VOL 59 – JANUARY - DECEMBER 16TCERCEHANTIONLGOVGAYLUEPaving the way forIndia’s manufacturing sector Scan-QR eNews15 Case Study 17 Innovation & Solutions 19 Customer Care–VAS Effective Enhancing Productivity Understanding the Collaboration the MGT Way Voice of Customer
MessageStriving TowardsExcellenceDear Readers,As we enter another year my wish for all of you is the thirst for learning N K Dhandand excelling in all that you do. Because only if we take pride in Chairmanour intrinsic abilities we can develop homegrown technologies Micromatic Grindingand achieve the goal of “Make in India”. Even ex-President late Technologies (MGT)Dr APJ Kalam in his book has mentioned that the machine tool [email protected] is the key to self-sustaining development of strategic sectorslike aerospace, nuclear, defence, and so on.Against this backdrop, we present the curtain-raiser theme forEQUILIBRIUM 2017 & IMTEX 2017 – “Technology Creating Value”. It isa privilege to present insightful views of our valued stakeholders, inthis Annual issue. Prof N Ramesh Babu - V Balaraman Institute Chair,Manufacturing Engineering Section, Department of MechanicalEngineering, Indian Institute of Technology Madras; P MohanramSenior Advisor - Technology, Indian Machine Tool Manufacturers’Association; Mamoru Nagasawa, Managing Director, ToyodaMicromatic Machinery India Pvt Ltd; Sonali Kulkarni, President & CEO,FANUC India and her team; Dr S Devarajan Senior Vice President TVSMotors, and his team members and of course our own Brij Bhushan,who is currently pursuing his doctorate at MIT USA. We are thankfulto each one of them for having contributed significantly duringthe last many years to MGT’s technology development story, andare continuing to do so. Last but not the least, I am very thankful toDr K Subramanian, STIMS Institute, USA for his impeccable mentorshipof our young R&D engineers over the last five years, rising early in hispart of the world to review their progress through one-to-one Skypesessions.I thank all of you - contributors to this issue, our valuable customersand all stakeholders for your encouragement and support on thisjourney towards excellence.Without much ado, I invite your feedback on this issue packed withinteresting pieces and wish all of you a successful year!2 Equilibrium
Contents06 TECHNOLOGY CREATING VALUE Paving the way for India’s manufacturing sector 17 INNOVATION & SOLUTIONS Enhancing Productivity the MGT Way15 22 20CASE STUDY BEST PRACTICES CUSTOMER CARE - VASEffective Collaboration Reliability is the LUCAS TVS Chennai extracts more corner stoneL to R: Senior Vice President, from their machineTVS Motors, Dr S DevarajanGM-PED, TVS Motors, Ramesh Ramachandran Content & Design: Published by 3Micromatic Grinding Technologies Printed by CAG Advertisingw w w.micro m aticg rin din g.co m
MessageMe After You!Dear Readers,Welcome to 2017! I hope it ushers in a period of prosperity, fulfilmentand growth – personally and professionally.The last six months have been very enlightening for me as I completedthe VLFM* (Visionary Leaders for Manufacturing) course for SeniorManagers under the guidance of Guru Prof Shoji Shiba. Ultimately, itis all about changing your approach and mindset. It is so true that Kapil Dhand“Altitude is determined by your Attitude.” Managing DirectorThe key takeaways on how to change your inner dialogue: Micromatic Grinding Technologies● No “Me First Attitude” – Develop “Customer First Attitude” [email protected]● No “Talk Talk Talk” – Develop “ Listen Listen Listen” Habit● No “Pass the Buck” – “The Buck Stops Here”The path to realizing this philosophy starts with a change in mindset followed by action – and this is whatensured MGT’s success at IMTEX 2015.Looking Back, Looking AheadAt IMTEX 2015, MGT explained its new core philosophy “In the Pursuit of ZERO,” to achieve Zero Defects,Zero Downtime & Zero Emissions, in all our processes and products. In a historical “Customer’s” recognition,MGT received orders for three new machines displayed at IMTEX 2015. MGT is adding a new DIXI JIG Boringmachine and a MAZAK Laser Cutting Machine to take its precision manufacturing capability to the next level.Lastly, I want to thank all our customers, suppliers, employees and associates for the confidence and trustreposed in us. We look forward to your continued support.Wishing all of you a successful 2017!*The VLFM programme aims at transforming India’s manufacturing sector, and is conducted in technical coordination with Japan InternationalCooperation Agency (JICA), along with active support from Government of India & Confederation of Indian Industry (CII).(http://vlfm.org/)Build Your BrandDear Readers,As we usher in 2017, let’s take a hard look at how we are marketing Sidhartha Dhandour brand in the machine tool space. B2B marketing is paradoxically Director Marketing Strategyoverlooked, considering it can make the difference between a hard- & Corporate Communications,working company and a successful one! Micromatic Grinding TechnologiesWe at MGT believe in helping our customers build their brand. One way [email protected] achieve this is by consistently meeting with their expectations, andengaging with them at multiple levels.Witness our philosophy at work in the upcoming IMTEX 2017 in Bengaluru.The Technology & Innovation Corridor at the MGT stall in theAce Micromatic Group Pavilion in Hall 4, Stall B106 is an extension ofour branding pursuit.Here’s hoping the new year is an exciting ride for your business!4 Equilibrium
Accolades / People MatterAnd the Winner is…..Micromatic Grinding Technologies wins the 1st Prize in the competition conducted by AOTABKS – CUMI 5s in the Medium Scale Category for Implementing 5S Practices in the Unit.L to R : B.Vijay Kumar, Praveen Ganachari, Sheela NN, V.Segar, Vijay Kumar D, S.ArmugamSharing and Caring isWhat MGT Believes in“MGT is a company that treats employees as family learn and broaden his horizon. All three agreed thatmembers,” is the common thread that ran through the colleagues were amicable, support one another andconversations we had with the company employees. share the work. “This company is like a family. As muchMost companies have policies and initiatives in place, but as you give you get,” said Chand.after talking to three employees who’ve been with MGT Last Wordfor a long time it is clear that first come people. While Opportunities, compassion, an atmosphere where theit’s important to adopt leading-edge technologies, the mind can roam free – this is what the MGT employeescompany believes it is even more important to ensure a have experienced. When a company lives up to itsconducive and collaborative work environment. values the employees feel that they belong – and this sense of family and belonging is what makes MGT aDialogue with the Employees great company.In a freewheeling dialogue, Engineer MGT, HarishChand (1987); Senior Manager, Technical, MGT, L to R : Harish, Sita Ram, R.K.GuleriaR K Guleria (1988) and Engineer, MGT, Sitaram(22 years) opined that the work culture is very openand supportive and provides lots of opportunities andexposure for career growth. When Guleria met with an accident and underwentankle surgery, the Chairman and Managing Director,Dhand visited him – this showed how much he caredfor his employees. Sitaram spoke about the trainingprograms he was sent for to and how it helped himw w w.micro m aticg rin din g.co m 5
Cover Story TCERCEHANTIONLGOVGAYLUE Paving the way for India’s manufacturing sector Historically the manufacturing sector has been conservative and slow to migrate to newer systems; but in an increasingly connected world it is mandatory to adopt new trends and technologies that are sweeping across the globe. India’s manufacturing sector is the mainstay of its economy and is projected to touch $1 trillion by 2025. The government plans to create as many as 100 million skilled jobs in the manufacturing sector by raising its share of GDP from 16 to 25 percent. If the “Make in India” vision has to become a reality organizations need to undergo major transformation across their processes, by introducing new and innovative technologies. The multiple emerging technologies are: Internet of Things; Big Data; mobility; cloud; analytics; 3D and visual simulation; and mechatronics. All these technologies are creating waves of change across all industries. These technologies result in zero downtimes, improved profitability, enhanced productivity and optimized resource utilization. By connecting machines to the internet via software, data is produced and insight into the manufacturing process is gained. These machines become part of an intelligent network that can automate information and action to optimize plant floor performance. In this context, the views of five stakeholders of Micromatic Grinding Technologies are being presented. An interesting read… Collaborative efforts can do wonders 6 Equilibrium
IIoT Creates ConnectivityInternet of Things will have a FOCAS - Fanuc Open CNC API FANUC is working on “Deep significant impact on industrial Specification as libraries/ drivers learning technology,” which is a companies by providing more providing communication access new wave in computing wheresensors, data, automation, and to CNC data via Ethernet. To software learns and machinessoftware applications, including address the challenges, FANUC reason. Soon FANUC expectspowerful new advanced developed a complete solution this to result in intelligentanalytics that will help transform MT-Link i. a data collection robots that would understandthe massive amounts of software for machine tools. MT their environment and interactdata generated by intelligent, Link i makes it possible to connect with people.connected assets into timely, to machine tools over Ethernet,in-context information for both Collect data, monitor their Gone is the age of Internet ofplanning purposes and real-time live status, and then feed this People which connected justdecision support. There are four data to the Company’s ERP people. Today we are in the agemain parts to the IoT: intelligent software easily.” of “Internet of Things” –whereassets with sensors, processors, MT-Link i collects all data anything can be connected, atmemory, and communications from CNC. CNC Status Signals any place, any point of time.capability; data communications (Cycle Running, Cycle Stopped, As Broadband becomes moreand infrastructure; software Emergency State, Alarm State). accessible and “Smart” Devicesand analytics; and people proliferate, the right platformand business entities that use FANUC’s Vision for IoT: for IoT is emerging. It is goingthe technologies for better FIELD – FANUC Intelligent Edge to transform lives and workdecision making and improved Link & Drive system equally.”business processes and models. This is a platform which enables President & CEO, FANUC India,“To manage its own shopfloor, FANUC and MTB to create Sonali KulkarniFANUC came up with inter- new value services using IoT.connected machines,” said “FIELD is both a hardwareSenior Manager–FA Sales, FANUC and software. It allows multipleIndia, Gomtesh Ekhande. external computing devicesExplaining further, Manager, to be added to the plant networkFA Application Vivekanand in a very secure manner,”Chikale, said “FANUC developed explained Ekhande.w w w.micro m aticg rin din g.co m 7
Cover StoryKulkarni said, “The convergence the value proposition for the practices and people orchestratesof Internet of Things and IoT opportunity extends beyond the entire smart manufacturingindustrial manufacturing has simple connectivity into the infrastructure. Standardized andbegun. Connectivity to equip- ability to build new products well-defined business processesment on the factory floor is and services and achieve are a significant part of anygrowing. This will further open competitive differentiation. successful and efficient business.the vistas to new sources of data Smart manufacturing will needenabling applications that can The Way Ahead is Smart to integrate all the businessleverage this data to deliver Seamless integration – between processes along the value chainreal business value.” Clearly, processes, technologies, best through seamless data connection to improve productivity andFANUC IoT Smart Factory Smart Manufacturing ensure efficiency. FANUC approach towards IoT Collection and Visualization of equipment’s data in factory A software MT-LINKi MT-LINKi Open source Server PC Applications A software A hardware Deep learning MT-LINKi FIELD BASE Organized data FA environmentOnly library Mongo Data base ECC Supported 2016-17 Collector PCStaggered data Flexible No data lossNeed appl. prog FOCAS OPCLess flexible 2015 2016 Ethernet-I/O Converter Robot Multi-sensor unit 2004 Interface IP67 I/O unit OPC I/O Machine tools Existing machine Existing machine Robots Equipment with Ethernet without Ethernet with PLC Field System What is FIELD system? FANUC Intelligent Edge Link & Drive system Platform which enables FANUC and MTB to create new value services with using IoT technology ERP, SCM, MES Network Application Application … Application layer Hardware •BASE0: simple system FIELD Web Device Database Deep Platform layer •3rdParty: high level system e.g. Deep server driver learning learning, Real time control System … Software Edge Linux, Windows • Use of open source middleware Network specified by FANUC • Application prepared by FANUC, MTB, etc. Machine, Robots, PLC, Sensor devices8 Equilibrium
Connecting Technology withthe CustomerHow MGT is using these latest Technologies from FANUC, Creating Value for the Customer…..“AGI – Automation of Grinding Process Intelligence”Project – MGT & IITM (funded by DHI-Govt of India)The vision of this project is to gather in-process, post-process and ERP data; all the three levelsof data associated with discrete parts manufacturing, and apply the principles of ManufacturingProcess Science together with data science to provide a truly autonomous and intelligent solutionthat can optimize the efficiency and economics of the manufacturing industry. This project is mentoredand guided by STIMS Institute, USA.Mission: Industry 4.0: MGT Grinding machines should be able to help you:● Improve part quality, reduce cost, rejection and re-work.● Online assessment of Total cost/part specific to the machine.● Input part quality monitoring.● Process stability and capability improvement.● On line calculation of wheel usage, wheel life, Dresser life, Sub-system performance - sub assemblies like wheel spindle etc.● Predictive maintenance of machine, coolant and oil.● Traceability of the process for critical components such as for aerospace and defence.● Machine R&R (repeatability and reproducibility) information, MTBF and MTTR information.● Database for performance of tooling (work holding, steady-rest, wheel, coolant) for planning of future and new processes.● Rating of similar machines, tooling, across vendors based on line performance.● Management dashboard Project AGI Blue-Print • Grind TrackTM - Software • Remote Diagnoisis ‐ IOT loaded on windows used to communicate with platform. Machine Tool Builder/Service unit. • VFD data is recorded and used for Process • Focas Library used for CNC improvement. data analysis & Process VARIABLE improvement. FREQUENCY CNC WITH • Fanuc Picture for DRIVE & WINDOWS Management GRIND TRAK HMI WITH Dashboard REMOTE DIAGNOSIS INTERFACE INPROCESS READY GUAGE, ACCESSORIES LIKE 3D BALANCER, VIBRATION, AIR GAP •&P • MT‐Link i collects TEMPERATURE the data from CRASH the CNC in real time. SENSOR • Profibus system and Focas system utilized. With it one can track • Process monitoring using patterns in production Marposs OPC server system cycles and derive Servo load, , Tool life, Parts count for further analysisw w w.micro m aticg rin din g.co m 9
Cover StoryBridging the Gap betweenIndustry and AcademiaAcommon complaint that tool market by indigenous and mentoring through all one hears from employers machine tool manufacturers phases from the STIMS Institute, is that “our graduates mandates the incorporation of USA – a knowledge integrationare not industry-ready.” But this technological advancements, company.”scenario is definitely changing. which would enable them to buildRecently, the Indian Institute next generation high precision What can we learn fromof Technology, Madras (IITM) grinding machine tools.” this?and Micromatic Grinding Added to this Senior AdvisorTechnologies, Ghaziabad jointly - Technology, Indian Machine These are the learnings, not onlydeveloped advanced grinding Tool Manufacturers’ Association, for MGT but for other industriesmachine technology. The project P Mohanram, “The whole as well:was supported by the Office of program was driven by a Cooperative R&D is entirelythe Principal Scientific Adviser Project Review and Monitoring possible between industry and(PSA) to the Government of India. Committee (PRMC) constituted academic/R&D institutions in IndiaStarting with the company’s best by the Office of the PSA, which as long as everyone is focusedpresent product, applying a had renowned academic and on the same common goalthorough scientific approach to industry members on it. This i.e. advancement of academicthe subject, IITM has helped the project also received guidance knowledge that supportscompany develop a substantially commercially viable end results.improved grinding machine, Tapping the high precisionwith superior accuracy and machine tool market by The whole program was driven byproductivity. indigenous machine tool a Project Review and Monitoring manufacturers mandates the Committee (PRMC) constituted by A remarkable aspect of incorporation of technological the Office of the PSA, which hadthe project, which took around advancements, which would renowned academic and industrythree years for completion, enable them to build next members on it. This project alsowas the close and continuous generation high precision received guidance and mentoringinteraction between IITM faculty, grinding machine tools.” through all phases from the STIMStechnical and project staff and V Balaraman Institute Chair, Institute, USA – a knowledgescholars with technical staff of Manufacturing Engineering integration company.”the company at every stage Section, Department of Mechanical Senior Advisor - Technology,of design, manufacturing, Engineering, Indian Institute of Indian Machine Toolassembly, integration and testing. Technology Madras, Manufacturers’ Association,Prof N Ramesh Babu, V Balaraman Prof N Ramesh Babu P MohanramInstitute Chair, ManufacturingEngineering Section, Departmentof Mechanical Engineering,Indian Institute of TechnologyMadras highlighted, ““Tappingthe high precision machine10 Equilibrium
Such an approach is most managed periodically (as by the of six machine tool companies. Ifappropriate for medium to long PRMC), it is possible to complete these projects can be successfullyterm R&D projects (3-5 years), such projects within the time and completed and the concernednot those requiring immediate budget allotted. companies derive marketdevelopment. It is heartening to note that advantage, then it can truly beAt higher reaches of technology, the Government of India has said that industry-academiathe scientific inputs can only be supported 11 more such projects cooperative R&D has reached abrought by academia, since for the development of advanced mature stage. There is in fact noindustry mostly does not have the machine tool technology at IIT other way to develop advancedneeded resources. Madras with the participation technology in India.There are tools and resourcesavailable from facilities like DEVELOPMENT OF NEXT GENERATION HIGH PRECISION GRINDING MACHINE TOOLAMTTF that could be deployedby the students and industry a Project Funded byprofessionals. Developing sucheco-system enhances efficiency OFFICE OF THE PRINCIPAL SCIENTIFIC ADVISER TO GOVERNMENT OF INDIAand reduces the total cost andinvestments needed in such Model Aboutprojects. Ÿ Government of India - Academia - Industry A structured project with SystemThinking leading to clearly laid collaborative effortdown quantified objectivesstands a good chance of success. Funding Governing Ÿ Develop capabilities to manufacture high precision There must be a driver each from machine toolsindustry and academia, whomake it their personal mission to Of ice of the principal scienti ic adviser to Government of India Ÿ Development of indigenous technologiescomplete the project successfully. ObjectivesIt is essential for the industryand academic institution to Ÿ Characterization of indigenous built cylindrical continuously interact and jointly grinders work on the project at everystage. Such collaboration also Research Development Ÿ Identi ication of possible modi ications to upgrade benefits from engagement of its precision capabilitiesorganizations such as IMTMA as Indian Institute of Technology Madraswell as international experts in Ÿ Development of framework for upgrading the Knowledge Integration. precision level of grinding machine toolA free exchange of informationand data is essential, without Ÿ Evaluation of precision capabilities of the developed being worried about Intellectual cylindrical grinder Property (IP) confidentiality atevery stage. This can be secured Manufacture Design Deliverablesthrough a mutual Non-Disclosure Ÿ Next Generation Precision GrinderAgreement (NDA) at the start.If properly reviewed and Micromatic Grinding Technologies Ÿ Framework for characterization of precision capabilities of machine tools Indian Machine Tool Manufacturers’ Association Advanced Machine Tool Testing Facility Automotive Component Manufacturer Association of India Ÿ Framework for development of high precision machine tools Supporting Agencies Framework Time line Existing Machine Tool Developmental Framework for High Precision Machines Geometric Static Dynamic Thermal Process NGPG Testing of NGPG Alignment Error Subassembly Natural frequencies Structural deformation Force Manufacturing of NGPG 2016 Positioning Error Stiffness Mode shape Spindle drift Power / Torque Damping Axes growth Location Error Loop Stiffness Temperature Form Error Dynamic rigidity Vibration / Noise Development of design speci ications Characterization Framework Design suggestion Identi ication of technological 2015 pathways for high precision Volumetric Tolerance Static Dynamic Thermal Process Stiffness Rigidity Thermo- Model Error Synthesis Model Model Mechanical Development of Characterization Model Model Model Framework 2014 Characterization of performance of SOT machine Developmental Framework Design Manufacturing Assembly Selection Development of analytical tools Science Driven Functional Machine Tool 2013 Testing of built SOT machine Machine & Controller Documentation of machine building process Tool Subassembly Manufacturing of existing SOT Indian Machine Elements Structures Development of diagnostoc tool Identi ication of State of Art Indian machine HIGH PRECISION MACHINE 2012 Identi ication of Industrial Partner The “Framework” presented above consists of two sub frameworks, one for characterizing Development of project roadmap the precision of an existing machine tool and the other for the development of high precision machine tools. Both the sub frameworks can be used independently. The complete November 2011 framework provides a science driven methodology to develop high precision machine tools. Sanction of Project Indian Institute of Technology Madras Micromatic Grinding Technologies Limited Prof. N Ramesh Babu Mr. N K Dhand Email: [email protected] Email: [email protected] w w w.micro m aticg rin din g.co m 11
Cover StoryHerald the Latest TechnologyA glimpse of unveiling Next Generation Precision Grinders (NGPG)at IIT Madras…In June 2016, the Next Generation Precision specialized skills and advanced technologies. Grinder (NGPG), an indigenous high-precision Tapping the high precision machine tool market cylindrical grinder was inaugurated at the by indigenous machine tool manufacturersIIT Madras campus by the Principal Scientific mandates the incorporation of technologicalAdviser (PSA) to the Government of India, Dr R advancements, which would enable them to buildChidambaram. This Precision Grinder has been the Next Generation high-precision machine tools.built made as a joint collaborative effort between In this project, IIT Madras generated theindustry and academia i.e Micromatic Grinding necessary information and knowledge to realizeTechnologies (MGT) and IITM, a project funded the precision for the grinding machine, from theby PSA’s office GOI. The aim was to indigenously existing best available from an Indian machinedevelop the technologies to bring-out a best – tool manufacturer, prepared a framework toin-class Hi-Precision Machine, such as Cylindrical design and analyse the existing grinding machine,Grinding Machine tool in the country. and finally developed the methodology for theThere is an increasing demand for high precision next generation indigenous high-precision CNCequipment and components in strategic sectors cylindrical grinder. The “Make in India” dream forlike automobile, aerospace, defence, nuclear the domestic and global markets is coming true.and medical. These sectors typically employlarge numbers of imported grinding machines tomeet their demands, due to inability of such hi-precision machines being manufactured by theIndian machine tool manufacturers. Traditionally,the development of high-precision machine toolsis treated as something very complex and knownonly to foreign machine tool manufacturers with Dr R Chidambaram Principal Scientific Advisor, Govt. of Equilibrium India at the Inauguration at IITM of NGPG machine, built by MGT, along with Prof Ramesh Babu, Mr N K Dhand, Dr K Subramanian & PRMC team members.12
StrengtheningPartnership BondsMGT has forged strong 25S, mainly to cater to the two- technology, enhanced quality and industrial partnerships wheeler industry. The journey has performance. This new product will to provide more value to been wonderful and successful; debut at IMTEX 2017 in Bengaluru atthe customer and JTEKT has been the company has manufactured the Toyoda Micromatic Machinerya partner for over a decade. JTEKT and supplied Cam Grinders not India Pvt Ltd (TMI) stall No. I-101 inoccupies a unique position being a only to industries in India but also Hall No 4.part manufacturer that possesses to the markets in Thailand andthe machine tool technologies Malaysia, keeping values and It has been 10 years sinceand provides solutions from technical expertise of both JTEKT JTEKT Corporation, Japanthe customer perspective. In and MGT.” and Micromatic Grindingthe words of the Managing In continuation of the strong bond Technologies (MGT) enteredDirector, Toyoda Micromatic and success and as a part of into a Joint Venture forMachinery India Pvt Ltd, “Make in India” campaign and manufacturing CNC Cam lobeMamoru Nagasawa “It has been future expansion, a new product, Grinder GC20M-25S, mainly10 years since JTEKT Corporation, high-end CNC Angular Wheel to cater to the two-wheelerJapan and Micromatic Grinding Head GL4A, manufactured by industry. The journey has beenTechnologies (MGT) entered into MGT with JTEKT’s technology wonderful and successful; thea Joint Venture for manufacturing is being added to cater to the company has manufactured andCNC Cam lobe Grinder GC20M- industry demand for high-end supplied Cam Grinders not only to industries in India but also to the markets in Thailand and Indonesia, keeping values and technical expertise of both JTEKT and MGT.” Managing Director, Toyoda Micromatic Machinery India Pvt Ltd, Mamoru Nagasawaw w w.micro m aticg rin din g.co m 13
Cover StoryTrue-life Storyabout the IndustryAcademia LinkageStudents are often confused work on diverse projects, such as to apply knowledge and skill about what they would like development of: learnt across the globe. Investing to do or have a natural flair in yourself is the most importantfor and tend to have the herd Grind Trak and training and investment that you can make.mentality of following their peers. education of the application Keep learning, the best peopleM. Brij Bhushan, while studying at engineering team to effectively use I have met are the people whoIIT Madras applied to Universities this as a tool for quicker problem have this constant desire to learnin the US and was shocked to solving on the field; internal protocol something new that is what makesreceive rejection letters. In his for machine tool testing; non-round them expert in their fields over time,”words, “I found that the major grinding algorithm and machine shared Bhushan.reason was lack of clarity of what for grinding of non-axisymmetricI wanted to do, and that was parts; Grinding Process Solutions – I received immense support fromclear from my application. This is development of a service solution the the top level managementwhen Dr K Subramanian, of the offering in collaboration with STIMS during my tenure at MGT. OneSTIMS Institute, who was one of my Institute, USA for complete grinding on hand I was given the liberty toadvisors, along with Prof Ramesh system solutions. After three years experiment with new things, onBabu, for my B.Tech project - of industrial experience Bhushan the other I received guidance to“Development of a monitoring got admission into the prestigious address the most critical issue.”tool for the grinding process,” MIT for his Masters in Mechanical Brij Bhushanintroduced me to Chairman Engineering. Asst. Manager R&D atand Managing Director, MGT MGT from 2012-15 &NK Dhand, and offered me an His advice to young now M.Tech.-PhD scholar at MIT USAopportunity to refine and deploy professionals is to seek outthe tool in the industry with a opportunities to learn. “Gettingfocus on commercializing the tool a good mentor is very importantand developing an application and I have been very fortunateengineering team around it.” to get the trio of Dr Ramesh Babu, Dr K Subramanian and He got the opportunity to NK Dhand. Now, more than ever, there are tremendous opportunities14 Equilibrium
Case Study Effective the plot of the power consumption Collaboration during the cycle with regard to the time, through the complete Grinding cycle The essence of the GPS tool is in-process measurement of the interactions in grinding process and using the data for diagnosis. The principle behind this development is the Systems Thinking (by Dr. K. Subramanian, STIMS).In a fast-paced world the 3Cs Customer: Analysing the Outcome are vital - communication, TVS Motor Company Ltd., Following were the inferences and collaboration and convergence Hosur, Tamilnadu, India actions:– of ideas, best practices ▶ Power consumption was moreand technologies industries business practice for productivityhave realized the potential of solution for grinding applications. after dressing cyclecommunicating via the Internet The unique capability of the ▶ Wheel to dresser interactionand rapid developments in GPS is that it is a standardizedsensor technology combined with methodology using process was more of sliding rather thanembedded systems development science and in-process data cutting action resulting in sizeare providing options for obtained with a portable installer variationdeveloping intelligence in the kit called GrindTrakTM. This unit ▶ Wheel Over-lap ratio (OLP) ismanufacturing process solutions.. can be installed on any grinding high and varies with the wheel machine. The easy-to-use front diameterThe Backdrop end software enables the The above inferences analyzedIndustry 4.0 is gaining momentum in customer to quickly understand using the Systems thinkingIndia. Many industries have realized and interpret the reports to arrive generated following actions:the potential of communication at possible improvements.through the internet and rapid L to R: Senior Vice President,developments in sensor technology GPS Case Study at TVS TVS Motors, Dr S Devarajancombined with embedded systems Evaluating the GPS business GM-PED, TVS Motors, Ramesh Ramachandrandevelopment bringing many practice, TVS installed the GToptions for developing intelligence in their Angular wheel headin the manufacturing process grinding machine for crankshaftsolutions. The machine tool industry component at the Scooteris striving to keep abreast with the Crankshaft Production cell at thetechnology revolution. Hosur unit. This machine has beenUnder the guidance of President in production for about 6 yearsSTIMS Institute, USA, Dr K and is maintained under TPMSubramanian, in Systems Thinking, standards & practices to ensurethe GPS has been developed as a consistent >85 percent OEE. With support from MGT, the Grind Trak TM was installed on the machine and through the GPS analysis tool & software, the company generatedw w w.micro m aticg rin din g.co m 15
Case Study▶ Increase dressing feed rate to ratio (OLP) in grinding cycle, to significantly promote cutting action and ▶ Single pass dressing cycle reduce the quality issues of size space for chip release. variation and taper on diameter. Return on ROI Also they gained a cycle time▶ Program to link dressing feed Through this analysis the company saving of 20 percent through rate to Wheel diameter to optimized the cutting parameters the optimization. The company maintain constant Over-lap realized a productivity increase of 23 percent in the cell and with an annual power cost saving of Rs.7.5 lakh for 2 machines.Fig. 1 Systems ThFinigk. i1nSgysatepmpsliTehdinkininGg arpinpdlieindginpGrroincdeinsgs process Collaborative SynergyFig. 2 GPS Output of Crankshaft grinding cycle (Before Optimisation) Measurement tools like GrindTrakTM and business practice like GPS will facilitate the data capturing of processes and support in problem diagnosis and solutions. Algorithms can be made to use this data and build intelligent systems for Grinding machines. This will make the machines self- diagnostic and send proactive signals & communication to maintenance & engineering teams for improvements needed in the machine to restore performance. The GPS as a business practice requires active collaboration between TVS, MGT and the STIMS Institute by bringing together the knowledge from every partner in a synergistic manner. Work towards remote capture of in-process signals and the automated analysis of such signals is now in-progress under a project titled: Automation of Grinding Process Intelligence (AGI). This project is being carried out collaboratively between the industries and IIT – Madras. This is part of the industry / academic consortium called Next Generation Manufacturing supported by the DHI and IMTMA. Fig. 3 GPS Output of Crankshaft grinding process (post optimization)16 Equilibrium
Innovation & SolutionsEnhancing Productivity theMGT WayMicromatic Grinding Technologies (MGT) manufactures a wide range ofExternal, Internal, Universal and special purpose cylindrical grinders in CNC,PLC and Hydraulic versions to the exacting requirements of its customers fromits plants in Ghaziabad near New Delhi. Their customers range from Bosch,Rane, Tata Motors …and the marquee list goes on.CAM Profile rough Grinding on a MGT StandardCylindrical Grinder The objective was to provide CAM CAM rough grinding in MGT Std Cylindrical grinder grinding capability in a standard cylindrical grinder, with no special Machine tool Component configuration and development cost. This was achieved by off-line Model SM-120 SWH CNC Description CAM Shaft simulation of CAM profiles, special work driver to ensure exact Work holding type Between centres Material Steel C-45 orientation and confirmation of orientation repeatability. The results proved that the MGT approach was correct & for the first time in MGT history, CAM profile grinding capability was proven on a standard cylindrical grinder, and the profile accuracy was also fairly high!Grinding Output Wheel head HYDRO DYNAMIC Hardness 60 HRCw w w.micro m aticg rin din g.co m 17
Innovation & Solutions IncreasingProductivity The target was to achieve Productivity improvement betterqualitybut with reduced cdyrcelsesintigmeaonfd35grsiencdsin(ginclutidmineg). Thesamecomponent isbeing optolrdooldinugmceadcahanintde5s.5ospWeticmisthizoinngpMroGpthTe’esrCo mponent: Turbine Shaft processparameters,productivity Machine tool Component increasedby60percent,quality parametersandh ighersurface Model SH-40 Description Turbine shaft lfiifneisihncwreeraeseadc.hieved,anddresser Workh oldingtype Between centres Material 20 Mn Cr5 Wheel head Antifriction Hardness 57-62 HRC EarlierGrindingprocessModifiedGrinding process ReducingTarget CycleTime The goal was to achieve Productivity improvement better qualitybut with reduced cycletime of 25 secs.Samecom ponent is beingSapmreoducedat 37 secsonmachines of other brands.W ith propertooling and optimizing theprocess param eters, productivity Machinetool Component aei6pna0nrcod0rrldeieaucrcstoee4hmdd0e0pbp.ayetroer3tda5slhpitfoetprcwaterhantesst Model E-Grind 200 Description Material Spool WWoherkelhhoeldaindgtype HBeYtDwReOenDcYeNnAtrMeIsC Hardness 16 Mn Cr5 675 ± 75 HV10 GrindingInputGrindingOutput Productivityincreasedby35 18 Equilibrium
Customer Care - Value Added ServiceUnderstanding theVoice of CustomerEATON Ahmednagar TATA Motors Pune getsplaces orders for four new Reconditioned machinescentreless grinder machines from MGTContended with refurbishing of imported centreless Due to multiple issues, such as unsafe machine conditions,grinder machine Eaton placed orders with MGT for chattering marks on OD and face, size variation and poorfour new machines. Valve stem grinder is a very high- surface finish the company reconditioned the equipmentprecision requirement. It is mostly manufactured by with MGT’s GCE 350x500 CNC.top-end machine tool builders from Europe and Japan. Tata Motors wanted to recondition the machine toEaton had four such unused imported machines. Due original accuracy standards; tool it up for an additionalto unsatisfactory performance, the machines were idle. part requiring different set of tooling; prove-out cycleThe company challenged MGT to furbish the machines time & Cpk requirements for both original as well as newand bring at par with the new machine requirements. part and make it safe for the new environment.Aside from overcoming the challenge, MGT exceeded Overwhelming ResultsEaton’s expectations in delivering results and bagged The below results achieved post reconditioning &orders for four new machines from Eaton post refurbishing. retooling overwhelmed the customer. (Multi-dia. Gauge & 2 sets of Active Flagging on the Wheel Head added toParameter Required Achieved perform flagging of both type (LH, RH) of components)achieved OD size within 5μmRoundness 5 Micron 2 Micron No Chattering marks on OD and faceCircularity 10 Micron 2 Micron Ovality within 2μmCycle Time 7.2Sec(Including 6.5 Sec Surface finish Ra 0.4μm Load & Unload) Cp/Cpk 1.67 achievedRa 0.2 0.15 Safe Guarding – complete covered enclosurew w w.micro m aticg rin din g.co m 19
Customer Care - Value Added ServiceLUCAS TVS Chennai extracts more from their machineThe company’s objective was to increase productivityand quality on their GCE260×400 (4093) machinethrough consistent dressing operation and reducingset-up time. MGT evaluated the requirements andstudied the existing process to arrive at a solution. TheMGT team assisted Lucas TVS with sub system fitment onsite, electrical interfacing, operational trials as well astraining the operators on the new system.Thus, the customer could deskill the grinding wheeldressing operation in addition to eliminate operatorfatigue - the system is easy to operate at the push of abutton. It comes with a variable dressing speed optionand allows for grinding wheel dressing without removingthe grinding job, thus achieving reduction in set-up timeby 28 percent.Thanks to the reconditioning, the client was able toachieve a dresser longitudinal traverse rate of 160-180mm/min, a 0.035 mm depth of cut for coarse dressing(on dia), while the same for fine dressing up to 0.015 mmwith a minimum dressing infeed of 0.020.Parameter achieved 160-180 mm/min.Dresser longitudinal traverse rate 0.035 mmDepth of cut for coarse dressing(on Dia) 0.015 mmDepth of cut for fine dressing(on Dia) 0.020Minimum dressing infeed20 Equilibrium
CSR Initiatives Reaching Out to Help Others While the company strives for excellence, it also shoulders civic responsibilities and helps the community. CSR is about accountability and an obligation to make a measurably positive impact on society at large; and this MGT is conscious about. Because only if you care about overall development can the company thrive on customer goodwill. CSR is more about giving than getting – and that is the company’s maxim. MGT Builds Awareness and Helps Chennai Flood Victims Women and children, including those with special needs received adequate attention and encouragement through various awareness camps. An awareness generation camp was organized in Sadarpur village on the “Socio- economic Condition of Women.” An “Environmental Sanitation Rally” was organised at Rahispur and Sadarpur by the children of Balwadi and Government School. On the MGTB Founder’s Day, sweets were distributed at a school for specially abled children in Dobaspet and an orphanage at Solur. On the World Environment Day, employees of MGT planted trees for a greener world. Because the company realizes that only if the environment is nurtured and preserved can we lead healthy lives. Destroy nature and you destroy man. During times of crisis, like the Chennai floods, MGT was at the forefront helping those in need. The company takes pride in sharing philanthropic activities of its members such as Senior Engineer PED, Nilanjan Deb who has been associated with a socio- cultural foundation called Prakriti and actively engaged in providing relief to Chennai flood victims.World Environment Glimpse 21Relief camp for Chennai Flood Victim Blood Donationw w w.micro m aticg rin din g.co m
Best Practices Reliability is the corner stone In the last edition of IMTEX, MGT committed itself to the philosophy of, “In the pursuit of zero” - zero defects, zero downtime, and zero emissions. Following this philosophy MGT has adopted new Reliability Test to ehance productivity and deliver error free results. This philosophy has been guiding all its endeavours, including product innovation. The newly launched high precision grinding machine in collaboration with IIT Madras bears testimony to this. Complete Testing Protocol for MGT Machines Equilibrium 1 Features of scope 2 CE Safety Test 3 Guideway Straightness Measurement 4 Geometric alignments Test 5 Linear Axis Accuracy Test 6 Rotary Axis Accuracy Test 7 Wheel Head Vibration Test 8 Plunge Grinding 9 Traverse Grinding 10 Axis Functional Reliability Test 11 Wheel Head Functional Reliability Test 12 Work Head Functional Reliability Test 13 Tail stock Functional Reliability Test 14 Multi-Function Reliability Test 14 Specification 15 Statistic Stiffness Test of complete machine 16 Natural Frequency Measurement Test (Modal Analysis) 17 Operational Frequency Measurement Test (ODS) - Idle running 18 Operational Frequency Measurement Test (ODS) - Grinding 19 Axis Thermal Stability Test 20 Spindle Thermal Stability Test 21 Process capability on Long Run (8 Hour) 22 Wheel Head Functional Reliability Test22
Micromatic Grinding Technologies & IIT Madras jointly developed the Next Generation High Precisiongrinding machine NGPG in 2016. Testing at every stage was carried out by an independent agency,Advanced Machine Tool Testing Facility (AMTTF).A very valuable bi-product has been learning a systematic way of “Qualifying a PrecisionMachine Tool”, which has resulted in MGT‘s new “Machine Testing Protocol”. All MGT machines arecharacterised mainly into four modules (refer chart) and all these tests are being done according toISO-International standards.Whenever we build a new machine model now, the prototype passes through all the tests shownbelow to ensure that the physical prototype adheres to the design intent and high reliability standardsexpected. Equally, now all our production machines also undergo 14 compulsory tests to achieve theZero downtime through the new, “MGT Reliability Test standard”.w w w.micro m aticg rin din g.co m 23
CAG ADVERTISING: 9810612122, 9871197377Head office & North India Plant Bengaluru – South India PlantMicromatic Grinding Technologies Micromatic Grinding TechnologiesC-27 & 28, Industrial Area, Meerut Road, 5/A, Servey No.74, 103, 106, 107,Ghaziabad, Uttar Pradesh - 201 003, INDIA KIADB, Industrial Area, Dobaspet,T: +91 120 2712137/69/79, 2723216 Nelamangala Taluk, Bangalore,E: [email protected] Karnataka - 562 111, INDIA T: +91 080 27735383/85/86/87, 27702449 E: [email protected]/micromaticgrindingtech //tinyurl.com/z7264wo micromaticgrinding.com
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