eMagazine - MMI - Sept 2017

MODERN VOL 1, ISSUE 3 - SEPT 2017 MANUFACTURING INDIA The Official Magazine ofW W W. M M I N D I A . C O . I N In Association with INDIA @ Industry 4.0: Manufacturing’s Next MoveCOUNTRY FOCUS: 32 AERODEF: 46 LUIGI GALDABINIINDIA-ITALY SOARING HIGH President, CECIMO, The European Association of the Machine Tool Industries & Managing Director, Galdabini SPA

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CONTENTS VOL 1, ISSUE 3, SEPT 20174006 FOREWORD 4208 PUBLISHER’S NOTE 46 AERODEF Soaring High10 EDITORIAL 50 PLASMA CUTTING12 IMTMA’S DESK Raising Productivity with Right Cutting Consumables14 PANORAMIC PERSPECTIVE 54 INDUSTRY - ACADEMIA Forging Ties for Bigger Prospects16 NEWS 58 BEST PRACTICES20 MARKET INSIGHT Propelling Towards Excellence24 COVER STORY Industry 4.0: Manufacturing’s Next Move28 BIG INTERVIEW Luigi Galdabini, President, CECIMO, The European Association of the Machine Tool Industries & Managing Director, Galdabini SPA32 COUNTRY FOCUS India-Italy: Championing Synergy36 INDIA @EMO Showcasing India’s Manufacturing Prowess40 COMPANY PROFILE Customer is the Priority42 AEROSPACE MACHINING Rough Boring Tool Cuts Challenging Material4 | Sept 2017 Modern Manufacturing India

INDIA @ IMPRINT 36 PUBLISHER & DIRECTOR GENERAL & CEO, IMTMA58 V Anbu60 SAVE THE DATES–EVENT CALENDAR62 NATIONAL PRODUCTIVITY SUMMIT 2017 EDITORIAL Editor-in-Chief Leveraging the Power of Examples64 DMTX 2017 Soumi Mitra Marking Another Episode of Stellar Success Chief Copy Editor67 PRODUCT70 ADVERTISER & COMPANY INDEX Poonam Pednekarwww.mmindia.co.in Senior Correspondent P K Chatterjee Head Creative & Production Shanmugam Pillai (Som) Snehal P SALES & MARKETING Indian Machine Tool Manufacturers’ Association (IMTMA) Murali Sundaram, 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. | 5Sept 2017

FOREWORD PG JADEJA President Indian Machine Tool Manufacturers’ Association (IMTMA) GROWTH OPPORTUNITIES IN AEROSPACE & DEFENCE SECTORS Greetings from the Indian Machine Tool Manufacturers’ Association (IMTMA) and Modern Manufacturing India (MMI) magazine September 2017 edition. M anufacturing needs to take a quantum leap in new and emerging areas such as defence and aerospace. This may perhaps open doors for the machine tool industry to develop new and innovative technologies and strengthen its inherent innovation capabilities. This would also supplement our export potential as well besides giving a big push towards the mission ‘Make in India’. India’s machine tool industry is eyeing aerospace and defence sectors as growth markets. Change is on the cards with the Government of India attempting to give thrust to Make in India in policies such as defence procurement policy and strategic partner policy and facilitate partnership between Indian and foreign firms for manufacturing aerospace and defence equipments in the country. It is expected that private sector will make full use of the opportunities presented before them and forge technology and production partnerships with overseas aerospace and defence companies. IMTMA is organizing a group participation of Indian machine tool companies at EMO Hannover 2017 in Germany. The exhibition is an excellent opportunity for Indian companies to understand trendsetters in digital transformation and navigational aids for smart factory of the future and technologies that are used by the global machine tool industries. I firmly believe that EMO Hannover 2017 will be an enabler for the Indian manufacturing industry to strengthen its presence in the global marketplace. India is working on a roadmap for modernizing its armed forces. An estimated 100 billion USD contracts are likely to be signed in around 10 years. This provides a window of opportunities for Indian and foreign firms to forge alliances for mutual benefit. The Association will continue to project the machine tool industry as a key enabler of the ‘Make in India’ initiative and strive to make the industry a global player. I call upon the industry to support IMTMA’s initiatives by giving feedback which will guide us in our journey to make the manufacturing sector competitive. This issue of MMI focuses on defence and aerospace sectors. The magazine also includes an opinion piece from IMTMA in which the Association shares its thoughts on various opportunities in aerospace and defence sectors. Readers can download previous editions of the magazine from IMTMA website. Happy reading. PG JADEJA President, Indian Machine Tool Manufacturers’ Association6 | Sept 2017 Modern Manufacturing India



PUBLISHER’S NOTE Dear MMI Readers, I t’s the pursuit for knowledge and a relentless curiosity to explore that enable manufacturing industry to stay ahead in a world that keeps changing with the blink of an eye. As the manufacturing industry embarks upon its onward journey, it becomes imperative for it to invest in the latest technologies to stay competitive in its domain. The right use of technology will open avenues for you to be a trailblazer in manufacturing. The strength of Modern Manufacturing India (MMI) has been its ability to reach out to the core manufacturing sector. Its unique selling point is that it takes the news closer to the users of machine tools, giving them an insight into the most advanced manufacturing requirements critical for industries through informative stories, interviews, case studies and so on. In this edition, we provide you a first-hand view of the Indian machine tool and manufacturing industry. The issue features an article by IMTMA on aerospace and defence sector manufacturing. The sectors have been earmarked as “key sectors” under the ‘Make in India’ framework by the Government of India. I thank you for your continued interest in the activities of the Association by providing your valuable feedback which is beneficial in our onward journey. I hope that you cherish the time you spend with MMI. Thank you once again for your support. Cheers and welcome. V ANBU Director General & CEO Indian Machine Tool Manufacturers’ Association8 | Sept 2017 Modern Manufacturing India



EDITORIAL WHERE THE LAND IS FULL OF MARVELS! eing an ardent admirer of engineering marvels of the past and present B and with a dream job to witness them on a frequent basis, I have groomed myself to notice intricacies in the engineering art when I encounter it. During my recent trip to the Konark Sun Temple, I yet again found myself engulfed in stupor, wondering over manmade miracles and the ability of people behind them to have brought such majestic things come alive and stand tall for centuries with an unabating capacity to induce awe. Perched on the shores of the Bay of Bengal, the temple, built in the 13th century,SOUMI MITRA is a massive conception of artistic magnificence and engineering dexterity. It isEditor-in-ChiefModern Manufacturing India a monumental representation of the Sun God, Surya‘s chariot with its 24 [email protected] decorated with symbolic designs being led by a team of six horses. The entire structure is built of stone and interlocked by metals, At first they will ask held together by a huge magnet why you are doing it. weighing more than five tonne. Later they will ask I could now decipher Nobel how you did it. Laureate Poet Rabindranath Tagore’s line: “here the language of stone surpasses the language of man“, written in his ode to the motherland, known widely for architectural greatness, and sophistication and abundance of sculptural work. Today, the materials to work on differ, the tools to shape them have evolved, and the things that take life suit the modern day and age, but the legacy continues. We, the land of engineers, still are in possession of the same talent our ancient engineers had. EMO Hannover 2017 is an opportunity to showcase that and take pride in the journey that has led us to this juncture in the world of manufacturing. The Indian exhibitors at the trade fair are all set to show the best we have and our capacity to make it still better. Here’s wishing them all and us the success we deserve!10 | Sept 2017 Modern Manufacturing India

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IMTMA’S DESK Source: SKF EvolutionIMMENSE PROSPECTSFOR PRIVATE SECTORIN AERODEF12 | Sept 2017 Modern Manufacturing India

HIGHLIGHT space for investments the pros- space sector also shares a simi- India’s share of the global pects for growth are brighter lar story. aerospace industry is than never before. It is the motto of the Govern- around $250 million and Significant factors fuelling ment of India to domesticize as per a joint report by growth are the government’s the aerospace industry, attract IESA, NASSCOM and Roland offset policies, robust pool of global players and lower depen- Berger the total opportunity workers, cost advantages and dence on imports in the sector. in aerospace and defence so on. Aerospace and defence India’s share of the global aero- market may touch around business which until now was space industry is around $250 $70 billion by 2029. largely centered on public sec- million. It is still a fledgling in- tor is now open for private dustry but with high growthAerospace and defence firms as well. potential. As per a joint reportmanufacturing are The Government of India, in by IESA, NASSCOM and Rolandtwo key critical line with its Make in India pol- Berger the total opportunity insegments earmarked icy has given prominence to lo- aerospace and defence marketfor development and cal industry by making it as the may touch around $70 billionmanufacturing growth centre for defence production by 2029.in India now. The twin which creates a tremendous op-sectors which often portunity for the private sector. Opportunities aboundoverlap one another Giving wings to the Make inthrow immense Defence-private India policy is the numberpossibilities for connection of private sector companiesbreeding upstream and Indian private firms making marking their presence in thedownstream investment use of the opportunity have aerospace sector through jointprospects besides signed developmental contracts ventures. Examples include:promoting innovation with the Ministry of Defence. Adani Aerospace and Defenceand growth. Notable ones include Tata which is setting up a modern Advanced System for surface aerospace ecosystem in Mundra,A s India provides robust surveillance radar project for Airbus partnership with Tata infrastructure, excep- the Indian Navy and Larsen & Advanced Systems for final tional port logistics, in- Toubro for production of guns assembly of C295W militarydustrial corridors, availability of for the Indian army. transport in India, Airbusland, availability of power and a To be in sync with its Buy in partnership with Mahindraconducive environment for busi- India, Make in India mantra the Defence for production ofness, the developments can be ex- government has given impetus airbus military helicopters,pected to progress rapidly. to local manufacturing. The Israel Aerospace Industries government has announced and Kalyani Strategic SystemsFavourable policies that it will launch around six joint venture to manufactureIndia’s aerospace and defence to eight “Make” projects every and market the Israeli firm’ssegment is evolving. It is attract- year which raises the prospects defence systems.ing all major names across the for greater involvement of India’s defence needs is still metglobe in terms of investments. private sector in defence manu- through imports and it is one ofWith the Government of India facturing in the years to come. the largest importer of conven-bringing to the fore investor As per the Ministry of Defence tional defence equipment. Na-friendly policies and providing so far the government has is- tional security and geo-political sued 342 industrial licenses to requirements necessitate the 205 Indian companies and un- need to build additional capac- til now 66 licensed companies ity through investments. The have reported commencement opportunity is knocking on the of production. The defence door and private sector could items produced by these com- play a vital role across the aero- panies are sold to the Ministry space and defence value chain of Defence. in terms of research, design, development, manufacturing, Boom in Aerospace maintenance, quality control, Interestingly the Indian aero- training, and so on. www.mmindia.co.in Sept 2017 | 13

PANORAMIC PERSPECTIVETRADE FAIRS: MORE THAN JUST A MARKETING INSTRUMENTF rom gaining visibility to striking new deals, exhibitions and trade shows offer opportunities no business would want to miss out on. It is a strategy that has withstood the test of time, playing a significant role in the success of most machine tool companies that have beenreaping rich dividends in terms of experience, product development, while forging relationships,building brand and, most importantly, bringing sales from new markets.Trade shows are preferred Exhibitions offer easy access toExhibitions offer easy access to enthusiastic prospects enthusiastic prospects open toopen to research and deal, foster direct communication, research and deal, foster directreal-time feedback and regional to global exposure thatact beneficial in expanding a company’s customer base. communication, real-time feedback and exposure thatIt is simply a profitable choice of medium since none helps in expanding a company’sother has the potential to physically get one prospectsor harness a company’s assets or help set and achieve customer base.multi-disciplinary goals namely marketing, sales,relationship management or aid in knowing the T K RAMESHmarket or one’s position vis-à-vis the competition’s, all Whole time Director and CEOat one go. Micromatic Machine Tools Pvt LtdChoose and compareGiven the scope of trade events as export buildingplatforms, it is crucial to choose the best one, establishkey goals and measure the outcome against them, andthen compare with other promotional methods. Thetargets should be made clear to the team along with thefact that the results are getting measured.Evaluating exhibitions is not just about counting the collected visiting cards or the visitorsregistered in the stall; several things need to be measured at the same time -- the market, product and service, promotion, price and competition. Every exhibition is different for every exhibitor and no single measurement methodology will work for all. However, the effort should be to put together a simple methodology into a practical framework. The best goals are the quantifiable goals since numbers motivate and drive action. For example, instead of the goal to get media coverage, it must be to get five articles or product reviews printed in the show daily since it is much easier to judge a performance against a hazy goal when stated in a measurable way. Post-event action Once back in office, the results should be summarized and shared with the team. More leads, sales or benefits are likely to come in for months after an event. Hence, the show report must be kept updated and shared with key managers from sales, marketing and top management. This helps in realizing the value of participating in a trade event in the first place and making room for the improvements needed. The views expressed by the author are personal and he can be contacted at [email protected] | Sept 2017 Modern Manufacturing India



NEWSIMTMA’s 71st AGMBangalore, India – The 71st Annual Speaking on the occasion, insightful presentation on IMTMA’sGeneral Meeting of IMTMA held Dr S Raghunath, Prof-Corporate Governance Policies. During the AGM,recently at Banagalore International Strategy and Policy Indian Institute of an announcement was made aboutExhibition Centre, witnessed President Management Bangalore (IIM) oriented P Ramadas, Managing Director, AcePG Jadeja appraise the performance of the audience on the topic “Preparing Manufacturing Systems Ltd beingthe Indian Machine Tool industry in the for Transformations in Manufacturing the next IMTMA President-Elect andlast one year while drawing attention Industries - Electric Vehicles’ Impact on Indradev Babu, Managing Director,to the Association’s efforts instru­- Machine Tool Industry” and Shailesh UCAM Pvt Ltd as the new Vicemental in its progress. Sheth, Past President, IMTMA gave an President, IMTMA. Source: IMTMADr S Raghunath, Professor - Corporate Strategy and Policy, IIMB, addressing the (L-R) L Krishnan, Managing Director, TaeguTec India Pvt Ltd & Past President, IMTMA; P Ramadas, Managing Director,audience during the 71st Annual General Meeting. Ace Manufacturing Systems Ltd; PG Jadeja, President, IMTMA and V Anbu, Director General & CEO, IMTMA during the AGM. Jadeja’s remarkable contribution to the association during his tenure was acknowledged with a memento.Manufacturing NITI Aayog’s Adani, Saabsector bounces initiative to collaborateback have mentors for AerodefNew Delhi, India – Purchasing New Delhi, India – The National New Delhi, India – Swedish de-Managers’ Index (PMI) Data has Institution for Transforming India fence and security company Saab andrevealed that the manufacturing (NITI Aayog) – the premier policy Indian infrastructure conglomerateactivities in the country bounced ‘Think Tank’ of the Government of Adani Group have announced a part-back to growth path in August after India, providing both directional nership for defence manufacturing.having contracted in July due to the and policy inputs – has launched The project would encompass de-confusion pre-GST (the Goods and the Mentor India Campaign, a sign, development and production ofServices Tax). strategic nation building initiative Gripen jets for India in line with theThe Nikkei India Manufacturing to engage leaders who can guide Make in India initiative. It will com-PMI rose to 51.2 in August from 47.9 and mentor students at more bine the technical and product excel-points in July. A reading above 50 on than 900 Atal Tinkering Labs, lence of Saab, along with the industrialthe index denotes expansion. established across the country as a engineering, syst­em integration and“August’s PMI results showed that part of the Atal Innovation Mission. mega project execution capabilities ofmanufacturers in India recovered Atal Tinkering Labs are dedicated Adani with the intention to manufac-quickly from the sharp slump workspaces where students from ture defence systems locally in India.that followed the introduction of Class 6th to Class 12th learn inno­ Gripen is a modern multi-role fighterthe GST,” said Pollyanna De Lima, vation skills and develop ideas aircraft featuring state-of-the-art tech-Principal Economist at IHS Markit that will go on to transform India. nology, including advanced data linksand the author of the report. The labs are powered to acquaint and sensors plus a unique extensiveThis ray of hope came on the heels students with state-of-the-art electronic warfare suite. Gripen canof the release of gross domestic equipment such as 3D printers, perform all air-to-air, air-to-surfaceproduct (GDP) data that indicated a robotics & electronics develop­- and reconnaissance missions withthree-year dip in economic growth ment tools, Internet of things & the most modern range of weaponsat 5.7 percent in the first quarter of sensors etc. and systems.the current financial year.16 | Sept 2017 Modern Manufacturing India

NEWSMeet on Sunshine SectorsPune, India – Yamazaki Mazak India methods; component engineering A two-hour interactive session withPvt Ltd and Seco Tools India (P) Ltd solutions; dig­ital solutions; and global international experts was scheduledrecently organized ‘Innovation competence centers. to seek winning solutions for theDays’, a joint seminar on enhancing As part of the seminar, a live various manufacturing challenges.comp­etitiveness in Aerospace and demonst­ration was held on the latest A host of industry experts such asMedical sectors. The event focused machining trends on Mazak machines Tom Massey, Regional Asia Pacificon topics including machining of at Mazak Technology Center, Pune. Expert, Aerospace & Medical;trending materials in Aerospace and Also a visit to the state-of-the-art Seco Vipin Rajput, Regional Asia PacificMedical industries; latest machining manufacturing facility was lined up. Expert, Aerospace and K S Chong, Senior Director, Solution Engineering spoke on the topics exhaustively. Massey has decades of machining background in the Aerospace sector and Rajput specializes in Metal cutting. Source: Yamazaki Mazak India Pvt LtdA live demonstration on the latest machining trends on Mazak machines at Mazak Technology Center, Pune An interactive session with expertswww.mmindia.co.in Sept 2017 | 17

NEWS HAL to supply 41 Advanced Light HelicoptersVDMA Bengaluru, India – Hindustan executed in 60 months and adds to Aeronautics Limited (HAL) has signed the 32 ALH ordered by the Indiancelebrates its `6,100 crore contract for supplying Navy (IN) and Indian Coast Guard (ICG) 41 Advanced Light Helicopters (ALH)- in March.125th anniversary “The order reflects the trust on HAL’s 40 to the Indian Army and one to the capabilities and gives an impetus to Cologne, Germany – With ‘Make in India’ campaign. It reposes the aim to establish a network Indian Navy. The contract will be faith of Indian Defence forces in of contacts for the mechanical indigenous ALH which has been engineering sector, which was Source: Department of Defence Production serving them with distinction for a long to communicate common interests time,” said T Suvarna Raju, Chairman, with one voice, 29 machine Managing Director, HAL. The factories in Cologne, Germany indigenously designed and developed laid the foundations for the chopper is a twin engine, multi- VDMA in 1892. Today, it is role, multi-mission new generation the largest industrial association helicopter in the 5.5 tonne weight class. in Europe with around 3,200 member companies. Hyundai to manufacture For the anniversary, the website Verna in India www.mensch-maschine- fortschritt.de shows in German Chennai, India – South Korean automobile giant Hyundai Motors has and English in the form of announced that it will be shifting its entire production of its mid-sized multimedia reports how important sedan Verna from South Korea to India. machine and plant engineering The move is expected to boost the “Make in India” initiative. The is for everyday life. Almost every manufacturing facility in Sriperumbudur near Chennai will start product is produced by machines, supplying Verna to nearly all of Hyundai’s global markets from January from nano to giga, in all dimensions 2018. YK Koo, Managing Director, Hyundai Motor India disclosed that and application areas. Topics of they are targeting annual production of about 1.3 lakh units of the mid-size the reports are for example: energy sedan in India in the next few years. The company also hopes to export supply, infrastructure and mo- 60 to 70 percent of those units. Its factory currently operates at bility, food supply and human- 95-98 percent of capacity. It plans to manufacture around 50,000 units of robot collaboration. Verna for the Indian market and another 80,000 units for global markets, including Latin America, Africa, Middle East and other Asian countries.New PCD processingat EMO 2017 Schneider Electric India commissions 720 kWp solar plantIndia – A new Neo laser roughingmachine to preprocess polycrystalline Vadodara, India – Schneider much as 20-25% annually. Further,diamond (PCD), cubic boron nitride Electric India recently announced the company will be able to cut its(CBN) and other super-hard materials the commissioning of a 720 kWp carbon dioxide emissions by 1,018could be witnessed at this edition of capacity solar power project at its tonne per year, which is equivalentHannover. In conjunction with fin- manufacturing facility in Vadodara, to planting 50,000 trees.ishing the work piece on an Agath- Gujarat. The solar project, built on a The project demonstrates its com-on grinding machine, companies will rooftop area of 6,000 sq mt, covers mitment towards green manufactur-benefit from extremely short cycle almost 45% of the total factory load ing in India. This is the second solartimes, low acquisition and production and will produce over 1.05 million project commissioned by Schneidercosts, as well as the technological ad- units of electricity per year which Electric at its m­anufacturing facilityvantages of industry 4.0 features. would help cut power costs by as in India.Visitors can visit Agathon in Hall 11,Stall C62 in EMO Hannover.18 | Sept 2017 Modern Manufacturing India



MARKET INSIGHT POWERED BY: HIGH DEMAND IN AEROSPACE INDUSTRY A BOON TO MACHINE TOOL MARKETSource: shutterstock.com A strong global growth of both passenger and freight air transport demand followed by strong demand for new aircraft and increasing competition between aircraft manufacturers point to a robust aerospace market in the near future, with opportunities galore for machine tool builders. The global aviation market represents a significant source of future growth for the machine tool market. MICHAEL GUCKES M ultiple market forces point to a robust aerospace likely in excess of $2 trillion, as Chief Economist are working to the market for years to come that Airbus stated in mid-2017 that Gardner Business advantage of the may present opportunities for its backlog value alone exceeds Intelligence aviation market, representing a machine tool builders to make $1 trillion. To clear the total mguckes@ significant and sustainable long-term investments and backlog using recent annual gardnerweb.com growth opportunity for grow their businesses. delivery data from both firms machine tool builders. These would take more than 8 years. forces include the strong global Robust backlog This estimate does not account growth of both passenger and Backlog orders across the in- for future expected orders, can- freight air transport demand dustry are robust with the cellations or expanded man- followed by strong demand for combined backlogs of Airbus ufacturing operations. Lastly, new aircraft and increasing and Boeing exceeding 12,000 these figures do not account for compet­ition between aircraft aircraft. This backlog is split aircraft orders and deliveries by manuf­acturers. The combined evenly between the two rivals. other firms such as Mitsubishi, results of these factors should The value of all these planes is Bombardier or Embraer.20 | Sept 2017 Modern Manufacturing India

Narrow body jets successful Sept 2017 | 21In a June 2017 release from Boeing, the companystated that it will produce a modified 737 calledthe “737 MAX 10” to compete with the successfulAirbus A321Neo. Both planes are designed tofill the “middle of market” (MOM) passenger jetsegment. MOM jets are described as narrow-body aircraft, meaning they are single-aisle jetsless than 4 meters across. A MOM jet is typicallycapable of carrying approximately 200 passengersdepending on the cabin configuration and numberof seating classes. In June, competing jet enginemanufacturers General Electric and Safran bothindicated that they stand ready to provide newhigh-efficiency engines for Boeing’s new jet.The Airbus A321—a member of Airbus’ A320family of narrow body jets—has been extremelysuccessful for Airbus. According to Airbuswebsite statistics as of June 16 this year, theA320 family of jets comprised 75 percent of thecompany’s current orders and deliveries. In total,Airbus reported in June that it has more than5,050 firm orders for planes using Neo engines.Boeing’s response to Airbus’ success, however,will not be immediately felt until capacity atBoeing’s manufacturing facilities is freed up fromthe completion of existing orders for its 777X and737 MAX planes.The Chinese state-owned Commercial Air-craft Corp. of China (COMAC) is also bringingits own narrow-body jet, the C919, to marketin the near future. The C919 which will carryfewer than 200 passengers, made its first flightin May 2017 and is expected to enter servicein 2020.Increase in passenger growthPassenger and freight statistics produced bythe World Bank and China’s National Bureauof Statistics are highly impressive. Data fromthe World Bank indicates that the worldwidenumber of passengers on planes from 2005 to2015 increased by almost 75 percent. Worldwidegrowth as measured by this metric showedsignificant variation by nation. In the US, totalpassenger growth increased by 11 percent, whileChina experienced total growth of 219 percent,representing 12.3 percent annual growth.According to data released in April 2017 fromChina’s National Bureau of Statistics andseasonally adjusted (SA) by Gardner BusinessIntelligence, in the five years ending April 2017,Chinese passenger-kilometers traveled increasedby 88 percent, representing more than 13 percentannual growth. Similarly, Chinese air transportof freight measured in ton-kilometers increasedwww.mmindia.co.in

MARKET INSIGHT jets able to transport more people to more destination pairs. Tech- nological advancements which have brought geographically diverse sources of oil from shale rock formations and deep-sea de- posits to market will limit OPEC’s ability to inflate oil and jet fuel prices. The dynamics of the oil market moving forward will re- sult in airlines being able to prof- itably sell seats to cost conscious travelers, driving the quantity of seat-miles consumed even high- er. We expect this combination of a growing consumer base and low operating costs to benefit the aerospace components manufac- turers and the OEMs well into the future.The international Source: shutterstock.com Aviation industrydemand for important for machineaircraft and air tool markettransportation The global aviation market rep-is reflected in the resents a significant source ofvolume of future growth for the machineshipments for aircraft tool market. It will be importantcomponents for machine tool firms to buildrequiring machining. international relationships that will allow them to capture mar- by 51 percent during the same sult of increasing demand for ket share and growth in those time, representing almost 9 air services. Using data for the regions of the world that are ex- percent annual growth. These five years ending in April 2017, periencing double-digit demand impressive growth statistics the value of power cylinders for air transportation. If aircraft are supported by comparable and actuators shipped grew by manufacturers such as Boeing, aviation data gathered by the 12.9 percent on an annual basis, Airbus and others are going to World Bank. while the value of pumps and run their facilities at ever high- motors shipped increased 5 per- er levels of capacity for the next Increase in the value of cent annually. five or more years, it will be aircraft components Looking to the future, GBI ex- important for their component The international demand for pects the aircraft components suppliers to have strong opera- aircraft and air transportation industry will experience con- tional and logistical capabilities is reflected in the volume of tinued growth as low operating to support these demanding air- shipments for aircraft compo- costs and a growing worldwide craft delivery schedules. This nents requiring machining. The population of air-travelers pow- will mean that machine tool value of aircraft components in- ers the expansion of the world- providers will also need to be cluding pumps, motors and ac- wide aviation market. As the prepared to meet the growing tuators have increased thanks flying population continues to and highly demanding needs in small part to new aircraft grow, this will create strong de- of their customers at all levels production, but largely as a re- mand for new and reconditioned of the aerospace manufactur- ing supply chain—having new equipment ready for sale and to be able to quickly support ex- isting equipment maintenance and repair needs. 22 | Sept 2017 Modern Manufacturing India

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COVER STORY Industry 4.0: Manufacturing’s Next Move The Industry 4.0 concept will be ushering in a favorable sea change in the world of manufacturing. However, for the small and mid-tier enterprises (SMEs) to make the most of its phenomenal digital opportunities, the trend requires more openness in the machine tool industry and in the user sectors involved.Source: Magic Wand Media Inc I ndustry 4.0 is influe­ textbook example for Industry ncing the process chain 4.0 is obtained. in two ways: firstly, in “This applies in regard to qu­ terms of technology and engi- ality and disturbance variables, neering, and secondly in terms but also and increasingly to pre­ of the data flowing along dictable parameters such as tool with it. When both of these paths and tool lifetimes, achiev­ interact to optimum effect, a able surface qualities, and for24 | Sept 2017 Modern Manufacturing India

“I would like to see even more “In future, tool data will be necessary. Universities andshared projects with partners from acquired over the entire life-cycle. large corporations are alreadythe academic community and the This applies particularly to tools well advanced in this respect,industrial sector representing a that are re-sharpened or whereas many of the small andhighly disparate range of scientific retrofitted.” mid-tier companies are stilldisciplines, which elucidate in the exploratory phase. Forquestions not least with the aid of Markus Kannwischer meaningful analysis, moreover,live demonstrators, for example.” Head-Technique and Member of a comprehensive data history is the Board at the tool manufacturer required, in order to correlate itDr Frank Barthelmä Hartmetall-Werkzeugfabrik Paul with new key statistics.Executive Director and Institute Horn GmbH, Tübingen According to Dr Barthelmä, weManager of the German Society for need an even more collabora-Production Technology and tion between the academic andDevelopment, GFE business communities when it comes to generating new ideas,maintenance intervals for ma­ intelligent holistic solutions All available models and new solutions. Idea­chines and lines,” explains Prof are talked about in which tool data can lly, there should be more jointDr Frank Barthelmä, Executive sensors and actuators play an now be projects involving partnersDirector and Institute Manager, important role. “That correctly recorded and from the academic communityGFE – Gesellschaft für Ferti­ makes them ‘state-of-the-art’,” evaluated and the industrial sectorgungstechnik und Entwicklung stresses Dr Barthelmä. “Not in real- representing a highly disparateSchmalkalden e.V. only in terms of using increas­ time, and range of scientific disciplines,Ideally, users receive all import­ ingly miniaturized and more control loops which can elucidate theseant information on the entire energy-efficient sensors or ac­ created so as questions with the aid oflivespectrum of process-related tuators in the tool itself, but also to upgrade demonstrators.factors. What is more, all data with a view to their utilization the efficiencyavailable can now be record­ in the overall system compris­ of the Collaboration betweened and evaluated in real-time, ing the tool, the machine and its processes software analysts andand control loops created, so control system, and the applica­ and the metal-cutting expertsas to upgrade the efficiency tion concerned.” quality of This will work if the SMEs getof the processes and the qual­ the products involved at an early stage. Theity of the products involved, Evaluating multiple data involved. networks supported by the Fed­thanks to more transparent Many potential users of eral Ministry of Economic Af­metal-cutting. intelligent solutions, especially fairs, for instance, have proved SMEs, are sometimes unable to worthwhile in this context. ForRole of tool sensors and assess what data they actually example, the GFE is currentlyactuators need in order to render their a partner in the SME 4.0 Com­About a decade ago, there was technology/IT fit for purpose, petence Centre of the Ilmenauan ongoing debate on whether and to generate from these University of Applied Science,or when a tool can be classed new production lines when and in a model factory is ad­as intelligent. Today, within needed. This extends to new dressing problems encounteredthe context of Industry 4.0, business models that may prove with data generation and data transfer in connection with metal-cutting – for transfer es­ pecially in SMEs. The question involved here is this: how can a control loop in the machine be utilised so as to ensure that quality, efficiency and produc­ tivity can serve as controlling target variables? Source: VDW - VDW - German Machine Tool Builders` Association GFE – Gesellschaft für Fertigungstechnik und Entwicklung Schmalkalden e.V.www.mmindia.co.in Sept 2017 | 25

COVER STORY of analytics. “There is still quite developed a sensor-integrated a bit of work to be done on the tool for hard machining, which, path to purposeful evaluation. thanks to direct integration in There is room for improvement, the machine’s control, enables too, in the transparency of the the process to be controlled al­ results. A pre-competition plat­ most in real-time. form should be accessible to The Dyna-Tool consortium manufacturers and users alike,” has succeeded in putting more opines Dr Barthelmä. A data transparency into the metal- pool should also be in place so cutting process, so that it can that everyone does not have to be kept within defined limits keep on re-inventing the wheel. for low vibrations, but at the It is worthwhile for a manufac­ same time is able to exploit turer if users learn which of its performative potentials to his tools are best suited for effi­ the full. ciently machining new materi­ GFE is also currently examin­ als. GFE is contributing towards ing the integration of high-res­ this with the SME 4.0 Compe­ olution metrological devices in tence Centre. the tool, including an interface with the control system, so as Source: GFE Current highlight to use this to create a real-time from the work control loop. Anyone interestedLooking into the Analysing metal-cutting The EU’s “Dyna-Tool – En­ can learn more about this andfuture: at the EMO parameters hanced Efficiency in Metal- other projects at the EMO Han­Hannover, In the case of new materials, it Cutting Applications” project, nover and its forum entitledthe GFE will be is becoming progressively more supported by the German Engi­ “Innovative Solutions for Indus­showcasing the important to close the loop in neering Federation’s Pre­cision try 4.0” hosted by the Germancurrent status of the control circuits with the aid Tool Association and the re­ Engineering Federation’s Preci­digital matters as search institute Forschungsku­ sion Tool Association.exemplified by the EU ratorium Maschinenbau e.V., isproject tasked with investigating how I4.0’s influence onentitled “Dyna-Tool – vibration-stable metal-cutting metalcuttingEnhanced Efficiency in processes can be designed using Dr Niklas Kramer, DirectorMeta-Cutting sensor technology in the tools Product and Industry SegmentApplications” and the tool holders. Management, Sales Area For this purpose, GFE has with­ Central Europe, Sandvik in the framework of the project Coromant, gives three reasons why Industry 4.0 is influencing EMO Hannover 2017 the world of metal-cutting: “Firstly, it focuses attention EMO, the world’s premier trade fair for the metalworking sector will on the value-adding processes be held in Hannover, from September 18-23, 2017. The fair will be involved, since resource- showcasing the entire bandwidth of today’s most sophisticated gobbling activities around the metalworking technology, the latest machines, efficient technical actual production process can solutions, product-supportive services, sustainability in the production hopefully be automated to an process, and much more. increasing extent using I4.0.” “Secondly, metal-cutting is a The 2,000 manufacturers from 42 countries will be presenting the highly empirically-based field. entire assortment from machine tools, precision tools and automation The more we succeed in gaining components up to customer-oriented systems at the fair. However, it is insights either on the basis the key focus on digitization and Industry 4.0 this year that makes it a of data or by means of ‘must-attend’ affair. statistical methods, the better we shall be able to design EMO’s spotlight on the concept will help overcome the skepticism around and optimise metal-cutting this emerging trend, better understand the reasons it is gathering force processes,” he adds. and thus, take advantage of the new opportunities. Join the historical Lastly, the sector is nowadays congregation as it gears towards another industrial revolution.26 | Sept 2017 Modern Manufacturing India

though, a solid basis of data will allow a tighter process window when running in workpieces involving familiar materials. Source: GFE Networking at EMO Acquiring the metal-cuttingexhibiting a major gap between towards sensor technology, Transferring parameters also facilitates mac­metal-cutting research and that in the tool, in the vicinity ideas: digital hining – e.g. with a view topractical applications. A of the blade, acquires, processes transformation is a new materials. “Often they aremodest plus in terms of and transmits measured values. difficult undertaking, not very amenable to metal-system intelligence would From these data, algorithms especially for small cutting because the empiricalbe helpful here, whether it is are then tasked with drawing and midtier knowledge and the researchan I4.0 machine or a process conclusions on machining companies. It may results are not available, or wemonitoring system, for example, parameters and regulating the prove helpful for first of all have to try out the oldenabling better decisions to be control systems accordingly. them to solutions before we develop anymade faster, and deviations to To quote Kannwischer: “Ideally, tackle the issue jointly new ones,” explains Dr Kramer.be detected earlier. it will no longer be necessary in networks, as is the “I believe that if we could to enter feed and setting case here at the GFE in bring together the global firstCloud instead of a values in the control system; Schmalkalden. tentative steps involving a newphysical tool ID rather, the tool itself will material at a single location,Similar developments are also continuously send information we would have significantlytaking shape in Tübingen at on its condition and the steeper learning curves. OneHartmetall-Werkzeugfabrik control system will take appro­- aspect we’re generally focusingPaul Horn GmbH. “In future, priate action.” on in the context of Industrytool data will be acquired 4.0 is rapid response based onover the entire life-cycle,” says Real trials are not passé simply edited data.”Markus Kannwischer, Head of But the virtual future is On this subject, SandvikEngineering & Member of the not rendering real trials Coromant will be showcasingBoard. “This applies particularly superfluous. For example, design enhancements of theto tools that are re-sharpened the machinability of new CoroPlus platform at the EMOor retrofitted.” In these cases, materials will still have to Hannover 2017, which offers itsall relevant geometric data be determined by actual users networked solutions forshall then be transferred to trials, despite simulations and increased process dependabilitythe cloud; a physical tool ID is analytical methods. However, and savings in terms ofthus superfluous. the number of trials can be design and planning. To quoteThe tools are changing too: restricted because a better data Dr Kramer: “Since 2016, quitethere is an accelerating trend basis is available. Generally, a bit has been firmed up and design-enhanced, so we are hoping that this time, like at the last fair, we will once again be able to elicit an enthusiastic response.” Meanwhile, Dr Barthelmä, with his primary interest in the examples of best practices, will be seen talking to other advocates of these ideas on more transparency at the event: “I shall thus be attempting at the EMO Hannover, within the context of my networking activities, to gain additional co-campaigners for more openness and transp­ arency in the sector.” www.mmindia.co.in Sept 2017 | 27

THE BIG INTERVIEWCREATING RIPPLES IN THEMANUFACTURING SPACE Source: CECIMO How should the machine tool GALDABINI: Digitally speaking, sector keep pace with the European machine tool build­ “The theme As we come close to changing requirements of the ers should not delay the chosen for the witnessing the latest in digitized manufacturing sector, development of their strategy manufacturing trends especially in terms of imple- to remain competitive in the 2017 EMO at EMO Hannover menting new business models market. Indeed, the array of edition cannot 2017, Luigi Galdabini, such as “product-as-a-service” possible data-related services President, CECIMO, the or “knowledge-as-a-service”? is quite heterogeneous, so be more European Association companies will need to tailor indicative of of the Machine Tool LUIGI GALDABINI: As the cost their approach in accordance the trends we Industries & Managing pressure increases, customers with their own strengths. Some see today in Director, Galdabini are continuously looking to European machine tool firms SPA, helps us do our maximize their overall equip- will want to position themselves advanced homework on the ment effectiveness (OEE). In as suppliers of high-qualitymanufacturing.” emerging technologies Europe, machine tool builders machine tools in combination poised to transform the are increasingly realizing that, with digital solutions to exploit Luigi Galdabini, ways of doing business as key players in several value machine’s generated data so to President, in the machine tool chains, they can make the most improve production. space. out of this overarching digitiza- A common underlying element CECIMO, The tion trend. Through data storage in all these strategies should be, European and analysis, digitization gives us as said before, closeness to the many opportunities to expand customer. Collaboration with Association of our portfolio of customer solu- end-users is essential to make the Machine tions. We are now able to offer them aware of the benefits of add-on services together with digital services for their busi- Tool Industries the high-performance machines ness. In this sense, machine tool & Managing for which we are renowned. For builders will need to work with Director, example, condition monitoring them on real-case applications of sensors allow the customer to these services so to demonstrate Galdabini SPA track down the status of a range their added value. of aspects of the machine and In this process, we should not for- thus boost its productivity. Or get that entering the digital ser- predictive maintenance solu- vices’ realm requires investment tions can dramatically diminish in talent. There will be a need to machine downtime for the cus- strengthen the digital expertise tomer. From a supplier perspec- of the existing workforce and tive, these are just a few practi- implement HR strategies aimed cal examples of the many digital at attracting key IT experts for paths that the European machine the creation and marketability of tool industry is taking. In all that, a customer services’ portfolio. it will be important to get a sense of the customer’s needs in order Speaking of innovation, which to offer tailored digital services. production technologies do you think will predominantly prove In a competitive market, how to be game changers in the can machine tool builders manufacturing sector? leverage the best out of avail- able opportunities and be on GALDABINI: In addition to digi- the winning edge in terms of tization, additive manufacturing providing innovative solutions (AM) and robotics are two tech- to customers at an economical price?28 | Sept 2017 Modern Manufacturing India

nologies that will significantly Second from left: Luigi Galdabini, President, CECIMO, the European Association of the Machine Tool Industries &impact the manufacturing sec- Managing Director, Galdabini SPA addressing the first EU Industry Daytor.Additive manufacturing is like- all the tools to succeed in the policy-making process. We want “Additively to have a significant impact additive space. In the advanced to show authorities which mea­ manufacturingby enabling mass customization, manufacturing context, the sures in the education domain will be areducing inventories and cutting mix between solid engineering they should take. game-time-to-market. Our companies know-how and highly skilled changer, but itrepresent some of the leaders in shop floor employees has been CECIMO is organizing an in- will notthe production of metal additive one of the main ingredients for ternational conference on AM displace high-machines for industrial use, as our leading position. European during the EMO show. What is performance,well as of hybrid systems where machine tool companies willing the objective behind holding traditionaladditive and subtractive tech- to enter the additive industry the conference at the fair? machining orniques are integrated in a single are already in a strong starting cuttingset-up. Additive manufacturing point for successfully thriving GALDABINI: Through this event, techniqueswill be a game changer, but it into it. Indeed, looking at the CECIMO intends to raise aware- alreadywill not displace high-perfor- additive market, I can say they ness of the critical developments familiar withmance, traditional machining or are already proving so. happening in industrial additive volumecutting techniques already fa- CECIMO considers the skills is- manufacturing. Innovation is production.”miliar with volume production. sue in additive manufacturing a spanning across the entire val- Luigi GaldabiniAdditive machines should rather priority and we have obtained ue chain. New production tech-be complementary to subtractive EU funding for a series of projects niques are being developed bysystems on the shop floor. on the topic. One of them is MET- machine manufacturers, andRegarding robotics, we are no- ALS, which investigates further new applications are emergingticing the emergence of more to what degree the workforce in in mainstream industries. Thecollaborative robots able to work our sector should be trained to event aims to highlight some oftogether with people to further interact with additive machines. the most relevant developmentsincrease flexibility and efficien- We are in the process of under- in the field.cy. They are capable of boosting standing the competences that Our association represents man-the productivity of a factory by can be transferred from the sub- ufacturers at the cutting-edgeexecuting a range of supporting tractive to the additive environ- of technology development andtasks, like handling. ment, and those to be acquired we have a long tradition of R&DIn the future, the key will be to by workforce from scratch. projects at EU level. The CECIMOintegrate traditional and inno- The projects’ results will not additive manufacturing confer-vative technologies to develop only strengthen our knowledge ence at EMO 2017 has been con-overall efficient process chains. of the industry from a skills’ ceived with these considerations perspective, but will also in mind. Additive Manufacturing market contribute to the Europeanis slated to touch $21 billion by The interview was conducted by:the year 2021. In this context, Soumi Mitra, Editor-in-Chiefhow should the manufacturersgear themselves to upgradetheir skill sets to run in the race?GALDABINI: The growth ofindustrial additive manufact­uring points to many opport­unities for machine tool builders.Production with additivemachines entails challenges of itsown, which require strong skillsto be mastered with effectiveness.Thus, new competences, specificto the characteristics of theadditive process, have emerged,though the European machinetool sector, relying on theexcellence of its workforce, haswww.mmindia.co.in Sept 2017 | 29





COUNTRY FOCUS Source: Magic Wand Media Inc INDIA-ITALY: CHAMPIONING SYNERGY Post India’s major economic reform, GST, many a foreign company is getting drawn to India for mutual trade gains. Europe’s second biggest manufacturing hub, Italy has also recognized opportunities in the country’s industrial sectors and is on the way to beef up the bond.P K CHATTERJEE E ach country has their cently getting Italy’s biggest advanced technology, as well asSenior Correspondent own strengths and re- trade and investor delegation to information and communica-Magic Wand Media Inc sources which, when India to boost bilateral relations tion [email protected] brought together, can create re- in its areas of expertise includ- Italy is currently 13th largest sults that are greater than the ing food processing, infrastruc- investor in India with over sum of their parts. This truth ture, heavy machinery, auto- 600 Italian companies present must be the key enabler in re- motive, renewable energy, here. And Italy is India’s fifth32 | Sept 2017 Modern Manufacturing India

trading partner in EU. The bi- “Despite the registered down- “There will be a wide andlateral trade in 2016 amounted turn, India always remains a comprehensive display ofto around €7.3 billion and Ital- very important market for the technologies related to Industryian foreign direct investment Italian manufacturers world- 4.0 from 270 participatingin India amounts to around €5 wide,” he added. Hence, the companies from Italy. I would likebillion. association is involved in an to invite the readers of ‘Modern intensive activity aimed at Manufacturing India’ to visit theMachine Tools scene promoting the sector’s Made stands of these companies andThe Italian machine tool ex- in Italy within this area. This witness their interestingports to India reached its all- materializes in specific actions, novelties.”time high in 2012, when sales such as those developed in part-amounted to €147 million. The nership with Indian Machine Massimo Carbonierotrend had a progressive rever- Tool Manufacturers’ Associa- President, UCIMU-SISTEMI PERsal post this. In 2016, sales did tion (IMTMA), or those carried PRODURRE, Italian Machine Tools,not exceed €70 million, making out by PLATFORM INDIA that Robots & Automation ManufacturersIndia the eleventh market of provides assistance and advice Associationdestination for the Italian prod- to the Italian enterprises inter-uct offering of the sector, from ested in working in the area.being seventh in 2012, noted ITC India, Italian TechnologyMassimo Carboniero, President, Center deserves a particularUCIMU-SISTEMI PER PRO- mention: With regard to theDURRE, Italian Machine Tools, technologies requested by theRobots & Automation Manufac- market, the Indian users are in-turers Association. terested both in metal cutting Visit us @ Hall 6 / Stall L97www.mmindia.co.in Sept 2017 | 33

COUNTRY FOCUSIn 2015, Italian machines: grinding machines, MACHINE TOOL EXCHANGEimports from non-conventional technolo- ITALY - INDIAIndia increased gies and machining centers,by 51 percent representing 61percent of total (thousand euros)compared to exports; and in metal formingthe previous technologies: folding machines, 2007 Exports vs var. Imports var. Source: elaboration on ISTAT datayear. Around 91 bending machines, trimming 2008 India from Indiapercent share machines and presses. 2009 64,8% -43,2%of imports “A constant growth is regis- 2010 94.715 19,6% 1.441 72,5%is related to tered with regard to the Italian 2011 113.281 -33,6% 2.485 -36,7%the sector imports from India that has 2012 75.189 83,2% 1.573 -40,2%of cutting now become one of the major 2013 137.778 -1,5%machines, manufacturing countries in the 2014 135.770 8,2% 941 6,6%particularly world, capable of ensuring a sat- 2015 146.941 -15,2% 1.003 -18,5%machining isfactory technological level for 2016 124.595 -32,6% 281,9%centers many types of machining, espe- 83.985 -6,0% 817and milling cially for the machines with a 78.979 -11,3% 3.119 7,4%machines medium technological degree,” 70.039 3.349 51,0% said Carboniero. 5.057 -36,8% 160 In 2015, Italian imports from 3.196 140 India increased by 51 percent 120 million euros compared to the previous year. high standards and strong cus- well-performing and easily re- 100 Around 91 percent share of tomization, “he shared. Howev- configurable machines, but also 80 imports is related to the sector er, due to the incentives offered Source: elaboration on ISTAT data systems capable of interacting 60 of cutting machines, parti- by the Italian Government, the within a factory according to 40 cularly machining centers and enterprises of the sector have the principles of a more and 20 milling machines. been working intensively on more extended digitalization,” the technologies of Industry pointed out Carboniero. 0 Italian offerings for aero- 4.0 that are increasingly be- 2007 space sector and medical ing integrated in the solutions UCIMU plans at EMO engineering made in Italy. “This is all for Hannover “The Italian products of the sec- the users’ benefit; they actually With massive work underway tor are well-recognized for their have at their disposal not only for making Italy Industry 4.0 ready, the country is looking 2008 2009 2010 2011 2012 2013 2014 2015 2016 forward to be an active partic- Export vs India Import da India ipant at EMO Hannover 2017, which has its special focus on the advanced manufacturing trends. As a testimony to its high importance to the Italian manufacturers, 270 Italian com- panies are to showcase their in- novative developments in the area. “The Italian enterprises will certainly not miss the op- portunity to show themselves to the international public that is coming to Hannover over the six exhibition days,” said the President. “Considering the pos- itive context and the strong ac- celeration, I am sure that EMO HANNOVER will turn out to be a profitable occasion for all players, in particular for the Italian enterprises.”. 34 | Sept 2017 Modern Manufacturing India



INDIA @EMOSHOWCASINGINDIA’S MANUFACTURING PROWESSPOONAM PEDNEKAR With a growing strength in the manufacturing sector and the government’sChief Copy Editor encouraging initiatives, India seems to be soon realizing its dream of becomingMagic Wand Media Inc the next manufacturing destination. Being part of the EMO Hannover 2017poonam.pednekar@ will help gain the much-needed exposure for us to explore contemporarymagicwandmedia.org trends and for the world to realize our potential. I n the pursuit of transform- industrial output. Through the Lucrative Indian market ing itself into a manufac- “Make in India” initiative by India, today, shares spotlight with turing powerhouse, the the government, new horizons the world’s largest machine tools country has been encouraging have opened up for the home- markets and ranks 8th among domestic and multi-national grown players who are now them. Over the past three years, compa­nies to manufacture their all set to prove their mettle to the subcontinent has further ex- products in India, thus expand- the world with their cost-effec- tended its overall machine tool ing its economy along with its tive, yet high-quality products consumption volume by almost and technologies. a fifth, reaching a volume of € 1.7Source: freepik.com EMO Hannover 2017, the world’s billion in 2016, corresponding to a premier trade fair for the metal growth of 11 percent in euros. For working sector, is a great opportu- 2017-2018, too, a continuingly nity for the Indian manufacturers moderate increase in consump- to represent all the players back tion is predicted, thus making it home and promote the nation’s an attractive, high potential mar- strengths in the sector. ket with the need to be focussed The Indian export figures so far upon at the EMO. give a bright picture and make In- The fair is being held at Hannover, dia a suitable candidate to be part Germany from September 18-23, of a trade show of such stature. 2017, after a gap of four years. It According to German Enginee­ is being organised by the VDW, ring Federation (VDMA), the Frankfurt am Main, Germany bilateral trade between India on behalf of the European and Germany grew to € 17.42 Association of the Machine Tools billion in 2016 from a figure of Industries from Brussels, Belgium nearly € 17.29 billion in 2015. and in conjunction with Deutsche Indian imports from Germany Messe AG, Germany. amounted to € 9.8 billion. The exports from India to Germany attained a value of € 7.62 billion in 2016.36 | Sept 2017 Modern Manufacturing India

“IMTMA provides opportunity to “IMTMA will have a strong “The main aim of the India Day isforge alliances with foreign presence in the show representing to showcase the possibilities thatentities, develop technological Indian companies, connecting India offers, especially for thecapabilities within the country and with industries and associations machine tool and cutting toolsupplement our export potential. through various forums such as manufacturers in sectors likeThis bodes well for India’s ‘India Day’, and disseminating automotive, aerospace andmanufacturing industry as well as information through the stalls of general engineering.”‘Make in India’ initiative.” Indian companies participating in the exhibition.” Rajesh NathP G Jadeja, Managing DirectorPresident, IMTMA & V Anbu VDMA IndiaCMD, Jyoti CNC Automation Ltd Director General & CEO IMTMAJai Ho at EMO! Representatives from Indian speed drill tap machining solution 1 TCV-540To celebrate India’s growth in user sectors will be addressing with a high-speed pallet change - High Speedthe manufacturing sector and technical and commercial tre­ feature. It provides low chip toexplore factors contributing nds from the automotive and chip times and also masks the Drill Tapto a probable industrial revo­ aviation, and mechanical e­ngi- component exchange time with Machining Centerlution, a session, ‘India Day’ neering industries. Rajesh Nath, the pallet changer. This productis to be hosted by the VDW, Managing Director, VDMA is most suitable for high volume 2 Direct DriveGerman Machine Tool Builders’ India will be moderating the components with short machin- AutomatedAssociation, at the event on overall event. ing times and for applications20 September. The EMO’s India demanding frequent tool chang- Carbide RodDay will also be supported by India at its manufacturing es with multiple drills and taps Cutterthe Indian government. The best to be performed on the compo-event will also play host to The Indian exhibitors at the EMO nents. The versatile machine has 3 Totem toolssix delegations of high-ranking 2017 are all set to wow their glob- the ability to cut components of portfolioIndian entrepreneurs, which al counterparts with their inno- different material compositionswill be organised and a­ccom- vative display. to suit specific applications. Suchpanied by various Indian machines are widely required incustomer associations and India Ace Manufacturing Systems Ltd the auto component and the elec-VDMA office. Hall: 17, Booth: F07 tronics manufacturing industries. AMS will be displaying a high- 1 Source: Ace Manufacturing Systems Ltdwww.mmindia.co.in Source: Chennai Metco Pvt Ltd Source: Forbes and Company Ltd 23 Sept 2017 | 37

INDIA @EMO “India is now positioning itself as “Additive Manufacturing, also “Machines with specialised and a source for reasonably priced known as a disrupting manufac­ intelligent features such as auto alternatives to high volume machi­ turing technology, has been diagnostics, remote scheduling & ne tools. However, in coming gaining momentum in the recent programming, adaptive cutting, months, Indian manufacturers past. This is an opportunity for built-in gauging and auto would incorporate higher levels of Indian machine tool manufacturers correction will provide an enha­ intelligent production capabilities to diversify and not be left nced experience to the user in the in tune with the changing scenario behind.” coming days.” in manufacturing.” Indradev Babu Dr. Vishwas R. Puttige C Renganathan Managing Director Head – Business Development Director UCAM Pvt Ltd Ace Manufacturing Systems Ltd Chennai Metco 1 SPMS Chennai Metco Pvt Ltd aerospace, die & mould and for conveyor systems etc., it is built Supramatic graphite machining; and high- for high volume production and Hall: 6, Booth: E 42 performance drills up to 36D for is used by leading automotiveCMA Series The company will be showcasing a variety of industries. OEMs globally including Europe,Superfinishing its direct drive cutter developed South America, China etc.Machine in collaboration with IIT Madras Grind Master Machines Pvt Ltd and supported by MHI. It will Jyoti CNC Automation Ltd 2 Multi also be displaying automatic Hall: 11, Booth: A65/A67 Tasking carbide cutters / metallography Grind Master along with its Hall: 27, Booth:D70/D78 preparatory machines. French subsidiary SPMS will be Jyoti CNC’s exhibits range fromMachine showcasing Supramatic range speed-oriented compact footMTX 300 Forbes and Company Ltd of superfinishing machines for print machines to sophisticated Powertrain Shafts. Using modu- multitasking machines. It also 3 MOBIMARK Hall: 4, Booth: F96 lar elements including MBA se- includes a new avatar of its - the cordless Forbes will exhibit its: high- ries superfinishing modules, the largest selling variants DX 200 performance taps for aerospace, CMA series machine generates as DX 200 nvu and VMC 850Marker and automotive sector; applic­ precision engineered surface fin- as VMC 850 nvu, which are ations for difficult-to-machine ish and geometry characteristics much advanced and improved 4 UDDR- materials and the ever-increa­ on automotive powertrain shafts Gen-Next machines. A highly 450-TN sing use of stainless steel such as input and output shafts sophisticated high precision Turn for valve and processing of gearbox. With automation Mill Center AX 300, Tachyon 7 industry and threading tools for loading/unloading including is yet another state-of-the-art for super alloys; end mills forSource: Grind Master Machines Pvt Ltd Source: Jyoti CNC Automation Ltd Source: Stamp IT Robotai & Solutions Pvt Ltd 1 23 Modern Manufacturing India38 | Sept 2017

“Indian manufacturing companies “India has, and will remain, the “Indian machine tool building hasare working on adopting Industry global laboratory to test ideas, moved from standalone machine4.0. Technologies emerging in this innovation, and experiences. With to integrated automation line. Wespace from India are likely to be manufacturing as its focal point, can offer best market option withhighly innovative, cost-effective all these aspects will take center important requirements for intel-and applicable in global manufa­ stage.” ligent production system.”cturing companies.” Ravi Prem Vijay ZalaSameer Kelkar Chief Operating Officer Executive Head, R&DCEO and R&D Director Forbes and Company Limited Jyoti CNC Automation LtdGrind Masterhigh dynamic Drill Tap Center Source: UCAM Pvt Ltd less hand-held marker compl­ emerging trends such as additivefocused on Automobile and etely innovated in India, the only manufacturing (AM) for whichElectronics sector. The K Mill 10, machine with a Wi-Fi hotspot the world is getting ready for.exclusively built for catering to operated with a smart­phone At present, AM in India is up tothe requirements of high-end Die app used for industri­al mark- building prototype in selectiveMould application and a battery ing. This machine is suitable to sectors and with the developingof high-tech 5-Axis machines create permanent, clearly visible efforts towards cost viabilitynamely K3X8 (Five) nvu, U Mill deep alphanumeric marking on and productivity aspects, it5 and 6, 5-Axis Double Column metal components. would expand in many cornersMachining Center KX50R nvu, in near future. But as rightly put5-Axis Universal Machining UCAM Pvt Ltd by Vijay Zala, Executive Head,Center MX 10 and Multitasking R&D, Jyoti CNC Automation, toMachining Center MTX 300 for Hall: 12, Booth: E15 keep pace with the developedAerospace and Energy sector UCAM is exhibiting new 5-axis economies, the Indian machinewill also be on display. solutions. One particular unit tool industry must think outStamp IT Robotai & is a direct drive tilting table of the box, prioritize upskillingSolutions Pvt Ltd 450mm in diameter, and is and reskilling of the work forceHall: 11, Booth: F19 powerful and compact. This and emphasize considerableThe company will be launching a product would be of interest to investment in R&D. A parallelnew product “Mobimark”, a cord- both international and domestic segment must be structured customers. The company has to develop core technologies 4 orders for this product from rather than the ongoing its European customers. Its div­i- machine tool manufacturing as sion Nimble Machines is show- integration and adoption of AM casing motors for 5-axis turning, is easy but development is more milling applications. challenging. However, being part of the mega machine tool show, Gearing up for advanced in proximity to trends that rule trends the world of manufacturing will Along with the focus on the provide Indian players enough traditional machine tools at tools to come back home and fill the show, which are not going the gaps. to be pensioned off soon, there is a special focus on thewww.mmindia.co.in Sept 2017 | 39

COMPANY PROFILECUSTOMER IS THE PRIORITYLike most success sagas, Yamazaki Mazak India too had a humble beginning. It has risenin stature by staying keenly attentive to its customers’ needs and catering to them in duetime. More on the company and its philosophy that has taken it places…POONAM PEDNEKAR A leading player in the ma- parts for the machines supplied India Pvt Ltd.Chief Copy Editor nufacture of advanced in India and UAE. Its Spindle For medical implants, the com-Magic Wand Media Inc technology solutions in- repair and assembly set up is a pany has a strong customer basepoonam.pednekar@ cluding multi-tasking, 5-axis, replica of its Japan facility with in Rajkot, Vapi and Vadodara,magicwandmedia.org milling, turning, CNC controls temperature controlled environ- Gujarat with the requirement of and automation, Yamazaki Ma- ment and Spindle Clean room multitasking machines.Yamazaki Mazak zak India Ltd has an interesting with dust level as low as (10,000 Mazak has intensively workedIndia Ltd’s Technology growth story to share. From just ppm). The Spindle repaired in on developing multitaskingCenter in a small team in Chinchwad, Pune this facility gives the same accu- machines and has introducedSanawadi, Pune in 1998 that was formed to offer racy as of new machines. ‘Done in One’ concept whereinsprawled over after-sales support, the company Today its customer list includes multiple operations like turning,a luxurious grew exponentially in terms of Mahindra & Mahindra, Ashok milling, drilling, tapping, camfive-acre area. sales, service and application Leyland, Jaya Hind, Sundaram cutting, deep hole boring can be network all over India. Fasteners, Ramkrishna Forgings, combined on one machine that In 2011, the company moved to Sandvik, and Atlas Copco. can process an entire workpiece, its new Technology Center in from raw material input to final Sanawadi, Pune sprawled over Market potential machining, in a single setup. The a luxurious five-acre area, which The market scene is quite op- company’s Integrex and Variaxis today has the most advanced ma- timistic for the company with models are the most popular and chines installed for live demon- demands from commercial ve- widely accepted machines in stration and training purposes. hicles, aerospace, and medical the industry. Its other five technical centers sectors. “Aerospace is a booming “For small entrepreneurs and are in Delhi, Ahmedabad, Ban- market in India. Since worldwide SMEs, the dual challenge is to galore, Chennai and Coimbatore. we have a very good footprint in get good quality machines as The facility also houses Online aerospace industries, those refer- well as manpower. To overcome Support System, state-of-the-art ences as well as of our service and this challenge we manufacture Spindle Repair Facility and Na- application support in India are and supply the machines with tional Parts Center that main- fetching us good enquiries and customized first-level automa- tains an inventory of approxi- orders,” said Anil Bhardwaj, Man- tion from our Singapore facility,” mately `20 crore worth of spare aging Director, Yamazaki Mazak he added. Source: Magic Wand Media Inc Customization is the key In line with its philosophy of staying well connected to its customers to gauge their needs, Mazak India offers total turnkey solutions including advanced machines from Japan, and fix- tures, tooling, process engineer- ing from India. “Today customers want the latest in technology to overcome de- pendency on skilled manpower. With a ‘Turnkey Team’ of ded- icated and highly skilled engi- neers we understand customer40 | Sept 2017 Modern Manufacturing India

Yamazaki Mazak Corporation Hall 27 Stand B56“Our latest Mazatrol Smooth “In EMO Hannover show we will “Our training program gives thecontroller with most advance be displaying 22 advance power to achieve morefeatures like Conversational machines including models productivity and profitabilityProgramming, Temperature specially developed with additive from Mazak equipment, as wellControl, Vibration Control, Voice manufacturing and machining as to stay abreast of the latestAdvisor, Dynamic Balancing capability which will be one step manufacturing technologyhelps to create cutting program ahead of competition.” trends.”with minimum skill and ease.” Hiromasa Ohtake Pramod KoreAnil Bhardwaj Deputy Managing Director General Manager-Customer SupportManaging Director Yamazaki Mazak India Pvt Ltd Yamazaki Mazak India Pvt LtdYamazaki Mazak India Pvt Ltdrequirements and provide cus- The company focuses on its cus- Mazak purchase, gain the besttomized solutions in India,” stat- tomer support functions such as possible competitive advantageed Bhardwaj. Single-Source Support through as well as keep the Mazak equip-According to Hiromasa Ohtake, dedicated toll-free number and ment running smoothly at allDeputy Managing Director, Ya- email; Technical Support for the times.mazaki Mazak India, around 65 Machine & CNC Control; Facto- Further to facilitate its custo­percent of the business comes ry trained team of experienced mers on new machiningfrom providing customized solu- field service engineers at 15 trends, said Ohtake, “Mazak hastions and 35 percent from stand- different locations across India invested heavily on R&D to gearalone machines. for quick support; Spindle and itself up for the current industry Unit Rebuild; Parts Support and trends of Industry 4.0, IIoT,Support just a click away Machine maintenance and op- and additive manufacturingMazak India is the only import- eration training; and Automa- that are slated to influence theed machine tool builder to have tion and engineering support to machine tool sector as well asonline services to resolve its cus- ensure the customer is able to upgraded its existing productstomers’ issues. In this context maximize the value of their accordingly.” Bharadwaj shared, “Sensing thepulse of market we have focused (L-R) Anil Bhardwaj,more on customer support func- Managing Director,tions such as Online Application Yamazaki Mazak Indiaand Service Support. We are just with company Deputya phone call away for shop floor Managing Director,as well as management team of Hiromasa Ohtakeour customers.” Adding to this, at the showroom inPramod Kore, General Manager, Mazak’s Pune facility.Customer Support, YamazakiMazak India, stated, “Our total Source: Magic Wand Media Incsupport program combines manystandard-setting programs thatwe have developed over yearsof working as a strategic partnerto manufacturers.”www.mmindia.co.in Sept 2017 | 41

AEROSPACE MACHINING POWERED BY:ROUGH BORING TOOLCUTS CHALLENGINGMATERIAL By resorting to the recommended Sandvik Coromant’s DuoBore 821D rough boring tool approach in the cutting of Nitronic 40 for aerospace work, Excelco/Newbrook Inc. effectively increased feed rates and saved shop production time. I n high-stakes aerospace was able to double its feed rate difficult to machine. Much of applications in which a and finish the part 90 percent this equipment is deployed in nearly complete work- quicker than it could with its such critical-use applications pie­ce is worth more than a original process. as nuclear propulsion systems, decent-sized home in virtually undersea systems, and deep- any suburb, tooling can be ENI’s specialization space equipment, and all critical to a shop’s success. In business since 1947, ENI are made to demanding Excelco/Newbrook Inc. (ENI) fabricates complex aerospace requirements. was at a crucial juncture, having and defense equipment for At first glance, the shop floor tried every boring solution it clients such as Lockheed Martin, might appear fairly typical, even could think of, when it called in Boeing, Northrop Grumman and though most of its equipment is cutting tool supplier Sandvik General Dynamics. It specializes large: a handful of boring mills, Coromant. Using the company’s in Titanium, Inconel, Hastelloy one of which is big enough to rough boring tool, ENI says it and other metals equally machine a semitrailer; lathes Instead of using the obvious choice of a CoroBore 825 fine boring system, Sandvik’s Christian Waggoner suggested using the DuoBore 821D rough boring tool, but with a twist–the two inserts would cut at the same diameter to lend cutting stability and cancel potential vibration.EMILY PROBSTManaging EditorModern Machine [email protected] Source: Modern Machine Shop42 | Sept 2017 Modern Manufacturing India

capable of turning shafts 6 ft. indiameter and nearly three timesthat in length; a flying-bridgewaterjet; an assortment of high-tech welding equipment; and anumber of super-sized CMMsand 3D gaging arms to measurethe shop’s output.Machining Nitronic 40 Source: Modern Machine ShopDespite these capabilities, ENIrecently ran up against a job forming an outward-facing-C especially with blind holes. The The most difficultthat tested the shop’s machining shape that makes for a severely chips tend to pile up in front of operation was drillingmettle — a large, precision interrupted cut. Worse, the the tool, and hitting the bottom 50 flat-bottom holesclosure head in excess of 70 in. hole tolerance is +0.002/-0.000 of the hole can spell disaster. The measuring 1.9 in.in diameter and 18 in. thick in. on the diameter, with true closure head took boring to a in diameter by 6 in.made of Nitronic 40, a very position accuracy within 0.010 new level of difficulty—between deep, situated aroundchallenging material to in. It was enough to keep any the interrupted cuts and the the periphery of themachine. The high-strength, seasoned machinist awake at Nitronic’s poor machinability, workpiece. Each ofcorrosion-resistant stainless night, Penkaty and Dorman say, ENI’s machinists were forced to these holes breakssteel is typically used in and they were no exception. index the finishing insert after into a matching slotchemical processing, nuclear- “You’re not working with much every hole. This meant they had milled through thecontainment systems and tolerance, and with that kind part’s OD, forminga variety of aircraft engine of material, there’s no room for Source: Modern Machine Shop an outward-facing-components. According to the a mistake.” C shape.American Steel and Iron Institute The operation took 80 hours(AISI), this stubborn superalloy per part. Each hole was roughed The boring tool stickscarries a machinability rating of out with a spade drill, followed out around 11 in. from22 — comparable to Waspaloy or by a modified drill to flatten the spindle face, soNickel 600, is far tougher than the bottom of the hole and reducing vibrationmost 300-series stainless steels. successive passes with a boring during the boringAccording to ENI, it requires a bar prior to milling the slot. process was critical.heavy feed and rigid tooling, “Because of the hole depth,and it will work-harden if you we had a lot of problems withgive it half a chance. In short, taper,” says programmer DanNitronic 40 is a real bear to cut. Kreamer. “Also, there’s a boss at the top of the hole we have toProduction challenges work around, so the boring toolOperating a Doosan Infracore sticks out around 11 in. from theDBC 130 horizontal boring spindle face. Everything worksmachine, machinists Dale against us on this part.”Penkaty and Troy Dorman Once the slot was milled, a finalspent weeks working across two boring pass was needed to bringshifts to get the closure-head the hole to its final diameter.parts completed. One operation Boring can be a challenge underin particular posed a significant the best machining conditions,production challenge: boring aseries of 50 flat-bottom holesmeasuring 1.9 in. in diameter by6 in. deep, situated around theperiphery of the workpiece—likeholes drilled in the face of a giantsoup can.Each of the holes breaks into amatching slot milled throughthe part’s outer diameter,www.mmindia.co.in Sept 2017 | 43

AEROSPACE MACHININGSource: Modern Machine Shop recommend the DuoBore 821D rough boring tool. Machinists Dale to back off the boring head, take logic said he should recommend Designed as a roughing tool, Penkaty and Troy a test cut, measure and adjust a CoroBore 825 fine-boring the 821D carries two cutting Dorman operate the until the correct diameter was system. With the ability to inserts, each 180 degrees apart. Doosan Infracore achieved. adjust boring diameter in Under normal use, one of those DBC 130 horizontal increments of 0.002 mm inserts is set to a slightly smaller boring machine where For a better boring solution (0.00008 in.), a cartridge-style diameter than the other and the closure head At this point in the machining insert and a system size range shimmed to sit a few thousands was machined. With process, the workpiece was to handle most anything ENI ahead, thus creating a step- Sandvik’s tooling, the nearly complete, but with the could throw at it, the 825 should boring effect at twice the feed men could complete a production backlog mounting have been the tool of choice, rate of a single-edge boring part in a single shift, behind this stalled job, ENI’s and would have surely provided tool. Waggoner knew that if a 90 percent time production crew knew they had the accuracy and repeatability he could set the two inserts to savings compared to to find a better boring solution. needed to complete the holes in cut at the same diameter, each the previous process. They tried different carbide a reasonable amount of time. would lend stability to the other grades and insert geometries, a when it swung out of the cut, range of feeds and speeds, larger The DuoBore 821D thus canceling any potential and smaller nose radii, but approach vibration. Also, because nothing worked. But that’s not what he did. the 821D utilizes Sandvik Kreamer suggested they give The problem, he explains, is Coromant’s Silent Tool boring- Sandvik Coromant a call. the interrupted cut. With bar shank, the harmonics The team had worked with the 825’s single insert, every generated by the interrupted cut Sandvik’s Christian Waggoner rotation of the spindle takes and extended-reach application in the past and, based on his the insert in and out of the would be canceled. recommendations, were having cut, creating harmonics and good luck on a similar, yet tool vibration sure to destroy Favorable results smaller, application. even the best of carbides. He says it took some finagling, Waggoner visited the facility, Given the interrupted nature but Waggoner worked with observed the machining of the cut, and considering ENI’s machinists to set up a operation and spoke with the the need to bore 50 holes per test fixture and map out a machinists. Considering the workpiece, Waggoner decided process to set the tool. With part tolerance, conventional to take a different approach and fingers crossed, the team took the first cut. The results were astounding, Kreamer says. “You have to be careful when you set the tool, because the cut needs to be perfectly balanced. Even so, we finished the first part in a single shift, a 90-percent time savings over the previous process,” he says. In addition, they no longer have to index the insert after every hole. Instead of 50 insert tips per part, ENI now uses five to six, with minimal test cutting. “The tool is exactly where we expect it to be, every time,” Kreamer says. The collaborative problem- solving of both the production team and Waggoner helped the company create a sound machining process, reducing the shop’s backlog by nearly one month. 44 | Sept 2017 Modern Manufacturing India



AERODEF Source: SKF Evolution I ndia’s machine tool industry has its gazeCollaborating with SOARING fixed firmly uponits global HIGH Aerospace and Defence sectors,counterparts will recognizing them as newhelp Indian industry sunshine markets. The country’sgain access to critical developing infrastructure andtechnology needed to the government’s attempts atbuild armed forces. providing impetus to ‘Make in India’ through its investor-POONAM PEDNEKAR friendly policies such as DefenceChief Copy Editor procurement policy andMagic Wand Media Inc Strategic partner policy, presentpoonam.pednekar@ an attractive and significantmagicwandmedia.org opportunity for the foreign firms to forge alliances with the local players to make equipment for the two sectors. Making full use of this opportunity, OEMs and their suppliers are leveraging India’s competitive advantages in manufacturing by setting up units in India. Bharat Forge, Reliance Industries, the Tata group, Ashok Leyland, Larsen & Toubro, the Godrej Group and the Mahindra Group are some examples that have entered into such strategic partnerships, with the latest being the Adani Group. “In continuation of our vision of nation building, we are keen to play an instrumental role in helping transform India into a destination for world class high- tech defence manufacturing,” says Gautam Adani, Chairman, Adani Group over its tie-up with Sweden’s Saab to bid for defence deals in India, with a focus on manufacturing Gripen fighter jets in the country. Opportunities are brimming in India’s emerging Global players important aerospace and defence sectors, leading to large scale for Indian firms tie ups between Indian and foreign companies. The Indian industry with all its Certain initiatives like IMTMA’s AeroDef project capabilities is still at a stage of have surfaced to help Indian machine tool builders evolution. Collaborating with its better equip themselves to cater to the precise global counterparts will help it demands of the sectors and fill the gaps. gain access to critical technology needed to build armed forces. According to Dr Wilfried Schae- fer, Executive Director, German Machine Tool Builders’Associa-46 | Sept 2017 Modern Manufacturing India

“An estimated $100 billion “In continuation of our vision of “Metalworking machine tools andcontracts are likely to be signed in nation building, we are keen to manufacturing technologies usedthe next decade to modernize play an instrumental role in helping in aerospace sector require aIndia’s armed forces, providing transform India into a destination unique set of knowledge, skills,opportunities for Indian and for world class high-tech defence precision, and technology-intensi-foreign firms to forge alliances for manufacturing.” ve focus.”mutual benefit.” Gautam Adani Shailesh ShethPG Jadeja, President, IMTMA & Chairman, Adani Group Past President & Mentor, IMTMACMD, Jyoti CNC Automation Ltdtion, VDW, European machine “Manufacturing aerospace com- ventional processes and tech- India’stool manufacturers, especial- ponents is not everyone’s cup nologies,” opines Milind Kelkar, spendingly German ones, are in a very of tea. It is recognized that met- Chairman, Grind Master Group. in thegood shape for supplying to the alworking machine tools and Understanding the economics next fiveaerospace sector. “Since progres- manufacturing technologies of investment by the buyers in years issively more components in an required by aerospace sector aerospace industry is yet anoth- expected to beaircraft are being manufactured are specialized – large in size, re- er essential feels Vivek Nigam, $25 billion forwith the aid of industrial-scale quiring very different approach Executive Vice-President & commercial3D printing, companies here in the entire process of ‘design Head of Business Unit – Machine andhave excellent opportunities to to delivery’. These include a Building, Isgec Heavy Engineer- $100 billionscore highly on the up-and-com- unique set of knowledge, skills, ing Ltd. “Investments are made for defenceing Indian aerospace market,” precision, technology-intensive for long term and low price is aircrafts.he adds. focus,” he says. mostly not a criterion.”This is because in regard to ad- However, Vikram Salunke, “There is a need to focus on theditive manufacturing processes Managing Director, Accurate consistency in the precisionfor metal components, espe- Gauging & Instruments Pvt Ltd, class of machines, in order to becially, German manufacturers strongly feels that there is a lack a global player in this sector. Theare playing a front-runner role. of awareness of local machine challenge is to develop machinesThese processes enable lighter tooling capabilities of India which perform consistentlyand more stable structural com- among most global companies in-spite of thermal variationsponents to be produced. involved in aerospace. “Hence, due to the heat generated in the most recommendations of RFQ, machines, especially the onesChallenges encountered therefore, refer to few interna- used in tropical regions. WeWith all the developments tional brands, which becomes a are working towards providinghappening, there is still a lot of show stopper for an Indian com- these solutions. The Indian ma-room for the Indian machine pany to get an equal opportunity chine tool industry also needs totool industry to optimally cater during the bidding process.” look at building larger machinesto the precise requirements of Another challenge is the sector’s for structural parts of aircrafts.aerospace and defence sectors. demand for specialized materi- This segment is at present ad-Shailesh Sheth, Past President als, accuracy and quality check dressed only by overseas man-& Mentor, IMTMA lists sever- process. “In order to fulfill these, ufacturers,” explains Soundharal constraints to entering into local machine tool manufactur- Rajhan, President, Machine Toolthe space. ers need to develop non-con- Division, LMW.www.mmindia.co.in Sept 2017 | 47

AERODEF “Since progressively more aircraft “Machine tools built in India are far “We are well ahead with our components are being manufac- more robust and have significant advanced 5-axis solutions and tured with the aid of industri- advantages on the after sales and already supply them to intern­ al-scale 3D printing, German com- future upgrade capabilities. Indian ational OEM customers. We await panies have excellent opportuni- companies need to increase their challenges of supplying them ties to score highly on the up-and- brand awareness at decision ma- high-performance units for b­ u­ coming Indian aerospace market.” king level with global customers.” ilding their machines for aerodef applications.” Dr Wilfried Schaefer Vikram Salunke, Managing Director, Executive Director, German Machine Accurate Gauging & Indradev Babu, Managing Director, Tool Builders ‘Association, VDW Instruments Pvt Ltd UCAM Pvt LtdAeroDef Industry gearing up ket of advanced 5-axis solutions in next five years is expected tocan create a Despite various odds, the ma- and is already supplying these be $25 billion for commercialplatform chine tool manufacturers of to international OEM customers and $100 billion for defencein India for the country such as Jyoti CNC for aerospace parts machining. aircrafts. Assuming an offset ofknowledge Automation are relentlessly Grind Master too has strategic 30 percent, total offset opportu­sharing trying harder to make the most alliances with MJC, USA for its nity for aerospace sector aloneon the of the present opportunities in Flow Forming technology; ACT is valued at minimum $10-15technical the aerospace and defence sec- Robotics, USA for Robotic Grind- billion of manufactured parts, ifrequirements tor with their innovations. The ing & Finishing of Turbine Blade; not more,” points out Sheth.such as result of which is a host of awe and Timesavers, Holland for As a first step, on Baba Kalyani’smaterials, inducing names in its client list Robotic Grinding & Finishing of suggestion, IMTMA organizedmethods and including BrahMos Aerospace; Turbine Blade. “These partnersmachinability. ISRO (SAC - Space Application are well-established and regu- “The machine tool manufacturers Centre, VSSC- Vikram Sarabhai larly supply their technology to need to understand the demands Space Centre); Tata Sikorsky Aerodef sectors,” informs Kelkar. of special materials, accuracy Aerospace Ltd, Tata Advanced levels, and quality check process Systems Ltd; Huron; Heavy Al- Project AeroDef of the aerospace sector, and loy Penetrator Project; Airbus; The project came into being develop non-conventional proces­ Boeing; Bombardier; European when the need to aid local ma- ses to fulfill them.” Aeronautic Defence and Space chine tool players overcome Milind Kelkar, Chairman, Company and Sukhoi. hurdles in catering to aerospace Grind Master Group The company’s offerings for and defence sectors and curtail- the sector include: KX FIVE ing imports was strongly felt by Series, HSM concept that the Indian Machine Tool Manu- enables operations in 5-axis facturers’ Association (IMTMA). simultaneous from roughing to Hence, the name AeroDef. finishing of a variety of complex high precision applications, “Around 65-70 percent of especially designed for complex India’s defence requirement is aerospace components and imported from global aerospace high integrity mechanical parts and defence companies, manufacturing. making it world’s eighth largest UCAM is well ahead with its bas- purchaser of defence armament and equipment. India’s spending48 | Sept 2017 Modern Manufacturing India

technology missions to various “Today, we have many players like “The ‘Make in India’ initiative laun-institutions in the UK, Germany us supplying parts to major OEMs. ched by Prime Minister Narendraand Spain. There is a vast resource and Modi, as part of a wider set of na-Through the project, IMTMA capability in our country, which is tion-building initiatives, has pavedaims, with some encouragement largely under-utilized in terms of way for India machine tool manu-and support, to groom the knowledge on some critical para- facturers to cater to the require-Indian machine tool players me­ters and materials.” ments of aerospace and defenceto quickly graduate to meet Soundhar Rajhan, President, sectors.”these specialized requirements. Machine Tool Division, LMW LtdThe process is to first select Dr Arvind Patel, Managing Director,companies on the basis of their been established by the Aero- Sahajanand Laser Technology Ltdcapabilities. An agency is then space OEMs.hired to help them through “Machine tool and tooling com- this is required to be generateddocumentation, get them trained panies can offer their products among the customers as well asfor the certifications required, and services to cater to global various trade promotion bodiesand put their internal systems in requirements helping several of like CII, FICCI, ASSOCHEM,”proper order. defence players fulfil their off- says Salunke. set obligations. The new defence For Nigam, AeroDef ProjectThe key projects objectives are procurement policy has provid- can substantially contribute into: ed certain measures in this direc- amplifying influence of ‘Make-Expose and familiarize select tion. An effective awareness of in-India’ pitch, particularly inindustry CEOs to advance and Government controlled invest-high technology developments “The AeroDef Project can contri- ments. As a group, it can high-at leading global aerospace insti- bute in bringing openness among light opportunities offered bytutions; Meet and interact with public and private sector buyers Defence sector to its members.manufacturers of aerospace for indigenous development. Fo- It can contribute in bringing anraw materials, components, and rums of equipment users and open mindset among public andmachines for the aerospace and selectors make ideal platforms to private sector buyers for indig-component industries; Under- make them aware of high reliabili- enous development. Organizingstand the type and nature of ty of Indian machine tools.” meet ups at different forums ofmetalworking machine tools Vivek Nigam, Executive Vice-President & equipment users and selectorsand manufacturing technolo- Head of Business Unit–Machine Building, can make them aware of highgies required for aerospace and Isgec Heavy Engineering Ltd reliability and productivity ofdefence manufacturing, to en- Indian machine tools. able indigenous developmentand manufacture in India; and To know about IMTMA’sExplore possible alliances with initiative on the Aerodef Projectmachine manufacturers, so asto jointly exploit market oppor- please write to us attunities in the Indian aerospace [email protected] defence industries. We will be glad to connectIndustry expectations from you with the concerned teamAeroDef members from the Association.According to Soundhar Rajhan,“AeroDef can create a platformin India for knowledge sharingon the technical requirementssuch as materials, methods andmachinability. This will help theIndian suppliers respond fasterto the requirements of the Aero-space OEMs, rather than eachcompany spending enormoustime and money to arrive atresults, which have alreadywww.mmindia.co.in Sept 2017 | 49

PLASMA CUTTING Source: HyperthermImprovements in hole RAISING PRODUCTIVITY WITHand slot cut quality RIGHT CUTTING CONSUMABLESwere observed in thepart cut with genuineCu+ consumables. To reduce costs, manufacturers, at times, resort to cheaper alternatives from unauthorized suppliers, which, rather than being profitable as expected, turn out to be fake and counterproductive. An account of Bharat Foils Ltd’s inadvertent use of counterfeits of Hypertherm that impacted its manufacturing process and how genuine cutting consumables helped it attain its productivity goals.SANJAY KUMAR C urrently where compet­ steadily with the advent of turers, sheet metal cuttingConsumable Sales Manager it­ ion is rife, productivity technology, and one of the key is a common procedure inHypertherm India and cost-effectiveness aspects of production lies in the their factory. India-basedHTIndia.info@ machinery, where metalworking Bharat Foils Ltd is one suchhypertherm.com are often key differentiators that plays an important role. company. Established in 1975, the family-owned business has allow companies in the manuf­ Plasma system and its a long history in equipment consumables manufacturing, and currently acturing sector to stand out For many equipment manufac­ specializes in the production amongst their business rivals. Over the years, manufacturing processes have progressed50 | Sept 2017 Modern Manufacturing India