ePaper-MMI - July 2017 issue

MODERN VOL 1, ISSUE 2 - JULY 2017 MANUFACTURING INDIA The Official Magazine ofW W W. M M I N D I A . C O . I N In Association with IIoT TRANSFORMING THE BUSINESS ECOSYSTEMCOUNTRY FOCUS: 28 38 MEDICAL CARL MARTIN WELCKERJAPAN MACHINING General Commissioner EMO Hannover 2017 24



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CONTENTS VOL 1, ISSUE 2, JULY 201732 344 | July 2017 50 06 FOREWORD 08 PUBLISHER’S NOTE 10 EDITORIAL 12 IMTMA’S DESK 14 PANORAMIC PERSPECTIVE 16 NEWS 18 COVER STORY IIoT: Transforming the Business Ecosystem 24 BIG INTERVIEW Carl Martin Welcker General Commissioner EMO Hannover 2017 28 COUNTRY FOCUS India-Japan: Untapping the Potential through Synergy 32 COMPANY PROFILE Raising the Bar 34 INDUSTRY VIEWS Implications of GST 38 MEDICAL MACHINING For a Good Cause 40 ADDITIVE MANUFACTURING Can 3D Printing Increase Milling Feed Rates? Modern Manufacturing India

58 IMPRINT42 INDUSTRIAL WASTE MANAGEMENT PUBLISHER & Chip Compacting: DIRECTOR GENERAL & CEO, IMTMA Making the Best Out of Waste V Anbu46 AUTOMATION & CONTROL Ensuring Maximum Productivity EDITORIAL Editor-in-Chief48 INDUSTRIAL PARTS CLEANING Snow-Jet Technology: Soumi Mitra For Ideal Coating Results Chief Copy Editor50 BEST PRACTICES Making Life-Changing Devices Poonam Pednekar54 SAVE THE DATES Senior Correspondent55 EVENT SNAPSHOT P K Chatterjee INTEC 2017: A Window of Opportunities Head Creative & Production58 EMO PRESS PREVIEW A Glimpse of EMO 2017 Shanmugam Pillai (Som)64 EVENT PREVIEW: NPS Snehal P Conquering the Summit66 EVENT PREVIEW: DMTX 2017 SALES & MARKETING An Impetus to the Manufacturing Sector Indian Machine Tool Manufacturers’70 COMPANY / ADVERTISER INDEX Association (IMTMA)www.mmindia.co.in Magic Wand Media Inc Published and Printed by V Anbu on behalf of Indian Machine Tool Manufacturers’ Association. Printed at Pentaplus Printer’s Pvt Ltd 20/1, 4th main, 5th cross, Industrial Town, Rajaji Nagar, Bangalore-560044, Karnataka and Published from Indian Machine Tool 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. | 5MJualy 2017

FOREWORD PG JADEJA President Indian Machine Tool Manufacturers’ Association (IMTMA) FUELING MANUFACTURING GROWTH Welcome once again to Modern Manufacturing India (MMI) magazine July 2017 edition. T he much talked about tax reform in the country – the Goods and Services Tax (GST) came into effect from July 1. The new paradigm in India’s cooperative federalism is expected to bring marked improvement in tax compliance and facilitate the ease of doing business. The applicability of the standard GST 18 percent rate for machine tools may result in reduction in overall indirect tax. IMTMA, to build up on the current economic scenario and bright economic prospects, is organizing the 11th edition of the National Productivity Summit on August 04-05, 2017 in Pune. The Summit brings out why manufacturers should embrace an integrated approach to optimizing manufacturing productivity and how to prepare their workforce, processes and technology for productivity excellence. The Association will also organize the second edition of the Delhi Machine Tool Expo (DMTX 2017) from August 10–13, 2017 in New Delhi. DMTX 2017 also focuses on Metrology and Welding. METROLOGY EXPO, an exhibition for testing instrument, metrology and equipment and WELDEXPO, an exhibition for welding, cutting and joining, will be held concurrently. IMTMA will continue organizing a wide range of training programmes at its Technology Centers in Bengaluru, Gurugram and Pune to hone the skills of the manufacturing industry’s workforce. The new industrial Policy likely to be released this year is expected to put Indian manufacturing industry on the global map. With this note of optimism, I call upon the industry to wholeheartedly support Association’s initiatives by giving valuable feedback which will help us in our journey to strengthen the Indian manufacturing sector. Readers can also download previous issue of the magazine from IMTMA website. Happy reading. PG Jadeja President Indian Machine Tool Manufacturers’ Association6 | July 2017 Modern Manufacturing India

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PUBLISHER’S NOTE Dear MMI Readers, M odern Manufacturing India (MMI) magazine has had a grand beginning. Our widely circulated bimonthly magazine has been well-accepted by the global manufacturing fraternity and serves as a reading lens to the manufacturing world that is constantly undergoing changes with technology replacing labor. India is witnessing some rapid changes in the manufacturing landscape. The country is embracing new technologies and innovations that would spur manufacturing industry to greater heights and position it firmly on the global map. This month’s edition carries insightful and informative articles on machine tool and manufacturing industry. Read on for a quick peek into a special article by IMTMA on how Industry 4.0 will shape manufacturing and open up a plethora of opportunities to place the Indian machine tool industry on the global radar. The Indian machine tool industry has welcomed this initiative of IMTMA with open arms. The Association has been encouraged by the positive feedback for the many iterations made to make the content more exciting including the typefaces and page designs. IMTMA is excited to continue bringing valuable content to enable the machine tool industry to achieve the widest possible reach and create an impact at the global level. Any publishing process is incomplete without feedback from readers, and therefore we solicit your valuable thoughts to make our MMI more insightful and interesting. This will also enable our young magazine to mature in stature. As always, I hope you enjoy the time you spend with MMI and thank you once again for your support. Warm regards, V ANBU Director General & CEO Indian Machine Tool Manufacturers’ Association8 | July 2017 Modern Manufacturing India



EDITORIAL NLIKOETTIHMEE PRESENT… t the outset, I wholeheartedly thank you, “our valuable readers”, for A your encouraging words on the refreshed version of MMI. Your continued support and faith provide us the confidence to recognise opportunities coming our way and make the best of them while reaching out to a wider global audience. A few weeks ago, I had the privilege of being part of the EMO Press entourage and getting a sneak peek into the latest production technologies to be showcased at the event from Sept 18–23 in Hannover. A 25 percent rise in Asian participation gives an interesting twist to the 2017 edition of the show. It will, quite possibly, be breaking all its records in terms of participation.SOUMI MITRA That a day has been People will try to tell you that allEditor-in-Chief dedicated to focus solely the great opportunities have beenModern Manufacturing India on India’s competence in snapped up. In reality, the [email protected] mechanical engine­ ering and capital investment, changes every second, blowing reiterates the potential new opportunities in all directions, India holds in the global market and gives us including yours. another reason to look forward to the show. ~KEN HAKUTA The current issue celebrates India’s prowess in manufacturing and highlights advanced manufacturing technologies that present a mega opportunity to the country to yet again demonstrate its leadership in the field. Wish you an insightful read! READER’S CORNER “The look and feel of the new avatar “I am much impressed with of MMI comes across as fresh. The TK Ramesh’s write-up that appeared font, its depth, and the shade of in Modern Manufacturing India May blank ink all contribute to make it issue. His advice to people of the highly readable, especially for old industry to be cautious in changingpeople like me! I found the content quite informative. operational practices in a changed environment isThe case study on Volvo about 3D Printing sheds apt and timely. I shared this nugget of wisdom withlight on the latest trends in the industry. I look my colleagues and my mentors to acknowledge theirforward to such topics and on how different efforts to ‘Teach and Train’ us.”industries influence the machine tool sector.” Narasinh K Balgi, Director,N K Dhand, Chairman, Ferromatik Milacron India LtdMicromatic Grinding TechnologiesPast President, IMTMA10 | July 2017 Modern Manufacturing India



IMTMA’S DESK TOINMDAUKSTERINYD4.I0A: AMANUFACTURING POWERHOUSEIn its consistent efforts towards zero-defect, increased productivity goals,the Indian manufacturing industry is embracing smart technologies that herald an era of unprecedented benefits. T he manufacturing changes that machine tool cost advantages of traditional industry of India will manufacturing industry is locations shrink and Industry 4.0 derive optimum benefits witnessing in terms of scale and becomes vital. from technologies that connect magnitude for increasing its productivity through Industry Relevance of Industry 4.0 systems for intelligent 4.0 is one which has never been Customers today demand for experienced before. zero defect products and it is production. Technologies that difficult for manufacturing Why the need for industry to satisfy the enable Industry 4.0, capturing Industry 4.0 demands of customers without Tobeginwith,companiesinitially embracing smart technologies. data and data sources, focused on mass production and Industry 4.0 is relevant in this customized production. Now as it enables the industry to communicating data between cus­to­mers are demanding for produce zero defect products customized production in mass. besides increasing productivity. machines, sensors and data This necessitates production As the industry upgrades its system and processes to be machinery to modern ones sources, 3D printing, robots and flexible and smart. Moreover, which are compatible with when production becomes Industry 4.0 we would see systems such as Internet of capital intensive, the labor productivity levels scaling up.Customers’ Things (IoT) have madedemand forcustomized manufacturing ‘smart’.production inmass necessitates Indian companies areproductionsystem and embracing these technologiesprocesses tobe flexible and and investing in the fourthsmart. industrial revolution (Industry 4.0) just as any other major economy of the world. The12 | July 2017 Modern Manufacturing India

India and Industry 4.0 National Productivity Delhi Machine ToolIndian companies are offering Summit 2017 Expo 2017first generation 4.0 solutions. Companies are being constantly IMTMA is organizing the second editionAn awareness is being built challenged to increase competitiveness of its northern regional show, the Delhiup on smart manufacturing in manufacturing to increase their Machine Tool Expo (DMTX) 2017, onthroughout the industry growth, reduce cost of operations, August 10-13, 2017 at Pragati Maidan,workforce. Many individual enhance productivity and thereby, build a New Delhi.companies are adopting sustainable competitive advantage. With The expo will also focus on Metrology andadvanced ERP systems which the growing merger of physical and digital Welding: METROLOGY EXPO, an exhibitionmonitor production process in manufacturing worlds, technological for testing instrument, metrology andmore detail and generate data advancement is becoming a key facilitator equipment; and WELDEXPO, an exhibitionfor the management on real- in this pursuit. Companies need to adopt for welding, cutting and joining, will betime basis. Many companies in a highly structured approach to manage held concurrently.auto component and automobile innovation, while at the same time, not DMTX will showcase state-of-the-artsector are shifting to Industry losing out on time to reach the markets. technologies focusing on manufacturing4.0. in production process. To champion the cause of productivity solutions for metal cutting and metal and enhancing competitiveness in the forming industries located in North India.Smart manufacturing is Indian manufacturing industry, IMTMA is Focus will be on the large number of smallSmart manufacturing organizing the 11th edition of the National and medium enterprises spread across Productivity Summit on August 04-05, the states including Delhi, Rajasthan,envisioned as the future 2017 in Pune. Haryana, Uttar Pradesh, Uttarakhand, and The summit will showcase the best Himachal Pradesh.of manufacturing. It is a practices in manufacturing. It will Expressing his views about the expo, have inspiring keynotes from eminent PG Jadeja, President, IMTMA, said, “Northprocess that integrates human speakers, seven case study presentations India has many industries, and is a hub by manufacturing companies contesting for engineering and manufacturing. Theingenuity with data and for the IMTMA-ACE Micromatic first edition of the show held two years Productivity Championship Awards ago provided a common platform fortechnology to revolutionize the 2017, and three plant visits to Spicer manufacturers to expand their range. India & Bosch Chassis Systems India, This show will also have presencedevelopment and application Cummins India & Tata Cummins, and from domestic and international machine Mahle Behr India & Concentric Pumps to tool manufacturers.”of manufacturing intelligence witness how productivity improvement Concurring with Jadeja’s views, V Anbu, projects are being translated into action. Director General, IMTMA, added, “We expectto all aspects of a business. To The Productivity Championship Awards a bigger level of participation and better will recognize and reward outstanding footfalls for this edition from the regiondevelop smart manufacturing efforts from the shortlisted case studies cutting across various industry sectors.” of companies who have excelled in DMTX 2017 will feature over 200 exhibitorsand build intelligence in achieving superior performance and occupying a gross exhibition area of give cash prizes worth `10 lakh. around 12,000 sq mt in three exhibitionbusiness processes, Indian halls. Seven foreign countries (Czech transformation. This will en­ Republic, Germany, Italy, the USA, China,Machine Tool Manufacturers’ able the Indian manuf­acturing Taiwan and Australia) are expected industry to become globally to participate.Association (IMTMA) organizes competitive. facturing sector. The g­overn-a symposium on Smart Government support ment is also committed to Recognizing the importance developing Industry 4.0Manufacturing in Bangalore. of smart manufacturing and technology through national Industry 4.0, the Government institutions such as CMTI andThe symposium acts as a of India has been promoting IITs, etc. The Department of Industry 4.0 through various Heavy Industry is also thinkingforum to address the queries seminars and stakeholder of supporting Experience discussions for showcasing Centers for Industry 4.0 jointlyand challenges in this area. its relevance for the manu­ with industry partners with multiple locations. Two Symposiums on SmartManufacturing have beenorganized by IMTMA in 2016and 2017.Roadmap for futureThe industry can leap forwardwith smart manufacturing.Industry leaders must pro­vide a direction in this. Interms of cost and adaptingto new systems, a phasedapproach will be practical.Companies need to assessthe overall manufacturingfacilities, plant integration,plant-wide optimization andmanufacturing intelligenceand knowledge for businesswww.mmindia.co.in July 2017 | 13

PANORAMIC PERSPECTIVEENCOURAGING FIDELITY IN BUSINESSI n the manufacturing B2B space, most of us believe our customers are loyal since we keep getting repeat business from them over time. It is also perceived that the capital equipment purchase in manufacturing is driven by the same sentiment because it is fairly common tosee lines of machines from the same manufacturer. However, a different picture emerges when weseriously ponder over the noble quality of loyalty and its attributes.Faithfulness in a relationship inherently implies The decision of sticking toadhering to the chosen one and not getting strayed the same company, despiteby equally or more attractive options. The emotion isfar from being logical. It is similarly irrational when enough knowledge of aan existing customer continues to do business with a better offer, has more tocompany even when a cheaper, more convenient or do with the buyer thaneven higher-quality machine is available from another.The decision of sticking to the same company, despite the seller.enough knowledge of a better offer, has more to do withthe buyer than the seller. T K RAMESH Whole time Director and CEOThere is a great divide between loyalty and repeat sales. Micromatic Machine Tools Pvt LtdTechnology, price, aesthetics help influence the initialsales, whereas repeat sales happen due to familiarity,habit, and difficulties in switching. Repeat buying is acalculated move driven by sellers who sweeten thedeal, making it difficult for the existing buyer to leave.Loyalty, on the other hand, is led by an emotionalconnect. It stems from the buyer’s belief system andidentity, which are deeply personal. He must be ableto relate to the company’s philosophy, its way of doingbusiness and what it stands for.Apple customers best exemplify the loyalty in question. While the price of any Apple productis at least 25 to 40 percent more than its competition’s products that offer higher specifications in phones, tabs, note books and computers, Apple has no threat with regard to its customer base. They remain fiercely dedicated, having no qualms with fewer peripheral choices, difference in chargers, proprietary software etc. The decision to buy an Apple is emotional and owning it reflects a sense of identity. Closer home akin to the Harley Davidson furor is our very own Enfield motorcycle following, which helps to reiterate that loyalty is more about a company’s ability to express a distinct sense of why they exist and what they believe in rather than what they make or the quality of what they make. The clearer the belief, the greater the appeal of the company to those with similar beliefs. From a Machine Tool perspective, the philosophy of service—standing with the customer in times of need, handholding him with a strong belief of customer support and practicing the belief across the company—drives loyalty. When put in practice, the company reflects an authentic belief system that will be supported by a loyal customer base. The views expressed by the author are personal and he can be contacted at [email protected] | July 2017 Modern Manufacturing India



NEWSManufacturingSees Dip inNegative GrowthNew Delhi, India – The manu- Source: Zavenirfacturing sector outlook showsimprovement in the first quarter of Saket Bhartia, Managing Director, Zavenir and Martin Kluthe, Managing Director, Kluthe Group (Germany) signing the MoU of thethe fiscal (April - June 2017-18) due to joint venture.a rise in the percentage of respondentsreporting higher production as Zavenir and Kluthe Groupcompared to previous quarter, into JVaccording to FICCI’s latest QuarterlySurvey. While the percentage of Gurugram, India – Zavenir and of-the-art technologies, will bring inrespondents reporting an improved Kluthe Group have announced a competitiveness to users, apart fromoutput growth in the first quarter has major strategic 50:50 joint venture, enabling them to adopt solutionsincreased from 47% (January - March named Zavenir Kluthe. The aim of which are greener. Since 2011, Zavenir2016-17) to 49%, there is a dip in the this tie-up is to cater to the needs of has been a licensee partner of Kluthereports of negative growth from 27% Automotive, Automotive Ancillaries, Group. This joint venture is an ex­(the previous quarter) to 17% (April – Heavy Engineering, and Plastic tension of this relationship aimed atJune 2017-18). The survey assessed Industry. Post tie-up, Zavenir will increasing manufacturing, marketing,the manufacturers’ expectations help the venture with its domestic and sales of all Kluthe’s products andfor 11 sectors - auto, capital goods, infrastructure in marketing and technologies in the field of metalcement and ceramics, chemicals and sales of specialty chemical products. working fluids, surface treatment, andfertilizers, electronics & electricals, While, Kluthe, by sharing its state- paint shop management.leather and footwear, machine tools,metal and metal products, paper FAG Bearings Indiaproducts, textiles and technical changes to Schaeffler Indiatextiles, and textiles machinery. Mumbai, India – FAG Bearings India Ltd, a leading manufacturer ofUS Cutting Tool industrial and automotive bearings, has changed its corporate name toConsumption Up Schaeffler India Ltd recently. The process of changing the company’s name was completed after the required regulatory and subsequent shareholderCleveland, US – The US cutting approvals were obtained. This change of name is an important step in thetool consumption recently totaled to rollout of the new global strategy “Mobility for tomorrow” of the company’s$191.93 million according to the US parent group, Schaeffler AG, a global automotive and industrial supplier.Cutting Tool Institute (USCTI) and “By adopting thethe Association for Manufacturing Schaeffler name, we aimTechnology (AMT). With a year-to- to unite and strengthendate total of $908.04 million, 2017 is the Schaeffler brandup 5.8% when compared with May2016. “As domestic manufacturinggrowth is projected to continue,2017 will be a much better year forthe Cutting Tool Industry,” said BradLawton, Chairman, Cutting ToolProduct Group, AMT. both internally and externally in order to increase awareness and enhance our corporate profile inSource: AMT Source: Schaeffler India,” said Dharmesh Arora, CEO, Schaeffler India.16 | July 2017 Modern Manufacturing India

| MW11-03E | From compact to complex: The scalable Beckhoff CNC. Servo drives Industrial PC I/O system www.beckhoff.co.in/cnc POWERING YEAR 10 PC-based controllers from Beckhoff cover the whole range of Beckhoff Automation Pvt. Ltd. high-precision CNC applications, from compact to complex. Pune – 411 006, India Phone: + 91 20 40 00 48 00 Highly scalable: the TwinCAT software platform for engineering and runtime [email protected] Highly scalable: the Industrial PC range with processors from Intel® Atom™ to many-core Highly scalable: the I/O system for all signals and fieldbus systems Highly scalable: the highly dynamic servo technology for all performance classes Highly scalable: the safety solution, from system-integrated I/Os to drives

COVER STORY IIoT TRANSFORMING THE BUSINESS ECOSYSTEMSource: Fraunhofer IPA PROF DR THOMAS Current trends in production such as digitization, including the shift to mass BAUERNHANSL personalization, lead to significant changes in manufacturing. The stages of digital Director - Fraunhofer transformation in the framework of the Industry 4.0 concept have a long history Institute for starting with mechatronic systems leading to cyber-physical and eventually Manufacturing autonomous systems to the final degree of autonomization. The traditional Engineering and automation pyramid is thus dissolving. Automation IPA and the Institute of Industrial T he revolutionary aspect can communicate via the an innovative user interface for Manufacturing; & of Industry 4.0 is not Internet without time delays integrating human beings into Management IFF - digitization itself, but or barriers. Cyber-physical the process, the digital shadow University of Stuttgart the ability to network technical systems (CPS) are the core (a virtual real-time image of thomas.bauernhansl@ systems in real time. Machines, technology of Industry 4.0. The reality) and software services ipa.fraunhofer.de sensors, tools, orders and people key structural elements include which generate added value. It18 | July 2017 Modern Manufacturing India

Technologies revolutionizing production systems Horizontal networking: The use of the Internet of Things (IoT) and Services in value creation systems – across different companies, at the same stage of the value creation chain, from the customer to the supplier. Vertical integration: Changing machine architecture from a mechatronic system to a cyber-physical system. Machines or tools then communicate with other CPS in the Internet – vertically within a company, on a technical level from the sensor to the decision-making system on the top floor. Real-time optimization of complex value creation systems: This is done by processing big data and using it to make predictions about the future.also incorporates cloud-based computerized numerical gether. Then, the era of virtu-platforms which supportcommunication, a life cycle control (CNC) technology. In alization began. Cyber-physicalenvironment for physicalsystems and software services the 1970s, it was joined by systems were developed andand analytical tools based onbig data and machine learning. computer-a­ided design (CAD) the integration of all value cre-CPS use data from the Internetof Everything – the Internet of and enterprise resource plan- ation processes via broadbandpeople, things and services. ning (ERP) and others. The first communication was realizedReal-time integration isthe key tentative steps towards devel- with the help of cloud comput-The development of dig­itizationstarted with mechatronic oping Industry 4.0 can be found ing and the industrial Internet.s­ystems in the 1950s including,for instance, digital imaging in the computer-integrated The last decades witnessed anof analogue processes or manufacturing (CIM) strategies unprecedented acceleration in of the 1980s. However, in those the development of new digi- days, the necessary technol- tal technologies: the Internet, ogies were not available and WLAN, high-performance there was a widely held belief comp­ uting and finally big data. that centralized controls were These technologies have been essential. At that time, design- the key to creating completely ers envisaged humans being new opportunities in network- removed from the factory alto- ing and data processing, andwww.mmindia.co.in July 2017 | 19

COVER STORYSource: Fraunhofer IPA/Rainer Bez These achievements would be impossible without the rapid The capabilities thus facilitating the so-called app- and cloud-based services growth in computing power, offered by IT are truly Fourth Industrial Revolution. have broken way out of the in- continuously expanding Inter- transforming the Since the 1990s, the degree of formation and communication net bandwidth and the greater digitization evolution networking has grown at a sector into the world of produc- mobility of the technologies into a revolution. breath-taking rate. Trends such tion and are adding still more and user devices. The final step as the Internet of Things (IoT) or fuel to the networking boom. of crosslinking-yielded autono- mous systems leads to increas- Source: Fraunhofer IPA Economic Benefits of Industry 4.0 ing autonomization. This will be achieved through the com- New innovation bination of classic technologies and artificial intelligence which Disruptive business models create autonomous, self-orga- Customer-centered innovation processes nizing systems (e.g. autonomous Open X (innovation, funding, creation, source etc.) transport systems, autonomous robots). Personalization The capabilities offered by IT – communication and data Complexity as competitive factor storage using Internet technol- Personalized products and services ogies as well as the exponential increase in computing capaci- Regionalization ty – are truly transforming the digitization evolution into a rev- Frugal products olution. Local value creation Micro factories Cloud-based platforms Cloud-based platforms offer Flexibility applications that run in the cloud, or use services provided Decentralized work systems (swarm) from the cloud, or both. There Plug and produce (cyber-physical systems) are various kinds of platforms today. IT-oriented production Cost optimization platforms take their origin in IT. Many services and apps ex- Variabilization of costs (XaaS) ist already. The usual business Reduction of complexity costs (prosumer, platforms, communities etc.) approach/model is Pay-per-Use Data-based productivity optimization (big data) for everything. But there are no manufacturing applications. In Sustainability this environment, big data will be expensive for the user. Savings in energy and material (smart grid, zero waste etc.) Also in business-oriented plat- Resource protection / environmental friendliness (sharing economy) forms there are many apps al- ready. The service shops offer Staff internal and external services. Some of the apps could be used Better working conditions (personalization of work places, reduction of waste, in manufacturing and some appreciation of competences) platforms are available as pri- vate clouds. Industry-oriented New working-time models (work-life integration) platforms, however, are at a na- scent stage of development. New imperatives of value definition The value of a company today does not necessarily depend on20 | July 2017 Modern Manufacturing India

Development Stages of the Digital Transformation sustainability aspects of val- ue creation systems – from the FrDomevdeilgoiptaml iemnatgSettaogaeustoonfotmheouDsigsyitsatel mTransformation process to the business ecosys- tem. This perfectly integrates From digital image to autonomous systems all the value creation partners and the end customers. This Autonomous 4 Autonomization capability is new. Networking Systems based on platforms, which per- Cyber-physical mit both horizontal and vertical Systems 3 Crosslinking integration, can, therefore, be used to generate and distribute Mechatronic 2 Virtualization specific tasks or machine func- Systems tionalities within this economic ecosystem. 1 Digitalization 1950 1980 1990 2000Source: Fraunhofer IPA Digital image Digital modeling of Integration of all value Combination of classic technologies and Advantages of of analog processes processes creation processes artificial intelligence create autonomous, (e.g. NC technology, 2-D (e.g. CAD/CAM, FEM, via broadband self-organizing systems CAD, MRP/ERP) digital factory) telecommunication (e.g. autonomous transport systems, (e.g. industrial IoT, cloud autonomous robots) computing, CPS, 5G) Industry 4.0 Four core theses for the valueVertical Integration creation model of the futureVertical IntegrationCoQrueellee: FlraeunmhofeernIPAts of the fourth industrial Revolution 2 describe the advantages of © Core elementsFraunhofer IPA, IFF Universität Stuttgart of the fourth industrial revolution Industry 4.0: Infrastructure (physical, digital) Optimum distribution of value creation processes in an eco- Cyber-physical System nomic network. This connects Product Life Cycle (valuable = personalized + sustainable) all the value creation partners, Interaction suppliers and customers in a Physical Systems (act, sense, communication) Human Beings (decide, create, communicate) structure with minimal hierar- Reflection chies and leads to low complexi- Digital Shadow (real-time model of everything) ty costs and, thus, a higher total Transaction Software Service (machine skills, Apps for humans, platform services) margin. Interoperation Optimum distribution of func- Cloud-based Platforms (private, community, public)Source: Fraunhofer IPA tionalities (services) in the Prescription Analytics (Big Data/machine learning) cyber-physical system archi- Communication tecture. This leads to scale ef- Internet of Everything (human beings, services, things) fects and greater adaptability 3 of functions throughout the life© Fraunhofer IPA, IFF Universität Stuttgart cycle of technical systems. Forecasts and future scenarios resources, namely the number Use and benefits based on big data and the digi- of employees, the machines and The advantage of Industry 4.0 plants or the produced and sold is that it offers versatile, highly tal shadow of reality. This pro- number of products. It depends flexible systems which make it on customer access. The more possible to transfer value cre- vides the foundation for high customers are being integrat- ation to the location where it ed via business platforms, the can best take place. This reduces productivity and agility in com- more the value of a company complexity costs and generates rises. Data is the gold of our new potential for improving plex value creation systems. business ecosystems. efficiency. The overall system These examples also show that of objectives for value creation Adaptive, self-teaching hu- the characteristics of digital – in terms of time, costs, quality, business models are low fix costs flexibility and sustainability – man-machine interfaces. These (XaaS), because time is money. remains unchanged but the re- The marginal costs are close to quirements rise in each individ- integrate employees into the zero and the revenue develops ual area. Industry 4.0 extends after generating a lock-in effect the scope of solutions used in process and eliminate waste. by gaining a critical size. designing the economic and In 2020, They also ensure full accep- there will be an estimated tance in the work system and 50 billion devices to create the basis for agile, robust the Internet, enlarging the value creation systems which IoT rapidly. are capable of learning. New technologies and business models thus enable suppliers, service providers and customers to take on new roles www.mmindia.co.in July 2017 | 21

COVER STORY once again become competent to make decisions in every area – using assistance systems where necessary – and concentrate on high-value tasks such as decision-making and design. Seen from this standpoint, Industry 4.0 will bring back the expertise of the engineers directly into the value creation process and improve the status of production workplaces.Source: Fraunhofer IPA/Rainer Bez Challenges of dealing with big data Industry 4.0 will bring and collaborate in the value and removing hierarchies from In the framework of Industry back the expertise of creation process. The product value creation responsibilities. 4.0 and the digitization of value the engineers directly can become an information In this “prosumer” model, the creation within platform-based into the value creation carrier and, therefore, support customer is not just a consumer ecosystems, there is a change of process and improve every phase of its life cycle but also one of the producers. perspective, because of the use the status of autonomously. This is known He performs tasks which used of big data. Complicated con- production workplaces. as digital product memory. It to be the responsibility of texts are being systematically also opens new horizons for the manufacturer. This offers analyzed through root cause In the designing and optimizing the further cost savings. analysis. The complicated net- framework value creation process. It offers Companies can download CAD work is divided in small entities of Industry the potential for major savings software, design the part they and correlations are being ex- 4.0 and the in almost every area of value require and then order it at the amined. There is only random digitization creation. click of a mouse. Everything as sample analysis and thus a de- of value The use of real-time stock a Service, the XaaS concept, is ductive approach. The question creation data and other information also leading to the emergence behind is “why?”. within throughout the supply chain of “complexity bundlers”, which In contrast, complex contexts platform- can reduce stock costs by up focus on one topic and develop are no longer being analyzed based to 40 percent. Production and special expertise in that area. with regard to their causes. ecosystems, logistic costs can also be reduced They offer services to match, This way, correlation replaces there is a by 10-30 percent by using such as procurement platforms causality. Regularities are being change of smart wearables at production that select the best quality and derived from all available data, perspective, workplaces or analytics to boost best value suppliers. This cuts because pattern recognition because of overall equipment efficiency. the manufacturer’s workload is available, e.g. customers be- the use of Complexity costs are usually without compromising on the haviour patterns. The complete big data. indirect costs and offer even scale effects. data screen is being analyzed greater potential savings. They Step-by-step, the digital in an inductive approach. The can be reduced up to 70 percent transformation is breaking question here is “what?”. by integrating the customer down the Taylorist principle of of the product into the value separating labor and knowledge. The Road Ahead creation system in each case, In future, knowledge will be Cyber-physical systems con­ using comprehensive service transferred directly to the nect the IoT with people and products and decentralization, production line. Employees will new tools, resources and services in production systems – in real-time. This lies at the heart of the Fourth Industrial Revolution, in whose context value creation is platform- based and integrated in business ecosystems. Today, the market is ready and consumers buy eagerly. 22 | July 2017 Modern Manufacturing India

VISIT 10 -13, August 2017 HALL 11, 12 & 12A Pragati Maidan, New Delhi Register Online & Print your own badge Special Pavilion Delhi Machine Tool Expo 2017 FEATURED EXHIBITORS & many more...

THE BIG INTERVIEW Source: VDW “India’s PRODUCTION industrial TECHNOLOGYsector is very active, and @ ITS BEST! keen to play The EMO Press Preview, held a few weeks ago, presented Modern a role Manufacturing India the opportunity of an exclusive interaction with on the international Carl Martin Welcker, General Commissioner, EMO Hannover 2017. stage.” An insightful read on the bandwidth of the latest production technologies Carl Martin in metal-cutting and -forming machine tools to be displayed in the fair. Welcker GeneralCommissionerEMO Hannover 2017 The theme for EMO Hannover trial sector. With the combina- operation, the complete value- 2017 is “Connecting systems tion of digitalisation and added chain. In a consistently for intelligent production”. networking, the protagonists networked manufacturing line, Against this backdrop, please involved are anticipating the flexible production is possible elaborate on how Industry 4.0 next boost to productivity. with optimised work sequences is contributing towards metal- In the machine tool itself, so that even rush order can be cutting applications? digitalisation has long since been accepted in small batch sizes. implemented. The task now is to Complete networking with real- CARL MARTIN WELCKER: network the entire production time communication and control Industry 4.0 describes the current mega-issue in the ind­us-24 | July 2017 Modern Manufacturing India

creates the greatest added value to meet these requirements. “There will be a display ofwhen it implements horizontal The EMO Hannover will be productive multi-purpose andcommunication from the order showcasing affordable standard specialised machines for ultra-booking to actual dispatch. machines with simple concepts, stringent qualitativeInside the value-added chain, maintenance-friendly standard requirements in large-series andmoreover, logistical partners and components and numerous mass-production applicationscustomers need to be networked customisation options. The other in EMO Hannover 2017.”in addition to the vendors, to side of the spectrum consists of Carl Martin Welckerachieve maximised productivity, productive multi-purpose andflexibility and efficiency. specialised machines for ultra- markets. With its good develop- stringent qualitative requir­How can the software analysts ements in large-series and ment prognoses, India isand metal-cutting specialists mass-production applications.collaborate to bridge the gap of They incorporate multifaceted an obvious choice. In 2017,understanding between metal- automation solutions, andcutting applications and big ensure favorable unit costs, the exhibitors in Hannoverdata analytics? thanks to complete machining and technology integration include 35 Indian firms. ThisWELCKER: The integration of coupled with maximised re-machines into evolved IT systems produ­cibility and availability. number is considerably higherfaces the challenge of having to Then there’s Industry 4.0 asoperate with highly disparate well. We shall see at the EMO than last time and showsinterfaces. In this context, soft- Hannover what solutions will beware specialists play an import- attracting particular attention. that more Indian vendors areant role in making trouble-free Unfortunately, this is verydata interchange possible. Fur- difficult to estimate beforehand. internationally active. At thethermore, large quantities of datahave to be managed. This is not For the Indian participants – last EMO Hannover, moreover,the traditional core competence exhibitors as well as visitorsof machine tool manufacturers. - what are the key takeaways Indians were the third-largestRather, it requires smart data for from this edition of the megaits analysis. In order to develop show, especially when there is a visitor grouping from outsidefit-for-purpose approaches here, dedicated day for India in EMO?the empirical knowledge of pro- Europe. For September, sixduction technicians will be, in its WELCKER: Indian exhibitors andturn, essential. Therefore, inter- visitors will once again be able to entrepreneurial delegationsdisciplinary teams will be indis- confirm for themselves that thepensable in the future. EMO Hannover is the hotspot have already announced they for all the sector’s players. As theThe global manufacturing sector world’s premier trade fair for its will be attending, organisedis waiting for the EMO Hannover chosen sector, it is truly inter-to take place as it is the national in character. Exhibitors by various trade associationsbiggest platform for witnessing will be coming from 45 differentthe latest advancements in countries and visitors from more and institutions. For the Indiaproduction technology. Kindly than 100. This is being reflectedelaborate on the new additions in the global machine tool busi- Day, we have succeeded inthis year. ness. And India is significantly involved, both as a customer, an bringing directly on board manyWELCKER : Despite digitalisation investor, and a vendor as well.and networking, the traditional experts from India, who willrequirements for machine tools What is the objective behindand manufacturing systems organising the India Day at the be presenting their appraisal ofremain crucially important, EMO and what potential do yousince after all, customers wish think India holds in terms of ongoing developments. Overall,to produce their parts pro- offering its technologies to theductively, in high quality, and global machine tool sector? this picture shows that India’scost-efficiently. New machineryconcepts, reliable components, WELCKER: In its supporting industrial sector is very active,dependable machine control program, the EMO Hannoversystems plus intelligent process repeatedly focuses on attractive and keen to play a role on thedesign and control combine international stage. The interview was conducted by: Soumi Mitra, Editor-in-Chiefwww.mmindia.co.in July 2017 | 25





COUNTRY FOCUSINDIA-JAPAN:UNTAPPING THE POTENTIALTHROUGH SYNERGYIndia and Japan have a history of mutually benefiting industrial collaborations. Recentdevelopments in their engagement paint a brighter picture as the countries are recognisingeach other’s strengths and are leveraging them for their growth. In the machine tool sector,Japan has its expertise and know-how to offer to India, while India can reciprocate with itsmarket size, technological concepts and skilled workforce.POONAM PEDNEKAR T he exchange between Stronger bond overall FDI during this period.Chief Copy Editor I­ndia and Japan that Japan is currently India’s third The machine tool sector beingMagic Wand Media Inc started centuries ago has largest source of foreign direct the backbone of the manufactur-poonam.pednekar@ sustained and kept gaining investment. Investments from ing industry, its prowess deter-magicwandmedia.org momentum due to stark Japan have made a quantum leap mines the success of manufac- complim­entaries between the during 2016-17, reaching $4.7 turing. Hence, Japan being one two Asian economies. Recent billion from $2.6 billion during of the leaders in the machine tool developments in the trade 2015-16. Cumulative Japanese sector, holds immense potential scenario have further stren­ FDI in India is $25.67 billion be- for India in terms of expertise gthened their relation which still tween 2000 and 2017, which and know-how. India, on the has a vast potential for growth. constitutes 8 percent of India’s other hand, is important to Japan Source: Magic Wand Media Inc28 | July 2017 Modern Manufacturing India

“India has the highest economic “Japanese manufacturers and “Japanese companies are poisedgrowth rate at present, and market are open to accept high to supply IoT enabled machinesmachine tool demand here is quality advanced products and to Indian users particularly inexpected to continuously expand technologies. We hope to see automotive sector that willin the future. In recent years, the more proposals from Indian change the demand likely to beinvestment of Japanese machine manufacturers that suit posed to Indian suppliers.”tool manufacturers in India has Japanese market.”increased remarkably.” Vivek Nigam Yutaka Nakau Business HeadYoji Ishimaru President Machine Building DivisionPresident Japan Forming Machinery Isgec Heavy Engineering LtdJapan Machine Tool Builders’ Association (JFMA)Association (JMTBA)due to its market size and human a transformational phase, with unmanned technology utilizing Metal Formingresources. new machines and technologies robots, Precision processing tech- & Fabricating redefining the way production nology such as 5 axis machining Fair TokyoA perfect alliance happens worldwide. “Optimiz- centers and turning centers are (MF-Tokyo) is Japan’sThe Japan Machine Tool Build- ing the manufacturing processes among other trends. “Japanese specialised tradeers’ Association (JMTBA) is an and services by making full use machine tool manufacturers are fair that witnessesindustrial collective dedicated of Internet of Things (IoT) and actively working on the develop- participation fromto taking on scientific and tech- Artificial Intelligence (AI) is the ment of these new technologies many countriesnological challenges, and pro- focus,” shared Ishimaru, describ- and can provide high perfor- including India.moting Japanese machine tool ing the machine tool scenario in mance machines that respond toindustry globally. Yoji Ishimaru, Japan. Additive Manufacturing the development of Indian civilPresident, JMTBA, said, “In India, (AM), 3D printers, Automation / demand,” he added.advanced manufacturing indus-tries such as automobile, aircraftand electronic devices have beendeveloped. In the future, the de-mand for mass-production andproduction efficiency will bestrengthened. We assume theneed in India for technologiessuch as robot-based automation,processing that complies withlarge-scale work or complexshapes, and energy-saving thatcorresponds to environmentalproblem will increase. Japanesemachine tool industry has ad-vantage in all these fields.”Trends in Japan Source: JFMAThe machine tool industry is inwww.mmindia.co.in July 2017 | 29

COUNTRY FOCUS“Since IT industry has already puts it in the world’s top two Source: JFMAdeveloped in India, Japanese IoT countries in development andand AI technologies that connect production. Through industry Japanese machine become a global machine build-all the machines and industries fairs and exhibitions, the coun- tool manufacturers ing company. MF-Tokyo provideswill be easily accepted in the try disseminates its latest tech- are developing the visibility one needs and themanufacturing sector in India, nologies of the metal forming technologically more opportunity to get up close withfurther contributing to improve industry to the world. advanced the key decision-makers of Jap-efficiency. We believe that Jap- Metal Forming & Fabricating machine tools to anese MNCs around the world.”anese additive manufacturing Fair Tokyo (MF-Tokyo) is one withstand the “Today IoT and 4.0 is the thingtechnology will also be required such specialised trade fair which competition and which most manufacturersin the development of Indian attracts high-quality visitors and maintain its lead. globally would follow. India,manufacturing industries in the witnesses participation from inherently known for a strongfuture,” he emphasised. many countries including India. software base, is likely to lead Organised by the Japan Forming the trend. Next most researchedSynergy at its best Machinery Association (JFMA) area is tribology involved insideIndian machine tool makers can and the Nikkan Kogyo Shimbun the mechanical arrangementslearn a lot from their Japanese Ltd, the 5th edition of MF-Tokyo of metal forming machines,” hecounterparts. “After the Second was held on July 12-15, 2017 at shared. Further he added, “A newWorld War, the machine tool Tokyo Big Sight, Tokyo. concept of ‘Textured Bushings’ isindustry in Japan has greatly de- introduced in which micro dim-veloped through the cooperation Latest on the display ples are made on Bushings withand collaboration of industry, ac- With the sub-theme of “Connect- Laser. It gives better lubricationademia and public sector. Japan ing to the Future and Beyond”, oil retention, and the limits ofhas also developed world-lead- MF-Tokyo 2017 brought together bearing pressure capacity can being high-performance machines metal forming machines, auto- stretched far beyond the presentand offers them to manufac- mated equipment, related equip- limits.”turers worldwide. Japan can, in ment, processing technologiesturn, benefit from adopting tech- and service technologies. The Future exchangenology concepts from India,” Ishi- fair attracted attendance of in- According to Yukata, Japanesemaru conceded. “In India where fluential industrial professionals market is open to high-qualityIT software technology is highly in the fields of press, sheet met- advanced products and technol-developed, many engineers are al processing and forming from ogies from India. “Machines net-working on the development of world over. worked with the software appli-superb software. There is a vast “IoT is the key emphasis in order cations based integration couldpossibility to incorporate Indian to collect operational status of be a major contributor fromIT technology for Japanese ma- the machines and feedback India. For imports into Japan,chine tools,” he noted. with corrective actions, which there is still room for an appro- leads to high productivity and priate technology that can offerTough competition high quality manufacturing,” value to the users there,” stat-Japan, by keeping itself abreast informed Yutaka Nakau, ed Nigam, having had a recentof the global trends, has main- President, JFMA. “Processing brush with Japanese market. tained its lead in machine tools. technologies of new materialsOut of the top 10 global machine (composite materials and hightool vendors, five are from Japan. metal alloys, etc.) and interfacingHowever, the manufacturers in machine operational statusJapan are receiving tough com- in production with analysispetition from China in terms of technologies will play importantproduction. Hence, are devel- role in the future,” he elaborated.oping technologically more ad- From India, Isgec Heavy Engi-vanced machine tools to with- neering Ltd participated in thestand the competition. show. Speaking on its relevance, Vivek Nigam, the company’sMF-Tokyo 2017 Business Head, Machine Build-Japan takes pride in producing ing Division, highlighted, “Ourstate-of-the-art technologies in objective was to assess ourselvesmetal forming machinery that against the best in the world to30 | July 2017 Modern Manufacturing India



COMPANY PROFILERAISING THE BARLakshmi Machine Works Ltd (LMW) seems to have mastered the art of staying aheadof the game. One of its strong arms, the Machine Tool Division, has been garnering ravereviews in the industry for its relentless focus on customer satisfaction.POONAM PEDNEKAR T o make it big in business, K Soundhar Rajhan, President, Tier-2 manufacturers form theChief Copy Editor one needs to be gifted Machine Tool Division, LMW bulk of our customers. We alsoMagic Wand Media Inc with the knack of recog­ Ltd. Today, the enormity of have a large presence in the jobpoonam.pednekar@ nizing gaps in the market and the division can be determined shop and general engineeringmagicwandmedia.org filling it innovatively. from its built-up area of sectors. We are a complete The machine tool division of 32,000 sq mt spread over solution provider on a turnkeyLMW’s impressive LMW Ltd owes its birth to sprawling eight acres in basis. Presently around 30Machine Tool Division one such gap of high-end CNC Coimbatore. “Almost all major percent of the machines soldin Coimbatore machines in the country in Automobile OEMs and Tier-1, are either turnkey or tooled 1988. The machines were then up solutions and the trend is getting imported from countries “Our focus will be to moving towards more tooled such as Japan, Germany, the address the market needs up,” he elaborated. USA, Italy etc. “Since we had and ensure that we meet been successful in fulfilling the our customers’ Going strong high-end textile machinery expectations to their According to him, the machine need in the country since utmost satisfaction.” tool sector has been a highly 1962, we could recognize challenging industry in terms the opportunity,” recounted K Soundhar Rajhan of precision engineering, as President–Machine Tool Division LMW Source: LMW32 | July 2017 Modern Manufacturing India

Source: LMW 12they are the mother machines 3 solutions and support oper­ 4which churn out components ational improvements.for every engineering industry. effectiveness of the operations 1 LMWBut despite all odds, the in our organization. The benefit Exports Assemblycompany’s growth has ever is passed on to our customers,” “Our textile machinery divisionsince remained consistently he stated. is one among the top three global Linepositive, barring a couple of “Synergy and talent within players in spinning machineryyears of global recession. LMW group is a great and has presence in all yarn 2 JU 40 -Its tie up with Moriseiki-Japan advantage for us,” beamed producing countries,” he shared. Simultaneousand Mikron-Switzerland help­ Soundhar Rajhan with obvious The Machine Tool Divisioned the company gain the admiration for his teams. caters to the domestic market 5-axis Machiningtechnological advantage. “Our He gives credit to the company’s at present and is expanding Centerteam has since then grown proactive marketing and its reach to Russia, the Middleand gained great experience in business development team East and the South Asian 3 LMWthe last two decades. Today, we that keeps tabs on the market countries. “We will achieve Verticalhave evolved as an integrated trends and the ever-changing about 10 percent of businesssolution provider in metal requirements of every industry, from exports in the next couple Machiningcutting for the manufacturing and covers the entire array of of years,” he added. Centersindustry,” he enthused. its customers, ranging from OEMs to job shops. Further plans 4 JU 40 -Customers across diverse The efficient R&D team is On a concluding note he shared, 5-axisindustries always on the ball to assess “We are upgrading by addingThe company caters to a the latest global trends and new mother machines on need Machining Centernumber of industries in­ recognize opportunities. From basis and expanding the capacitycluding Pump & Valves, Oil visiting major international appropriately. Our focus will& Gas, Aerospace, Tool & Die, exhibitions, interacting with be to address the market needsDefence, General Engineering, specialists in the field of ma­ and ensure that we meet ourand predominantly to the chine tools and manufacturing, customers’ expectations to theirAuto industry, which makes to interacting with the utmost satisfaction.” 60 percent of its business. customers, the team is well-It has recently added an trained to provide innovativeAdvanced Technology Center toproduce precision componentsfor the Aerospace Industry.Outpacing competitorsSuccessful businesses competeon quality. LMW is a firmbeliever in this proven mantra.“All our initiatives towardsenhancing the quality alsohelp improve the efficiency andwww.mmindia.co.in July 2017 | 33

INDUSTRY VIEWS IMPLICATIONS OF GST India’s biggest tax reform has finally arrived. Hailed as a potential game-changer for India Inc, Goods & Services Tax (GST) has evoked a mixed bag of responses from businesses. While some are all praises for thefavorable changes in the system, others view differently. An insightful read... LAUNCH of GST has brought in a simplified tax regime, which is easy to comply with. Cascading of taxes on account of levy of various taxes have been eliminated with GST coming into effect. Removal of check-posts is helping movement of goods without hindrance. The benefit of GST will reduce the manufacturing costs and hence increase the baseline profit. Reduction in costs will provide headroom for price reduction, benefiting end-users. Post-GST, Indian manufacturing eco-system will become competitive in the global market.” GIRISH SHANKAR Secretary Department of Heavy Industry Ministry of Heavy Industries & Public EnterprisesINDIA is now “One Tax One Nation”. However, there is a need to correct some anomalies in GST rates, whereby some industrial intermediates. For example, CNC system, ball screws, etc., which are critical inputs to building CNC machine tools, attract GST at 28 percent, whereas the end products (CNC machine tools) are at 18 percent. The ideal situation would be to tax raw materials, intermediates and finished products at successively increasing GST rates (say 5 percent, 12 percent and 18 percent). It may take some time for SMEs to move from the earlier tax compliance to GST, but once it is done, it would be a game changer for the Indian machine tool industry.” V ANBU Director General & CEO Indian Machine Tool Manufacturers’ Association (IMTMA)34 | July 2017 Modern Manufacturing India

GST can be seen to bring transformational change in the indirect tax system of the country. The manufacturing industry, with a significant amount of input originating in different states, will save directly on CST. Since the manufacturing industry has been otherwise claiming ED, CVD/SAD and VAT benefits already, it may not make much difference to the cause of reducing cost. However, transparency in the system will certainly be a boon for all above-board tax paying organizations in the country. Over time, simplification of procedure and transparency will certainly help to improve the size of tax benefits. It is a welcome change that will have a significant impact going forward.” L KRISHNAN Managing Director TaeguTec India Pvt Ltd & Past President, IMTMAGST aims to replace a plethora of cascading taxes in the states and the Centre and simplify the procedure. It is poised as a catalyst for driving growth in the manu­ facturing industry. In this transition period, a major concern of the industry is therefund of Input Tax Credit, the realization of which will occur once the final supply isconcluded. This may impact the manufacturing segment in a major way due to interruptionsin the cash flow and blockage of funds. The domestic industry will need to re-engineer itssupply chain strategies in order to cope with the new system. GST, coupled with theGovernment’s ambitious “Make in India” initiative, will definitely boost India’s manufacturingsector.”BHASKAR SARKARExecutive Director and SecretaryEngineering Export Promotion Council of India (EEPC India) WITHIN the electrical industry, there are mixed feelings about the impact of GST. The reduction in the rate for coal to five percent will slightly bring down the cost of procurement, mainly benefitti­ng thermal projects under operation. How much will it cushion the increase in the operational cost on account of a higher rate for services under GST is yet to be seen. IEEMA is seriously concerned about the higher rate of 28 percent GST announced on some electrical products. It has made a representation to the government for reclassification of GST on these products from 28 to 12 percent. Through our efforts, GST rates of some of these products were brought down to 18 percent, which is a good news for electrical equ­ipment manufacturers.” SUNIL MISRA Director General Indian Electrical & Electronics Manufacturers’ Association (IEEMA)www.mmindia.co.in July 2017 | 35

INDUSTRY VIEWS THE manufacturing sector of the developing economies is their major economic driver. However, India’s manufacturing industry is still striving to increase its contribution to the country’s GDP. The sector will be revived under the focused efforts of the government and by the implementation of a GST regime. One of the advantages of GST is the reduced cost of production that is expected to be spurred by tax reduction. Another is that the non-accessibility of central tax credit over state taxes and vice versa will be removed. Checkpoints at the state border along with the regulatory obstruction reduce the efficiency of Indian manufacturers. The new GST model will unify the Indian market and assist the smooth flow of goods within the country.” RAJESH NATH Managing Director VDMA IndiaTHE Auto Component industry whole heartedly welcomes this path-breaking reform. While tier 1s larger companies are GST ready, I am a bit apprehensive about the preparedness of tier 2s and tiers 3s, the small and medium enterprises. Needless tosay, any non-compliance on any part of the value chain will defeat this reform. Tier 1s will,therefore, have to ensure that their downstream industry is GST complaint. Being anintermediary industry, we had made a plea to the government that the auto componentsattract 18 percent GST rates. However, most components have been put at 28 percent. Cons­idering we have a growing aftermarket in the country, a moderate rate would have resultedin better compliance and, thus, enabled tackling the grey and spurious product sales.”VINNIE MEHTADirector GeneralAutomotive Component Manufacturers Association of India (ACMA) FOR the Manufacturing sector, the net effect is more positive as logistic inefficiencies are greatly reduced. Now GST credit can be taken on all purchases including the admin costs, resulting in the reduction of the cost of operations. The GST law has more clarity with a single rate of GST on a chosen product pan India, though there may be minor anomalies. As the law is implemented and enforced digitally, there will be a greater transpa­ rency to it, which will reduce litigation. The businesses too will have to deal with a single authority. Hence, the situation is favorable for further growth in the sector since it will attract more FDI and create more jobs. Finally, the sector’s contribution to GDP will also go up.” INDRADEV BABU Managing Director UCAM Pvt LtdTHIS transformational policy initiative will drive economic growth in the manufacturing sector. GST will usher in a number of positives including elimination of the cascading effects of tax. Applicability of taxes only on value additions and availability of morecredits will lead to reduced cost of production for the manufacturing companies. As morebusinesses from unorganized sectors come under GST to compete in the market, there willbe an increase in the revenue collections. Hence, businesses which are fully compliantunder GST will have better chances to survive and grow. Re-organization of supply chainsand distribution networks will result in reduction of costs and business complexities.”BC RAOManaging DirectorKennametal India Ltd36 | July 2017 Modern Manufacturing India

THE country’s biggest tax reform ushers in a new era that impacts everyone, from the common man on the street to business boardrooms. We can see this as another action in the series of actions taken by the government to improve India’s compe­titivenessand the ease of doing business. The biggest beneficiary of GST will be the Manufacturingsector that has an extended value chain which will be relieved of the burden of cascadingtaxes. This singular tax structure has the potential to enable seamless logis­ tics flow, improvegoods availability across the country and allow manufa­cturers to build new capabilities inefficient distribution systems.”DHARMESH ARORAManaging Director, FAG Bearings India Ltd &CEO, Schaeffler IndiaTHE immediate impact of GST can be seen in the Auto sector and the FMCG, where the prices have dropped between five to seven percent soon after the GST rollout. This is not the case in other sectors. Price reduction in these sectors will depend uponhow the Anti Profiteering authority func­ tions. Machine tool manufacturers (MTBs) areexpected to see a surge in order inflow due to a lower cost of investment, beca­use customerswho were not under Excise in the past have moved to GST, wherein GST paid on capitalgoods is available for set off. Organised machine tool companies concentrated in the SouthIndia can save time in transporting machines to customers in the North or far off placesdue to abolition of check posts across various state borders.”B RAGHAVENDRACFOAce DesignersTHE implementation of GST will significantly improv­ e the compe­titiveness and perfo­rmance of India’s manufac­ turing sector. The compl­exity of multiple indirect taxes had led to significant administrative costs. GST will bring in the ease of doingbusiness in this sector. The manufacturing sector stands to benefit significantly from theintroduction of GST. The overall reduction of cascading effect of taxes, especially on theProcedu­ral Cost, Pricing and Profitability, Redress locati­on bias, Post-manu­facturingactivities and Supply chain should have a positive effect on the cost of manufacturedproducts in the hands of consumers.”ARUN NENEManagerChannel SupportJyoti CNC Automation LtdTHE impact of GST will definitely be positive due to reasons including reduced cost July 2017 | 37 of produc­ tion, scrapping of multiple evaluations, ease of registration, improved cash flow, and a unified pricing system across the nation. However, the manufacturing sector has to cope with some immediate and short-term challenges like the availability of resourceful and knowledgeable skilled manpower to implement this system, transaction scheduling as per prescr­ibed deadlines, coordi­nation between the supplier and the buyer, and the revival of special sanctions to specific states/regions/SEZs etc. Last but not the least, GST will surely contribute to the faster realization of “Make in India” initiative by the Hon. Prime Minister of India. It will simplify the tax structure, thus encour­aging foreign investors to invest in India.” SACHIN S GAMBHIRE Senior Manager-Laser Products, Yamazaki Mazak India Pvt Ltdwww.mmindia.co.in

MEDICAL MACHININGFOR A GOOD CAUSE Proton Beam Therapy has several advantages over traditional forms of radiation that destroy healthy human tissues. Learn about the required equipment that will help serve a large number of people desperately in need while it gets manufactured for the first time in India. W hile continuing to and supports medical devices the IBA’s projects is for TATA manufacture and software solutions for Memorial Hospital, Mumbai, that sophisticated cancer treatments. will be using it in its treatment of precision heavy machines and Considered as the most advanced cancer and saving thousands of form of radiation therapy lives every year. equipment of fine tolerances, available today, Proton Beam Therapy uses an external beam How Proton Beam Isgec Heavy Engineering Ltd of radiation to kill tumor cells. It Equipment works has many associated advantages Protons after coming out of has now committed itself to a over traditional forms of the cyclotron and an energy radiation such as x-rays that selector system arrive in the cause that can help cancer destroy healthy tissues while treatment room via a gantry entering into the body. One of which revolves 360o around the patients. It has taken up the challenge to manufacture Proton Beam Therapy Equipment for IBA, Belgium. IBA develops, manufacturesAdvanced ProtonTherapy Equipmentmanufactured by Isgec VIVEK NIGAM Source: Isgec Heavy Engineering Ltd Business Head- Machine Building Modern Manufacturing India Division Isgec Heavy Engineering Ltd [email protected] | July 2017

According to the InternationalAgency for Research on Cancer(IARC), India had 1.8 millionpeople living with cancer (withinfive years of diagnosis) in 2012.patient so that the beam can beSource: Isgec Heavy Engineering LtdIsgec’s other machines diameter: 1100mm, length: Plano Millerdelivered at the optimal angle. Source: Isgec Heavy Engineering LtdIn its endeavor to reduce the10000mm) and 9 VerticalTable Size: 6000mm xThe highest level of geometrical range of tolerance and to Boring Machines (maximum 3000mm (240\" x 120\")accuracy of the gantry is increase the quality of precision capacity diameter: 6.1m, Clear Height: 3000mmrequired to position the patient in its products, Isgec’s has height: 3.1m). Isgec’s group in (120\")at the desired location and installed CMM (Coordinate compliance with world-classprecisely treat the cancer cells. Measuring Machine) of size: practices follows ISO 9001:2008It carries the final section of 6m x 3m x 2m. It has currently quality management systemsbeam line and beam spreading 15 Horizontal Boring Mills and updates to ISO 9001:2015,nozzle to direct the beam at (maximum size: 16m x 4.5m x besides being OSHAS 18001 andtumor cells. 2.4m (X x Y x Z), 3 Plano Millers ISO 14001 certified.The Proton Beam gantry, a (table size: 6000mm x 3000mm,massive steel structure having clear height: 3000mm), 6 CNC A glimmer of hopean assembly weight of 120 ton, (maximum turning capacity Though the situation today is faris rotated through servo motors. from ideal, the manufacturingEach gantry is over 5m in industry is doing its bit bydiameter and envelopes a space inventing machines that canof 10m (L) x 10m (W) x 10m serve humanity. Isgec’s and(H). The accuracy requirement IBA’s collaborative effort,for such equipment is highly which is soon to see light of thecritical with major emphasis day, certainly is a breakthroughon concentricity of two that will present tremendousrings within 20 micron, benefits to those suffering. which is a major challengefor manufacturing industryengineers. It will be the firsttime such equipment will bemanufactured in India.CMM (Coordinate Measuring Machine)Table Size: 6m x 3m x 2m The accuracy requirement for these equipment is highly critical with major emphasis on concentricity of two rings within 20 micron, which is a major challenge for manufacturing industry engineers.www.mmindia.co.in July 2017 | 39

ADDITIVE MANUFACTURING POWERED BY:CAN 3D PRINTINGINCREASE MILLINGFEED RATES? With PCD tooling, yes it can. The diamond cutting edges demand a large number of flutes to realize their full effectiveness. While traditional methods for making cutter bodies limit the number of flutes, 3D printing delivers tools with higher flute density and other enhancements as well.PETER ZELINSKI T he promise of additive Source: Modern Machine ShopEditor-in-Chief manufacturing will beModern Machine Shop found in products thatpzelenski@ are designed for additivemmsonline.com manufacturing—that is, products that take full advantage of the geometric freedom that 3D On this 10-flute tool, the narrow and deep pockets between flutes could be produced through machining, but printing can realize. A recent the machining cycle would be complex and long. A high helix angle for the flutes compounds the geometric successful example of this relates challenge. But additive manufacuring makes this form easy to achieve—the cutter body was grown through to milling cutters. Komet’s selective laser melting. “Revolution” line of milling tools includes tool bodies made through metal additive manu­ facturing to realize design features including a flute density higher than what is practical to40 | July 2017 Modern Manufacturing India

1 The achieve on conventionally advantage of all the flutes it can Benefits abound possibilites manufactured tools. When it get, he says. It is capable of such Morrison says the advantages comes to cutting edges made of high material removal rates in of additive manufacturing forextend beyond PCD (polycrystalline diamond), the materials it typically cuts— the cutter heads go beyond flutemilling. This new more flutes on the tool translates aluminum and carbon fiber density. There is also the flutedrilling tool from directly to faster feed rate. composite—that the number of pitch. Previously, a pitch of 4 toKomet also Thus, Komet is actually using flutes can be the limiting factor 5o is the best the company couldleverages 3D additive manufacturing to make on feed rate and productivity. efficiently achieve, because theprinting. Complex subtractive manufacturing more This is increasingly true as clearance challenges of reachingfeatures of the productive. facilities using this tooling a cutting tool past the flute intool provide Additive manufacturing: a adopt modern machine tools order to mill out the pocketpassages through more efficient option with high acceleration rates. precluded a steeper angle thanthe flutes Cullen Morrison, Director, However, obtaining a high this. But in this case as well,enabling the chips Production, Komet, sees making number of flutes is problematic the geometry considerationto be safely tool bodies through 3D printing in cutter bodies made through poses no challenge for additive.transported out of as being the way of the future, machining, because the small On the new tools, Komet hasthe drilled hole. at least for PCD. This cutting pockets resulting from high produced flute helix anglesThis tool design tool material often can take flute density have to be milled up to 20o.leverages additive out painstakingly using light The 3D printed tools likelymanufacturing 1 cuts with small tools. Additive will also realize longer life,for the manufacturing offers a more he says. The reason is coolantgeometrically 2 efficient option. delivery. With additive, coolantcomplex Now, high-flute-density bodies channels can be grown insidecomponents, with are grown several at a time the tool along snaking pathsmachined and 3D at Komet’s headquarters in that exit precisely where theprinted pieces Germany on a selective fluid can be most effective. Onassembled laser melting machine from previous tools, the positioningtogether to make Renishaw. After these bodies of coolant channels was alwaysthe final tool. are separated via EDM from a compromise resulting from the build plate used in the the need to drill a straight hole 2 The shank of additive process, they are past the clearance obstacles in the tool is ready for the PCD edges to be the way of this drilling. brazed on. Komet grows only One other advantage of additivestill produced the heads of the tools this way, manufacturing might be theconventionally, laser welding them onto the most transformative of all,because shanks, because the shanks Morrison adds: It will permitmachining is far can be manufactured more faster lead times for specialmore efficient for economically in conventional tools. With 3D printing, thea form such as processes. range of design options forthis. The head these special tools increases,and shank are and unusual designs specifiedcombined by special-order customers canthrough laser move into production pra-welding. Welding ctic­ally as soon as they3D printed heads are modeled.to mass-producedshanks will also No hindrancesprovide an It will take more additiveeffective way to manufacturing capacity todeliver fully realize the promise ofspecial-order the capability for specialtools. orders, informs Morrison. The company is exploringCutter bodies are how far to advance withgrown several at a this means of production, andtime in each additive how quickly. cycle. Differentstandard or customtools can be growntogether in the samebuild as they areneeded. Source: Modern Machine Shopwww.mmindia.co.in July 2017 | 41

INDUSTRIAL WASTE MANAGEMENT CHIP COMPACTING: MAKING THE BEST OUT OF WASTE The country’s manufacturing sector is constantly on the lookout for ways to minimise waste streams and maximise its cost savings. Chip compacting could be a major step towards industrial waste management for reducing national loss and contributing to sustainability.Metal swarf before andafter compacting. A BHASKARAN Source: Yuken India Ltd Ex-General Manager - HMT Machine Tools Ltd Modern Manufacturing India & Yuken India Ltd alakkil.bhaskaran@ gmail.com42 | July 2017

Source: Yuken India Ltd Briquetted steel and Source: Yuken India Ltdcast iron chips. Metal Cutting Industries - Tiny, Small, Medium and Large - of our country, a huge wastage is happening unabated. There lies an enormous potential of tapping big benefits out of80 T Chip Compactor manufactured at Yuken India Ltd. BENEFITS OF CHIP COMPACTINGI t is a point to ponder that Recycle. If practised with zeal despite no dearth of and commitment, it guarantees The coolant which is carried with chips commitment, our leaders saving in terms of money, is squeezed out making it available forare still far from providing a materials and labor, which, in reuse.large part of our country turn, can be effectively usedthe basics such as clean as the means for fulfilling the The volume of chips to briquette isdrinking water, good roads above basic needs. 4 – 40 times depending on the type ofand uninterrupted electricity. There is a fourth R – chips. This makes transportation safeWhat we fall short of is the Responsibility, which means and cheaper by 75 percent.resources, which can be saved a measured accountabilityif all resolve to participate that should start from top and The surface area of briquette inand contribute. Our industry percolate down. comparison with chips is less thanleaders, economists, leaders, 0.1 percent. This reduces oxidationbureaucrats and experts often Wastage in and slag formation and gives 5 – 20present the excellent solution Manufacturing percent more yield, all for free.of 3Rs: Reduce, Reuse and In the current scene of the The briquette is safe for handling and transportation. Hard and sharp pieces of chips that fall on the road are a big danger to the vehicles that use the same road. Dry briquettes compared to dripping wet chips do not contribute to ground water pollution. Rules in place With the goal of making green technology a reality, it should be made mandatory to recycle 100 percent metal chips produced in our industries – Tiny, Small, Medium and Large – without any exception. Every drop of coolant needs to be extracted and suitably treated and reused. This is possible if chips are compacted at the source into dry briquettes, transported safely to foundries and melted. If required this should be part of the Factories Act.www.mmindia.co.in July 2017 | 43

INDUSTRIAL WASTE MANAGEMENT Automatic Chip at all and allowed to pollute Compactor with the environment. What is conveyor loading. recycled is not done efficiently. Metal chips are injury prone for handling and transport, yield more slag and less metal, and consume more energy and labor. The coolant carried by chips burn in the furnace giving thick fumes, leading to pollution and wastage. Aluminum chips if compacted into briquettes and melted will yield a neat 15 percent more in comparison to melting loose chips. The logic is simple: Loose chips have several hundred times more surface area exposed to air and heat in comparison to briquetted chips. Source: Yuken India Ltd A large amount of coolant which is cutting oil, neat to 5 percent solution in water, which is otherwise carried by the chips, is expelled and saved during compacting into briquettes. Almost 95 percent of smoke and fumes are eliminated by briquetting. the waste if certain issues are where large scale continuous Briquettes get immersed controlled. machining happens. And in the in the molten metal (chips Machine Tools and Equipment, process of machining, metal float) making efficient heat Automobile, Tractors, Aircraft, chips are generated. By a safe transfer and less energy Heavy Electricals, Defence estimate, the quantity of chips consumption. The extra yield Production, Railways, Motors, generated in India is to the tune alone will take care of the Engines, Engineering, and of 15-20 lakh tons per year. cost of compacting. Ancillary Industries are These chips are of cast iron, steel, aluminum, copper, brass, Loss that can be savedSource: Yuken India Ltd bronze, titanium, and silver etc, In a nutshell, there is a huge and are of different sizes and national loss of 4-5 lakh tons of shapes. This is not treated as metals of different types every metal but just scrap. year just because the generated chips are not recycled the right Resorting to right way. Starting from mining, measures transporting, smelting and The agony is that approximately processing, to making it ready one fourth of the chips of the for use, approximately `4000 cheaper metals such as cast crore is the amount of money is iron and steel are not recycled spent into making them, which adds to the loss. 44 | July 2017 Modern Manufacturing India

Witness best practices in manufacturingProductivity Summit National Productivity 2017 Summit 2017 “Showcasing Competitiveness in Manufacturing” 4 - 5 August 2017, Hyatt Regency, PuneTo champion the cause of Productivity and enhancing competitiveness in the Indian manufacturingindustry, Indian Machine Tool Manufacturers’ Association (IMTMA) is organizing the 11th edition ofNational Productivity Summit on 4-5 August 2017 at Pune. The event showcases best practices inmanufacturing through Inspiring Keynotes, Live Case Study Presentations and Plant Visits.4 Enriching 6 Insightful 8 Interesting Keynotes Plant Visits Case StudiesLive case study presentations on best productivity practices from renowned companies Contesting companiesRegistration for participation must be made online only.To register online, log on to www.productivity.imtma.in ORGANISED BY AWARDS SPONSOR For details, contact : Abhishek, tel : 080-66246829 / 9886611007; ([email protected]) Indian Machine Tool Manufacturers’ Laxmikant, tel : 080-66246665; ([email protected]) Association Indian Machine Tool Manufacturers’ Associationwww.imtma.in @ Bangalore International Exhibition Center (BIEC), 10th Mile, Tumkur Road, Madavara Post, Bangalore - 562 123 www.imtma.in

AUTOMATION & CONTROL ENSURING MAXIMUM PRODUCTIVITY A CNC-based hybrid tool solution, the Ambit multi-task system, from Hybrid Manufacturing Technologies, can be integrated into almost any CNC metalworking machine. With an upgrade to Beckhoff’s PC-based control platform with EtherCAT as the fast fieldbus system, the Ambit solution enables the alternate use of metal removal and metal deposition heads in the tool spindle, and ensures optimized machine communication.The hybrid system T he hybrid tool solution change is performed auto­ sandblasting, can also be doneis controlled via a from Hybrid Manufa­ matically. Machine tool manu­ with the same machineBeckhoff CP2218 cturing Technologies facturers who opt for the Ambit equipment – so that transfer tomulti-touch combines conventional CNC hybrid solution can expand the another production cell forPanel PC. technology and additive pro­ possibilities of their standard finishing is not required. The duction processes with the CNC machine by integrating use of different material ability to provide both machin­ additive manufa­cturing without compositions for the same ing and metal deposition tools additional and tedious re- product is also possible, and on the same spindle. The tool clamping operations and progr­ inspection during production amming steps. The post- guarantees quality grades that Source: Beckhoff Automation Pvt Ltd treatment of components, such cannot otherwise be achieved as polishing, milling and surface or determined. Source: Hybrid Manufacturing Technologies46 | July 2017 Modern Manufacturing India

Fully-automatic tool 1Source: Hybrid Manufacturing Technologieschange for CNC machiningand 3D printing 2Source: Hybrid Manufacturing Technologies“The Ambit hybrid kit wasdeveloped to offer compatibility technology in the processing the advanced hybrid solutions 1 The hybridwith most CNC machine head,” stresses Dr Jones. we supply to the global market.” tool solutionconfigurations and robot Peter Coates, Co-founder, Efficient engineering withplatforms,” explains Dr Jason Hybrid Manufacturing Tech- TwinCAT 3 developed byJones, Managing Director and nol­ogies, adds: “We can supply “It was a significant upgrade HybridFounder, Hybrid Manufacturing our customers with processing from our previous solution, ManufacturingTechnologies. “Equipping an heads tailored precisely to and after a minimum amount Technologiesexisting multi-axis CNC unique application requirements of training, we were able to facilitates themachine with automatically that are usable on just about integrate all our engineering alternate use ofexchangeable deposition heads any machine tool. The use of processes into TwinCAT 3. The chipping andmakes 3D printing in metal EtherCAT as the communication advantage of programming with metal applicationpossible without having to system makes connection to structured text is that we do not heads in thepurchase a separate machine. other production cells simple. have to change the platform; tool spindle.This not only reduces costs, but TwinCAT 3 also simplifies the instead, we can simply add newalso enables extensive options in connection to other company PLC code. This means that all 2 The hybridthe operation of CNC machines.” systems, even extending into the controllers run programs made systemThe hybrid system supports a integration of customer-owned with the same code, which iswide range of processing heads Ethernet-based control and ERP incredibly helpful,” comments supports a widewith different geometries, solu­tions. In the future, we will Coates on the transition to the range oflaser profiles, powder supply continue using Beckhoff control PC-based control solution. processing headsconfigurations and unfocused technology as the standard in with differentbeams in order to enable a geometries, laservariety of processing steps. profiles, powderThese include 3D metal supplyapplication, welding, marking, configurationschipping, drilling, pre-heating, and unfocusedannealing/relief, surface re- beams.melting and cleaning, and muchmore. The standard equipmentcan accommodate up to 15processing heads. However, anunlimited number of heads canbe added, depending on thespace in the tool changer andthe control system performance.Beckhoff controltechnology selected as thenew standardThe Ambit control platformconsists of a CP2218 Panel PCwith 18.5-inch multi-touchdisplay that runs TwinCAT 3automation software, as wellas an EK1100 EtherCATCoupler with in-line connectedEtherCAT I/O Terminals.“Hybrid Manufacturing Tech-n­ologies was particularlyimpressed by the HMI solutionfrom Beckhoff and thepossibility to use EtherCATwww.mmindia.co.in July 2017 | 47

PARTS CLEANING Source: acp - advanced clean production GmbHIntegrated into a SFNOORWI-DJEETATLECCHONAOLTOINGYG: RESULTSflatbed coating line, allprocess parameters, Due to higher quality standards, increasingly complex component designs,such as flow rates as well as modified coating materials and layer structures, cleaning plasticfor compressed air automotive parts in flatbed coating lines is becoming a major issue. OEMsand carbon dioxide, too are increasingly demanding automated cleaning processes. Suitable forcleaning time, angle Industrie 4.0 applications, the quattroClean snow-jet technology meets theseof the cleaning jets demands with ease.and motion sequence,are tailored to thegeometry of the part tobe coated.DORIS SCHULZ R egardless of whether it quality standards for coatings the specifications for suchJournalist (DJV) is classical spray have also never been so high. For components to include anSCHULZ. PRESSE. TEXT. painting with water- this reason, cleaning parts before automated cleaning [email protected] based or solvent-based paints, they are coated is becoming an fast-drying UV paints, PVD ever-more crucial process for Space-saving, dry cleaning coatings or laser paints for day/ conventional flatbed coating system night designs – today there are lines. This is because the A conventional power wash more ways than ever of adding cleanliness of the surface to be system that uses an aqueous decorative, functional and coated decisively affects coating cleaning medium and a individual features to plastic results. It is, therefore, no wonder downstream water dryer has interior parts destined for the that an increasing number of its limits. On the one hand, the automotive industry. However, vehicle manufacturers expect process is expensive, energy-48 | July 2017 Modern Manufacturing India

consuming and takes up a lot of • Impulse transmission of brittle contamination Source: acp - advanced clean production GmbHspace, making it expensive as accelerated snowfar as costs are concerned. On (micro-blasting effect) micro-dry ice crystalsthe other hand, liquid residuesare sometimes still present • Thermal strains due to rapid sublimining CO2when parts reach the coating cooling (embrittlement)line, which impairs coating three dimensional movementsresults. Consequently, some • Rinsing due to the increase in volume – can be specifically adjustedcoating line manufacturers see of approx. 600x during sublimation to the part requiring coatingthe environmentally-neutral and filed as a cleaning programCO2 snow-jet cleaning system • Solvent effect: the dissolving potential in the controller. The effectivequattroClean from acp GmbH as of supercritical CO₂ is comparable with range of the nozzle array isan alternative. The system uses the cyclohexane´s (C6H12) also automatically scalablea dry, residue-free process to to workpiece geometries.clean the areas of parts requiring quattroClean system to reliably For applications With this degree of flexibility,coating in-line. Its compact remove filmic contamination, for in flatbed coating whole surfaces - or just specificdesign, as well as the flexible example residues of separating lines, one or more areas - even of delicate partssupply options for carbon dioxide agents, silicones and fingerprints, nozzle arrays are are cleaned effectively, whileand compressed air, makes it easy as well as particulate airborne used depending on simultaneously minimizing theto integrate the cleaning module contamination, such as dust and requirements. The consumption of compressed airinto new or existing coating lines. fluff. When integrated into a consistent power of and carbon dioxide.Depending on the requirements flatbed coating line, one or more the jet over the entire The cleaning system is alsoof the coating process, the coating nozzle arrays are used depending cleaning surface suitable for Industrie 4.0line manufacturer or operator on requirements. The jet is guarantees uniform applications; via interfaces suchdecides whether the system applied evenly to the complete results. as Profibus, it can be linked withshould be mounted onto an area to ensure a uniformly clean the control unit of the coatingexisting axis or integrated into surface. And in a quality that line or production planninga robot. gives first class results, even system. This enables the when it comes to sophisticated production facility to functionReliable with uniform coatings such as piano lacquers. fully automatically without anycleaning results Thanks to the aerodynamic need for manual intervention.Since it is generated as a by- force of the jet, the detached Thanks to its reliable cleaningproduct from chemical processes contamination is carried process tailored to the geometryas well as from the production away and removed by an of components, as well as theof energy from biomass, the integrated extraction unit ability to integrate it into anliquid carbon dioxide used to prevent recontamination. existing flatbed coating line,in the cleaning process is Since CO2 sublimates instantly the quattroClean system fromenvironmentally neutral. Non- at atmospheric pressure, acp goes a long way towardscombustible, non-corrosive and components are dry at the end meeting today’s high coatingnon-toxic, the carbon dioxide of the cleaning process and are standards. At the same time, itis fed through the non-wearing ready for ionizing or coating offers great potential to maketwo-component ring nozzle of straightaway. coating and painting processesthe acp system and expands more cost-effective and gentleron exiting to form fine CO2 Customized application on resources. crystals. These are then bundled The modular design of theby a circular jacketed jet of quattroClean system meanscompressed air and accelerated to that it can be tailored perfectlysupersonic speed. The impact of to requirements. All processthe non-abrasive jet of snow and parameters, such as flow ratescompressed air on the surface for compressed air and carbonto be cleaned at a temperature dioxide, the angle of the jet andof minus 78.5°C triggers a motion sequences – includingcombination of thermal,mechanical, sublimation andsolvent effects. These fourcleaning mechanisms enable thewww.mmindia.co.in July 2017 | 49

BEST PRACTICES POWERED BY:MAKING LIFE-CHANGINGDEVICES Modern medical machine shops are constantly striving to meet the demands of acute precision and complexity. An account of how a tool and die shop came up with innovative solutions in the face of challenges. C omplexus Medical, also provides metallic and non- challenges that shops serving metallic implantable compo­ the medical industry, face today. located in Mishawaka, nents for knee replacement and And those challenges impact related medical procedures. not only the equipment that Indiana, has evolved Since medical device OEMs are this company has purchased looking for suppliers that offer over the years, but also the shop from a small tool and die shop competitive cost advantages for floor practices and business the parts and assemblies, price strategies it has adopted to to a supplier of complex pressure becomes a challenge. become more competitive. However, that is just one of the Given below are a handful of components and assemblies challenges that the company faced as well as the actions the to the medical market. The shop has taken to address them. bulk of its business is dedicated to producing complex ortho­ paedic instruments, although itComplexus Challenge: Increasing partMedical relies on complexity; tighter partmultifunction tolerances.equipment such as Solution: Increased adoptionB-axis turn-mills of multi-axis, multifunctionto produce complex equipment.medical devicecomponents in one Complexus has a number ofsetup rather than conventional CNC machines,running parts across including VMCs, turningmultiple machines. centers, and wire and sinker EDM units. That said, it seemsDEREK KORN that the shop’s multifunctionExecutive Editor turn-mills and Swiss-typeModern Machine Shop lathes are essential these daysdkorn@ to efficiently produce somemmsonline.com of the complex, contoured medical work that runs through Source: Complexus Medical the shop. For instance, Complexus has three turn-mills from DMG MORI that operate virtually 24/7: two 12,000-rpm NT1000 models and one 20,000-rpm NXT1000. Each of these offers50 | July 2017 Modern Manufacturing India