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02'(51 VOL 1, ISSUE 1 - MAY 2017 0$18)$&785,1* ,1',$ The Official Magazine ofW W W. M M I N D I A . C O . I N Partnered byHITTING THE OPTIMIZEDSWEET SPOTMacro economy of optimal material removalCOUNTRY FOCUS: 31 38 AUTO COMPONENT ANANT G GEETEGERMANY MARKET Hon’ble Minister - Ministry of Heavy Industries & Public Enterprises, Government of India 24

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CONTENTS VOL 1, ISSUE 1, MAY 201727 364 | May 2017 42 06 FOREWORD 08 PUBLISHER’S NOTE 10 EDITOR’S DESK 12 IMTMA’S DESK 14 PANORAMIC PERSPECTIVE 16 NEWS 20 COVER STORY HITTING THE OPTIMIZED SWEET SPOT 24 BIG INTERVIEW SHRI ANANT G GEETE, HON’BLE MINISTER, MINISTRY OF HEAVY INDUSTRIES & PUBLIC ENTERPRISES, GOVERNMENT OF INDIA 27 MARKET DYNAMICS UNDERSTANDING THE MACHINE TOOL INDUSTRY’S UPS AND DOWNS 31 COUNTRY FOCUS INDIA-GERMANY: MAKING THE BEST OF EACH OTHER’S STRENGTHS 36 COMPANY PROFILE EMPOWERING PARTNERS 38 AUTO COMPONENT MARKET REVVING UP THE GROWTH ENGINE 42 3D PRINTING RETOOLING THE ENGINE Modern Manufacturing India

52 IMPRINT45 METROLOGY PUBLISHER & FOR GOOD MEASURE DIRECTOR GENERAL & CEO, IMTMA47 METAL FORMING V Anbu RETROFIT TUNES FORD PRESS TO HIGH PERFORMANCE EDITORIAL Editor-in-Chief49 HONING SKILLS BRIDGING THE INDUSTRY-ACADEMIA GAP Soumi Mitra52 MACHINE TOOL PROBING Chief Copy Editor STREAMLINING COMPONENT SETTING AND INSPECTION Poonam Pednekar54 COOLANTS Senior Correspondent A STEP TOWARDS A GREENER PLANET P K Chatterjee56 GRINDING BEING ON THE EDGE OF SUCCESS Head Creative & Production58 BEST PRACTICES Shanmugam Pillai (Som) INNOVATION ON THE ASSEMBLY FLOOR Snehal P60 MANUFACTURING SOFTWARE SALES & MARKETING CHOOSING AN ERP SYSTEM FOR Indian Machine Tool Manufacturers’ DATA-DRIVEN MACHINE SHOPS Association (IMTMA)62 EVENT SNAPSHOT Magic Wand Media Inc CIMT 2017: A STEP TOWARDS GROWTH Published and Printed by V Anbu on behalf of Indian66 PRODUCT Machine Tool Manufacturers’ Association. Printed at69 SAVE THE DATES–EVENT CALENDAR Pentaplus Printer’s Pvt Ltd 20, 4th main, 5th cross,70 COMPANY & ADVERTISER’S INDEX Industrial Town, Rajaji Nagar, Bangalore-560044, Karnataka and Published from Indian Machine Toolwww.mmindia.co.in Manufacturers’ Association; Head Office : 10th Mile, Tumkur Road, Madavara Post, Bengaluru - 562123, Karnataka. Editor: Soumi Mitra Publishing frequency: 6 times per year Manuscripts: No liability is accepted for unsolicited manuscripts. They will be returned only if accompanied by sufficient return postage. All rights reserved. Reprints, digital processing of all kinds and reproduction only by written permission of the publisher. Any views, comments expressed are the sole responsibility of the respective authors, IMTMA and Modern Manufacturing India and its partners do not undertake any responsibility, implied or otherwise. Disclaimer: Every effort has been taken to avoid errors or omissions in this magazine. In spite of this, errors may creep in. Any mistake, error or discrepancy noted may be brought to our notice immediately. It is notified that neither the publisher, the editor or the seller will be responsible in respect of anything and the consequence of anything done or omitted to be done by any person in reliance upon the content herein. This disclaimer applies to all, whether subscriber to the magazine or not. © All rights are reserved. No part of this magazine may be reproduced or copied in any form or by any means without the prior written permission of the publisher. All disputes are subject to the exclusive jurisdiction of competent courts and forums in Bangalore only. While care is taken prior to acceptance of advertising copy, it is not possible to verify its contents. IMTMA cannot be held responsible for such contents, nor for any loss or damages incurred as a result of transactions with companies, associations or individuals advertising in its newspapers or publications. We therefore recommend that readers make necessary inquiries before sending any monies or entering into any agreements with advertisers or otherwise acting on an advertisement in any manner whatsoever. May 2017 | 5

FOREWORD PG JADEJA President Indian Machine Tool Manufacturers’ Association (IMTMA) DAWN OF A NEW ERA IN MANUFACTURING Greetings for the season! I welcome you once again to Modern Manufacturing India (MMI) which will now be published under the Indian Machine Tool Manufacturers’ Association (IMTMA) banner. Manufacturing, especially machine tool manufacturing, has generally been considered a mainstay and a core driver of economic growth. The manufacturing sector provides employment to a sizeable section of the highly skilled, semi-skilled and unskilled workforce in the country. MMI magazine looks to serve as a window to the manufacturing world with a refreshingly new perspective. The Union budget was a significant step in solidifying India’s macro-economic stability. Incentives such as 5 percent reduction in income tax for MSMEs, carry forward of minimum alternate tax credit, 3-year tax exemption for start-ups, doubling of lending rate under MUDRA Yojana, etc. have heightened the “feel good factor” within the manufacturing segment. The passing of Goods and Services Tax (GST) bill in the Parliament could eliminate fiscal barriers and unify India into a single market. It is anticipated that GST is likely to strengthen manufacturing. Following its targeted July 2017 rollout, manufacturing activities could gather pace and the Indian machine tool industry will have a catalytic role to play in the coming future. The Association, true to its endeavour of strengthening manufacturing and building a new India, is bringing forth a wide range of activities. In August this year, IMTMA is organizing the National Productivity Summit in Pune and the second edition of Delhi Machine Tool Expo in Pragati Maidan, New Delhi. We will also continue with a wide range of exciting training programmes at IMTMA Technology Centres in 3 cities ( Bengaluru, Gurugram and Pune ) to hone the skills of the industry workforce. I call upon readers to wholeheartedly support our initiatives and give your valuable feedback which will help us in our journey to strengthen the Indian manufacturing sector. Happy reading.6 | May 2017 Modern Manufacturing India



PUBLISHER’S NOTE Dear MMI Readers, W e are delighted to bring you the Modern Manufacturing India (MMI) magazine. Indian Machine Tool Manufacturers’ Association (IMTMA) now owns this magazine and will publish this under its banner. As you would appreciate it, manufacturing doesn’t succeed in isolation. The thoughts, innovations and actions which define it add a much wider reach. MMI magazine provides the manufacturing industry with a common platform to voice its opinions and also to understand the opportunities and challenges for machine tool business in India. The month’s issue focuses on automotive manufacturing which is widely seen as a trendsetter and engine for growth of machine tool business. We welcome your valuable feedback and suggestions. Your continued support will be critical in shaping the progress of this flagship magazine. Once again, many thanks for your continued interest. Warm regards, V ANBU Director General & CEO Indian Machine Tool Manufacturers’ Association8 | May 2017 Modern Manufacturing India

www.mmindia.co.in May 2017 | 9

EDITORS’ DESK NOTHING CHANGES IF NOTHING CHANGES! elcome back to your very own Modern Manufacturing W India! We have been crafting for the past few weeks to present to you the new look of the magazine. Our efforts were sought to bring forth an original as well as familiar descendant of the publication.SOUMI MITRA With MMI being five years old and well-accepted by the globalEditor-in-ChiefModern Manufacturing India manufacturing fraternity, there was no need of any [email protected] ment. We honoured the structure of the magazine, while Other people’s words are the creating a version as bridge you use to cross from never seen or read where you were to wherever before. you are going. ~ZADIE SMITH In this setting, we have made several alterations with concepts, ideas, typefaces, and page designs. What has not changed is our inquisitive spirit and the resolve to keep evolving our content to achieve the widest reach and create the largest impact. In this process of metamorphosis, we solicit your valuable thoughts to make your MMI more insightful and interesting. Without much ado, I sign off to let you peruse this avatar of MMI to keep tabs on the latest technologies and know-hows. Wishing you all an enriching read! SM10 | May 2017 Modern Manufacturing India



IMTMA’S DESKGST could turn Source: shutterstockto be agame-changingreform for Indiawhen it is implementedGST: AS SEEN FROM AMANUFACTURING PERSPECTIVEViewed from a business perspective, the Goods and Services Tax (GST) bill is on a mission —that of unifying India into a “one single market” for the ease of doing business. This, of course,has never been seen or experienced before.As state F or the first time since its time is ripe for us to make the tegrated Goods and Serviceslegislatures give independence India is best use of this historic Tax Bill 2017, Union Territorytheir nod to chartering on to a new opportunity. Goods and Services Tax Bill 2017their respective territory. This will be a fresh GST could turn to be a and the Goods and Services Taxstate GST bills, a experience for those doing game-changing reform for In- (Compensation to States) Billpan-India roll out business. It is widely believed dia when it is implemented. 2017, is a historic achievement.of GST will be a that GST will significantly The passing of four bills in the Of course, there would be ques-reality. improve the economic Parliament: the Central Goods tions such as what is the impor- conditions of the nation and the and Services Tax Bill 2017, In- tance of GST, what is its design,12 | May 2017 Modern Manufacturing India

how does it compare with tax structures seen in May 2017 | 13other countries?Notwithstanding questions such as these and manymore that may come up, it is but important that themanufacturing industry takes into considerationthe various positive results that could follow onceGST is implemented. It is therefore apt for theindustry to ready itself to embrace GST.Paybacks for Manufacturing IndustryVibrant manufacturing is important for India’seconomic prosperity and GST is expected to offermanufacturing and machine tool industry withthe much needed fillip to enable it to move in theright direction. Praising GST in his interviews tothe media, Prime Minister of India, Narendra Modistated it to be the best example of cooperativefederalism which will be instrumental in takingIndia to progress.GST is expected to propel “Make in India”. Todaythe market in India is fragmented along varioustax structures. There is the Central Sales Tax on in-ter-state sales of goods, many intra-state taxes, andcountervailing duty exemptions which favour im-ports as against indigenous production. GST wouldeliminate all these and pave way for a single na-tional uniform tax for goods and services acrossIndia from July onwards this year.Tax governance would get a facelift with GST im-plementation. The removal of cascading impact oftaxes would bring efficiency and expand tax payerbase as well. All this would boost the morale of thebusiness community.A United FrontThe passing of the GST Bills in the Lok Sabha andthe Rajya Sabha has come about as a collectiveachievement. As state legislatures give their nod totheir respective state GST bills, a pan-India roll outof GST will be a reality. It is good to see that whenit comes to the larger interest of business and ofthe nation, manufacturing fraternity has onevoice though we may face some teething problemsin its initial stages of implementation.To ConcludeIt is firmly believed that GST will ensure apredictable tax regime and ease the doing ofbusiness. Goods can move from one destinationto another within India without facing the usualhurdles. This may enable manufacturing industryto attract fresh investments. Indian MachineTool Manufacturers’ Association welcomes thecountry’s biggest tax reform for which it has beenwaiting for long.www.mmindia.co.in

PANORAMIC PERSPECTIVEGLOBAL COMPONENT MANUFACTURING:WHAT’S AHEAD?T he role as well as the operations played by Indian component manufacturing companies in the global supply chain have been evolving and gaining scale over the last two decades. The next few years, however, are expected to be tumultuous.The cost of machines and equipment has been undergoing a lot of rationalizing; there is a littledifference based on the location where it is purchased. It is now more a matter of servicesavailability and its cost that will be a big differentiator. Identifying this distinguisher duringmachinery and equipment purchase and its effective use will be an important aspect thatcomponent manufacturers need to leverage.Mindset shift requiredThe regular way of buying machines, creating and dedicating capacitybased on part numbers will no longer work. The mindset of size scaling Customers willfirst and efficiency scaling next or vice versa needs to be addressed. A no longer pay forline of machines dedicated to manufacture a part family needs to be overheads not usedworked upon, for both process efficiencies and speedy changeover in their specific parttimes, to meet a continuously moving productivity target.So while the traditional “M’s” remain the same, the approach is in need production.of a complete reversal, how radical should be the move of component T K RAMESHmanufacturers in order to cope with such challenging times? Whole time Director and CEO Micromatic Machine Tools Pvt LtdCrucial changesIn my assessment, recognition, formation and empowerment of theleadership team of owners, managers and executors is the first thing tobe overhauled. The belief that business is mainly about machines andequipment, with people as a necessary evil must alter.The next important change is the conversion and creation of flexible capacity, which is buildingcapability into the existing infrastructure to help the leadership team understand and read in thesituation in the shop super imposed with the market.Automation like gantry, robotics etc. is only part of such flexible capacity. This needs to beadequately supported with measuring, monitoring and scheduling software. They should be able to communicate their maintenance needs, predict failures and reroute their load in case of failure. The management and continuous improvement of this flexible capacity is what will give real-time returns and profitability. The brave will reign It is foreseen that companies will be forced to become highly aggressive in bidding for new jobs. They need to understand actual cost as against present methods of standard cost. This can only be done by evaluating and rating each individual operation and having intelligence and flexibility built in, rather than looking at the total manufacturing process which will hide the inefficient operations. Customers will no longer pay for overheads not used in their specific part production. Such bidding is not for the faint hearted though; it can only be done by those having flexible capacity, its management and absolute confidence in their intelligence data system. The views expressed by the author are personal and he can be contacted at [email protected] | May 2017 Modern Manufacturing India



NEWS Boost to Indian Defence Manufacturing SectorLamiera In Milan New Delhi, India – Domestic ed on the basis of financial strengthA Huge Success companies in India can now tie- and technical expertise. Under up with international partners this ‘strategic partnership’ model,Milan, Italy – LAMIERA, the and manufacturers of all forms of Prime Minister Narendra Modi hasinternational biennial exhibition defence equipment, according to a vowed to do away with the country’sfocused on the metal forming machine long-awaited policy approved by the current status of being the largest im-tool industry and related technologies, cabinet. High-tech equipment such as porter of arms in the world. “For eachwas a huge success. The trade show submarines, fighter jets, helicopters platform, one private sector strate-took place at fieramilano Rho from and armoured vehicles will be manu- gic partner will be chosen,” disclosedMay 17 – 20, 2017. The event, held factured by private companies select- Defence Minister Arun Jaitley.in a 40,000 sq mt area, hosted over480 exhibiting companies and 23,579 EMO Hannover 2017 builds Bridgesvisitors. Numerous operators came between Academia and the Businessfrom Switzerland, Germany, Spain,France, Poland, Serbia, Croatia, Slovenia, Frankfurt, Germany – The EMO Source: VDWRussia, Japan, India and Great Britain. Hannover 2017 is exploring new“The results we had are an excellent approaches for strengthening mutual “For the WGP, Industry 4.0 is a crucial Source: VDWbasis for the next edition of LAMIERA, feedback between the academic and issue for the future, which we aretaking place from May 15 – 18, 2019 business communities. In line with the addressing in numerous institutes.in fieramilano Rho,” added Massimo EMO’s motto of “Connecting systems Because only companies that areCarboniero, President, UCIMU-SISTEMI for intelligent production”, the German receptive to this issue will remainPER PRODURRE, the Italian machine Machine Tool Builders’ Association competitive.””tools, robots and automation systems (VDW) is therefore organizing the Eberhard Abele, President, WGPmanufacturers’ association. Industry 4.0. Special Show area, on which Fraunhofer and university- The factory of tomorrow is digitised and networked. NineGrowth in affiliated research institutes of WGP institutes will be presenting solutions from researchSpanish Machine the German Academic Society for projects showing precisely what it might look like.Tool Sector Production Engineering (WGP) will be showcasing the latest advances inSan Sebastian, Spain – The year networked production technology.2016 witnessed an interesting growth Besides the WGP, representatives ofin machine orders, with an increase the industrial sector will be showingof more than 22 percent. Exports what solutions they have alreadygrew by 6.6 percent, reaching € 1.18 implemented in practical form. In anbillion. This growth is due to an accompanying presentation forum,extremely high investment of the eminent academics will be elucidatingautomotive sector, which has drawn their latest research results, and firmslarge press manufacturers and the will be spotlighting their competencesmetal forming subsector with it. in regard to the smart factory concept.This led to a major increase in orders The WGP is a group of leading(+56 percent) and the largest capture German professors from 40 researchever registered by the subsector. “An institutes. They represent aroundincrease in turnover of between 2,000 academics working in the8 and 10 percent is foreseeable in 2017, field of production technology, whotapping into the pull of the capture in are globally networked. The WGPthe metal forming subsector. We expect represents the needs and concernsa similar growth in exports,” said Xabier of the research and teachingOrtueta, Director, AFM. communities in their dealings with politicians, the business community and the public.16 | May 2017 Modern Manufacturing India



NEWSYour Source: ABBmagazine Key dignitaries at the Raigarh-Pugalur (RP) green energy corridor ground-breaking ceremonynewis back with a India’s First Green Energylook! Corridor Project Begins Raigarh, India – A ground breaking when there is excess wind power. ceremony marked the beginning of The project, helmed by Power Grid work on India’s first green energy Corporation of India (POWERGRID) corridor project with a ultrahigh- and being executed by Asea Brown voltage direct current (UHVDC) link Boveri Ltd (ABB) in partnership with over 1800 km to bring power to 80 Bharat Heavy Electricals Ltd (BHEL), million people. It will integrate thermal is aligned with the government’s focus and wind energy for transmission of on renewable energy and 24x7 reliable power to high consumption centers power for all. This project is also a located thousands of kilometers away, great example of the Make in India supporting electricity demands in the initiative where design, engineering, south, when wind strength is low, and manufacturing of major components transmitting clean energy to the north, and project execution is done locally. Schunk bags the winner of the Hermes Award 2017 Hannover, Germany – Schunk, the competence leader for gripping systems and clamping technology of Lauffen, Germany, was presented with one of the world’s most prestigious technology prizes, Hermes Award 2017 by Prof Dr Johanna Wanka 02'(51 at the Hannover Messe. On her tour of the exhibition, Chancellor Angela Merkel 0$18)$&785,1* ,1',$ visited the SCHUNK booth, while the Managing Partner & CEO, Henrik A Schunk,W W W. M M I N D I A . C O . I N presented smart gripping modules that enable direct human/robot collaborationBOOK (HRC). The company received the award for the SCHUNK JL1 Co-act Gripper, theYOUR SPACE world’s first intelligent gripping module for human/robot collaboration (HRC) thatNOW! directly interacts and communicates with humans. The HRC gripper is developedCONTACT: with the guiding principle ofM: +91 9740048390 Industry 4.0 in mind. Complex +91 9870401498 sensor systems and artificial decentralized intelligence, which are fully integrated in the gripper, allow it to constantly gather information Source: SCHUNK about the component being gripped and about the environment, to process this information and to German Chancellor Angela Merkel at SCHUNK booth at the execute appropriate responses based Hannover Messe. on the specific situation.18 | May 2017 Modern Manufacturing India

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COVER STORYHITTING THE OPTIMIZEDSWEET SPOTMacro economy of optimal material removal20 | May 2017 Modern Manufacturing India

Most manufacturers across industries operate farless efficiently than they should. It is important forthem to initiate the changes required to optimizecutting tools, toolpath, and machine performance,and view them in an integrated relationship forbetter machining effectiveness. The payback isworth it.W hether be it tool Based on the cutting tool Source: Mastercam costs, raw materials, manufacturer’s recommen- capital equipment, dations, import the correct Cost breakdownmanpower, or production costs, parameters for consistentmost of the times, production chip load machining into even a short time ago. Today, itcost centers are often evaluated toolpaths having this capa- is much more prevalent. Theseindependently. But incremental bility. tools promise huge material re-savings in each mostly do not Optimize the cut parameters, moval gains, yet require exactadd up to overall significant if necessary, to match the full adherence to recommended cutgains. The areas of cutting tools, capabilities of the machine conditions and chip load to gainCAM, and production, parti- the job is running on. optimal performance and pre-cularly the newer toolpath Repeat for every toolpath dictable tool life to address ma-technologies, along with process you create using chining effectiveness.machine capabilities and inve- CAD/CAM software where Optimal material removal andstment, should be looked at the same tools, material, and cutting tool performance occurconcurrently with the goal of machine are used. when CNC machines are pro-optimization as they relate to grammed using newer, readilyeach other. What we are looking Present day’s tools are available CAD/CAM softwarefor is hitting the optimized advanced technology. This technologysweet spot of all three, referred Tools today have come a long continually maintains the cut-to as machining effectiveness, way from what the previous ting tool manufacturer’s recom-to gain significant production generation used. The caliber mended cut conditions and chipcost savings. and quality of carbide, advanc- load, regardless of part geome-Adoption of this approach pur- es in new ceramics, new grades, try. Significantly higher mate-sues a very simple formula: coatings, tool geometries, and rial removal rates, with more the design engineering going predictable and extended tool Select optimal cutting tools into these tools are far differ- life, translates into the higher for the part. This will often ent and more capable today reductions in cycles times and be high quality carbide, but that what were available just production costs necessary for can be ceramic, insert tool- five years ago. Full slotting tools achieving machining effec- ing, or any other type of tool. capable of going 2x, 3x, or even tiveness. And, the machining The key is optimizing the 4x deeper in not only hard- chosen tool(s). ened steels and stainless, but super alloys were unheard ofSource: Mastercamwww.mmindia.co.in May 2017 | 21

COVER STORYSource: Mastercam and cutting tool selection more speed, feed rate, and horsepow- traditional, users might opt for er are also considered prior to Maximum machine effectiveness of the newer tool- a higher feed rate and small processing the program. Using efficiency path strategies are not limited step-over approach to maxi- toolpaths that maintain consis- to just the new breed of cut- mize material removal rate and tent chip load and safe cutting Around 20 percent ting tools. Improved material lower cycle time. If set up is on conditions is simply a matter of improvement in removal rates and tool life can a higher horsepower machine, taking the program out onto the material removal be realized with virtually any that tops out on feed rate yet machine. Machine performance DɭBHDMBXÉB@MÉ tool, since these newer toolpath where the workholding can be is validated relative to holding XHDKCÉ@ strategies are based on consis- locked down, a company might the programmed feed rate, en- 15 percent tent cut conditions. run the newer, full slotting-ca- suring the right workholding improvement in Over the better part of a decade, pable tools. Matching tool to setup is in place for strategy, and manufacturing since these new toolpath cutting tool capability can pro- that spindle load is maintained costs per unit. strategies have been available, vide heavy step-overs of 65-80 under the set requirements. manufacturers of all types percent at 2x to 3xD or more. typically report CNC machine Material removal gains increase $GMXVWPHQWVIRUIXOO cycle time reductions for their well beyond 70-75 percent over advantage roughing operations of between traditional toolpath strategies, Once the program is running on 25 to 70 percent- sometimes resulting in a huge production the machine, it may be neces- much more. Recently, a manufa- cost savings. All this is feasible sary to make some minor adjust- cturer reported that a part with once companies put machining ments to toolpath parameters to a machine cycle of 32 minutes effectiveness into practice. make sure the software is taking had been reduced to 12 minutes full advantage of the machine’s by implementing a machining Slow and steady capabilities. Conversely, some effectiveness mindset. However, adoption of these machine controller settings may newer strategies and embrac- need adjustment to take full ad- 'LƱHUHQWPHWKRGVIRU ing a machining effectiveness vantage of the toolpath. Very IXUWKHUFRVWUHGXFWLRQ mindset has been slow, yet often, cutting tool vendors, CAD/ Machining effectiveness gets there are signs they are finally CAM resellers, and technical spe- another cost savings boost beginning to take hold. Straw cialists are happy to help maxi- when one begins to match ma- polls of CAD/CAM users and in- mize performance and prove out chine capabilities to cutting dustry event attendees indicate the application. tool performance potential and that 30-40 percent of program- Once the process and strategy toolpath strategy. With a tool- mer/machinists are using these is validated, the approach can path that always keeps the tool new toolpath strategies with be applied every time that tool in a safe cutting condition and increasing regularity. But what is used to machine a part made does not violate the tool man- about the other 60 percent of from that material. Benefits can ufacturer’s recommended chip CAD/CAM users? They fre- be seen in everything from sim- load specs, CNC programmers quently report not considering ple to extremely complex, aero- can apply different methodolo- it because, honestly, they have space and thin wall parts, and gies. On faster machines where not had the time, nor given ap- more easily machined materials workholding might be lighter proval to do so. to super-alloys. For example, a Tool manufacturers’ recom- job shop recently took six hours mended cut parameters are of- off of a 24-hour cycle for an ten provided in available tool aerospace part by adopting ma- libraries and easily imported di- chining effectiveness method- rectly into toolpath operations ology. This conversion paid for of the CAD/CAM system when itself immediately after the first selecting a tool and material. part was produced. Adjustments are made based on tool capabilities such as wheth- 2SWLPL]DWLRQIRU er to use a small or large step- VLJQLƲFDQWJDLQV over approach and what limits The bottom line is that many need to be applied to depth cuts manufacturers in many indus- based on the type of tool. Ma- tries are operating far less effi- chine limits relative to spindle ciently than they could be and22 | May 2017 Modern Manufacturing India

HIGHLIGHTS ÉRHLOKDÉENQLTK@ÉENQÉF@HMHMFÉRHFMHɫB@MSÉ OQNCTBSHNMÉBNRSÉR@UHMFR !@RDCÉNMÉSGDÉBTSSHMFÉSNNKÉ L@MTE@BSTQDQRÉQDBNLLDMC@SHNMRÉ HLONQSÉSGDÉBNQQDBSÉO@Q@LDSDQRÉENQÉ BNMRHRSDMSÉBGHOÉKN@CÉL@BGHMHMFÉHMSNÉ SNNKO@SGRÉG@UHMFÉSGHRÉB@O@AHKHSX .OSHLHYDÉSGDÉBTSÉO@Q@LDSDQRÉHEÉ MDBDRR@QXÉSNÉL@SBGÉSGDÉETKKÉB@O@AHKHSHDRÉ NEÉSGDÉL@BGHMDÉSGDÉINAÉHRÉQTMMHMFÉNMÉ 1DOD@SÉENQÉDUDQXÉSNNKO@SGÉOQNBDRRÉXNTÉ BQD@SDÉTRHMFÉ\" #\" ,ÉRNɯV@QDÉVGDQDÉ SGDÉR@LDÉSNNKRÉL@SDQH@KÉ@MCÉL@BGHMDÉ @QDÉTRDCSource: Mastercam Efficiency applied to tool leaving money—lots of it—on huge amount by making a sim- tential payback and production the table by not optimizing cut- ple purchasing decision. costs savings of 15-25 percent ting tool, toolpath, and machine Around 20 percent improve- or more, isn’t it worth it? Isn’t performance and viewing them ment in material removal effi- the pressure of a tight deadline in an integrated relationship. ciency can yield a 15 percent loosened by the opportunity Cutting costs is necessary to improvement in manufacturing of getting jobs done faster and compete and remain profitable. costs per unit. For example, a with fewer issues or setbacks? However, there is a lost oppor- shop with $100 million in sales What is needed is a little bit of tunity cost for companies, and could realize a $15 million gain planning and optimization tar- possibly for entire manufactur- by making an average 20 per- geting better machining effec- ing sectors, that do not leverage cent across-the-board improve- tiveness up-front. This can less- everything they can get from ment in machine cycles using en the impact of tight deadlines inter-related technologies. By mostly existing equipment and as well as down time incurred aiming at that optimized sweet software. If parts manufactur- due to lack of efficiency. It is not spot called machining effective- ers in just the automotive, aero- uncommon to find initiatives ness, the gains company-wide space, and energy industries of this sort yielding total man- or even for an industry, can be embraced this idea, the savings ufacturing process cost reduc- significant. would easily be billions. tions of 15–25 percent or more. Cutting tool manufacturers are Savings of this magnitude could very confident that their best *HWULGRIWKHFRPIRUW]RQH be used to achieve such worthy route to justify the benefit of It all comes down to a change objectives as improving profits, higher quality and cutting tool in viewpoint, finding the time capturing more business, and performance is to show new us- to save time, and making a doing the modest amount of ers improved productivity. The commitment to get better. Pro- training required for more ro- cost of the tool is insignificant duction deadlines are always bust workforce development compared to the benefit of im- looming and one gets comfort- and continuous improvement. proved machine cycles. Cutting able with current processes, People who are in charge of the tools amount to about three per- whether they are managers or day-to-day operations at ma- cent of a typical CNC shop’s total programmers. It takes valuable chine shops are frequently un- costs. If tool life can be doubled, time and resource to test and der too many pressures to take then that ROI amounts to less evaluate new technologies and the lead in initiating the sort of than 1.5 percent of the shop’s methods, or experiment with changes that are required. That total costs for cutting tools. It the outer boundaries of what sense of urgency needs to come can reduce its tooling costs by a is possible. Yet, with the po- from the top. www.mmindia.co.in May 2017 | 23

THE BIG INTERVIEW ON THE GROWTH PATH A lot is in progress to elevate the nation from its current position. Shri Anant G Geete, Hon’ble Minister, Ministry of Heavy Industries & Public Enterprises, Government of India gives a glimpse of the state of affairs to Soumi Mitra. An insightful read... “The Machine India has emerged as the world’s less looms manufacturers has Tool park will fastest growing economy and commenced in April 2015. The be open to the demand for capital goods design phase of the project is Foreign OEMs has also considerably increased. complete and manufacturing for setting up Yet there is a limited presence of parts is in progress. Further manufacturing of indigenous sophisticated activities like assembly, inter- units.” manufacturing technologies. facing of various sub-systems, What are the Government’s testing and trial runs is expected Anant G Geete initiatives in this regard to be completed by July 2017. to facilitate the domestic IIT Madras: Development of capital goods manufacturers 11 machine tools technologies has for developing advance commenced at Research Park II technologies? situated near IIT Madras with six industry partners which include ANANT GEETE: The Government three SMEs. All the projects are has launched a Scheme for the under implementation and being enhancement of competiti- worked out as per respective veness in the Indian Capital project milestones. Goods Sector in 2014. One PSG College of Technology, of the Scheme components Coimbatore: Three Welding is setting up of a Centre of Technologies are under develop- Excellence (CoE) for Technology ment in CoE related to automa- Development in Institutes of tion in welding, intelligent power national eminence like the supply system and development Indian Institute of Technology, of electrodes and filler materials Central Manufacturing Tech- for alloy materials. All the proj- nology Institute etc. in colla- ects are under implementation boration with the Industry. and being worked out as per Brief particulars of the projects respective project milestones. undertaken under CoE com- Eight projects from IIT, Delhi ponent are indicated below: relating to Textile Machinery and CMTI, Bangalore: Development 12 projects from IIT, Kharagpur in of 450 and 550 rpm & above the field of specific and additive speed shuttle less looms in CMTI, Bangalore, in partnership with a consortium of five shuttle24 ModernManufacturingIndia

“The new CG Scheme provides Capital Goods Scheme launched Currently, the domestic Capitalfor promotion of Advanced by the Department, initiative Goods industry meets aroundManufacturing by establishing has been taken to make machine 30-50 percent of the demand inDemonstration and Training tool companies competitive at the country and 40-45 percentCentres for Industry 4.0/ 3D global level through the compo- is met by imports. To bridgePrinting etc.” nent of Technology Acquisition the gap of demand creation, Fund Programme (TAFP) for ac- how does the GovernmentAnant Geete, Hon’ble Minister quisition/transfer of technology. plan to contribute in terms ofMinistry of Heavy Industries & Under TAFP programme two ma- procurement policies andPublic Enterprises chine tool projects relating to the non-tariff barriers?Government of India development of four Guideway CNC Lathe and Turn Mill Centres GEETE: The Government of Indiamaterials, manufacturing, auto- are presently under implementa- has approved of a policy for pro-mation and fabrication are tion in HMT Machine Tools Ltd. viding preference to ‘Make in In-presently under examination in Further, under the Integrated dia’ in government procurements.the Department. Industrial Infrastructure Facility The new policy will give a sub-Further a new Capital Goods Centre (IIIFC) component under stantial boost to domestic manu-Scheme is presently being the Scheme, an Integrated facturing and service provision,formulated incorporating the Machine Tools Park is coming thereby creating employment. Itrecommendations of the National up at Tumkur in Karnataka in will also stimulate the flow of cap-Capital Goods Policy launched association with the Government ital and technology into domesticby DHI in 2016. The new CG of Karnataka and an active manufacturing and services andScheme provides for promotion of involvement of Indian Machine provide a further thrust towardsAdvanced Manufacturing by the Tools Manufacturers’ Association manufacture of parts, compo-establishment of Demonstration (IMTMA). The state-of-the-art nents, sub-components etc, in lineand Training Centres for Industry 500-acre Machine Tool Park with the vision of ‘Make in India’.4.0, 3D Printing and so on. is being set up as Greenfield According to the policy, project at Vasanthanarasapur procurement of goods for `50India’s domestic machine tool near Tumkur with global level lakhs and less, and where theindustry is weighed down industrial infrastructure. The land Nodal Ministry determines thatby low investment in talent has been acquired by Karnataka there is sufficient local capacityand is unable to move up the state Government in the National and local competition, only localchain in terms of designs and Industrial Manufacturing Zone suppliers will be eligible.advanced technologies. How is (NIMZ). The project is likely to For procurements valued at morethe Government facilitating the be completed in two and a half than `50 lakhs (or where thereIndian machine tool companies years. All the facilities and their is insufficient local capacity/to upscale their products to utilisation have been planned competition) if the lowest bid iscompete with global market with the users ie. the IMTMA. not from a non-local supplier, theplayers? SPV has been formed. Once lowest-cost local supplier who is completed it is expected to double within a margin of 20 percent ofGEETE: Other than setting up the existing turnover of the the lowest bid, will be given theCentres of Excellence for Tech- Indian Machine Tool sector with opportunity to match the lowestnology Development under the an associated increase in export bid. If the procurement is of a type and employment. that the order can be divided and Additionally, a Common Engi- given to more than one supplier, neering Facility Centre under the the non-local supplier who is the Capital Goods Scheme is being set lowest bidder will get half of the up at Chakan for Tools, Dies and order and the local supplier will Moulds industry in and around get the other half if it agrees to Pune. These interventions un- match the price of the lowest bid. der the Scheme -- Centre of Ex- If the procurement cannot be cellence, Common Engineering divided, then the lowest cost local Facility Centre and Technology supplier will be given the order if Acquisition Fund Programme— it agrees to match the lowest bid. together will boost the domestic Small purchases of less than Machine Tools Industry. `5 lakhs are exempted. The order also covers autonomous bodies, government companies/entitieswww.mmindia.co.in 25

BIG INTERVIEW“India has under the government’s control. GEETE: The Government of opment Initiative and Plant mod-brought out a The policy also requires that India has brought out a National ernization have been incorporat-National specifications in tenders must Capital Goods Policy which also ed under the new Scheme beingCapital Goods not be restrictive e.g. should covers Machine Tools Industry formulated in the Department forPolicy which not require proof of supply as a sub sector of Capital Goods Capital Goods. These initiativesalso covers in other countries or proof of Industry. A Capital Goods Scheme along with Integrated MachineMachine exports in respect of previous with increasing scope in line Tools Parks being developed nearTools experience. They must not result with the recommendations of Tumkur are expected to increaseIndustry as a in unreasonable exclusion of local the CG Policy is presently under cost competitiveness of the do-sub sector of suppliers who would otherwise formulation. The CG Scheme mestic manufacturing sector thatCapital Goods be eligible, beyond what is will provide for, inter alia, study will translate in enhancing utili-Industry.” essential for ensuring quality or of gap analysis and standards zation of the domestic capacity. creditworthiness of the supplier. development programme and The Machine Tool park will beAnant G Geete The policy lays down a setting up of testing and open to Foreign OEMs for setting procedure for verification of certification facilities. The up manufacturing units. local content relying primarily standardization initiative will Further an Inter-Ministerial on self-certification. There will be taken in active involvement Standing Committee has been be penal consequences for false with the Standard Development formed to address the issues of declarations. In some cases, Organization, like Bureau of Capital Goods such as Public Pro- verification by statutory/cost Indian Standards. curement, Inverted Duty Struc- auditors etc. will be required. ture and Import of Second Hand Price preference policy has With ‘Make in India’ as a key Capital Goods which are inhibit- already been reflected in the growth driver for India and ing domestic capacity utilization. Revised General Financial Rules capital Goods policy industry Some actions have already been brought out by the Ministry of as a key manufacturing sector, initiatiated to improve the pub- Finance in this year. how is the Government lic procurement scenario by in- supporting to enhance the troducing provision in favour of How does the government utilisation of domestic demand domestic preference in General facilitate the indigenous as well as offering business Financial Rules and bringing out machine tool manufacturers in opportunities to both Indian a policy for purchase preference terms of upgrading the existing and foreign original-equipment for indigenously manufactured testing and certification facilities manufacturers (OEMs)? goods/machineries. and setting up new ones and making standards mandatory to GEETE: In line with recommen- The new Capital Goods policy curb imports of sub-standard dations of the National Capital has been at an opportune machinery? Goods Policy, components like moment when the industry Heavy Industry Cluster Devel- is gathering momentum to go to next level. How can the Indian made capital goods to be promoted through HIEMDA (Heavy Industry Export & Market Development Assistance) scheme? GEETE: Under the new Capital Goods Scheme, presently under development, there is a compo- nent namely Heavy Industry Export & Market Development Assistance under which there are measures like Capital Goods Dis- play showrooms abroad, export assistance to capital goods indus- try associations and participation in major industrial exhibitions in India and abroad. The interview was conducted by: Soumi Mitra, Editor-in-Chief26 ModernManufacturingIndia

MARKET DYNAMICS POWERED BY: UNDERSTANDING THE MACHINE TOOL INDUSTRY’S UPS AND DOWNS In recent years, machine tools are the classic retical maximum consumption China’s patterns of example of a cyclical, boom- trend. Notice the gray line. It consumption have had bust industry. Although I was represents global consumption an exaggerated effect armed with that knowledge in US dollars, adjusted for infla- on global cycles. and had the data to back it up, tion. This line indicates that the I was nonetheless surprised increase in global consumption B oom and bust. Boom when I took a fresh look at the over time is caused by more and bust. If you have long-term global machine tool countries becoming industrial- been involved in consumption data from Gard- ized and not the weakening of metalworking and the machine ner Business Intelligence’s latest the US dollar through inflation. tool industry long enough to World Machine Tool Survey. From 1960 to 1970, global have endured and persevered machine tool consumption through several of these boom- Global Consumption of increased in an almost perfectly bust cycles, then you probably Machine Tools straight line. To almost anyone have this sense that the Chart 1 shows world machine in the metalworking industry difference between the boom tool consumption with a theo- today, an entire decade of and the bust has increased over a time. In other words, the peaks Chart 1: World Machine Tool Consumption with Theoretical Maximum Consumption have seemed higher and the dips deeper with each passing cycle. 120,000,000,000 100,000,000,000 80,000,000,000STEVEN KLINE, JR Well, this is not all in your head Real USD60,000,000,000Director of Market or your gut. This impression is 40,000,000,000Intelligence real. Source: mmsonline.com20,000,000,000Gardner Business Media I have spent the last 10 years at- tempting to forecast the metal- working industry, particularly 0 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 machine tool consumption. It 1960 1965 — Real Consumption - - - Theoretical Maximum Consumption did not take me long to under- stand that metalworking andwww.mmindia.co.in May 2017 | 27

MARKET DYNAMICS straight-line growth is almost beyond imagination. However, TROUGH ACTUAL THEORETICAL SHORTFALL PERCENT the boom-bust cycle that seems YEAR CONSUMPTION MAXIMUM CONSUMPTION (BIL. OF REAL USD) SHORTFALL (BIL. OF REAL USD) (BIL. OF REAL USD) normal today did not begin 1971 $26.7 $30.3 $3.6 12% Source: mmsonline.com until 1971. 1976 $29.0 $36.9 $7.9 22% Generally, a complete cycle 1983 $28.1 $46.2 $18.1 39% in machine tool consumption 1994 $35.4 $60.8 $25.4 42% has taken 10 years from peak 2002 $42.2 $71.4 $29.2 41% 2009 $60.8 $80.7 $19.9 25% to peak. In recent years, when interest rates were lowered to nearly zero (and in some cases as a logical supposition. This Table 1 shows that the cycles below zero), the cycle periods theoretical maximum gives us a were indeed getting worse, both became less regular. useful reference for examining in terms of the absolute distance the actual consumption results. from theoretical maximum In Theory In fact, the peaks of machine and the percentage below the In fact, the height of peak tool consumption generally fall theoretical maximum. Note consumption in those cycles on that line. We had no such that, even though the size of the increased over time, even peak in the late 1990s (thank shortfall gap grew in 2002, the though the periodicity (peak-to- you, dot-com bubble), and we shortfall represented a slightly peak time) did not. The dotted dramatically overshot the smaller percentage of the blue line in this chart represents theoretical maximum machine theoretical maximum than in a theoretical maximum con- tool consumption in 2008 and 1994. Then, in 2009, the shortfall sumption of machine tools. It 2011-2012 (more on that later). decreased significantly, and is based on the straight-line This theoretical maximum can with it, the percentage of the growth of recorded machine be compared to the bottom of theoretical maximum naturally tool consumption from 1960 to each machine tool cycle. For decreased as well. 1970. In other words, we can example, in 1971, the theoretical suppose that the straight-line maximum machine tool con- &KLQDƏV,QƳXHQFH growth during this period was sumption was slightly more The fact that the last two dips in the natural or “organic” pattern than $30.3 billion, but actual machine tool consumption have for machine tool consumption machine tool consumption was not been as severe and the fact and that the forces behind it only $26.7 billion. So, at the that machine tool consumption were normal and steady (at trough of the cycle, consumption dramatically overshot the theo- least in theory). Given this fell short of the theoretical retical maximum in 2008 and assumption, machine tool maximum by $3.6 billion, or 2011-2012 are related. Both consumption can be theorized 12 percent. History shows that, developments were caused by to “max out” at points on this cycle after cycle, this shortfall China’s influence on the global line in the period after 1970 has widened. market. The gray line in Chart 2 Chart 2: World Machine Tool Consumption vs. World Consumption excluding China shows world machine tool consumption, while the blue 120,000,000,000 line shows world machine 100,000,000,000 tool consumption with figures from China dropped from the 80,000,000,000 calculation. Notice that, until the mid 2000s, there was not a 60,000,000,000Real USD significant difference between the two lines. That’s because Source: mmsonline.com China only accounted for no 40,000,000,000 more than 15 percent of global consumption before that period. 20,000,000,000 By 2011, China’s machine tool consumption accounted for 0 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 40 percent of the global total. 1960 1965 — Real Consumption — Real Consumption excluding China Therefore, it seems clear that the influence of China’s suddenly28 | May 2017 Modern Manufacturing India

Chart 3: World Consumption excluding China with Theoretical Maximum Consumption machine tool consumption were less severe. It also is this low 120,000,000,000 end of the market that made it appear that global machine tool 100,000,000,000 consumption was overshooting its theoretical maximum.80,000,000,000Real USD60,000,000,000 More Insights40,000,000,000 Source: mmsonline.com This is not the end of the story. Simply taking China’s machine20,000,000,000 tool consumption from the calculations does not lead to0 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 an entirely accurate analysis. 1960 1965 — Real Consumption excluding China - - - Theoretical Maximum Consumption The high-end manufacturing taking place in China representshuge appetite for machine tools this effect may be impossible to a growing percentage of theis the reason the troughs have identify. However, I believe that Chinese metalworking andbeen less severe and the peaks two known factors provide a machine tool industry. Onehave been higher than expected. reasonable explanation. way to capture the size ofChart 3 shows world machine First, extremely low interest this high-end industry is totool consumption and the rates enabled global manuf- focus on Chinese imports oftheoretical maximum machine acturing companies to build machine tools. It stands totool consumption without new factories anywhere in the reason that these imports areincluding numbers from China. world in order to exploit low more sophisticated machinesThrough 1990, the peaks labor costs. Near-zero interest being installed by globalcontinued to hit the line while rates meant that financing new manufacturers and high-endChina still represented a small capital equipment was virtually Chinese job shops.percent of global consumption. free. So why not put that new Chart 4 has insights to offerThen, in 2008, instead of capital equipment where here. The gray line shows globaldramatically overshooting the labor costs were relatively machine tool consumption withtheoretical maximum, as might low compared to Western only Chinese machine toolbe expected, peak consumption manufacturing countries? As a imports included in the data. Itfell well short of this line. result, low global interest rates is significant that this methodMissing this level had never magnified China’s machine tool of analysis shows that globalhappened before. Likewise in consumption over that from any machine tool consumption2009, the trough is much deeper other country. falls almost exactly as expectedboth in an absolute sense and in Second, more than any other on the line of the theoreticalcomparison to the theoretical country in the world, China maximum. Therefore, true globalmaximum. Instead of the represents a distinctly two- machine tool consumption fallsexpected $19.9 billion shortfall, sided, yet lop-sided, machine somewhere between the graythe shortfall in global machine tool market. High-end manufa- and blue lines of chart 2.tool consumption widened cturing with high-end machine How does this understandingto $41.1 billion, a figure much tools is one side. Much of this shape our outlook for the futurelarger than in 1994 and 2002. capability is concentrated in of world machine consumption?And, without the numbers from the electronics and automotiveChina, the percent shortfall sectors. In contrast, the other What’s to come?increased to 51 percent from 25 side of the market consists of Chart 4 shows that globalpercent. low-end, even manual, machine machine tool consumption in tools. This side of the market is 2016 was $30.1 billion, or 33Two Reasons That Explain much larger than the high-end percent below the theoreticalAll of the factors that help side, and it is this lopsided low maximum. This shows that theexplain why China’s surge in end of the market that made it global manufacturing industrymachine tool consumption had appear that the troughs in global has not yet recovered from the great recession of 2008 to the extent expected. I forecast that global consumption willwww.mmindia.co.in May 2017 | 29

MARKET DYNAMICS increase in 2017, even though Chart 4: World Consumption excluding China + Chinese Imports many major national economies with Theoretical Maximum Consumption are still working through significant debt issues. 120,000,000,000 “The Fourth Turning,” an excellent book on long-term 100,000,000,000 cyclical forecasting by William Strauss and Neil Howe, describes 80,000,000,000 a theory that I believe applies to machine tool boom-bust cycles. 60,000,000,000 Based on this book’s theory, the current cycle in our industry 40,000,000,000 should bottom out between 2020 and 2025. Accordingly, 20,000,000,000 we should see a dip in global Real USD machine tool consumption 0 during those years. Source: mmsonline.com1960 1965 Ultimately though, this dip 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 may not be much deeper than current global machine tool — Real Consumption excluding China + Chinese Imports - - - Theoretical Maximum Consumption consumption. In the last few cycles, the troughs in machine Once a cycle bottoms out, Of course, these expectations are tool sales have been bottoming machine tool consumption tends speculative. Many unforeseeable out at about 40 percent below to grow for six or seven years. events may alter the situation. the theoretical maximum. Based If we hit bottom in 2020, then Nevertheless, insights into on a theoretical maximum we should hit the next peak the long-term growth trend in consumption of $95.3 billion in between 2025 and 2030. Based machine tool consumption, the 2020, the low point of global on the trend that began in 1960, cyclical nature of the industry and consumption would be about we can expect machine tool what is happening in China $57.2 billion. consumption to peak somewhere can help us understand these near $100 billion between 2025 shifts and their implications and 2030. as they occur. Yes, I wish to subscribe to MODERN MANUFACTURING INDIAOwned, Published, PERSONAL DETAILS DesignationPrinted and Circulated by CompanyINDIAN MACHINE TOOL NameMANUFACTURERS’ ASSOCIATION Departmentand partnered with Company AddressGARDER BUSINESS MEDIA INCMMI features all segments of City & Pin Code Countrymanufacturing. E-mail Contact No. IndustryKeep updated on the latest topicsfrom Turning, Milling, Cutting SUBSCRIPTION PAYMENT DETAILSTools, Tool Holders, CAD/CAMSoftware, CNC Machine Controls, Please find enclosed cheque / DD No.:Metal Forming, Laser Cutting,Welding, Titanium Machining Drawn on (Name of bank & branch):and so on. Dated 02'(51 0$18)$&785,1* For Rs. Rupees in words ,1',$ Favouring INDIAN MACHINE TOOL MANUFACTURERS’ ASSOCIATIONW W W. M M I N D I A . C O . I N Sources & Terms of Supply: Orders can be placed directly with the publisher. No claims for the supply of back copies or reimbursement of subscription fees can be entertained for non-delivery of the magazine for reasons beyond the publisher’s control.30 | May 2017 Modern Manufacturing India

COUNTRY FOCUS Source: Magic Wand Media IncINDIA-GERMANY:MAKING THE BESTOF EACH OTHER’SSTRENGTHSThe fifth largest economy in the world, Germany is India’s largest trading partner in the EUand has consistently been among top ten global partners. A look at the current juncture oftheir relationship and the things that make them important for each other’s progress.POONAM PEDNEKAR T he interesting Indo- global trade in 2016, the duo has German imports from IndiaChief Copy Editor German trade history been discovering opportunities increased by seven percentMagic Wand Media Inc dates to the 16th century in each other’s strengths. The compared with the previouspoonam.pednekar@ and since then the strategic volume of trade between the year and German exports tomagicwandmedia.org partnership between the two two countries has increased India by ten percent. This trend nations has only been getting rapidly since India’s economic continued in 2016. stronger. With Germany being reforms that took place in 1991. India’s seventh most important In 2015, the bilateral trade Last year’s trade in a trading partner worldwide and between India and Germany snapshot India ranking 24th in Germany’s grew further. According to Rajesh Nath,www.mmindia.co.in May 2017 | 31

COUNTRY FOCUSGerman imports Managing Director, Germanfrom India Engineering Federation (VDMA),increased by the bilateral trade between Indiaseven percent and Germany grew to € 17.42compared with billion in 2016 from a figure ofthe previous year nearly € 17.29 billion in 2015.and German Indian imports from Germanyexports to India amounted to € 9.8 billion. Theby ten percent. exports from India to Germany attained a value of € 7.62 billion in 2016, he informed. Source: VDW The total import of machinery Source: VDMA from the whole of Europe to India reached a volume of € 6.73 “Due to digitisation and “Maharashtra with around billion. This was an increase by networking of the machine tool 47.3 percent share of German 2.4 percent compared with the industry, the demand for investments remains to be the same period in the previous year. software and apps will continue most attractive destination for The total import of machinery to rise in the future. So, there is German investments in India. from Germany reached a abundant potential for expanding In the last four to five years, volume of € 2.97 billion. This bilateral business relationships.” Pune has become the hotbed for was an increase by 1.7 percent new German investments.” compared with the same period Dr Wilfried Schaefer in the previous year. Executive Director Rajesh Nath German Machine Tool Builders’ Managing Director Association, VDW German Engineering Federation (VDMA) India Indian machine tools export to Germany “India is a not-to-be-under- estimated supplier of machine tools,” said Dr Wilfried Schaefer, Executive Director, Machine Tool Imports of India: Main Supplier Countries German Machine Tool Builders’ (excluding parts/accessories) Association, VDW. “In 2015, Germany primarily bought parts and accessories from Indian 2014 2015 2016 1,055 1,095 1,181 manufacturers, worth just under Total imports (Mill. EUR) 27% € 9 million.” 17% Japan 12% According to a report by VDW, Germany %-share in total imports 8% China 28% 22% 7% Indian machine tools such Taiwan 13% 14% Italy 13% 15% as: laser machines; electrical 7% 9% 9% 9% discharge machines; machining centres; transfer lines; unit construction machines; lates; drilling machines; boring machines; boring-milling machines; grinding, honing, Machine Tool Exports of India: Main Customer Countries lapping machines; and gear (excluding parts/accessories) cutting machines; and metal forming tools such as forging Source: Official trade statistics of India, VDW machines and hammers; bending, 2014 2015 2016 155 folding and straightening ma- Total exports (Mill. EUR) 8% chines; shearing, punching and 114 166 7% China 6% notching machines, presses; and USA %-share in total exports Germany 9% 9% other parts and accessories were 6% 5% 7% 6% exported to Germany in 2016. Parts and accessories led the pack and amounted to € 10.8632 | May 2017 Modern Manufacturing India

German Machine Tool Imports from India evolved into one of the world’s by Machine Types most important suppliers of software. Germany, by contrast, Laser machines, other 1000 EUR 2014 2015 2016 is a front-runner in the field of physico-chemical process Units Industry 4.0. “Due to digitisation machines 36 62 and networking of the machine 34 tool industry, the demand for software and apps will continue Electrical discharge 1000 EUR 40 108 to rise in the future. Hence, machines Units 2 2 there is abundant potential for expanding bilateral business Machining centres 1000 EUR 767 75 204 relationships,” he added. Units 3 12 Lathes 1000 EUR 2,149 3,107 3,094 Units 300 2,410 341 Imports from Germany Drilling machines 1000 EUR 28 7 As per the information by Nath, Units 13 3 in 2016, out of approximately € 18.6 billion of machinery Milling machines 1000 EUR 32 773 1,923 imported by India, Germany had Units 4 22 17 a share of around 16 percent, 391 behind China (32.9 percent) and Grinding, honing, 1000 EUR 20 1,810 583 ahead of Japan (11.2 percent) and lapping machines Units 33 1 Italy (seven percent). 423 5 The report from VDW reveals Gear cutting machines 1000 EUR 23 10 2 that the kind of machine tools Units 4 1 that were exported, were 2 5,986 the same as exported from Sawing and cutting off 1000 EUR 166 372 Germany. The most important 3,834 29 machine type was machining machines Units 367 4 centers that amounted to 3 12 5 €33.6 million. Other metal cutting 1000 EUR 10 8 34 Among the machinery sectors machine tools Units 7 2 in India, major demand of 2 5,989 German equipment was for Total Metal Cutting 1000 EUR 2,507 738 Power Transmission Engi- Machine Tools Units 2 1,687 neering (10.8 percent), Textile 1 161 Machinery (without dryers Forging machines and 1000 EUR 855 3 1 (eight percent), Machine hammers Units 1,231 2 Tools (6.09 percent), Plastics 171 235 777 and Rubber Machinery (six Bending, folding and 1000 EUR 2 4 1,696 percent) and Valves and Fittings straightening machines Units 1,038 (5.03 percent). 1,246 12 Shearing 1000 EUR 2 Units 706 Punching and notching 1000 EUR 2,293 machines Units 306 Presses 1000 EUR 6 Units 1,420 Other metal forming 1000 EUR 2,308 Source: Official trade statistics Germany, VDW German investment in machine tools Units India A report produced by the Indian Total Metal Forming 1000 EUR Machine Tools Units Parts and accessories 1000 EUR 9,087 11,817 10,863 TOTAL MACHINE 1000 EUR 13,959 19,226 17,626 Embassy in Germany reveals TOOLS Units 1,613 4,815 2,068 that German investment in India in 2016 was to the tune of Euro one billion. Top sectors that have attractedmillion of export to Germany. substantial support that is being FDI inflows from GermanyThe industrial production received by the manufacturingoutput and capital investment sector due to “Make in India” are Automobile industry,for machine tools in India will campaign launched by thegrow significantly this year, country’s government. Services Sector, Constructionbelieves Dr Schaefer, given the India has, in recent years, (infrastructure) activities, Industrial machinery, and Drugs & pharmaceuticals.www.mmindia.co.in May 2017 | 33

COUNTRY FOCUS The state of Maharashtra has 47.3 percent share of German German Machine Tool Exports to India by Machine Types investments. It remains to be the most attractive destination for German investments, with 2014 2015 2016 Pune city becoming the hotbed Laser machines, other 1000 EUR 4,096 8,687 11,775 physico-chemical process Units 64 104 143 for the same. machines German companies are setting up manufacturing in India Electrical discharge 1000 EUR 122 3,192 3,306 machines Units 4 78 in addition to the sale and service offices. Many German Machining centres 1000 EUR 36,170 25,589 33,576 Units 125 103 127 companies and VDMA members are planning towards more Transfer lines, unit 1000 EUR 4,917 12 343 5 13 investments in India. German construction machines Units companies like Siemens, KUKA, Liebherr, Schwing Stetter, Lathes 1000 EUR 5,410 7,843 8,668 Units 180 164 161 Wirtgen, ZF and Thyssenkrupp, to name a few, have invested 1000 EUR 2,223 680 931 Units 285 214 183 substantially in the last three to Drilling machines 1000 EUR 3,290 8,513 1,495 five years, informed Nath. Boring machines, Units 62 52 44 boring-milling Knowledge-driven sectors machines 1000 EUR 4,855 10,372 7,200 Units 127 156 145 also hold good potential for Milling machines 1000 EUR 17,501 21,153 16,130 co-operation between the Grinding, honing, Units 308 323 526 lapping machines two countries. Fields such as 1000 EUR 12,069 12,499 13,399 Gear cutting machines Units 109 61 95 IT, biotechnology, renewable Sawing and cutting off 1000 EUR 1,786 671 553 energy, and green technology machines Units 63 62 63 Other metal cutting offer good scope too. machine tools 1000 EUR 3,235 1,133 990 Units 42 39 37 New technologies stirring a storm in manufacturing Total Metal Cutting 1000 EUR 95,674 100,344 98,366 “The digitisation and networking Machine Tools Units of production operations – from 1,374 1,286 1,535 the shop floor to order processing – is without a doubt one of the Forging machines and 1000 EUR 3,631 1,895 19,915 Source: Official trade statistics Germany, VDW most promising developments,” hammers Units 51 50 36 said Dr Schaefer. With Industry Bending, folding and 4.0, the German machine straightening machines 1000 EUR 4,253 5,850 7,471 tool industry thus offers the Units 81 106 130 Indian customers maximised Shearing expertise for the internet of 1000 EUR 1,026 616 650 things (IoT) in the production Punching and notching Units 46 35 15 environment. “This ties in with machines the internationally appreciated 1000 EUR 4,297 4,955 2,384 precision and productivity of Presses Units 67 81 36 machines ‘Made in Germany’,” he proudly added. Other metal forming 1000 EUR 9,926 14,661 2,474 Another future-friendly tech- machine tools Units 120 160 130 nology, according to him, is additive manufacturing. “Since 1000 EUR 7,392 17,003 24,542 it ensures more efficient material Units 37 77 307 utilisation and enhanced resource-economy, 3D printing Total Metal Forming 1000 EUR 30,525 44,980 57,436 indubitably has a future.” Machine Tools Units 402 509 654 Lightweight construction using fibre composite materials is Parts and accessories 1000 EUR 20,590 25,240 25,447 another topic to the list that TOTAL MACHINE 1000 EUR 146,789 170,564 181,249 TOOLS Units 1,776 1,795 2,18934 | May 2017 Modern Manufacturing India

German Machine Tool Imports German Machine Tool Exports from India - Overview* to India - Overview* 2014 2015 2016 2014 2015 2016 EUR millions 14.0 19.2 17.6 EUR millions 146.8 170.6 181.2 %-Change to +23 +38 -8 %-Change to -30 +16 +6 previous year 0.4 0.6 0.5 previous year 1.6 1.8 2.0 %-Share in %-Share in total imports total exports Import rank 23. 21. 20. Export rank 18. 18. 17. Mill. EUR parts machines Mill. EUR parts machines 25 300 8 9 12 11 21 21 25 25 20 250 189 126 145 156 4 5 7 7 29 2013 2014 2015 2016 15 2013 2014 2015 2016 200 10 8 150 100 218 5 3 50 0 0 2012 2012 Most important machine type 2016 (Mill. EUR) Most important machine type 2016 (Mill. EUR) Parts and accessories 10.86 Machining centres 33.6 Parts and accessories 25.4Source: Official trade statistics Germany, VDW Lathes 3.09 Forging machines and 19.9 1.92 hammers 16.1 Grinding, honing, lapping 0.74 13.4 machines Grinding, honing, lapping 11.8 machines 8.7 Presses 7.5 Gear cutting machines 7.2 Gear cutting machines 0.58 3.3 Laser machines, other Machining centres 0.20 physico-chemical process Electrical discharge 0.11 Lathes machines Bending, folding and straightening machines Milling machines Electrical discharge machines 0 KL W O L O GL W L has been addressed by many munity, explained Dr Schaefer. Getting stronger German research institutes and German manufacturers, there- The two countries have been machine tool manufacturers. fore, have well-trained engineers drawing strength from each and skilled workers who ensure other’s manufacturing prowess. German machine tool the high quality and reliability of Sectoral pundits are confident sector motivates the products, repeatedly finding that the new initiatives in That German machines are creative solutions for the multi- trade, bilateral investment, among the best in the world faceted production requirements energy, energy security, the is a well-known fact. German of their customers. They also environment, culture, education, companies cooperate with high- transfer their knowledge to their training, research, technology ly sophisticated component sup- customers and support them and defence will catalyse and pliers, customers and also work in setting up and maintaining activate the great potential of closely with the academic com- the machines. their bilateral ties. www.mmindia.co.in May 2017 | 35

COMPANY PROFILESource: TaeguTec India Pvt Ltd EMPOWERING PARTNERS With its turnkey and tailor-made modern machining solutions for an array of sectors, TaeguTec India is well recognized as the most preferred tooling partner in the industry. The company has achieved a jaw-dropping success by constantly innovating to cater to its customers’ requirements, all the way keeping its gaze fixed on the volatile market trends. TaeguTec India Pvt Ltd & Past President, Indian Machine Tool Manufacturers’ Association, shared nostalgically, “TaeguTec India’s journey has been exceptional. It has set a positive trend for new entrants into the Indian market. In a very short period of time, we emerged as one of the top three players of the industry. Our journey has been very satisfying to all the stakeholders of the company.”Source: TaeguTec India Pvt Ltd Impressive clientele base With its product lines of Tungsten TTIL’s cutting tools S prawled across a lush grown leaps and bounds offering Carbide cutting tools that include for metal working green area of six acres, a wide range of turnkey solutions inserts and holder bodies manufacturing sector. TaeguTec India Pvt Ltd and tailor-mades to its customers for turning, milling, drilling, (TTIL) is a leading supplier of for improving productivity and grooving, parting applications, P K CHATTERJEE modern machining solutions to cost efficiency on the shop floor. and Solid Carbide tools and Senior Correspondent myriad industry sectors such as tooling systems, TTIL serves the Magic Wand Media Inc automotive, die and mould, A journey to remember metal working manufacturing [email protected] aerospace, power generation and Taking pride of the company’s sector of the country. Auto and so on. Having started its Indian growth since its inception auto component companies form operations in India in 2001, it has L Krishnan, Managing Director, a major part of the company’s customer segment and contri- butes over 60 percent of its sales and revenue. “However, over the last five years, contribution from other sectors like power,36 | May 2017 Modern Manufacturing India

aerospace, to name a few, has explained, “In a competitiveincreased,” added Krishnan. The market, our customers arecompany’s customers include constantly exploring, innovatingmajor automobile OEMs like operations to improve theMaruti, Hero Motors Corp, Honda, productivity and reduce the costTata Motors, Ashok Leyland, of manufacturing.” In thisMahindra, Bosch, Toyota, Bharat backdrop, among several otherForge, etc. initiatives, a fully integrated philosophy incorporating prof-R&D is the backbone itability, increased productivity Source: TaeguTec India Pvt LtdSpeaking of meeting customer’s and expert knowhow –requirements, Krishnan shared, named TaeguTeconomics was “TaeguTec India’s journey has“Our facilities are modular and introduced. It includes been exceptional and has set aenable us to quickly enhance line improvement, project positive trend for new entrantscapacities to meet increasing management, tool cost ma- into the Indian market.”demands.” Presently, the nagement, and supply of toolcompany has a wide reach in dispensers. Such initiatives and L Krishnan, Managing Director,the Indian market with branch services offered by the company TaeguTec India Pvt Ltd &and channel-partner presence aim at helping its customers Past President, IMTMAin every major industrial town. reduce costs not just once, but onAcknowledging the contribution an on-going basis; and succeed inof a strong R&D as a requisite the face of acute competition.for growth, the company’s R&Dteam is continually engaged Aligning with changing consideration towards the naturalin innovating products for the trends world, along with its consistentmetal cutting industry. In this TaeguTec’s global presence commitment to its customers.context Krishnan averred, “R&D enables it to spot the trends early Sustainability is at the core of alland aggressive new products and proactively prepare for the TaeguTec’s operations, claimeddevelopment and deployment changing requirements. “More Krishnan. “We are guided bydifferentiate us from the pack. A than 50 percent of our employees the ‘reduce, re-use and recyclesignificant part of our revenue have a direct contact with our practice’.” The company has takencomes from new products and end-customers to observe and several initiatives to practice thesolutions.” anticipate emerging trends, and same with all its resources like formulate and develop strategies. land, water, energy, raw materialsCustomers before us Auto and auto This is a very critical component and other inputs. “Our desire isStrongly following its philosophy component companies of our customer engagement,” not just to minimize the negativeof ‘being a partner in cost form he shared. In addition, the impact on the environment, butreduction’ to the manufacturing a major part of the company’s design team also also to create a positive one,” heindustry, the company focuses company’s contributes in meeting its emphasized.all its efforts towards various customer segment. customers’ requirements.initiatives to help its customers TTIL is in the process of gearing Blue Printremain competitive. As Krishnan itself up with various digital With its constant innovations, tools to help its customers tailor-made solutions, and Source: TaeguTec India Pvt Ltd get information and select customer-favorable policies, it appropriate tools and processes is no surprise that the year for various operations. In this has been an optimistic one for connection, apart from digital TaeguTec India. The company catalogue, the company has a has registered a positive sales TT App for Android and an IOS growth during the year 2016-17. platform. “If the overall industrial growth scenario in the region continues, Contribution to the our company will further grow environment at the rate of 8 to 10 percent Maintaining a balance between in the current financial year the yin and yang, TTIL takes and in the years to come,” pride in being steadfast in its concluded Krishnan.www.mmindia.co.in May 2017 | 37

AUTO COMPONENT MARKETREVVING UPTHE GROWTH ENGINEOutnumbering the various odds,the advantages of India have helpedthe country rise from being a localto a major global supplier of autocomponents. A cursory glance atthe sector’s global standing andthe efforts that are being put in forchasing an ambitious target... POONAM PEDNEKAR Modern Manufacturing India Chief Copy Editor Magic Wand Media Inc poonam.pednekar@ magicwandmedia.org38 | May 2017

W here the global auto Export Destinations: Source: Automotive Component Manufacturers Association of parts and accesso- Top 10 countries in % India (ACMA) ries manufacturing industry, pegged to be around USA 23.59 Thailand 3.18 $1.75 trillion, is growing by 3.15 leaps and bounds, our Indian Germany 6.96 UAE 2.99 auto components industry has 2.62 also seen a robust growth in the Turkey 6.22 France 2.59 last few years. Driven by a HIGHLIGHTS strong surge in the domestic UK 5.43 Brazil market, higher localization by The Indian auto component industry original equipment manufac- Italy 3.86 Mexico aims to achieve $200 billion in revenue turers (OEMs), higher compo- by 2026, with exports in the region of nent content per vehicle, and ‘drive transmission & steering $70-80 billion. increasing globalization (includ- parts’ (19 percent). ‘2 wheelers’É 3GD HMCTRSQX HR BNMɫCDMS NE HSR DWONQSR ing exports) of several Indian is the largest domestic customer crossing $30 billion by 2020, with at suppliers, the industry is ex- segment for the industry. KD@RS ɫUD (MCH@M RTOOKHDQR L@JHMF HS SN pected to reach $115 billion by The regional base of auto the global top 100 list. FY20-21. components manufacturers is mostly concentrated in the Organised sector domi- West, North and South of India. nates The main auto components The auto components sector manufacturing hubs in India of the country can be broadly are situated in Pune, Gurgaon classified into the organised and Chennai with major and unorganized sectors. The automotive clusters in Western organised sector caters to the India: Mumbai - Pune - Nasik - OEMs and consists of high- Aurangabad; Southern India: value precision instruments, Chennai - Bangalore – Hosur; while the unorganized sector and Northern India: Delhi- comprises low-valued products Gurgaon – Faridabad. The state and caters mostly to the of Uttaranchal is also turning aftermarket category. into an autohub, because of the The manufacturing units in industry-friendly government the unorganized sector are policy. far higher than those in the organised one. Despite being Government initiatives fewer in number, the organised The Government deems the au- sector accounts for 85 percent tomotive industry as the fore- of total industry turnover most driver of the manufac- (FY15). Experts estimate that turing sector and has concrete the Indian auto components plans chalked out for turning aftermarket is expected to grow India into a leading destination at 10.5 percent to touch $13 for designing and manufactur- billion by 2019-20, as compared ing of automobiles and auto to $8.4 billion in 2016-17. components. The market is split into six Its special focus on exports of product segments: engine small cars, multi-utility vehicles parts, drive, transmission (MUVs), two and three-wheel- and steering parts, body and ers and auto components; and chassis, suspension and braking the deregulation of FDI in parts, equipment, electrical this sector, leading to foreign parts, and others. ‘Engine parts’ companies making large in- accounts for 31 percent of the entire product range of the auto components sector followed bywww.mmindia.co.in May 2017 | 39

AUTO COMPONENT MARKETSource: Automotive Component Manufacturers Association of India (ACMA)vestments in India, will alsoof India and the Indian of size, contribution to Source: Automotive Component Manufacturers Association of India (ACMA)be contributors to help realizeautomotive Industry outliningIndia’s development, global the goal. the growth trajectory of the footprint, technological matu- The Automotive Mission Plan Vehicles, Auto-components, rity, competitiveness, and 2016-26 (AMP 2026) is the and Tractor industries for institutional structure and collective vision of Government the next ten years in terms capabilities. According to AMP 2026, the Indian auto component industry aims to achieve $200 billion in revenue by 2026, with exports in the region of $70-80 billion, and a creation of an additional 50 million jobs, and to achieve this, the industry requires $25-30 billion in investments. Automotive Component Manu- facturers Association of India (ACMA) foresees a major change in the Indian automotive industry in the coming decade, driven by needs of safety, fuel efficiency, sustainability and customer preferences. The Indian auto components manufacturers will then be required to intensify their focus on quality and innovation more than ever to cope with the changes. Advantage India Along with the industry- friendly government policies such as AMP 2026; strong support for R&D; 100 percent FDI allowance under auto components sector; reduced excise duties in motor vehicles, there are a number of other factors that make India a prospective candidate for the top slot in the global auto components sector. Growing working population and expanding middle class; high vehicle production rate; geographic proximity to key automotive markets like the Middle East and Europe are the top contributors to the success of the sector. Competitive advantages such as: a cost-effective manu- facturing base; presence of a large pool of skilled and semi-40 | May 2017 Modern Manufacturing India

skilled workforce amidst astrong educational system; andthe cost advantage due to Indiabeing the third largest steelproducer; all add up to positionthe country in the global best.Export-Import stats Source: Automotive Component Manufacturers Association of India (ACMA)Aligning the national goal withthe ground reality, experts and Europe, they being high sector has been achieved in the We arepredict that India’s exports of opportunity areas, especially face of stiff odds. With around thankful toauto components could account for mature products and process 19 million direct and indirect ACMA forfor as much as 26 percent of the or skill-intensive components. employees, the $39 billion sharing themarket by 2021. The Middle East, Africa and industry still has a long way information onIn 2015-16 India’s exports of Australia are also emerging to go to make a mark on the the sector.auto components grew by as significant aftermarkets to global landscape. However, the3.5 percent to `70,900 crore pursue. Improving delivery industry has all the ingredients($10.8 billion) from Rs 68,500 and quality systems, and that make up a perfect recipecrore ($11.2 billion) in 2014- extending supply chains is also for success. It is just a matter of15, registering a CAGR of on the agenda. time until it emerges as a global18 percent in the last six years. The growth of the auto parts powerhouse.Europe accounted for a volumeshare of 36 percent during FY16in Indian auto componentsexports followed by Asia andNorth America with 25 percenteach in the same year.Key export items includehydraulic power steeringsystems & steering gearsystems; gear boxes & parts;parts of diesel engines; parts forautomobiles and earth movingequipment; drive-axles & parts;spark ignition; suspension syst-ems; crank shafts for engines;toothed wheels; brakes andservo brakes.Imports of auto componentsgrew by 9.3 percent to `90,600crore ($13.8 billion) in 2015-16 from `82,900 crore ($13.5billion) in 2014-15; Asia andEurope contributed to 58.6percent and 30.9 percent ofthe imports respectively.The road aheadThe industry is confident of itsexports crossing $30 billion by2020, with at least five Indiansuppliers making it to the globaltop 100 list. Component majorshave started putting in efforts inthe direction by building strongsales teams in North Americawww.mmindia.co.in May 2017 | 41

3D PRINTING RETOOLING THE ENGINEVolvo Construction Volvo Construction V olvo Construction Volvo engineers recentlyEquipment avoided Equipment successfully Equipment (VCE ) is one designed a water pump housingtooling costs by 3D managed prototype of the world’s largest for the company’s A25G andprinting a functional savings of manufacturers of construction A30G articulated haulers.prototype of a water 18 weeks and 92 equipment. The company’s Engineers used simulation topump for this A30G percent of costs with broad product line includes optimize the design of internalarticulated hauler, the help of Stratasys’ haulers, loaders, excavators, flow passages in the housing,saving 18 weeks and 3D Printer. compact equipment and road but needed to build a prototypeover $9,200. equipment. to perform functional testing to validate the new design. Until Source: Stratasys recently, the company would have invested in tooling. The42 | May 2017 Modern Manufacturing India

1Source: Stratasys Source: Stratasys Source: Stratasysinto the part and sealed the 2 1 Housing housing with epoxy resin and installed on a hardener to prevent leakage. the lead time on large engine They fastened the jacket to a projects from 36 to 24 months. water pump. water pump and then mounted Engineers felt 3D printing the pump to an A30G. would be a good benchmark to 2 VCE 3D Engineers took water flow and determine if printed parts could printed this pressure measurements from withstand functional testing. both the existing water pump Water pump housing prototypes water pump and the water pump with must be able to survive the heat housing in the new housing. The newly and high pressure of the engine transparent designed housing passed the compartment. material for quick tests. As a step toward achieving this functional testing. Since 3D printing the prototype goal, the company utilized a cost US$770 and took onlytooling cost for this project Stratasys Objet Eden260V 3D two weeks, including bothwould have been approximately Printer from its Shippensburg, design and development, VCEUS$9,090, with the part cost Pennsylvania site. completed its testing mucharound US$909. The lead time VCE engineers 3D printed the sooner than traditional methodsfor producing the prototype housing in transparent material would have allowed. VCE iswould have been 20 weeks called FullCure 720. They now ramping up production ofminimum. mounted nine threaded inserts the new part.Tackling the issue Future GainsVCE management tasked the This project demonstratedengineering team with cutting the feasibility of integratingdevelopment costs and reducing 3D printing into VCE’s engine development process. Each new generation of engines typically requires 15 to 20 new cast metal parts and 12 to 15 profile molded hoses for each engine. 3D printed prototypes can be produced in about 1/10th of the time required to producewww.mmindia.co.in May 2017 | 43

3D PRINTING HIGHLIGHTS CHALLENGES VCE needed to build a prototype to perform functional testing to validate the new design of a water pump housing for its articulated haulers. The tooling cost for this project was approx. US$9,090, with the part cost around US$909, with the lead time for producing the prototype around 20 weeks minimum. The company needed a reduction in development costs and also the lead time. SOLUTION The company used a Stratasys Objet Eden260V 3D Printer, and 3D printed the housing in transparent material called FullCure 720. 3D printing the prototype cost US$770 and took only two weeks, including both design and development. Source: StratasysWater pump installed in prototypes using traditional Product Designer, VCE. “This US$600 to US$1,000. Whilean A30G for functional manufacturing methods, which should reduce risk of errors and molded hose tooling fortesting. adds up to a hefty time savings. the need for changes at all stages prototypes cost around US$600 “3D printing will make it of the development process.” and its prototypes run betweenA Volvo A30G possible to build mock-up engine 3D printing also provides US$60 and US$90, metalArticulated Hauler. components so the platform a substantial cost savings. prototypes and molded hose and manufacturing teams can Tooling for metal prototypes prototypes can be replaced by provide feedback at a much cost between US$4,500 and 3D printed prototypes that cost earlier stage in the development US$18,000, but 3D printed between US$100 and US$800. process,” said Jeff Hartman, prototype parts cost only Multiple prototype iterations multiply the cost savings. “VCE is also looking at using 3D printing to produce jigs and fixtures to increase the efficiency of the manufacturing process and digitally manu- factured parts to address low-volume part production,” Hartman concluded. Time and cost saving after using Stratasys’ 3D Printer METHOD TIME COST ($) Tooling 20 weeks 10,000 and Part 3D printing 2 weeks 770 Savings 18 weeks 9,230 90% 92%44 | May 2017 Modern Manufacturing India

METROLOGY FOR GOOD MEASURE An account of how FARO’s 3D measurement system helped Anusaya increase its measurement accuracy levels and efficiency, reduce the amount of time needed for taking measurements and capture measurement digital data easily. FaroArm Provides P redominantly used to increased, more and more organizations, including Fiat Auto Parts Maker assess manufacturing companies are beginning to India, LG Electronics India, and with 3D Measurement quality, two-dimensional adopt advanced metrology Philips India. Capabilities. (2D) tools such as vernier calipers devices as they recognize the The company’s main competence or micrometers were widely tremendous benefits of utilizing lies in the forming of sheet employed across industries such tools over traditional 2D metals but it also has expertise before the development of more types. in handling sub-assemblies advanced solutions such and automotive frames. As the as three-dimensional (3D) Anusaya, the company company grew, its operational measurement devices. Compared A long-time user of 2D tools, focus became increasingly to 3D tools, 2D versions are more Anusaya Auto Press Parts Pvt divided between supplying for time consuming to operate, less Ltd had been tackling measure- the auto-ancillary as a major capable of measuring large ment challenges since it started industry and the consumer objects, and typically do not have business in 1996. A subsidiary durables industries - both of the means to capture and store of the Wadhokar Group, it was which require fast and precise measurement data digitally. In first founded as a major sup- measurement results. recent decades, as awareness for plier to Tata Motors starting its 3D measurement systems has presence in Maharashtra. Since Need for a catalyst then, Anusaya’s portfolio has “We had been using 2D measur- Source: Faro Business Technologies India Pvt Ltd expanded to include notable ement tools since the beginning,Source: Faro Business Technologies India Pvt Ltd ANUSAYA AUTO PRESS PARTS CHALLENGES High measurement accuracy levels had to be achieved. Objects had to be manually moved for the measurements. Project completions took a longer time because of 2D tools. SOLUTION The FaroArm Fusion that helped in: É ,D@RTQHMF CHɪDQDMS BNLONMDMS O@QSR É (MBQD@RHMF DɭBHDMBX Reducing the amount of time needed for taking measurements; Anusaya now saves up to 85 percent in total measurement time Reducing manual labor due to its portability Replacing 2D drawings with CAD data Capturing and storing digital data easily. www.mmindia.co.in May 2017 | 45

METROLOGYThe Fusion is slim “Coming from using 2D tools, needs for alignment, calibration,and compact. Anusaya has achieved inspection, dimensional calcul- countless benefits with Faro, ations, quality control, and free- Source: Faro Business Technologies India Pvt Ltd such as time savings, form component inspection. reduction in using manual Pleased with what they and it was challenging at times labor, ability to measure witnessed during the demon- when product order deliveries different component parts, stration, Anusaya made their first never seemed to end. Project capturing and storing digital portable CMM purchase in 2012. completions took a longer time data, and even to using CAD “The biggest surprise was that because the tools slowed us data to replace 2D drawings.” the Fusion was not just limited down, and sometimes we even to application during assemblies, had to manually move objects Umesh C Ahuja but that it was also capable of before we were able to measure Plant Head measuring any manufactured them. We believe that a catalyst Anusaya Auto Press Parts Pvt Ltd component,” informed Ahuja. was needed to encourage any change from taking place,” Widely known to increase $IXVLRQRIEHQHƲWV shared Umesh C Ahuja, Plant measurement accuracy levels, Capable of a wide measurement Head, Anusaya. 3D measurement devices also range, the 12-feet Fusion features have a good reputation in an extended-use battery, and The external push increasing efficiency, reducing infinite rotation for non-stop The catalyst that pushed the amount of time needed measuring. Operators no longer Anusaya to adopt more advanced for taking measurements, and need to transport objects to measurement equipment came capturing measurement digital a measurement device, they in the most unlikely of forms. data easily. simply did the reverse instead. “One of our major customers was “When word got out in the market With the Fusion, productivity actually the motivating factor that we were looking to purchase at Anusaya has increased due to behind this change,” explained 3D metrology equipment, we the time savings achieved. Ahuja. “As experienced users of were instantly presented with “Although we witnessed its 3D measurement systems, they an array of options from several ability to achieve time savings had so many positive things to 3D measurement providers,” during the demonstration, we say about the equipment – so added Ahuja. were still pleasantly surprised much so that they suggested when we carried out our first we invest in a portable 3D Anusaya’s Choice: the task with the device during measurement device as well. FaroArm Fusion first article inspection. In all The team was intrigued and we Once notified that Anusaya was our years of using 2D tools, we knew that we needed to enhance on the lookout for a 3D measuring never imagined that we could our productivity.” equipment, Faro was confident save up to 85 percent in total that its 3D coordinate measuring measurement time. A significant machine (CMM) could help presence within our operations, Anusaya with its measurement the Fusion is fully utilized every challenges, recalled Sushil Arya, day from first article inspection, Regional Sales Manager (North all the way to post production,” India), Faro. said Ahuja. “After assessing Anusaya’s Perhaps out of the many derived needs, Faro brought in the benefits, computer-aided design FaroArm Fusion for a demon- (CAD) and digital data are the stration, and right away there two that are most valued by was immediate acceptance of Anusaya. The Fusion is able to the device,” he added. utilize CAD data from initial With the reputation of being design through to the finishing a comprehensive portable tool stages. 2D drawings can now be for performing inspections, replaced by taking measurement tool certification, and reverse points from any 3D component engineering and used across the instead. Additionally, the device automotive, metal fabrication, is also able to capture and store molding, and aerospace indus- digital data. tries, the Fusion was able to meet Anusaya’s measurement46 | May 2017 Modern Manufacturing India

METAL FORMING Source: Schuler GroupWithin just seven RETROFIT TUNESweeks, Schuler FORD PRESS TOmodernized transferand blank loader ofFord’s large panel pressin Cologne. HIGH PERFORMANCE The installation of Schuler’s Tri-axis Transfer helped in the overhaul of Ford’s large panel press, resulting in a myriad benefits. T he large panel press at Solution from Schuler at the press in seven weeks. Ford in Cologne was no Schuler specializes in metal In the first six months after the longer up to date: Because forming technology. The modernization, the press already the transfer was mechanically company supplies presses, auto- produced over 1.2 million parts. linked to the rest of the system, mation solutions, dies, process This is mainly due to the good the motion curves could not be know-how, and services for cooperation between Schuler adjusted and the components the metalworking industry and and Ford. Ford itself, with its own had to be stored between the lightweight automotive design. qualified department, brought press slides. To address Ford’s issue, Schuler the control of the straight-sided installed a Tri-axis Transfer with press to the latest level and Source: Schuler Group overhauling carriages as well as a prepared it for the installation blank loader with a line scanner of the new transfer. The interimwww.mmindia.co.in May 2017 | 47

METAL FORMING HIGHLIGHTS Source: Schuler Group CHALLENGES 1 1 Schuler’s 2 The large panel press at Ford in new Tri-axis Cologne was in a need of an overhaul. 3 4 Since the transfer was mechanically Transfer takes the linked to the rest of the system, the and optimize on output. The parts from one as with conventional optical motion curves could not be adjusted dies are also easier to set up die to the other, centering stations – the system and the components had to be stored and adjust. As the profile of the interim is largely insensitive to ambient between the press slides the transfer rails reduces from storage becomes light passing through the ceiling 250 to 200 mm, the freedom obsolete. window, for instance. This SOLUTION of movement and visibility improves process reliability Ford installed Schuler’s Tri-axis into the die improves. And 2 Thanks to significantly. Transfer and modernized the transfer the energy supply as well the blank Unlike a mechanical centering and blank loader of its large panel as maintenance costs are station, the system with line press. reduced by the elimination loader with line scanner is also completely The Tri-axis Transfer takes the parts of the mechanical connection scanner, independent of the blank shape from one die to the other, hence to the press. productivity and and also protects the surface making the interim storage obsolete. process reliability of the blank. The maintenance Due to the free programmability of the Continuous location improve cost of the system is also low. transfer, which can be controlled by its detection increase significantly. The optical centering station own visualization, Ford can now design cycle times is accurate up to 3 mm, the MDVÉCHDRÉLNQDÉɬDWHAKXÉ@MCÉNOSHLHYDÉNMÉ The blank loader, too, improves 3 For location location in and at right angles output. the productivity of the press: detection, the to the transport direction can With a servomotoric overhauling slide The exact location of a blank be corrected by up to 100 mm. step distances of more than 3.60 m can is detected while it is passing blank can pass The maximum blank size is be realized. a line scanner; the blanks do below a line 4,100 mm. The line scanner also Because of the blank loader with line not have to stop anymore. On scanner and does captures double parts side by side scanner, productivity and process basis of this information, the not have to stop as well as in a row. QDKH@AHKHSXÉG@RÉHLOQNUDCÉRHFMHɫB@MSKX following centering robot can anymore. Thanks to a pre-commissioning For location detection, the blank can align the blanks optimally of Tri-axis transfer and blank pass below a line scanner and does not for the subsequent forming 4 The optical loader with line scanner at have to stop anymore. process in a press. Because the centering Schuler and a well-coordinated The optical centering station is line scanner is attached right construction site, the downtime accurate up to 3 mm; the location can above the belt conveyor – and station is accurate for Ford was less than two be corrected by up to 100 mm not at several meters in height up to 3 mm, the months. location can bestorage has now become corrected by up to 100 mm.obsolete: With a servomotoricoverhauling slide, which isintegrated in the transfer rails,step distances of more than3.60 m can be realized.The coupling and uncouplingtakes place automatically duringthe die change. This means thatall necessary setup procedurescan be carried out outside thepress and the die changeovertimes can be significantlyreduced. Schuler’s ProTransfeatures feed direct drives withhighly dynamic servomotorsas well as active vibrationdampening. An increase inoutput by up to 30 percentand more is therefore notuncommon.Thanks to the free programm-ability of the transfer, whichcan be controlled by its ownvisualization, Ford can nowdesign new dies more flexibly48 | May 2017 Modern Manufacturing India

HONING SKILLS Source: Jyoti CNC Automation LtdThe company believes in BRIDGING THEempowering women andprovides encouraging INDUSTRY-platform to groom ACADEMIA GAPthem as expertoperators.P K CHATTERJEE Despite an abundance of highly capable and qualified human capital, IndiaSenior Correspondent needs to focus on developing the skills of its workforce to become a globalMagic Wand Media Inc powerhouse. The task will be easier if the government, the private sector, [email protected] the academia join hands. Rajkot-based Jyoti CNC Automation Ltd is one of the pioneers that is doing its bit for the national cause. A s far as their nature of firms that were earlier engineering products for the work is concerned, engaged in just testing and global market. Today, Indian Indian manufacturing other back-end activities are companies are also undertaking companies are witnessing rapid now concentrating on global projects where accuracy, transformation. Manufacturing manufacturing complicated precision, timeliness and com-www.mmindia.co.in May 2017 | 49

HONING SKILLS Source: Jyoti CNC Automation LtdA training session inprogress with youngengineers at thecompany’s premises pliance are the basic criteria for plant training to gain practical time to be future ready for the success. Hence, the need for knowledge, and contribute to industry. industry-ready technocrats is the movement of technical growing; along with technical innovations in India. Through Aligning with the education of theoretical nature, in-plant training, a balanced PM’s call sound on-the-job field ex- schedule and focused guidance, Prime Minister, Narendra Modi perience in industries has the company offers exposure repeatedly stresses on the need become absolutely essential. to the activities that make the for technology centres in the students ready to work in an country to accelerate the skill Grooming the industrial environment with building process among the young talent hands-on skills. This initiative technocrats. Jyoti has already Rajkot is well known as the has boosted the confidence level built a dedicated Tech Center industrial hub of Gujarat. At of many young engineering to exhibit various engineering present, hosting 14 engineering students to serve in the actual capabilities and to train institutes in and around, the industrial field. different groups for operating city is also turning into the and programming modern CNC educational hub of the state. Creating platforms of machines. In order to provide the best performance The company’s Tech Center industrial exposure to the To address the challenge of is a part of Pradhan Mantri young talent on technical maintaining ultra-modern tech- Kaushalya Vikas Yojana ground, Jyoti has initiated nical laboratories in colleges, the (PMKVY). Under PMKVY, several programs that intend company has established full- students with technical back- to bridge the gap between fledged learning labs in some ground can opt for about 500 academia and industries. engineering colleges. These labs hours of training sessions that Considering the country-wide facilitate on-campus leaning provide high level of industrial need for skill upgradation, the opportunity for engineering exposure to them. With company invites students of students during their academic special selection criteria, many various engineering institutes studies. This drive has provided students are taken for special from all over India to conduct students with the best in-house learning programs of different their academic projects and in- platform for learning, saving divisions of the company – along50 | May 2017 Modern Manufacturing India