changing sales conditions and the challenges of warranty claims.
Dr Vinay G Vaidya CEO & Co-founder Pi [email protected]
COVER STO RY T ECHNOLO G Y
18 EM | Fe b 2020
19EM | Fe b 2020
TECHNOLOGY COVER STORY
Warranty is as precious as a diamond. When it is appropriately managed, it can give a big dividend and joy in terms of customer loyalty. However, if it is not managed well, it can lead to financial losses. Every amount spent on warranty claims takes away dollars from the company profits. Thus, ‘product, performance and reliability’ is an important topic. Product reliability creates everlasting impressions on consumer minds. Consumer impressions determine company reputation. The company’s reputation decides future sales. Future sales decide company growth or survival.
A warranty claim analysis is a subset of product performance and reliability analysis. Warranty is limited in duration. Performance and reliability also encompass the period after the warranty is over. One cannot keep customers happy by only managing product reliability only during the warranty period. Reliability has to be maintained throughout the product lifetime.
Introduction to warranty claim analysis
Complex products come with a manufacturer’s warranty. This gives assurance to customers that the manufacturer stands by what they have built. The flip side of it is that it poses a challenge to the manufacturer. Potentially, it can drain millions of dollars. At times, warranty claims may necessitate a change in the product design. This could lead to a disruption in the assembly line. This is especially true in the industrial equipment business. A disruption in a production line causes a lot of damage to the company’s reputation, along with financial losses.
The challenge of warranty claims further increases with the complexity of the product. On one hand, the product manufacturer has to pay for the cost of repair, and on the other hand, they have to ensure customer satisfaction. Every warranty
claim not only erodes the manufacturer’s profits but also impacts the customer’s perception of the product and the company. This puts in a lot of pressure on manufacturers. They not only have to analyse a large number of claims data to find out what needs to be fixed, but they also have to ensure a quick fix.
The three generations of warranty analysis
Manufacturing industries all over the world have one or the other method of analysing warranty claims data coming from service centers from across the globe. Some industries use basic techniques, such as using a spreadsheet. With spreadsheets as the only tool, the best analysis that is often conducted is to observe and track part defect count, part types that fail and corrective measures taken. Usually, the teams are very busy and overloaded with many tasks, and thus, have no time left to do anything more. Before one knows, the month is over. The next month’s data awaits the same analysis. This is what we call the first generation or 1G model of warranty claims analysis.
To gain deeper insights, we turn our focus on the cost of warranty claims in addition to defects. This leads one to find the financial root cause of high warranty claims. Best practices often tell one how to design a new product. These unique designs have a big chance of succeeding in the market since the word of good quality also spreads fast.
Putting a focus on cost, deriving inferential statistics, prioritising component inspection, calculating statistics for new product development are some of the main features of the 2G model of warranty claims analysis. Collectively, these advancements are termed as the second generation.
When an organisation matures to the 2G level, the next advancement comes from predictions. Warranty budget
Figure 1: The three generations
of warranty analysis
20 EM | Fe b 2020
COVER STO RY T ECHNOLOG Y
fluctuations are the hardest to manage. Thus, can one predict monthly warranty costs? How about predicting the number of parts that would fail in the next few months? Taking this further, would it not be nice to know partwise failures on a monthly basis?
Predictions of what defect is going to occur, which part is going to fail, the total warranty claims cost, form the part of the third generation or 3G warranty analysis.
Warranty costs & its phases under changing sales conditions
Every new product goes through multiple phases during its lifecycle. Each stage is unique and poses new challenges from warranty claims raised, to customer satisfaction, to costs incurred by the manufacturer. Naturally, one wonders when is the right time to invest in productivity tools. Although the answer is clear that one should invest as soon as possible, human tendencies are contrary to that. Following, we explain various phases of the sales cycle and its relationship with internal investments.
Launch phase
Any new major product comes with a lot of hype. New features are exciting. Competitors are kept at bay. Public sentiment is high and so are the management sentiments. Sales grow reasonably well. Less attention is paid to warranty claims related costs, since a new product takes time to iron out all issues.
Figure 2 is a graph showing this growth phase in sales along with an increase in units under warranty. Typically warranty costs also show a similar trend. The y-axis scale on the right is for units under warranty, and the one on the left is for monthly sales.
Since everyone is happy about the launch, very little attention is paid to warranty costs. In reality, it is better to control expenses at this phase so as to avoid further erosion of profits.
Plateau phase
Once the hype of the new product is over, it shows some signs of approaching a plateau phase. During this period, the organisation gets busy collecting warranty claims data, analysing the data, understanding the trends in part failure and fixing the issues. There is still less attention paid to warranty costs and engineering redesign of appropriate parts.
Warranty period validity
Each product comes with a specified period over which warranty is valid. In the following example, it is considered that the warranty period is 24 months. As the warranty comes to the end, the number of units under warranty starts declining.
The decline in sales
It is widely believed that during sluggish economic conditions, one should cut spending. This rule is used indiscriminately for any new purchases, as well as any new development.
If the company sales are as shown in Figure 5, one would think of cost-cutting measures. Ironically, very few companies would focus on warranty claims reduction. That is not the right approach. Warranty claims do not start coming down as soon as monthly sales are down, since they are cumulative based on previous sales. The right way to tackle this situation is to focus on the right tools for root cause analysis and fixing parts by redesigning them. It is possible to reduce warranty costs. Every dollar saved by reducing the claims cost goes straight into the company’s bottom line. There is hardly any other focus that could reward one 100% by increasing the focus.
Figure 2: Product launch phase Figure 3: The plateau phase
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22 EM | Fe b 2020
COVER STO RY T ECHNOLOG Y
Seven facets of the diamond
Analysis of product service data is like cutting a diamond. A well-cut diamond has the appropriate number of facets – not too many, not too few. This appropriate number of facets decides the value of a diamond. So is the case with proper data analysis.
For warranty claim data, more the facets, deeper are the insights. We certainly want to look at warranty claim data from all different facets. Yet, we want to be consistent every single time.
Every CEO has a set of questions in mind about their after-sale product performance. Unfortunately, these questions are not always answered quickly. Since they remain unanswered, parts with low reliability continue to infiltrate in complex products, and they continue to fail, especially when they shouldn’t. Any reliability-related perceptions leave a mark on the customer’s mind, and they vow to either buy the same product next time or to never buy it again. Thus, it is in the interest of the manufacturer to identify problems and fix them as soon as possible.
Unfortunately, only wishful thinking doesn’t help one achieve their goals. The reality is that the analysis of the service center data takes time. Often, it takes a month. By the time the analysis is ready, the next month rolls in, and the data for it is ready for analysis. Even if the analysis is completed in a month, there is no guarantee that all different facets have been looked through. Often, there is no consistency in the way the data is analysed.
Nevertheless, the questions are very important. They are grouped into three categories – cost reduction, quality improvement and strategic inventory management. The questions are:
Cost Reduction Strategies (CRS)1. How can the warranty costs be reduced? What strategies
should one use to reduce the cash outflow?2. How much warranty budget should one allocate in the
upcoming months?3. When we produce a product and ship it out of the
factory, can we tell five most likely failures that would occur in the field? What is the cost of not redesigning those failed parts?
Quality Improvement Plan (QIP)4. Are there any potential process issues? How can the
periods of process deviation be identified? How can they be fixed to avoid further incidences?
5. Out of the list of parts to be fixed, how can one prioritise the worklist?
6. How to find the best practices for part design and to minimise further financial losses?
Strategic Inventory Management (SIM)7. How can we proactively distribute inventory to various
service centers to ensure quick product fix and ensure customer delight?
These are all research questions. Answer to the warranty costs reduction lies in answering the seven questions. The clues followed by right and timely actions lead to high standards of product performance and reliability. The appropriate steps eventually lead to winning the hearts of customers. Customer satisfaction ultimately culminates in the company’s profitability and growth. ☐A major part of this article first appeared as blogs on www.piinnovate.com. One of the blogs was co-authored by You Mishima.
Figure 4: The start of units reduction Figure 5: The decline in sales
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24 EM | Fe b 2020
MANAGE ME N T I N TER V I EW
“ Innovation is one of the main parts in our strategy”
Oemeta was recently awarded as one of the most innovative German SMEs by the Top 100 contest. Tell us more about that and how Oemeta built this culture of innovation.Joksch: The innovative award is not just about proving products to be innovative but also proving company structures and processes to foster innovative ideas & technology. That was the main reason why we decided to be a part of this award, because we wanted to test ourselves. To generate innovation, we have several ways and sources. Of course, the most important way is to have this innovative mood in the employees and the staff. So, you have to be kind of ‘error tolerant’ for this to workout. We also have a new system where everybody can supply new ideas to do something better in a certain way and the idea is evaluated and then the person will be awarded accordingly. This is something we already have in a written form in a process, and now we will also put it on a software tool, so that we can use this system worldwide, and collect all the good ideas. Also, we have a close cooperation with our customers, because mostly the best ideas about something which optimises the production processes come from the customers. We also believe in open innovation, in terms of cooperation with universities and institutes.
Sustainability has become an important topic of discussion in the manufacturing sector globally. What are the initiatives from Oemeta in this area? How do you educate the customer about sustainability?Joksch: We have developed a product portfolio, which uses a lot of renewable ester oil. Compared to mineral oil, ester oil helps us deliver superior performance. Also, we develop products that are internally recyclable, which means it can be reused and recycled within the factory. Pertaining to customer education, there are two main areas for us – firstly, we have bilateral cooperation, which means, we have a lot of skilled engineers who are skilled in process optimisation and they talk directly to our customers. Secondly, we conduct seminars in our core markets to bring customers together and to transfer knowledge from us and other stakeholders in the metalworking market.
Legislations around chemicals (metalworking fluids) are becoming stringent; however, there is not the kind of harmonisation in the legislation as the industry expects. How has Oemeta been able to manage business challenges concerning chemical legislations so well?
Stefan Joksch, Member of the Board & Director Technical and Ulf Meyen, Head of Subsidiary Operations, Oemeta Chemische Werke GmbH in this tête-à-tête with Juili Eklahare, talk about managing business challenges concerning chemical legislations, the international market business becoming pivotal for the company and the role the Indian market plays for them. Excerpts…
25EM | Fe b 2020
INTERV I EW M ANAGEMENT
Joksch: We are lucky that we are from Germany, because Germany is known for the most stringent chemical regulations. It has changed a bit since the European Union has had its own laws, but before that, we had high standards. And it was helpful, because we could transfer all these standards to the other countries. But this will not work anymore as all regions have their own legislation. To cover that, we ramped up our workforce. We have hired chemists, who are focused only on this topic of Environment, Health & Safety (EHS). Plus, we have a very powerful software tool, which helps us with the classification and labelling of products for all the regions where we are active. This is backed-up by a big database, where all this worldwide regulations have been introduced. Also, there is an expert group behind that which is ready to consult us concerning classification. Besides, we want to use certain raw materials which are possible to use worldwide. So, they have to comply with stringent regulations. This is possible for production in Europe, the US and Asia.
Oemeta was amongst the first companies to launch Gas to Liquid (GTL) based neat metalworking fluids. Tell us more about this technology and how the OEMETOL GT range brings benefits to its customers.Joksch: The GTL based oil is synthetic-based oil, which is generated out of natural gas. So, the gas coming from the ground is chemically transferred in a base oil with unique properties. The main advantage against mineral oil is that we have lower evaporation rate, lower foam production and a higher flash point. Because of this, we have health, safety and economic advantages. Also, the density of GTL is lower
than that of the mineral oil. This means for every litre of fluid in the machine, the pump has to move less weight, and this saves energy. So, the power consumed by the pumps is lower, compared to mineral oil.Meyen: Highlights like high flash point bring an increased safety for customers. So, when with standard mineral oil, the machine starts to burn; in this case with the oils, the risk is very much limited. The misting/evaporation rate is far less than the standard oil. The workers do not breathe so much of the oil but more of
the air, and for the operations, we have properties with high lubrication so that tool life of the customers’ tools increase.
What are Oemeta’s initiatives concerning Industry 4.0?Joksch: Industry 4.0 is a focus point for us. We have a lot of data that we have to handle everyday and transfer to our subsidiaries. While we are on the way to install a new computer-based Customer Relationship Management (CRM) system, we have all the customer reports and data from our customers all over the world. We are also just on the way to program a new Laboratory Information Management System (LIMS) that will enable us to
see any data developed. Plus, we are working on an online monitoring and controlling system for our customers.Meyen: On the customer side, data management becomes more important for them. What we are about to provide them will give them a complete transparency of their own data. Besides, it won’t just be storage and management system but also a system that can measure the condition of the coolants online and see to it that the customer always has the latest information about the stages of the coolants.
OUR MULTINATIONAL CUSTOMERS EXPECT MORE PRESENCE IN INDIA
– Joksch
‘‘
ON A GLOBAL SCALE, WE ARE LOOKING FOR PROMISING PARTNERS
– Meyen
‘‘
26 EM | Fe b 2020
MANAGE ME N T I N TER V I EW
What are your products and market expansion plans, in India and globally?Joksch: We want to have a pertinent market share in all relevant metalworking markets, which also include China, India, Brazil in South America, the US and the whole of Europe. So, we want to be on the top supplier of metalworking fluid in all of these markets.Meyen: When it comes to India, we find highly developed industries here already, like aerospace, automotive, oil & gas. These kinds of industries are our target industries, where we, with our premium coolants, can contribute to their success.
What are some of the key initiatives by Oemeta that will drive the future of cooling lubricants? How do you see the demand for it evolving, globally and in India?Meyen: Innovation is one of the main parts in our strategy. That’s why we invest a lot in our research and development in order to really strive for the target and to maintain technology leadership. We are making our contribution in helping the focus industries to step into the next level of the future. With this, we are supplying them service, software and measuring devices and more, which are supposed to help the customers to modernise their production process to strive for zero CO2 footprint.
Environment-friendly and green production is becoming more and more important everywhere. Plus, legal requirements are forcing coolant manufacturers more to go for ingredients that do not cause people and the environment any harm. Additionally, with new industries and materials coming up, we have to deliver our best performance to our customers and follow the environmental, human health and safety demands.
Could you tell us about your export operations and global distributions? Is Oemeta looking at any collaborations & partnerships in India and globally?Meyen: For over two decades, we have had subsidiaries in North America, China and Great Britain. The international market business is becoming even more pivotal for us. So, following the trend of globalisation has been a focus for us, which our customer base, like multinational companies such as BMW and Volkswagen, expect us to follow.
On a global scale, we are looking for promising partners. In India, we are still at the beginning stage; it’s a huge country and market, and it’s not easy to cover the entire country just from the start. That’s why we already have distributors in India and are open to finding new ones. Plus, we are also looking for technology partners that can help us produce our products locally.
Can you tell us about the company’s operations in India? How important is the Indian market in Oemeta’s global operations?Meyen: Many of our key customers are located in India as well. Being able to supply to them in India is important to us and there is enough potential around this. The Indian market is one of the biggest single markets we find on a global scale. And, as it is one of the key markets in the world, there’s great opportunity to grow.Joksch: What’s more, our multinational customers expect more presence in India. There are a lot of OEMs and big automobile suppliers like Schaeffler Group that have plants in India. They tell their suppliers that if they want to be a preferred supplier to the group, then they have to be able to supply products and services in India, as well. ☐
“Stefan Joksch holds a degree in Chemical Engineering from University of Applied Science, Hamburg. He is the member of the executive board at Oemeta Chemische Werke GmbH. He is also Chairman of Metal Working Fluid Committee of the Association of German Engineers (VDI) & member of the Technical Advisory Board of the Union of German Lubricant Manufacturers (VSI).”
“Ulf Meyen has a degree in Electrical Engineering from University of Applied Science, Berlin and has been with Oemeta Chemische Werke GmbH since 2011, where he was the head of international sales from 2011 to 2018 and has been the head of subsidiaries since 2018.”
28 EM | Fe b 2020
V IEWPO INT | T ECHNOLOGY
Upgrading & upskilling – Creating enhanced manufacturing
VIEWPOINT T EC HNOLOGY
The manufacturing industry in India has the potential to emerge as one of the highest-growth sectors here. With the change in the face of manufacturing, the workforce needs to be upskilled and prepared for the future. During this period of change, right skills are the necessary antidote to emerge successful. With this viewpoint, EM magazine seeks to throw light on how organisations are creating an ecosystem for skill development to embrace the future technologies.
Anvita PillaiSub-Editor & [email protected]
“Make the ‘learning’ interesting”
We have structured our training sessions to impart on-the-job training to our workforce to improve & upskill them to deliver quality output. We encourage/induce our workforce to make them aware and teach them new technologies & adopt the same at their workplace. We coax our workforce to move out of the ‘comfort zone’ of their present skills to learn new set of skills. We need to demonstrate the advantages they can get by upskilling themselves; once they see the advantages, they show willingness to learn new skill sets. Also, make the ‘learning’ interesting through games (wherever possible), live examples, videos, etc.
Colleges and private institutions need to upgrade themselves with equipment & instruments by which students can be taught the latest developments in technology. Institutions need to work closely with the industry so that students get ‘hands on learning’ of new skills and practices that are being used in the industry. They also need to encourage students to work on new projects and research. Institutions & the industry need to partner to have a ‘win-win’ situation. For every one year of college academic studies, students can work on live projects in companies for six months to understand the reasons and solutions for the problems faced by the industry. The initiatives by the government will definitely help the manufacturing industry, as the industry will get employable workforce which will be open to upskill further. Over and above, the existing government industrial training institutes that are imparting manufacturing skills can explore ways to facilitate college/institution partnership.
Kabir Bhogilal,CXO – Corporate Strategy,Batliboi
29EM | Fe b 2020
TECHNOLOGY | V IEWPO INT
Upgrading & upskilling – Creating enhanced manufacturing
“Put thrust on practical training and add a generous dose of soft skilling”
At ASDC, we have created Industry 4.0-specific job roles so that the training for the same can be carried out to meet the needs of the industry. These qualification packs have been developed in consultation with the industry experts and have been validated by the industry. We hope these training programs become popular, as the industry adopts the same. Some of our key challenges for skill development have been – firstly, skilled jobs are not aspirational. Also, skill training is not aligned with the industry and there is a lack of credible assessments. We, in partnership with TCS iON, have embarked upon a digitised assessment process (both theory and practical). The entire process removes manual intervention to provide a rigorous, transparent and evidence-based assessment for the skilled trainee.
The employability of students graduating from Indian institutions have been a major cause of concern for the industry across domains. Not long ago, a report from McKinsey stated that only a quarter of Indian engineers are employable. According to an earlier NASSCOM report, only 35% graduates and 12% engineering graduates are employable. This is despite India having the second largest education system in the world, with more than 7,000 universities and 35,000 colleges. What the country is necessarily staring at is, while the industry is transitioning to a system based on advanced technologies such as AI, IoT, IIoT and CPS and embracing ideas of smart manufacturing, the workforce is largely unequipped to deal with the required skillset. It therefore becomes essential that the industry and institutions not only collaborate for job placements, but collaborate for education and skill-training across the 3-4 years of undergraduate college. Educational institutions also need to revamp their knowledge imparting system, put thrust on practical training and add a generous dose of soft skilling.
Government schemes, under the Skill India initiative, have catalysed the growth of the entire skill training ecosystem and has initiated a certain sense of competitive environment for skilled workforce. It has also promoted the WorldSkills competition to benchmark our skill standards against the rest of the world. The industry must take benefits of these schemes, which can fast track the internal initiatives of various organisations.
“Go beyond campus interviews and recruitment drives”
Early into the industry, we learnt that in order to stay ahead of the technology and success curve. We need to keep innovating, and not only keep the technology we develop ahead of its time, but also the skill sets of our people. That tradition continues till date. Presently, we are in a tie-up with about 20 private colleges of Maharashtra and overseas, from where we select students and give them the exposure of our company. The main challenge is that the current syllabus is already over-packed with activities for most colleges, not allowing them the time/effort needed to put to the true skilling needs. Moving forward, industries and educational institutions need to find a common platform to communicate, share, engage and assist each other with. It has to go beyond campus interviews and recruitment drives.
I stay connected with a lot of colleges and have requested many to start a separate topic of ‘start-up funding’, ‘entrepreneurship’, ‘value intellectual property rights registration’ and ‘patents, copy rights and trademarks’. Although a lot of excitement is shown by the college administrations, the curriculum largely hasn’t changed. I feel this is affecting all of us as a society adversely and it is majorly left to the industry to recruit and train the new entrants. Each new government that is formed every five years has declared various initiatives, and only a few have, perhaps, availed those. If not kept simple, SME/SSI units do not have the bandwidth to follow-up for its lengthy compliance. Therefore, they mostly remain unutilised by the neediest industry sectors. It is about letting the industry know the benefits of these initiatives, communicating and having a dialogue with the industry about it.
Arindam Lahiri,CEO,Automotive Skills Development Council (ASDC)
Arundhati,Managing Director,Plazma Technologies
30 EM | Fe b 2020
V IEWPO INT | T ECHNOLOGY
“Promote ‘learning by doing’ method”
At present, the productivity may be less due to lack of awareness of the emerging technologies by the user industry. As a training organisation, we train professionals on implementing Industry 4.0 and related subjects in order to make them aware. Since it’s interdisciplinary in nature, we impart training in related domains, which include mechatronics, industrial automation, sensors, robotics, etc, with hands-on practice. Many a time, organisations do not consider skill development as a priority due to budget and time restrictions. The industry should consider training/skill development as an investment and not cost, because the benefits realised through training are immense, resulting in productivity / quality improvement and enhanced customer delight.
The IMTMA Technology Centre is equipped with latest equipment digitally connected with CNC machines, CAD/CAM/CAE, CMM and metrology equipment, robots, automation training lab and other accessories necessary to impart hands-on training in automation, robotics and Industry 4.0. Our e-learning initiative, a web-based learning platform, wherein the courses can be accessed 24*7 from the desk, is also enabling learning to happen in flexible timings. Academic curriculum is theory-based and has less scope for practical work. Even if colleges have the machinery and equipment, the faculty is not well trained to use the equipment, and it in turn reduces the scope of practical work by students. Faculty development needs to be focused at colleges as one of the ways to prepare students for the industry.
This will enable the facilities available at the college to be used effectively for imparting practical training. Students should be guided such that an internship/project can be undertaken in the industry to help them gain the industry exposure. As an industry association, we collaborate with institutions in faculty development and student development programmes through industry visits, guest lectures, live demos of Industry 4.0-enabled connected factory, customised training programmes at the college, internships, etc. The government should focus on adopting measures for long-term benefits like updating the curriculum as per the industry needs, having a syllabus committee that comprise 50% academicians and 50% industry experts and building college infrastructure that promotes ‘learning by doing’ method.
M Krishnamoorthy,Senior Director - Training,IMTMA Technology Centre
“It is important to create an industry-relevant curriculum”
Our company is continuously working towards skill development, as this is the only way to meet the growing industry demands. We have launched the DEEP initiative under the government’s NEEM scheme (National Employability Enhancement Mission). As a part of this initiative, socio-economically underprivileged youth from local communities (in and around Greaves facilities – various factory locations) are shortlisted, trained and groomed. The talent pool is trained on fit-for-purpose vocational skills so that they can work independently or choose to join any other organisation outside Greaves, leveraging their learnings & skills acquired during the programme. Limited exposure to industry-relevant skills and theory-based curriculum are some of the key challenges with respect to skill development. Strengthening collaborations between academic institutions and the industry is the only way forward to bridge this gap.
Besides the reskilling initiative via DEEP/NEEM, our company has also tied up with RV College of Engineering, Bengaluru, under an incubation project to tap the talent pool & to train them on the upcoming EV technology. With the evolving technology and increasing need for innovation, it is important for academic institutions to upgrade themselves to create an industry-relevant curriculum for practical learning and provide more exposure to the current industry environment. This way, both the industry and the academic institutions will benefit from institutions providing industry-ready talent and, the industry saves time on extensive training and development.
M Mohanan,President – Farm Equipment Business, Greaves Cotton
31EM | Fe b 2020
TECHNOLOGY | V IEWPO INT
“Embrace the electric revolution while maintaining technological superiority”
We are focusing on developing core skill sets including paint, IMGL & VR technologies in our organisation. Advancing Digital Management System (DMC) is one of our digital initiatives. Through Faurecia University, we upkeep our workforce not only to upgrade their technical skills but also behavioural skills, which is a blended Massive Open Online Course (MOOC), focusing on our value system. Shifting from BS-IV to BS-VI has also emphasised on learning of new skill sets. We aim to embrace the electric revolution (battery-powered, hybrid and fuel-cell electric vehicles), while maintaining our technological superiority in combustion engines.
Faurecia has behaviour skills matrix at all levels across the globe through our leadership competency framework. Our university addresses priority skills which individuals need. Developing our plant & program manager is the key challenge, which is addressed by customised learning. For workmen category, getting hands on product knowledge is a key challenge for entry level populations across different business units. Generally, we use our dexterity centres in all our manufacturing plants to upgrade them with a target of 16 hours per person. Focusing on development of team leaders & supervisors is another key challenge. We have designed four modules to take their skill sets to a global level. We are developing operational skill sets through an e-school, which includes practical exposure, campus visits, live projects, internships & placements, guest lectures, etc. These are interventions between industry-institution partnership. We are also focusing on recent graduates & propelling women empowerment. With overall 23% hiring in women category, batch of women graduates have been groomed for future roles. For India to reach US $5 trillion economy ambition, the government should take advanced steps to boost job-oriented skill sets of millennials, which is almost 47% of population & also take appropriate steps for changing skill gaps in the industry and reset the talent demand supply equilibrium in the country. India can also follow France on their international internship programme (VIE) policy, for international assignments of recent graduates to create a talent pool with global exposure.
Rahul Bagale,Deputy Director – Human Resources,Faurecia India
“The government of India needs to stay involved and invested”
DesignTech has set up a new business division named DesignTech Education, which is dedicated towards working with educational institutions and the government to set-up Centres of Excellence (CoE), to articulate new skilling courseware, that can help students learn new skill sets in the area of electro-mechanical engineering. We have set up more than 65 CoE across India to train students in this domain. Some of these centres are also industry-focused, such as automotive, aerospace, industrial machinery, etc providing industry-based technological and applications knowledge. A couple of challenges that we came across were with regards to finding the necessary investment to set-up these CoE/technology upgradation and inducting trainers who can impart knowledge and education to the students. To overcome these challenges, the government’s Skill India initiative has helped in partnering with the industry and to set-up CoE to train students on the latest technologies.
Prashant Deshpande,Associate Vice President – Education & Trainings, DesignTech Systems
We firmly believe in skilling the youth at the academic level, and we are working with few leading institutions to set-up state-of-the-art Centre of Excellence (CoE) for electric mobility labs to influence the future of mobility and to act as mentor platform for students to conduct cutting-edge research. The government has been introducing various skill development programmes and initiatives and have built an encouraging ecosystem for job-oriented industry-ready courses. The Skill India drive is a good platform for the youth to get skill-based training, enabling them to become industry-ready for the long run.
32 EM | Fe b 2020
V IEWPO INT | T ECHNOLOGY
“Robust collaboration enables research and innovation”
With our smart factory in Bengaluru, we have set up a centre for skill development that showcases digital innovation and aims to prepare the people for further development and disruptive innovations in the future. As a company, we have taken several initiatives to address this skill gap in the country. We, in partnership with the Skill Development Institute (SDI), have established a state-of-the-art Centre of Excellence (CoE) in electricity, automation and energy management at a campus in Bhubaneshwar, Orissa. India is currently working towards becoming the ‘skill capital’ of the world. With demographic, technological and structural shifts transforming the nature of work in the country, the new entrants to the workforce must be trained, skilled and made employable. Various strategies such as skilling, reskilling and formal introduction to various skills that must be acquired have been reinforced. With India being one of the fastest growing countries in the world, the job market has witnessed a major transition with the presence of technologies like Big Data, Artificial Intelligence, IoT and Machine Learning, that has disrupted the employment market. Companies today feel that graduates lack the skills, aptitude and proficiency required to cope with today’s challenges.
So, it is advisable to step away from the existing curriculum and instead, focus on research, innovation and promote hands-on learning, teamwork and entrepreneurial skills that will help them gain knowledge and understand the changing business dynamics. Colleges and private institutions can help by taking various steps like – helping students work on their cognitive skills, organising workshops, going beyond classroom training, providing collaboration with foreign universities, offering experiential learning initiatives, etc. The government initiatives such as ‘Skill India’ and ‘Digital India’ aim to develop the right skills to address the growing skill gap in the country, in context of the changing industrial landscape defined by new-age technologies. Industry-academia collaborations have reaped great rewards and augers well for the economy. A robust collaboration enables research and innovation for corporates by producing an employment-ready workforce. For universities, these partnerships will help create training facilities and internships for students and thus, groom them for a solid career foundation.
Meenu Singhal,Vice President – Industry Business,Schneider Electric India
It also identifies execution partners, like DesignTech, that would look after the training and management of these centres. The changes in the curriculum do not correspond with the changes in the industry. Hence, colleges and educational institutes should partner with the industry, who can help them with setting up the right infrastructure and update their study curriculum. Engineering graduates today lack inter-disciplinary understanding. This should be considered by educational institutes while formulating and articulating their course curriculum. Colleges need to partner with the industry to help students gain practical knowledge through industry projects, internships, Centres of Excellence etc. The Government of India needs to stay involved and invested in regularly adapting and developing the right study curriculum and courseware for educational institutes. Industry 4.0, smart manufacturing, advanced robotics, industrial automation, Big Data, IoT and many other technologies are paving their way rapidly into the industry, and this knowledge needs to find a place in the students’ syllabus. Continuing with their existing efforts and with the backing of right policies, push in finance and investments, infrastructure development and international trade, would help the manufacturing industry further revive and thrive.
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34 EM | Fe b 2020
E-MOB IL I TY FO CUS
Gradual expansion of e-mobility – Benefits to the environment
E-mobility had been undergoing an exponential growth in sales. Under the right circumstances, EVs already contribute significantly to climate protection. In countries that generate only a small proportion of their power from fossil fuels (e.g. France and Norway), an EV saves more than 50% of CO2 emissions over its entire life cycle, compared to an efficient combustion engine. In many key markets such as USA, India, China and even Germany, electricity production is a lot less
clean – to the degree that pure EVs or Plug-in Hybrids (PHEV) are only worthwhile to a limited extent or even have a negative impact on the climate in the long-term compared to an efficient combustion engine. Globally, only 26% of the power came from renewable sources in 2017. Even in 2040, according to current forecasts, only 31% of the world’s electricity demand will be provided by renewable energy – as a result, most emissions are only shifted from the engine to a fossil power plant.
The transition from internal combustion engines to electric vehicles plays an important role on a global scale in mitigating man-made climate change. In many markets, electric cars are not necessarily beneficial for the climate at present and in the medium term. Instead, they can even cause up to 30% more CO2 emissions than combustion engines. The article presents an extensive market evaluation conducted on the status quo and the development of the world market as well as key regions.
35
FOCUS E-MOB IL I TY
EM | Fe b 2 0 2 0
Range of saved/additional CO2 emissions based on energy mix
Historical and expected development of battery prices
Expected surge in demand for key metals in EV batteries
Consumer perspective: The significant expense
The higher acquisition costs of EVs are only amortised to a limited extent. Ultimately, an EV will cost a driver an extra five cents per kilometre over their lifetime – in addition to an uncertain resale value. EVs and combustion engines face diverse challenges when it comes to driving restrictions. Range limitations, charging times and charging infrastructure will continue to deter many buyers from purchasing an EV in the near term. On the other hand, internal combustion engines are already subject to occasional local driving bans or registration restrictions, which prove to be quite effective to influence purchase behaviour.
Among these imperfect choices, many consumers will ultimately choose a combustion engine, if it seems to be the best solution for their individual mobility requirements. According to current forecasts, 85% of passenger cars will therefore still be produced with an internal combustion engine in 2025. CO2 emissions for these vehicles must be kept as low as possible.
Batteries – A bottleneck for EVs
Further breakthroughs with regards to battery technology are essential, since batteries are significantly handicapping EVs in several aspects:
• Significant additional manufacturing costs (around $200 per kWh)
• High emissions during battery production (150-200 kg per kWh) – a ‘mortgage’ that is difficult to offset even over the entire life cycle
• Rare raw materials with sharply increasing prices, partly mined in crisis regions (e.g. cobalt)
• Delivery bottlenecks that delay projects (e.g. Hyundai Ioniq Electric)
• Limited range discourages potential buyers
36 EM | Fe b 2020
E-MOB IL I T Y F OC US
48V hybrid technology as a viable alternative
In countries that generate most of their electricity from fossil fuels, a 48V hybrid constitutes the most climate-friendly solution now and is also viable for the long-term. For this, the conventional alternator is replaced by a 48V Boost Recuperation Machine (BRM). It employs the braking force recovery technology (‘recuperation’) familiar from Formula 1 to reduce fuel consumption up to 15%, which will be indispensable for achieving CO2 emission targets in the near and medium term. The solution also proves beneficial for consumers – in contrast to EVs and PHEVs, the additional costs of 48V are amortised through fuel savings.
Key markets: China leading the way
China has established itself as the largest car market in the world and is also leading in terms of EV sales. With a comprehensive package of measures (subsidies, local driving bans for combustion engines, CO2 targets), the government in Beijing continues to actively promote this transformation. In China, however, 70% of the electricity comes from coal, so electric cars keep cities clean, but do not yet make a significant contribution to climate protection.
The other key markets (USA, Europe and India) are similarly struggling with the energy mix. The shift towards EVs is also progressing even more slowly in these countries. USA and Europe in particular face the risk of losing their leadership role in the automotive industry. In all these regions, it is also becoming apparent that the current CO2 targets can only be achieved if emissions from combustion engines are reduced drastically. Especially the 48V and start/stop technologies have an important role to play in this regard. ☐Courtesy: SEG Automotive
Jato; IHS Markit: Energy Brainpool; International Energy Agency; U.S. Energy Information Administration
CO2 footprint small car (50,000 km mileage)
CO2 footprint upper middle class (150,000 km mileage)
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CAD/CAM | T ECHNOLOGY
38 EM | Fe b 2020
Benefits of automatic CAMWith innovation in technology, there is also a rising need for the CAM software to be more automated, consistent & efficient. The following article investigates the advantages of programming strategies like Automatic Feature Recognition (AFR) and feature-based machining.
When utilising CAM software, one of the common questions is ‘why can’t it be more automatic?’. There are many people that would like to simply load a CAD model and have the CAM software determine the best way to mill it and then automatically program it. While this utopia world of CAM programming may not exist for all types of parts, that precisely is one of the goals of Automatic Feature Recognition (AFR). To sort out the common elements of the 3D model and using rules and templates, create the CNC code on the part.
Automatic Feature Recognition (AFR)
Solid models have all the necessary information to describe a part’s shape. Users do not need to waste time re-creating the part data just for the CAM system. Most prismatic parts comprise standard features such as holes, pockets and bosses. Where other CAM systems may require users to define geometry, create boundaries and then, specify cutting operations, AFR eliminates that. Typical 2D parts can often be
programmed in just a few minutes, versus an hour or more.
Automatic vs interactive feature recognition
Users can typically run a wizard to automatically find and sort the different features within their parts. Typically, the input stock material size gives it an initial tool orientation, and the software then analyses the solid model and creates machinable features for machining. These features will then be listed and automatically sorted for logical machining operations. Alternatively, users that wish for fine control may select the features themselves interactively and sort them manually. Usually the best approach for any individual company is a combined approach of utilising AFR with some interactive selection or sorting of features for their personal preferences.
Feature-based machining
Once the features are defined, they are sorted for machining
TECHNOLOGY | CAD/CAM
39EM | Fe b 2020
efficiency, and then they can be machined with strategies ideal to the properties of the individual feature. For example, an open pocket may be machined with a different strategy than a closed pocket. Or shallow bosses will be milled differently than tall ones.
Programming with features
Once the features are found or selected, a three-step process or a wizard can be used to program parts utilising the features. Users first select from a list of features and you may input information regarding the shapes and sizes. Next, users select a preferred machining strategy based on the information provided or go with the recommended strategy. The programmer can accept the strategies suggested based on the type of features for rough, semi-finished and finished passes, or make changes to fit the machining needs for that part.
Lastly, the combination of feature dimensions, stock material and cutting strategies are analysed, allowing the software to recommend the most efficient cutting tools, toolpaths, and feeds & speeds for each cutting operation. The programmer can choose the recommended tool or search for another tool in the library. Users can accept or change the recommended feeds and speeds.
Although automatic programming provides a good starting point, users should still retain control over how the software generates its CNC code. Users can set machining preferences ahead of time for the CAM software to apply to future works. Although it recommends tools, feeds, speeds, etc, the users can override it with their own preferences at any time.
From different work offsets
AFR can extend beyond using just the tool axis and can be utilised in multiple setup orientations to find all features on a part, regardless of the orientation. These will then be sorted by the workplane and feature type. Users can then decide the order of various orientations and program the features accordingly.
Built-in intelligence
Based on the user’s manufacturing knowledge, AFR
intelligently makes decisions for them. It automatically selects the tools, stepover, stepdown and more, providing programming consistency, utilising parameters out of the box, or those that they customise for their own operations. These parameters, among others, form a part of the operations. As a user creates multiple features, the software dynamically updates their process planning, providing an optimal machining order, based on what they want to achieve.
Part updates
Part changes are an inevitable fact of working in a job-shop. If a part has already been analysed and programmed, then the part geometry changes, one can simply compare the updated part to the original. Feature list will automatically update for the changes, and the generated CNC code will update. This strategy is not only useful on part changes, but also for milling similar parts, or a family of similar parts. Simply utilise AFR to sort and program one part, tweaking with the user’s personal preferences, then apply all of those same strategies to a similar part, automatically.
Better utilisation of workforce
Utilising AFR allows the workforce to be utilised in a more efficient manner. AFR allows for standardisation of the entire machining process. The best expert machinists could set up the machining templates; and all programmers, regardless of the experience, would be able to utilise their knowledge and experience. This allows for consistency in the users to finish, tool life and overall quality of parts produced.
Retaining & simplifying processes
AFR and feature-based machining can simplify the machining processes of certain parts typical to the job-shop, allowing for programming to be completed in minutes instead of hours. Knowledge gained during the process can be retained for future jobs, for the user’s individual preferences. ☐Courtesy: Originally appeared on Autodesk.com
Once the features are defined, they are sorted for machining efficiency, and then
they can be machined with strategies ideal to the properties of the individual feature
40 EM | Fe b 2020
ENG INE E R IN G MAT E R IALS T E CH N OL OG Y
Additive Manufacturing with liquid materials
The use of Additive Manufacturing processes is increasing within industrial applications, as they bring some significant customer benefits compared to conventional processes. Additive Manufacturing is based upon the layered structure of a component. The production time, therefore depends on the volume to be applied to the component. The geometric shape of the individual layers has a minor influence. This results in a greater amount of design freedom, without incurring extra time and cost through additional steps, such as machining. This process is particularly suitable for the production of geometrically complex components, such as bionic structures. The process from the CAD file to the finished component is largely automated.
In this way, initial models of components can be produced quickly and cost-effectively.
As it happens, Additive Manufacturing processes are based on the extrusion of liquids. This area is still in its infancy, but is currently developing fast. In particular, the large number of new materials for 3D Printing creates great application potential for this technology. These include, for example, silicone, resins or metal pastes.
Methods for additive production with liquids and pastes:• Pneumatic dosing unit• Drop-On-Demand (Jet valve)• Endless piston principle
There are many advantages that have led to the fact that Additive Manufacturing has established itself in many industrial applications. The area that is still in its infancy but is currently developing fast, is that the Additive Manufacturing processes are based on the extrusion of liquids. This whitepaper examines existing technologies for the Additive Manufacturing of components from liquid materials and highlights the methods for additive production with liquids and pastes.
Simon KasböckBusiness Development – Additive ManufacturingViscoTec
41EM | Fe b 2020
TECHNOLOGY ENG I NEER I NG MATER IALS
Pneumatic dosing device
With the pneumatic dosing device (time-pressure method), a container is put under a defined pressure. The liquid is pressed out of the material outlet by a pressure force applied to the piston (Figure 1). The control parameter for this system is the pressure applied to the liquid. Due to temperature fluctuations or thixotropic properties of the fluid, the viscosity can change suddenly. This difference in viscosity, for same pressure, results in different quantities of applied fluid.
The system is, therefore, not distinguished by its process stability and has no high repeat accuracy. Fluctuating process conditions (e.g. temperature or humidity) require a daily calibration procedure. In addition, the desired suck-back of material (retract) in 3D Printing is not possible with this method since the pressure on the fluid can only be reduced and this does not lead to a reverse flow of the material.
However, the implementation of the system is very cost-effective, as it is a simple system with few components and no complex mechanics. In addition, the weight of the printhead is low compared to other printheads. The achievable minimum layer thickness depends on the needle at the material exit and can be >0.2 mm under ideal process conditions.
Drop-On-Demand (Jet valve)
The drop-on-demand system uses a jet valve to apply the liquid. Similar to the technology of an inkjet printer, this produces very fine droplets that are jetted onto a building platform. There is an air gap between the valve and the building platform, so there is no contact between the platform and the valve. Control parameters for the application of material are the
number of droplets per time unit and the size of the droplets. ‘BubbleJet’ or ‘piezo’ technology is usually used to generate the droplets. In the BubbleJet process, a local steam bubble is generated by a heating element, which displaces material through its volumetric size change and thus, produces a drop.
With piezo valves, the inverse piezo effect moves a cylinder that ejects a drop. The achievable droplet frequency is about 23 kHz. Depending on which fluid is applied with the jet valve, there are different terms for the processes:
• One of the first historical procedures with a jet valve is the ‘Binder Jetting’. A liquid binder is placed in a powder bed. Between each layer, a squeegee moves over the powder bed and applies the next powder layer to the component and the assembly space. The print head doses the binder at the desired points and therefore, solidifies the powder. With this process, components can be produced from a variety of powdery materials, such as starch, gypsum, aluminium and plastic. If the binder is dyed, components with any colour gradient are possible. In addition, no supporting structures are required, as the powder bed supports the component. Some materials require post-treatment in the furnace (sintering) to achieve greater strength.
• Another drop-on-demand system is the ‘PolyJet’ (material jetting) process. Instead of the binder, a photosensitive polymer is used. The component is composed of the polymer, which is jetted directly onto the printing bed. Therefore, no powder is required as in binder jetting. Each layer applied must be cured with UV light.
• A recently developed process enables the jetting of silicones and therefore, the production of silicone components using the drop-on-demand principle. As with the PolyJet process, the component is cured with UV light after each layer.
Figure 1: Schematic representation
of a time-pressure system
42 EM | Fe b 2020
ENG INE E R IN G MAT E R IALS T E CH N OL OG Y
A big advantage of jet printheads is their high resolution, which is linked to the size of the droplets. This allows minimum layer thicknesses of up to 16 μm to be achieved with low-viscosity materials. The result is a very high surface quality in which the layer effect is hardly noticeable. If silicone with a high viscosity is used, the smallest possible resolution is currently 0.1 mm.
During the generation of the droplets, a high local energy input is introduced into the fluid. The resulting shear force can be harmful to some materials. All systems based on a jet valve have one disadvantage: the fluid has to be precisely adjusted to the system so that the droplet application works as desired. This means that no standard materials can be used, but specially adapted fluids must be processed. These special materials are mostly very cost-intensive.
Endless piston principle
The progressive cavity pump, also known as the endless piston principle, is one of the rotating positive displacement pumps. The system consists of a rotor which is constructed like a round screw thread with a large pitch and a large depth. The elastic stator has double the thread and twice the pitch length of the rotor. This geometry results in closed cavities with the same defined volume between rotor and stator, which are pushed forward by the movement of the rotor. Thanks to the closed cavities, the pump is self-sealing and therefore, a valve at inlet and outlet is not necessary. The material output is volumetric and directly proportional to the rotation angle of the rotor.
By combining two pumps, two-component materials can also be processed. Both materials are each pumped into a static mixer and mixed. The mixing ratio is freely selectable and can be adjusted during the production process.
Compared to the other printheads, the design of the stator and rotor results in a relatively long design. In contrast to the time-pressure system, the high quality requirements placed on the components of the progressive cavity pump incur relatively high costs, which, however, remain below those of a drop-on-demand system.
By conveying the fluid in the cavities, very low shear forces are generated, which is why the system is also suitable for shear-sensitive media. An essential point in Additive Manufacturing is the material retraction (retract). The direction of rotation of the screw is reversed and material is returned to the pump. This creates a defined thread break. Unwanted dripping of material is therefore, prevented.
Another major advantage is the variety of materials that can be processed with this principle. These include low to very highly viscous fluids, liquids with a high filler content, temperature-sensitive materials and abrasive fluids. Concrete examples already in use are silicones, polyurethanes, epoxy resins and ceramics.
Thanks to the special geometry of the rotor and stator, the delivery of the fluid is pulsation-free, which leads to a constant width of the generated lines and an even outer contour. Due to the volumetric dosing, the adaptation to different nozzle diameters is very easy. The smallest inner diameter of the nozzles is currently 0.2 mm. Therefore, layer thicknesses of <0.2 mm can be achieved.
The most suitable process
Finally, it must be said that the various processes for Additive Manufacturing with liquids all have different advantages and disadvantages. It depends on the required properties of the component as to which process is most suitable. ☐
Figure 2: Structure of an
endless piston principle
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44 EM | Fe b 2020
TEST & ME ASURE ME N T | T E CH N OL OG Y
Jendamark Techcellency used to use traditional hand tools to carry out metrology tasks, but the company often struggled with time management issues and could not finish projects in a timely way. So, it turned to FARO for its 8 ft Platinum FaroArm to gain an improved solution for its metrology requirements. The case study discusses how this investment helped, which also further led Jendamark Techcellency to purchase the FARO Laser Tracker ION and QuantumM FaroArm.
With the help of the ‘Make in India’ campaign — launched in September 2014 to transform India into a global design and manufacturing hub — the country is on the path of quickly becoming a hub for hi-tech manufacturing. With the potential to reach US $1 trillion by 2025, the country’s manufacturing sector is expected to become one of the world’s top three by 2020.
A leading manufacturer that offers automation systems, aerospace tooling, pallets for engine assembly and sub-assembly fixtures & tables, Jendamark Techcellency Automation focuses largely on the manufacturing of automation assembly lines as well as aerospace and jig fixtures.
The company boasts of a state-of-the-art manufacturing unit that is well-equipped with both conventional and high-
tech equipment. To further expand its capabilities, the company has also invested in a new 10,000 sqft facility to support rising demand for its quality products, which are used by renowned aerospace and automotive manufacturers such as the Audi Group, Mahindra & Mahindra and the subsidiaries of the Tata Group.
The need to meet international standards
The manufacturing of the various parts necessary for automation systems, aerospace tooling and pallets for engine assembly and sub-assembly fixtures and tables require high levels of precision and accuracy.
In the past, Jendamark Techcellency would outsource
Ensuring precision & efficiency through measurement solutions
45EM | Fe b 2020
TECHNOLOGY | TEST & M EASUREMENT
metrology processes in areas such as alignment, calibration and inspection. An external service provider would be engaged to support product quality control and validation of products. However, with the increasing volume of production, the service providers could no longer support its production needs.
Previously, traditional hand tools, such as Vernier calipers, height gauges, tape measures and fixed coordinate measurement machines (CMMs) were used to carry out metrology tasks at the company. Due to the nature of this manual work, the company often grappled with time management issues and could not complete projects in a timely manner.
Sunil Megade, Plant Head, Jendamark Techcellency, shares, “The conventional measurement methods were time consuming and unable to provide the accuracy we needed for our products. Careful measurements need to be implemented at every stage, whether for inspection, calibration or alignment, to ensure that the quality of our products meet international standards.”
Streamlining processes for increased precision & time saving
Having heard about the benefits of FARO’s portable CMMs from their service providers, Jendamark Techcellency decided to invest in an 8 ft Platinum FaroArm in a bid to find a better solution for their metrology needs. A portable CMM, like the FaroArm, provides mobility, so the operators can deploy a solution wherever there is a need. It is also less cost-prohibitive when compared to fixed CMMs.
Dimensional
Measurement
Systems For
Manufacturing
Quality
Control
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T E CH N OL OG Y | TES T & MEASUREM ENT
46 EM | Fe b 2020
TEST & ME ASURE ME N T | T E CH N OL OG Y
Jendamark Techcellency’s operators no longer worry about moving a bulky, heavy object that can be as heavy as two tons, into a measuring room. In addition, measurements taken with the FaroArm are much more precise and accurate than those obtained using conventional methods.
Immensely satisfied with the positive results from their initial investment in the Platinum FaroArm, the company purchased the FARO Laser Tracker ION and QuantumM FaroArm to further improve their manufacturing processes, when the solutions became available in 2016 and 2017 respectively.
The FARO Laser Tracker ION, a state-of-the-art interferometer-based measurement system, allows Jendamark Techcellency to inspect large parts in both, the automation and aerospace products, with the highest precision due to its accuracy level of up to 0.015 mm. It can be applied during in-line measurements when setting jigs and aerospace parts for assembly lines, where accuracy is crucial. As the Laser Tracker ION is also useful for measurement of large objects, the company uses it to measure objects that are up to six metres long and weighs up to two tonnes.
The QuantumM FaroArm, on the other hand, is certified against ISO 10360-12:2016 and ensures maximum measurement consistency and reliability in all of Jendamark Techcellency’s applications. 20% lighter in the hand than its predecessors and immediately ready to use as it requires no warm up time, it also ensures better productivity during the inspection, design and manufacturing process, by enabling
When being set in automation systems and assembly lines, the intricate parts require accurate measurements — especially during calibration and inspection
operators to work for longer hours, more comfortably.FARO’s measurement solutions provided Jendamark
Techcellency with support throughout the pre-production, production and post-production process, eliminating concerns about human error and lengthy measurement times. Jendamark Techcellency was then better able to increase process efficiency without compromising on the quality and precision of its products.
Moving ahead
With enhanced efficiency and improved capabilities from FARO’s 3D measurement solutions, Jendamark Techcellency is now able to eliminate the need for additional verification and inspection at its customers’ facilities, many of whom are based overseas.
“We are constantly trying to improve our processes,” remarks Megade and adds, “FARO’s 3D measurement solutions have proven to be valuable additions and they have allowed us to streamline our operations while maintaining a high standard of quality. FARO’s solutions have helped eradicate the struggles we faced in managing our inspection and monitoring processes and improved our overall productivity. Going forward, we plan to invest in more of FARO’s solutions for their high-performance functionalities — especially when we venture into reverse engineering applications.” ☐Courtesy: Faro Technologies
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48 EM | Fe b 2020
COMPO S IT E MACH IN IN G SPE C I AL F E AT URE
Conventional machining of composite materials poses problems due to the combination of ultra-stiff fibers with relatively weak matrices. This case study discusses how Flow International Corporation selected Renishaw HS10 and HS20 laser encoders for the company’s Composites Machining Centre (CMC), that deliver part per million accuracy on X-axis motion during week-long machining cycles on composite panels up to 40 m long.
Flow International Corporation’s Composites Machining Centre (CMC) hits the mark for single setup processing of 40 metre long composite wing skins, and one of the keys to holding long axis accuracy during week-long machining cycles is Renishaw’s HS10/HS20 laser encoder. Measuring distance with the precision of a laser interferometer, the encoder and its companion RCU10 real-time compensation unit deliver part per million positioning accuracy on the CMC’s X-axis. The laser encoder eliminates variables that had to be compensated for when using a physical scale attached to the machine.
A one-stop processing centre
Flow’s CMC is one of the new machine tools developed to meet the aerospace industry’s need to produce large monolithic
parts with minimal dimensional variation. “Reduced variation in parts is an industry wide goal,” explains Mark Saberton, Director – Aerospace, Flow International Corporation and goes on, “The objective is reduced assembly time, effort and tooling. The OEMs want to eliminate assembly shimming, which adds weight to the product and time to the process. They want parts to meet tolerances when they arrive on the assembly floor, rather than using fixtures and shims to bring parts into assembly tolerance. Weight is also an issue; less variance on a plane’s parts ensures better control of the aircraft’s final weight.”
Flow’s CMC was created as a one-stop processing centre for composite parts that have been autoclaved. It can be configured as a mid-rail gantry or dual travelling column machine. The gantry design carries two rams on a single gantry with a 5-axis wrist on each ram, one for ultra high pressure
Enabling accurate machining of composite parts
49EM | Fe b 2020
SPEC I AL F EATURE | COM POS I TE MACH IN ING
waterjet cutting and one for conventional high-speed routing. The CMC can do all the finish machining on a wing skin: trimming, drilling, routing, surface milling, marking and inspection – in one setup, and parts leave the machine ready for assembly. The machines are widely used by Airbus partners around the world.
Gaining accurate feedback
The modular CMC is available in standard X-axis lengths of 6-50 m, as well as custom sizes. “We had always used tape scales on the X-axis, but a physical scale 30-50 m long, attached to the machine, introduces structural issues and makes thermal compensation much more difficult,” explains Todd Fuchs, Senior Electrical Project Engineer, Flow and continues, “The temperature differences the machine sees over a 40 m length during a 130 hour machining cycle can be relatively extreme, even in an air conditioned plant. Between changes in the scale itself and the substrate of the machine, the variables become too complex. The HS20 laser encoder is the easiest way to obtain accurate feedback on such a long axis.”
With a rack and pinion drive on each side of its gantry, the CMC uses split X-axis feedback with a laser on each side, working as a master and slave for positioning. The lasers are located under the way cover bellows near the drivetrain, in a duct purged with clean, dry air, ensuring stable measurements and protection from airborne debris, which might ‘break’ the laser beams.
Merits of HS10 and HS20
Flow has used Renishaw’s HS10 laser encoders and its successor HS20 on a total of 24 machine axes. Installations have been carried out in Germany, Spain, France and the UK, with support from Renishaw engineers. Both encoders use the same laser interferometry technology used for linear error measurement and compensation by machine calibration specialists, except the laser encoders are designed to be a permanent scale on the machine, replacing glass/tape fitment and resolvers.
Unlike a tape or glass scale, the laser encoder system has no short-term errors which can ‘stack up’ on long axes, and its 1 m/sec measuring speed accommodates today’s fast-moving machine tools. The HS20 is sealed to IP43 and hard anodised to provide all round protection in harsh machining environments. “Our X-axis repeatability spec for a 40 m gantry is 0.0381 mm (0.0015”), essentially equal to the laser interferometer used to calibrate the machine,” says Fuchs and adds, “The laser also provides twice the resolution of a tape scale, though a machine of this size and type is unable to make use of it.”
The significance of part probing
X-axis positioning precision is also a factor during part probing, which is vital to the cutting process. The CMC uses a Renishaw RMP60 touch probe for locating the part during setup and confirming finished dimensions after machining. “Some of these parts, such as wing skins, are worth nearly $1 million before machining,” Fuchs stresses and goes on, “When they come to the machine, they are seldom a match to the CAD model, so we probe extensively and do a lot of best fit calculations prior to machining.”
The touch probe’s compact design allows it to access and measure any point on the part that the machine head can reach. Its Frequency Hopping Spread Spectrum (FHSS) radio signal transmission allows multiple probe systems and other industrial equipment to coexist in ‘noisy’ industrial environments, particularly as wireless wi-fi and bluetooth communications proliferate.
Fuchs informs that the company has laser equipped machines in many European countries already, and the Renishaw HS20 laser encoder has proven easier to deploy than tape scales, and is reliable and robust. “For these long axes, where machines are cutting expensive and critical parts, customers appreciate X-axis positioning that is as accurate as the gold standard of linear measurement, the laser interferometer. Together, with the RMP60 probes, we are able to provide a real benefit to our customer,” he signs off. ☐Courtesy: Renishaw
Wing cover CMC at the Flow workshop, Indiana
EM | Fe b 2020
TECHNO LO GY | NEWS
50
Insulation monitors
DOLD Electric India recently offered the insulation monitors of the
VARIMETER IMD series, including MK 5880N and MH 5880, for monitoring
switched-off loads in earthed systems.
The insulation monitors MK 5880N and
MH 5880 are connected to a drive in
such a way that they only monitor the
insulation resistance if the drive is
disconnected from the mains. For this
purpose, an insulation monitor is
connected via the closed contact of the
contactor or the circuit-breaker and only
operates when the drive is disconnected.
These monitors are suitable for three-
phase and alternating current mains up to 500 V and for mains frequencies
from 10 Hz to 1,000 Hz. The devices are designed for installation on DIN
mounting rails; the connections are available either as screw terminals or
cage clamp terminals. The auxiliary voltage, measuring circuit and output
contacts are galvanically isolated from each other. The alarm value for the
earth fault can be set from 5 Ω to 100 kΩ for both devices. If the value falls
below the set value, the output relay drops out and the alarm is triggered,
and a red LED signals the insulation fault.
High speed & feed lines
TaeguTec’s latest product line – SFEEDTEC High Speed & Feed Lines –
categorised into SFEEDTURN, SFEEDCLAMP, SFEEDMILL and SFEEDDRILL
are high-productivity, high-performance
solutions engineered to meet the most
complicated challenges in machining, be
it surface finish requirements, high feed
rates, high accuracy or close tolerances.
The TURNSFEED tool enables high feed
turning up to 3 mm/rev, which is
important because machining depths are
progressively decreasing in the
manufacturing milieu. This tool also has a special capability to machine in two
directions. The MILLSFEED tool effectively addresses the applications with
many options of indexable-insert endmills covering diameter range of 6 mm -
14 mm, while the unique insert design enables light, moderate and high feed
milling. Its special insert seating surface ensures rigid clamping of insert in the
pocket. The DRILLSFEED tool effectively uses many unique features of Drill
Rush and tops it with self-centring 3 flute geometry. This helps customers to
reduce setup time and increase drilling feeds in rigid setups; available in
diameter 16-20 mm range bracket to start with. The triple cutting of the inserts
imply high productivity in addition to excellent hole accuracy.
Email: [email protected] | Tel: +91-99090 01585 Email: [email protected] | Tel: +91-80-4901 3211DOLD Electric India | Vadodara TaeguTec | Bengaluru
Insulation monitors from the
Varimeter IMD series
SFEEDTEC
Speech software module
Beckhoff Automation recently introduced the TwinCAT Speech software,
which is an automation system, that can learn to hear and speak. The
TwinCAT has now completed the analogy
with the capabilities of a human. The
speech-based input and output supports
operation and maintenance personnel,
eliminating the need to access
conventional control terminals. Few of
the advantages of the software are:
• Communication via the standard
audio output of the PC-based control
system (sound card with speakers,
headset, etc)
• Ability to speak and understand a
wide range of national languages (26
languages supported)
• Selectable different male and female voices
• Available online and offline (online: optionally with Amazon Polly;
offline: Windows)
• Optional caching of online-generated audio files
The new software module allows multilingual input from the machine
Email: [email protected] | Tel: +91-20-6706 4800Beckhoff Automation | Pune
TF4500 | TC3 TwinCAT Speech
operator and output control for queries or information is in line with the
industry standards. This enables interaction with the automation system to be
carried out much more efficiently and
conveniently by the machine operator.
The technology can be applied to any
machine control function across numerous
industries in a wide range of applications,
from machine designing to building
automation. The speech input is available
as an offline function, and it is implemented
based on a built-in Windows operating
system functionality. In other words, it is
accomplished without requiring an internet
or cloud connection.
The speech output from TwinCAT
Speech is available as both, an offline and online function. In case of an
offline function, support is provided by the appropriate Windows functionality,
and in case of online, via Polly – the text-to-speech service from Amazon. The
realistic sounding speech output for these applications is synthesised with
the aid of deep learning technologies. Multiple voices can be supported in
addition to the caching of audio files generated online.
EM | Fe b 2020
NEWS | TECHNOLOGY
51
Milling assortments
Dormer Pramet recently expanded its milling assortments for die & mould
and general machining applications with several introductions, such as, the
double-sided SNGX11 insert, SSN11 cutter and
ADMX07 milling program with a new F geometry
for finishing and semi-finishing applications. The
new insert can be used for high feed milling with
up to 1.7 mm depths of cut. A strong main
cutting edge ensures high level of durability and
process security – especially when machining
corners inside a pocket. With eight cutting edges,
the square shaped SNGX11 also represents an
extremely economical solution. Also, it is suitable
for copy milling, helical interpolation, ramping, progressive plunging and face
milling and is available in two geometries. M is for machining steel, but also
hardened steel and cast iron, while MM provides a smoother cut and is more
suitable for stainless steel, soft steel and super alloys. The new cutter range
is available in diameters from 32 to 125 mm, with intermediate sizes for die
and mould applications. All cutters feature a special through-coolant design
to further improve process security and a high overhang to support deep
milling up to 10xD. The ADMX range is a universal 90° tool suitable for a
variety of milling applications.
Leak detection camera
FLIR Systems recently announced the FLIR GF77a Gas Find IR camera, which
is a fixed-mount, uncooled, autonomous leak detection camera designed
specifically to visualise methane and other
industrial gases. A new camera in the
company’s Optical Gas Imaging (OGI) series,
the connected GF77a provides upstream and
midstream gas processors, producers and
operators with the ability to monitor
continuously for invisible, potentially dangerous
methane leaks at natural gas power plants,
renewable energy production facilities,
industrial plants and other locations along a natural gas supply chain. The
camera is engineered to detect industrial gases such as methane, sulphur
dioxide and nitrous oxide to improve inspections and reduce the chance of
false readings. Featuring a High Sensitivity Mode (HSM), the technology
enables better detection capabilities by accentuating movement to make gas
plumes more visible to the user. The radiometrically-calibrated GF77a also
measures temperature, making it a solution for monitoring tank levels and
inspecting components that may overheat. The camera provides advanced
connectivity protocols that allow for seamless integration into gas monitoring
systems to meet the needs of the oil and gas industry.
Email: [email protected] | Tel: +91-11-46015686 Email: [email protected] | Tel: +91-11-4560 3555Dormer Pramet | New Delhi FLIR Systems | New Delhi
Double-sided SNGX11
inserts and SSN11 cutter
GF77a
Machinery for vertical farming
igus recently introduced a machinery used in vertical farming works,
which ensures freedom from maintenance and trouble-free operation. Due
to the lubrication-free feature, FDA compliance and highest hygiene
standards, plants, vegetables,
salads and fruits are not
contaminated. In addition, the tribo-
polymers are corrosion-free and
low-maintenance as well as
resistant to dirt, dust and soil. There
is also great potential in the concept
of autonomously operating, fully
automated vertical farms. Low cost
automation systems enable cost-
effective vertical planting,
harvesting or packaging throughout
the year, along with a quick return
on investment.
Living Greens Farm (LGF) is an exemplary for its idea of converting
vacant skyscrapers into vertically arranged farms. These cultivation
techniques require special machineries for nutrient supply and irrigation of
the plants. A patented traverse system equipped with the company’s
Email: [email protected] | Tel: +91-93411 36381igus India | Bengaluru
Reduced plant downtime
e-chain carries enriched water directly to the plant roots. In an empty
warehouse in Minneapolis, about 4,000 square metres of space is used
in this way to yield the same quantity of food produced
from more than 40 hectares of
conventional agriculture.
Intelligent Growth Solutions
(IGS) also uses the motion plastics
for automation in vertical farming.
One of the goals of the company,
Growth Towers, is to make vertical
farming more economical by
improving productivity, yield, quality
and consistency, by drastically
reducing electricity and labour
costs. The vertically arranged IGS
systems must be reliable, yet low-
friction and easy to maintain. The
drylin linear guide systems from igus meet all requirements and ensure
trouble-free operation of the system. A year after installation of the
lubrication-free components, no noticeable wear of the bearing shell
could be detected at inspection.
52 EM | Fe b 2020
H IGHL IGH T S | CO MPAN Y INDEX | IMPR INT
» Production Software (ERP, MES)Typical organisations in manufacturing, distribution and services tend to feel burdened by their ERP system. That’s why organisations are adopting cloud-based enterprise management solutions. The upcoming edition explores the reasons to make the change.
Highlights - March 2020
COMPANY INDEXName . . . . . . . . . . . . . . . . . . . . . . .Page
Ace Micromatic Group . . . . Front Inside Cover
ACMA . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Atlas Copco . . . . . . . . . . . . . . . . . . . . . .13
Autodesk . . . . . . . . . . . . . . . . . . . . . . . .38
Automotive Skills Development Council . . . .29
Batliboi . . . . . . . . . . . . . . . . . . . . . . 23, 28
Beckhoff Automation . . . . . . . . . . . . . . . .50
Blaser Swisslube . . . . . . . . . . . . . . . . . . .21
Carl Bechem Lubricants India . . . . . . . . . . .7
Chiron India Machine Tools . . . . . . . . . . . . .6
COMSOL Multiphysics . . . . . . . . . . . . . . .12
DesignTech Systems . . . . . . . . . . . . . . . .31
DOLD Electric India . . . . . . . . . . . . . . . . .50
Dormer Pramet . . . . . . . . . . . . . . . . . 43, 51
Eaton . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Elgi Equipments . . . . . . . . . . . . . . . . . . .10
Faro Technologies . . . . . . . . . . . . . . . . . .44
Name . . . . . . . . . . . . . . . . . . . . . . .Page
Faurecia India . . . . . . . . . . . . . . . . . . . . .31
Flir Systems . . . . . . . . . . . . . . . . . . . 33, 51
Great Wall Motors . . . . . . . . . . . . . . . . . .10
Greaves Cotton . . . . . . . . . . . . . . . . . . . .30
Hindustan Aeronautics Limited . . . . . . . . . .10
igus (India) . . . . . . . . . . . . . . . . . . . . 15, 51
IHS Markit . . . . . . . . . . . . . . . . . . . . . . . .9
IMTMA Technology Centre . . . . . . . . . . . .30
Inniti . . . . . . . . . . . . . . . . . . . . . . . . . . .14
INSEAD Emerging Markets Institute . . . . . . .16
Intech Additive Solutions . . . . . . . . . . . . . . .8
Jindal Aluminium . . . . . . . . . . . . . . . . . . .27
Jyoti CNC Automation . . . . . . . . . . . . . . . .1
Kaizen Congress . . . . . . . . . . . . . . . . . . .47
L&T . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Mastercam . . . . . . . . . . . . . . . . . . . . . .11
MMC Hardmetal . . . . . . . . Back Inside Cover
Name . . . . . . . . . . . . . . . . . . . . . . .Page
Nicolás Correa India . . . . . . . . . . . . . . . .10
Oemeta . . . . . . . . . . . . . . . . . . . . . . . . .17
Oemeta Chemische Werke GmbH . . . . . . . .24
Pi Innovate . . . . . . . . . . . . . . . . . . . . . . .18
Plazma Technologies . . . . . . . . . . . . . . . .29
QVI India . . . . . . . . . . . . . . . . . . . . . . . .45
Reamtech Precision Tools . . . . . . . . . . . . .37
Renishaw . . . . . . . . . . . . . . . . . . . . . . . .48
Schneider Electric India . . . . . . . . . . . . . .32
SEG Automotive . . . . . . . . . . . . . . . . . . .34
Singapore Management University . . . . . . .16
ŠKODA AUTO . . . . . . . . . . . . . . . . . . . . . .9
TaeguTec . . . . . . . . . . . . 9, 50, Back Cover
Vargus India . . . . . . . . . . . . . . . . . . . . . . .2
ViscoTec . . . . . . . . . . . . . . . . . . . . . . . .40
Wipro 3D . . . . . . . . . . . . . . . . . . . . . . .10
» Casting & ForgingCasting and forging are one of the key engineering segments supplying various components to end-user industries such as railways, automobile, defence, aerospace, material handling, construction equipment and mines. The Indian casting and forging sector has equipped itself to retain its prowess to accelerate revenue from the auto sector. Heavy expansion by way of organic and inorganic growth has been playing an important role in this industry and will be highlighted in the upcoming issue.
Publisher / Chief Editor Shekhar Jitkar [email protected]
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» High-speed MachiningHigh-speed machining can be called rather the high productive machining when machining components in roughing to finishing and in finishing to super-finishing in components of all sizes. The use of HSM allows one to shorten the production time and increase the accuracy of machined parts. The following edition explores the uses of high-speed machining in various industry sectors.
» Additive ManufacturingAdditive Manufacturing defines what is done by actual fabrication techniques used. The AM processes make end-use parts as well as prototypes of testing form and function via layering. The forthcoming issue finds out the recent developments in the industry and the future of Additive Manufacturing.
TaeguTec IndiaNo. 120, Bommasandra Industrial Area, Phase -4, Bengaluru – 560099
+91 (80) 4901 3000 [email protected] www.taegutec.com www.taegutec-india.com
Mini Sized 90° Shoulder Mill and High Feed Mill with StrongV-Shaped Insert Smallest insert V-Shaped insert High productivity with maximum No. of teeth High positive rake angle High feed insert
RNI No. MAH/ENG/2010/34603
