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VOL 06 | MAR 2015

EF F IC I ENT MA NUFA CTUR ING

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Witnessing global trends in manufacturing technologies

GAME chAnGinG innovAtionS

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ED ITOR IAL

Manufacturers, today, have an increased focus on technologies that automate, simplify and enhance the efficiency of work sequences and optimisation of manufacturing processes involved. Integrating modern-day information technologies into machine tools make them more attractive and above all, easier for the operator to control. In addition to the technological advancements, the general trend is incorporation of styling and operator-friendliness. For example, emulating the smartphones, machinery control systems now feature a touch-screen. In conjunction with the design of other equipment, this combines to produce an attractive visual appearance.

New concepts for minimising change-over times in turning operations, enhanced operator-friendliness by using innovative information technologies, complete machining of workpieces for enhanced productivity, dry machining, using carbon-fibre composites in machine tools and tools, flexibility for large machines, laser & 3D printing, enhanced metrological efficiency, machine tools with parallel kinematics, expansion of tool management and enhanced efficiency for tools, user-friendlier interfaces in CAD/CAM, these are a few technology trends to look for in the coming years.

In this context, industrial trade exhibitions have developed over the years as important platforms to showcase the path-breaking production technologies that have created the foundations for maintaining corporate competitiveness against globalised competition. Exhibitions like IMTEX, EMO and IMTS have very much evolved, projecting as a diverse showcase of global manufacturing technologies. Numerous solutions get presented in these shows in response to the latest social and commercial trends.

The Cover Story in this issue presents some of the important technology trends and innovations witnessed during IMTEX, with experts commentary from industry connoisseurs. It highlights the latest machines, efficient technical solutions, product-supportive services, sustainability in the production process, automation systems, and much more. In short, it shows how Indian manufacturing is raising the competitiveness at par with global players so as to meet the challenges in the domestic market.

Shekhar Jitkar Publisher & Chief [email protected]

Technology trends to look for...

7

Integrating modern-day information technologies into machine tools make them more attractive and above all, easier for the operator to control

XXEditorial-NN-JJJJ

EDITORIAL ADVISORY BOARD

Sonali KulkarniPresident & CEOFanuc India

Dr Wilfried AulburManaging PartnerRoland Berger Strategy Consultant

Vivek SharmaManaging DirectorYamazaki Mazak India

N K DhandCMDMicromatic Grinding Technologies

Dr K Subramanian President, STIMS Institute, USATraining Advisor, IMTMA

S RavishankarManaging DirectorWalter Tools India

Raghavendra RaoVice PresidentManufacturing & Process ConsultingFrost & Sullivan

Dr P N RaoProfessor of Manufacturing TechnologyDepartment of TechnologyUniversity of Northern Iowa, USA

Satish GodboleVice President, Motion Control DivSiemens Ltd

Vineet SethManaging DirectorIndia & Middle EastDelcam Plc

Overseas Partner:

China, Taiwan, Hong Kong & South-East Asia

EM | Ma r 2015

Editorial_fullpage_Mar.indd 7 3/13/2015 7:36:16 PMFORM-1-2.indd 12 3/13/2015 9:43:49 PM

8 EM | Fe b 2015

CONTE N T S

Market Management

10 NEWS

16 THE MARKET GROWTH IS DIRECTLY

AFFECTED BY THE FINANCIAL GROWTH

Interview with Jeffery S Foregard, GM - Asia & Europe & Member of the Board of Directors, ANCA Machine Tool

EVENT REPORT

84 INNOVATIVE GRINDING TECHNOLOGIES

A post-event report on the Motion Meeting 2015 by United Grinding, held in Switzerland

88 SHOWCASING LATEST TECHNOLOGY

STANDARDS

A post-event report on the IMTEX 2015, and Tooltech 2015

Focus

26 IMPLEMENTING ROBUST & LEAN PROCESSES

TO ENHANCE COMPONENT MANUFACTURING

Interview with P Ramadas, MD, Ace Manufacturing Systems

ROUND-TABLE

28 V IS ION PROMISING BUDGET

The feature focusses on the measures introduced in the Union Budget 2015-16, to develop a manufacturing friendly environment

MANAGEMENT STRATEGIES

34 TRANSFORMING MANUFACTURING MODEL

The article analyses the critical role technology plays in addressing the modern business challenges

Metal Cutting42 APPROACHES FOR EFFECTIVE MACHINE TOOL

UTIL ISATION

The article briefs on the important components of effective machine utilisation by maximising the required timeline for metal cutting

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Country Special: CHINA74 CHANGING INDUSTRY LANDSCAPE

The article briefs on Chinas current changing ideological emancipation & concept innovation

78 LOOKING FORWARD TO CO-OPERATION

BETWEEN INDIAN & CHINESE ENTERPRISES

Interview with Chen Huiren, President & CEO, CMTBA

80 ESTABLISHING OUR BRAND IN INDIA IS A

MAJOR CHALLENGE

Interview with Dilip A Chauhan, DirectorBusiness Development, Henfux India

NEW PRODUCTS

82 NC series standing die spotting machine; Engraving & milling spindles; Machine tools for compressor & rolling components; Centreless grinding machine

83 Volumetric lubrication systems; Vertical machining centre; 6-axis coordinate advance milling & drilling machine

content Mar 2015.indd 8 3/13/2015 7:43:10 PMFORM-1-2.indd 14 3/13/2015 9:43:49 PM

9EM | Fe b 2015

CONTENTS

Technology

New Products

92 CNC grinding machine with turning function; Right-angle precision gearbox; Hydraulic press machine; Non-clog sewage submersible pump

93 Digital process planning application; Visualisation solution; Automatic 3D design tool; Highfeed milling cutter

94 CNC solution with software version 4.7; Digital control of spindle speed & power-stroke speed; Compact four corners double-sided insert

Columns

07 Editorial 08 Contents 96 Highlights Next issue 96 Company index

HIGH SPEED MACHINING

46 Reducing machining time The article deals with the parameters to

be considered for implementing successful HSM

MACHINING

50 Cost-effective cutting solution An application story on the high

performance Haas CNC machine tools used by Telgelgo

54 Innovation in precision boring The article features an innovative

asymmetric boring solution for increased productivity & cost reduction

TEST & MEASUREMENT

66 Saving time saves nine The article briefs on how Primo twin

probe system, developed by Renishaw has helped Victory Precisions to reduce part set-up time

MACHINE VISION

60 Building monitoring & alarming system

The article highlights how Eigen Innovations has developed smart hardware module with the help of FLIR

SPECIAL FEATURE

70 Sensor-based adaptive arc welding

The article highlights how the emerging sensor technology allows robotic automation to address welding challenges

Cover Story20 GAME CHANGING INNOVATIONS

An insight on the evolving trends in the Indian manufacturing industry, as witnessed in IMTEX 2015

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10 EM | Ma r 2015

MARKET | NEWS

According to CII SME Summit 2015, the micro, small & medium enterprises

(MSME) sector contributes nearly 8% of the countrys GDP, 45% of the

manufacturing output and

40% of the exports. It provides

the largest share of

employment after agriculture.

MSMEs are the nurseries for

entrepreneurship & innovation

and are widely dispersed

across the country. It produces

a diverse range of products &

services to meet the needs of

the local & global market,

along with the the national & international value chains. Highlighting the

challenges that MSMEs are facing in todays economy, K Nandakumar,

Chairman, CII (WR) Sub-Committee, Chairman & MD, Chemtrols Industries,

said, Since, MSMEs contribute nearly half of the countrys manufacturing

output, it is important to make them globally competitive so that India can

contribute effectively to honourable Prime Ministers vision of Make in

India.

Boeing has signed a multi-year contract with Bharat Forge to supply

titanium forgings to be used in the wings of next-generation 737 and 737

MAX. The company will supply pre-machined

forgings to Boeing in the first quarter of

2016. We have mastered the stringent

process requirements for titanium forgings

and will be supplying critical forgings for

wing components. This also confirms our

resolve to meet the Make in India drive,

said Baba Kalyani, CMD, Bharat Forge. The

titanium parts will be heat-treated, shaped

in a forging press, and machined by the

company before being shipped to Boeing

for finish machining into components. The

components will, then, be installed in 737

and 737 MAX wings at Boeings assembly

plant at Renton, Washington. We are

pleased to welcome Bharat Forge into our supply chain as they have an

impressive record of performance across many industries, said Kent Fisher,

VP & GMSupplier Management, Boeing Commercial Airplanes.

According to Baba Kalyani,

CMD, Bharat Forge, the

company has mastered the

stringent process requirements

for titanium forgings

The theme of the summit was Making Indian

MSMEs globally competitive

Bharat Forge partners with Boeing to supply titanium forgings Making Indian MSMEs globally competitive

> MORE@CLICK EM01553 | www.efficientmanufacturing.in > MORE@CLICK EM01554 | www.efficientmanufacturing.in

> MORE@CLICK EM01552 | www.efficientmanufacturing.in

Saint-Gobain celebrates 350th anniversary

Saint-Gobain had recently celebrated

its 350th anniversary, along with setting

sights firmly on the future and, in

particular, in India, with its strategy

Shaping the Future.

India has been an important market

and investment destination for us. We

believe that it can play an important

role in shaping the future by designing,

manufacturing and distributing building

and high-performance materials, which

provide innovative solutions to meet

the challenges of growth, energy

efficiency and environmental protection.

This is the core of Saint-Gobains

strategy, said Anand Mahajan, General

Delegate India, Sri Lanka &

Bangladesh, Saint-Gobain.

The company has entered India in 1996, and has achieved strong and

profitable growth since then. Today, it is a leader in all its major businesses,

and has 20 manufacturing sites and about 4,900 employees in India. In

2014, it has registered sales of about

` 4,800 crores. For the company, the

Indian market presents a huge

opportunity for growth. On our 350th

anniversary, we aim to strengthen this

commitment even further by becoming

the reference for sustainable habitat in

India and doubling our business in the

country in the next few years, added

Mahajan.

According to the company, two large

entities, Grindwell Norton Limited

(GNO), a publicly traded company, and

Saint-Gobain India (SGI) and a few

smaller entities house Saint-Gobains

businesses in India. Specifically for

India, we will focus on three strategic

priorities that are sustainable habitat, innovation, and local manufacturing.

We have also planned to double our business in India and to exceed sales

of ` 10,000 crores by 2019, added a company official.

Venkat Subramanian, MD, Gyproc; Anand Mahajan, General Delegate for

India, Sri Lanka and Bangladesh and B Santhanam, President, Flat Glass

Business (Glass & Sekurit), kickstart the 350th anniversary celebrations

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12 EM | Ma r 2015

MARKET | NEWS

The event provided the opportunity to ensure business

process delivers across the organisation

Building on rapid innovation

The 4th Asia Manufacturing Supply Chain

Summit was held from February 18 to 19,

2015 in Mumbai. The two-day event gathered

the manufacturing & logistics executives with

the theme Rapid Innovation. The keynote

session was addressed by Prof Dr rer pol Carl

B Welker, IUBH School of Business &

Management.

The event included panel discussions and

presentations with over 20 vital industry

topics from 40 senior global manufacturing &

supply chain professionals from companies

across Asia. The agenda of the presentation

centered on the key issues & challenges faced

by SCM & logistics professionals across the

world. Well-experienced speakers shared their perspectives on the

presentation.

The event provided the opportunity to ensure that the business process

delivers across all levels in the organisation through the latest in strategy,

planning and change management techniques; validate strategic vision &

investment decisions with industry leaders; create value through process

improvements; learn & benchmark from other

companies; know the best practices & market

trends; streamline operational process and

align these processes with overall business

strategy; explore new collaboration

opportunities and forge relationships with the

lean six sigma professionals.

Besides, the conference featured an exhibition

area with 20 top level companies showcasing

their products & services. It was also a good

networking event where consultants, logistics

solution providers and eProcurement solution

& service providers discussed how they

played an integral role in strategic

procurement strategy. With over 250

attendees, the summit brought together the leading thinkers and

practitioners in manufacturing, logistics and supply chain to network, learn,

debate challenges, discuss trends & share ideas. The summit witnessed

more executive insight from manufacturing & supply chain peers and more

thought-leaders in the industry providing with actionable take-aways.


Junker Group honoured with Leader of Technology Award

Junker Group has been recently felicitated with the Shanghai General

Motors (SGM) Leader of

Technology Award in

China. SGM confers awards

on its best suppliers in a

range of categories once

every two years. The

company is one of two

machine manufacturers

from Europe to be among

this years winners. The

award recognises

continuous investment in the development of new, economical grinding

machines for grinding a wide range of different car components, from

crankshafts to nozzle pins. We invest heavily in the development of new

machines and technologies. This makes us particularly proud to have been

distinguished with the award of Technology Leader by one of the worlds

biggest car manufacturers, said Rochus Mayer, CEO, Junker Group, on

receiving the award against the the backdrop of a show to launch new car

models complete with firework display.


GE opened its manufacturing facility at Pune

GEs multi-modal manufacturing facility was recently inaugurated at

Chakan, Pune, by Honble Prime Minister, Narendra Modi. Inaugurating the

facility, Modi said that there were

immense possibilities for

manufacturing in India. Indias

demographic dividend is a magnet

to attract investment. The

Government is working towards

creating a skilled talented workforce,

which will attract the world to India.

Global technology (Vishwa Dhan) and

the talent of Indian youth (Yuva Dhan)

can together result in a win-win

situation for all. He also congratulated the company for the state-of-the-

art manufacturing facility they had set up, and welcomed GEs announcement

for further investment. He said this was a big boost to the Make in India

initiative. The company has invested around $120 million (around `740

crore) to set up the facility, where a single machine can cut across

businesses such as oil and gas, rail and aviation and make products for

different sectors.


Honble Prime Minister Narendra

Modi inaugurated the facility

Rochus Mayer (third from the left) accepted the

award from Shanghai General Motors


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14 EM | Ma r 2015

MARKET | NEWS

The facility marks an important milestone in the centennial year of ZF Group

ZF Friedrichshafen AG inaugurates its plant in Pune

ZF Friedrichshafen AG has recently opened its new plant in Chakan, Pune.

With a total investment worth nearly ` 150 crore (20 million), the plant is

spread over an area of 85,000 sq mts (21 acres). This facility marks an

important milestone in the centennial

year of ZF Group.

This new plant is an important

investment in the centennial year of

ZF Group, said Wilhelm Rehm, Board

Member, ZF Friedrichshafen AG &

Global HeadMaterial Management.

Over the years, the company has been

successful in localising high

technology products in India. Now,

we will focus on the Make-in-India

theme and source quality products for

its global portfolio, he added.

Commenting on the development,

Rudi von Meister, PresidentAsia-Pacific, ZF, said, This multi-product

facility will house our car powertrain technology and commercial vehicle

technology divisions as well as ZF services under the same roof. The

synergies from this consolidation will enable us to improve efficiencies and

help us provide a compelling value proposition to our customers.

Speaking on the launch of the new facility, Piyush Munot, MD, ZF India, said,

We have established our presence in Pune in 2010 by introducing high

performance transmissions, followed

by chassis components both for

commercial vehicles and passenger

cars. Today, we enhance this product

portfolio by launching passenger car

clutch systems. These are specially

designed to meet the demanding

driving conditions in India.

Currently, the companys presence in

India consists of eight plants spread

across Pune, Pantnagar, Gurgaon,

Chennai, Coimbatore and Madurai,

with around 3,000 employees. The

new facility will have approximately

200 employees. It will also be a home to the headquarters of the after-

market sales and services, engineering and administration of

the company.


KBL inaugurated its warehouse facility in Kirloskarvadi

Kirloskar Brothers recently inaugurated its warehouse facility at

Kirloskarvadi, Maharashtra. The warehouse currently stocks all fast moving

spares for KBLs range of small & medium industrial pumps. This will enable

the company to quickly deliver spare

parts to customers in industries

such as coal, sugar, chemical

process, oil and gas, power, building

& construction and municipal water.

The opening of this warehouse and

service centre will enable us to offer

high quality services to our

customers. It will also help us to

increase our distribution reach. This

new initiative will provide

comprehensive and proactive

service facilities to our existing and potential end users, said Jayant Sapre,

Director, Kirloskar Brothers. With consumption-based stock and IT-enabled

process to monitor consumption and re-ordering of parts based on customer

demand, it will help the company to reduce the delivery time of spare parts

for small & medium pumps.


Renishaws new pioneering encoder goes into space

The European Space Agencys Sentinel-1A satellite was recently launched

from the European spaceport in Kourou, French Guiana with Renishaws

new space-encoder technology installed

on the advanced Optical Communications

Payload (OCP) of the satellite; part of a

revolutionary inter-satellite laser

communication system. The OCP

provides an optical Low Earth Orbit (LEO)

to Geostationary Earth Orbit (GEO)

communications link via a pair of Laser

Communication Terminals (LCT) by space

telecommunications company Tesat-

Spacecom (Tesat) of Backnang, Germany.

Tesat required a new rotary (angle) encoder for the coarse pointing assembly

(CPA) of its 2nd generation LCT, which is essentially a telescope with

coherent receiver and transmitter hardware. The space-qualified encoder

was developed in collaboration with Tesat and shares much of its core

technology with Renishaws proven TONiC encoder range. Radiation

hardening, combined with Renishaws extremely robust optical detection

principle, has resulted in the encoder achieving qualification.


Antarctica Peninsula image from

Tesat Sentinel-1AThe company showcased its

formulated comprehensive range of

greases available in India


FORM-1-2.indd 28 3/13/2015 9:43:51 PM

16

MARKE T | I N TERV I E W

EM | Ma r 2015

The market growth is directly affected by the financial growth

Jeffery S Foregard, General Manager - Asia & Europe and Member of the Board of Directors, ANCA Machine Tool, illustrates the latest technology advancements initiated by the company and underlines the need of the revival of the financial & banking sector to sustain growth in the Indian

machine tools industry, during an interview with Srimoyee Lahiri. Excerpts

With the Make in India initiative, how are you synergising your strategies with the customer requirements? Each customer is different with a different set of requirements. We are tailoring specific packages for specific customers. On the other hand, pricing in the market plays a big role. Since we specialise in CNC tooling, cutting and grinding, we work closely with the customer to tailor the supply of the product and target a specific market.

What are the latest innovations in the offing?The latest technology developed by us is in linear motions. We own a complete new machine, which is the FX series and on that we have deployed the linear motor technology, introduced by ANCA. The FX series consists of three machine levels FX3 Linear, FX5 Linear, and FX7 Linear. Suitable to multiple machining projects (light manufacturing, regrinding, full production), the series best performance and productivity range is for tools up to diameter 12 mm. It offers grinding capabilities for tools up to 200 mm diameter. Maximum wheel diameter is 8 mm. We produce our own software with our own control developed & manufactured by the company.

What is your focus on R&D?Our R&D team is based out of Australia. We are constantly looking at new developments and also improving existing platform. We contribute around 10% of our revenue to R&D in the areas of machine mechanical, electrical and software.

What is the general demand trend witnessed in the Indian machine tool industry?With the backdrop of Make in India initiative and the arrival

of new government, theres a lot of positive vibe amongst the crowd. Customers are now showing the general interest in the technologies and products offered in this platform. Going forward, the next 3 to 4 years will witness this positivity in the industry. The only challenge is the financial & banking sector.

It is an absolute disaster and a lot of revival in this sector is required. The loans provided in India compared to China, Europe or USA is a nightmare. Thus, the market growth is directly affected by the financial growth.

How has been the performance of the machine tool industry in 2013-2015?The performance of the machine tool industry has really been good. We have seen some growth over the past few years. It is steadily growing in India by 3% YOY. Since India doesnt have a tailored market, we are looking at a gradual growth in demand in this country.

What is your agenda for 2015-2016?With the launch of the new FX series and by making strong push in the global market, we are seeing a lot of activity in the IT sector, particularly in the mobile phones. We are ideally targeting Apple & Samsung and the entire IT sector, where we see a major growth. The company, being a market leader in quality CNC grinding machines and CNC systems, has steadily evolved through policies of innovation and technology and a determination to produce machines that satisfy our customers requirements and exceed their expectations. After 40 years of working with the industry, we continue to find new ways to deliver products that respond to market needs.


Jeffery_Market Interview_Mar_15.indd 16 3/13/2015 7:36:45 PMFORM-1-2.indd 30 3/13/2015 9:43:51 PM

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FORM-1-2.indd 36 3/13/2015 9:44:00 PM

20 EM | Ma r 2015

COVER STO RY T E CH N OLOG Y

20

GAME CHANGING INNOVATIONS

Witnessing global trends in manufacturing technologies

Imag

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EM | Ma r 2015


20

Highlighting the evolving trends in the Indian manufacturing industry, IMTEX 2015 was the apt platform to review & address the latest trends, as well as expose users & manufacturers to a range of value added machining solutions under one roof. This article details on the game changing innovations and underlines how Indian companies should provide an advanced position to R&D to strengthen the global positioning of the Indian machine tool industry.

Maria JerinFeatures [email protected]

Srimoyee Lahiri Sub-editor & [email protected]

Coverstory_Mar_2015.indd 20 3/13/2015 9:21:05 PMFORM-1-2.indd 38 3/13/2015 9:44:00 PM

21EM | Ma r 2015

TECHNOL OG Y COVER STORY

21

Given the current gap between demand and supply, there is a clear need for adding capacities in the machine tool sector. Indian companies are catching up with the speed of technological development and to showcase this, IMTEX 2015 provided a huge platform for the machine tool manufacturers. One of the general trends witnessed during the event was exhibitors moving to the next level of innovation in the incorporation of performance, access, ergonomics and aesthetics in their machines. The focus was on innovations that automate, enhance the efficiency of the work sequences involved and the productivity of machining operation. Numerous solutions presented are also motivated by currently expanding industrial sectors, like the aircraft industry and the energy utilities. The recent joint study by ACMA-IMTMA-Roland Berger Strategy Consultants, has suggested that the growth rate for Indian machine tool suppliers could be higher, due to import substitution in the automotive industry in light of fluctuating exchange rates. Indian manufacturers have raised the competitiveness at par with global players to meet the challenges of the domestic customers.

Heres a look on the latest innovation and technology trends emerging in the Indian machine tools industry.

What was witnessed?

Man-machine integration: The Indian machine tool companies have now come to an understanding of the rising level of automation, which is acceptable in the user sector and blends with the man-machine integration. Suggesting this, Shailesh Sheth, Chairman Programmes Committee, IMTMA, says,

Machines integrated with robots such as machine tending and pick & place are a good level of automation that can produce the stated number of pieces per hour. But the automation of machine-to-machine integration is costly and minimises the requirement of human labour. Thus, a proper manufacturing output is the one that integrates man and machine. In a complete production line conveyers & gantry robots are integrated to reduce the effort of man. The Indian companies have incorporated this appropriate level of automation, which suggests a positive and good level of innovation. There are

some areas in the complete lines of production that need to be automated because each station has to be in a balanced state. Indian companies have shown a good beginning towards this development. Companies like Jyoti CNC and TAL Manufacturing Solutions have come up with such level of automation that perfectly blends with the man-machine integration. Most of the customers are looking for automation not only for changing parts but also for loading and unloading of parts, cleaning, inspection and preparing parts for the next step. With the help of robots and integrated software, we are developing products to provide solution for big to medium sized companies. With the integration of automation, the efficiency can be increased from 65 to 85% ensuring quality and reliability, says Vijay Zala, Executive Head R&D, Jyoti CNC Automation. High precision machines: So far, in the minds of customers, Indian machines are good for the purpose of roughing. However, this perception is now gradually changing. Domestic manufacturers have come up with products, which are very close to the precision level and therefore, can meet the challenges of the domestic customers. Highlighting this, UCAM has launched the Noah series under the Nimble Machines brand. It is a 6-axis CNC gear hobbing machine that offers high productivity and precision with the incorporation of high-level technologies like electronic gearing, advanced software and the direct drive systems. The machine is developed at par with the global standards. On the other hand, GrindMaster in technical collaboration with Balance Engineering of USA, has launched Crankshaft Dynamic Balancing Machine, the CRH_MQL600 for automotive crankshafts. The machine gives the customer key process advantage in terms of accurate balancing under 10 gm cm consistently and zero job rejection & rework, says Sameer Kelkar, Executive Director, GrindMaster. Diversification: In early 2002, especially the automotive sector, witnessed increased investments as global majors started to outsource manufacturing to India. This led to a spurt in demand for machine tools. The machine tool industry, since then, has been growing at a healthy rate, even exporting general purpose and standard machine tools to industrially advanced


22 EM | Ma r 2015


22

countries. But now, with the changing demand trends, the industry is looking for more options to survive in the domestic market. Many Indian companies have widened the range to complete their metal cutting portfolio, thereby providing solution to non-auto segments like infrastructure, power plant, railways, defence & aerospace, die & mould, etc. So, these are the segments where lots of machinery is developed by Indian manufacturers, that witnesses the next level of innovation. Multiple operation machines: In multiple operation machines, Indian machines have still not achieved the complete level of multi-tasking. But there are a lot of machines with in-process measuring. Normally, in machining, one may come to conclusion of rejection after the production of the first component. With online measurement, this can be avoided and the first product waste can be saved. There also many machines with in-line washing or deburring. But still some developments that combine milling & turning and turning & grinding needs to happen. Indian machine manufacturers have been in the half way of the journey, said Sheth. Single set up machines are popular where multiple operation machining can be done at one time. Since loading and unloading is time consuming, the concept has undergone a change with minimum amount of handling with zero idle time. This is where the concept and the need of multitasking machining has emerged with the philosophy that minimises the amount of handling in machining.

Understanding this requirement, a similar trend has been observed where BFW has launched the twin spindle high-speed VMC for productivity enhancement in precision aluminium component machining. The machines integrated patent pending technology has the capability to convert raw

products to finished parts. It is developed for the single set-up machining of two wheelers and passenger car parts.

On the requirement of multi-tasking machines, Zala avers, We are competing with imported machines. We are more into developing multi-tasking machines. Customers demand a single machine that takes care of all operations such as milling, turning, grinding and gear cutting. This is the latest trend in the industry which is looking for high flexibility and minimal volume of production in terms of operations. Low cost machines: Development has happened in the peripheral areas like work-holding devices, clamping, fixturing and tool holding. Also, on some of the commodity products, like standard volume driven products; companies have come up with new price ratios, e.g. CNC lathe with the linear tooling have catalogue price of ` 10 lakh. This shows Indian companies are gearing up to compete with low cost supplying countries like China.

What to expect?

Larger component machining: Currently, the biggest gap is in the area of larger component machining. There are larger workpieces like axles that measure 1 m to 1.6 m long. It needs CNC machines heavy enough to carry those big wheels large diameters, gun barrel shells, aircraft cones, etc, that are very big.

There is not enough production of larger machines in India.

The eight pillars of TPM

Shailesh Sheth, Chairman, Programmes Commitee, IMTMA, shares the general overview of manufacturing technology trends showcased by Indian machine tool manufacturers

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level of high precision machining to meet the challenges of the domestic customers

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FORM-1-2.indd 44 3/13/2015 9:44:00 PM

24 EM | Ma r 2015


This gap needs to be bridged by the Indian manufacturers, said Sheth. Speaking further on this, Zala says, Now, we are in the stage of developing infrastructure. To develop infrastructure heavy industries play a big role. We have launched big turning centres for heavy engineering industries like mining, power engineering, railways, etc. We have milling machines to cater to these industries, so, for turning, we have developed these machines.Difficult-to-machine materials: Indian industries are used to machine standard materials like aluminium & steel. But, when it comes to non-standard high alloy steels like titanium & molybdenum, which are used in aerospace & medical engg, etc, there is a lack of knowledge on machining those materials. It needs different toolings with different cutting speeds, different coolant processes and the change in the whole machining gamut. At present, the major constraint is in the level of experience from where innovation needs to be derived. Factory of the future: The manufacturing industry in India is ZFUUPFOUFSUIF[POFPGA'BDUPSZPGUIFGVUVSF4VHHFTUJOHUIJTSheth opines, We are still not able to envisage what the factory of future would look like in terms of digital applications, CNC group controllers and offline monitoring. These concepts can be brought in India by global customers who set up the manufacturing base in India. We have achieved milestones in following TPS system. But there are not enough machines for factory automation. We need to work on the concept of smart factory of the future.

Speaking on the initiatives, Dr M S Kulkarni, faculty in-charge of the NIDAAN project (An indigenous diagnosis and prognosis system for machine tool spindle bearings) developed by Indian Institute of Technology Delhi, says, We look at mass manufacturing customers, who cannot afford to keep their

machines down at the production time that incurs huge loss. One of the factors, which affect the machine tools in terms of downtime is the spindle failure. This is mission critical stage and here the condition monitoring system is advisable. Analysing this challenge, we have developed this indigenise product. One of the objectives is the diagnostic analysis that tells exactly the nature of the problem and the remaining life of that part. This, now, has been filed for a patent and has been implemented on Micromatic Grinding machine. Going forward, we are also developing software with internet connection to access from remote systems.

Global innovations

At IMTEX 2015, numerous solutions were unveiled by global companies. DMG MORI premiered an operator control level with a touch-screen. It allows the user consistent management, documentation and visualisation of order, process and machine data. Similarly, Yamazaki Mazak with its new MAZATROL SmoothX, established a dramatic evolution in machine tool performance that spans the entire part-production landscape, from programming and setup to metal removal operations to automation and monitoring / data collection & transfer.

In general, high-speed machines are expensive and take up valuable shop-floor space and may often sit idle. Auxiliary spindles, while more flexible and less expensive, have performance issues. To address this challenge, Colibri Spindles has introduced the spindle technology, SPINJET HSM Jet spindle, which delivers the results manufacturers seek, making it a real alternative to investing in a high-speed machine.

Through a patented passive dynamic damping system called steadyline vibration damping, Seco Tools has improved

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the dynamic rigidity of milling and turning assemblies that increases productivity, improves surface finish and boosts both tool and spindle life. In this system, the vibration absorber is positioned, where deflection is highest in front of the bar. The absorber damps the vibration as soon as it is transmitted from the cutting tool to the body of the bar, thus limiting the deflection of the tool, says Raymond Tugend, Application Engineer, Winning Solutions Expert, Seco Tools.

With traditional methods of manufacturing, such as subtractive and formative processing, topological optimisation has to make certain compromises. However, Additive Manufacturing (AM) doesnt suffer from the same limits. As a result of building the part up layer-by-layer, more complex designs are possible with no need for tooling or cutting. Therefore, forms can be created that are closer to the optimum design. Taking advantage of this, Renishaws Additive Manufacturing technology, AM250, allows them to create a titanium alloy frame that would be both strong and light using

topological optimisation. The company has showcased this bike frame with individual sections have been bonded together and the new frame is some 33% lighter than the original.

Conclusion

The major crunch in the Indian machine tool industry is that the companies spend a minimum amount of their revenue in R&D. Worldwide the benchmark is somewhere near to 3 to 4% of the turnover. But presently, this is a rare sight across the industries. Some companies spend up to 10% on R&D in order to develop the new products and to keep the lifecycle of the products as short as possible. Most of the companies confuse New Product Development (NPD) with R&D. Indian companies should provide an advanced position to the R&D teams, which will provide more opportunities and strengthen the global positioning of the Indian machine tool industry.



26

MANAGE ME N T | I N T E RV I EW

EM | Ma r 2015

Implementing robust & lean processes to enhance component manufacturingP Ramadas, Managing Director, Ace Manufacturing Systems, in this interview with Maria Jerin, discusses that aerospace, manufacturing for IT (mobile phones & other electronics), defence projects and energy sectors will be the future of the Indian manufacturing industry, while analysing the current demand scenario

MANAGE ME N T | I N T E RV I EW

What is your success mantra behind designing new machines and building an organisation culture that instils a sense of ownership in the employees?We provide products and solutions with minimum cost of ownership. With continuous evolution and R&D efforts, we are narrowing down the gap between Indian machine tools and imported ones significantly. Contributing to the growth of Indian economy by substituting imports is also a factor behind new product development.

Caring for employees personality & professional development and growth is the overall reason for employees involvement as the part of the organisation. Our motto, In Pursuit of Excellence is being inculcated in the employees to become excellent professionals.

What is your focus on operational excellence models towards achieving long term goals in your organisation?We are currently working on implementing robust and lean processes to enhance the component manufacturing and machine assembly capabilities. Strong emphasis is given towards process centric approach with automated processes and leveraging of advanced information technology. Design standardisation, minimisation of number of parts, effective planning systems, reducing lead time of manufactured items, vendor development programs, improvement of process efficiency of component manufacturing and assembly are some of the key initiatives being undertaken. Importance is also given to employee engagement initiatives such as 5S, Kaizens and small group activities.

Management Interview_P Ramdas Ace Manufac.indd 26 3/13/2015 6:42:20 PMFORM-1-2.indd 50 3/13/2015 9:44:01 PM

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I N TERV I E W | MANAGEMENT

EM | Ma r 2015

set-up, promising almost double the productivity. Additional features like auto unloading, single machine loaders, and fully automation cell with unmanned operations are some solutions being offered.

With increasing response during IMTEX 2015 and optimistic budget, how are you viewing the current demand trend for the machine tools?IMTEX 2015 was a grand success for AMS. As compared to 2014, demand for machine tools is undergoing a swift change. Budget also seems very manufacturing-friendly; the effect of which will be seen on the machine tool demand in the near future. We believe the next few years are going to be very bullish in terms of capital investments. There is an increase in production demand; the requirement to deliver more in a minimal lead time is trending. Quality and productivity demands are leading to evolution of technology.

What are the latest growth strategies adopted synergising with the changing demand trends in the manufacturing industry?We are currently focusing on catering to the diversified customer base in new emerging market sectors. Enhancing existing products, development of new products and their promotions across all markets is being undertaken. We are gearing up for huge surge in demand by increasing its production capacity and also enhancing reliability of the products. We are also participating in over 10 international exhibitions overseas annually which has shown promising results in the recent years.

How do you think an aspiring entrepreneur in India can benefit from the present manufacturing scenario? What would be your advice to them?As per the international forecast, manufacturing is expected to grow from the present 16% to 25% of GDP in the next 10 years in India. Until recently, Indian manufacturing industry has been largely dependent on the automotive sector and its supporting industries. However, the future is going to be for non-auto sectors such as aerospace industry, manufacturing for IT (mobile phones & other electronics), defence projects and energy sectors, which will contribute significantly to the manufacturing growth. The 11 mega projects proposed by the Honble Prime Minister is going to add emphasis to manufacturing. Some advices for budding entrepreneurs include, looking out for sustainable opportunities in manufacturing that are likely to grow in the near future and being innovative in approach.

What are the recent developments in multi-tasking and multiple operation machines?Technologies such as turn mill centres and mill turn centres are gaining popularity as parts requiring variety of operations can be machined in minimum number of set-ups. There is large requirement for machines with pre & post processes that are combined to minimise set-up times. Inspection and gauging as a part of components machining in a single cell to reduce lead time of manufacturing is being sought after. Automated work offsets, tool offsets, tool ware measure, etc, are some features offered with the machines. We have also developed 5-axis machining centres for demanding applications such as aerospace and energy sectors.

With the background of rise in global competitiveness trends to develop machines with single set-up machining and minimum amount of handling; what are the latest approaches adopted by your company on the technology front? We are offering 1- and 2-axis rotary table machining centres to minimise set-up times and enhance productivity. Our innovation of twin spindle machining centres with & without rotary pallet changers have been very well accepted by the industry for high volume production in and out of India. Two identical components can be machined at a time in single > MORE@CLICK EM01563 | www.efficientmanufacturing.in

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Management Interview_P Ramdas Ace Manufac.indd 27 3/13/2015 6:42:23 PMFORM-1-2.indd 52 3/13/2015 9:44:01 PM

28 EM | Ma r 2015

ROUND - TABLE | M A N A G E ME N T

Vision promising budgetWith the new governments assurance to keep up the pace of reform, this feature aims at bringing the host of measures introduced in the Union Budget 2015-16, to develop a manufacturing-friendly environment, while analysing the challenges addressed in the budget, in discussion with the industry experts

As per the new GDP data, manufacturing has declined from 18% to 17% of GDP; and manufacturing exports have remained stagnant at about 10% of GDP. Finance Minister Arun Jaitley envisioned this challenge and unveiled a budget that aims to ramp up growth. The industry leaders commenting on the challenges addressed in the budget are L Krishnan, President IMTMA & MD, TaeguTec India; Ravi Raghavan, CEO, Bharat Fritz Werner; T K Ramesh, CEO, Micromatic Machine Tools

and Mohini Kelkar, DirectorSales & Marketing, GrindMaster Machines.

India as an investment destination

Foreign investors look for environments with minimum uncertainties in terms of infrastructure and other regulatory framework. They are looking to have their manufacturing hub

Maria JerinFeatures [email protected]

Round-Table_ Mar15.indd 28 3/13/2015 9:42:19 PMFORM-1-2.indd 54 3/13/2015 9:44:16 PM

29EM | Ma r 2015

MANAGEME N T | ROUND-TABLE

in countries like India, because of the availability of low cost manufacturing & engineering white collar talents. Speaking on the investment policy, Krishnan says, Union Budget 2015-16 clarifies several uncertain issues relating to the policy with a clear roadmap. It is directional and specifies mid-term goals of the Government of India. The positive factor is the governments commitment to build consumer market by bringing in GST.

On similar lines, Kelkar says, The budget hints that retrospective taxation will not exist & this will ensure security to the foreign investor. They will get the feeling of stability, which will help in receiving more foreign investments. It is also proposed that various exemptions will be removed & corporate tax will be brought down to 25% from 30%. Such clarity & simplicity in tax laws will help not only foreign investors, but also Indians to focus on improving their operational profitability, rather than increasing the profits by working around the vague tax laws. Highlighting on sustainable GDP growth, Raghavan opined that the macroeconomic indicators are clearly pointing towards environment of sustainable GDP growth at the outset.

The CPI and WPI inflation indexes show downward trends, current account deficit being low and foreign exchange reserves being healthy. All these indicators will boost investors confidence. Enabling indications like clear roadmap for GST implementation from FY 17, medium-term clarity on corporate taxation are encouraging steps from investor sentiment perspective.

Adding his thoughts on the budget, Ramesh said, The union budget has a clarity and is indicating continuity from the last budget. It also indicates the indent of not harassing investors unnecessarily. Speaking on job creation, he says, There are no specific indications that will radically help job creation, but we have to wait for the future policy announcements. On this, Krishnan opined, We need to work further on land and labour law reforms for simplification.

Ease of doing business

The government has articulated its vision to improve ranking for ease of doing business from current levels to 50 as a clear medium-term goal. Emphasising this, Krishnan says, We

see visible activities happening in the government. However, the challenge will be to align these simplified processes with that of states and ensure that the states also simplify their processes to realise the impact of these benefits. We are optimistic.

Opining that the budget will simplify business process, Kelkar says, The announcement of GST by April 2016 will go a long way in enhancing business environment & will certainly simplify business process. The announced e-biz portal is expected to give certain approvals on line. Good execution of all these declarations will simplify doing business in India and give a large boost to domestic as well as foreign investments & industry. Carrying the thought forward, Ramesh adds, The budget is making simplification on the ease of doing business process indirectly. But it is the proposal of indent; we have to look into the details. Indications are there to simplify the business process; we will have to see the actual translation on the ground level.

Make in India vision

The budget is optimistic, but it misses some policy steps to

The union budget has a clarity and is indicating continuity from the last budget. It also indicates the indent of not harassing investors unnecessarily T K Ramesh, CEO, Micromatic Machine Tools

The positive factor is the governments commitment to build consumer market by bringing in GST L Krishnan, President IMTMA & MD, TaeguTec India

Good execution of all declarations will simplify Doing Business in India & will give a large boost to domestic as well as foreign investments Mohini Kelkar, DirectorSales & Marketing, GrindMaster Machines


30 EM | Ma r 2015


position India as a manufacturing hub and to create an environment for local production. Commenting on this, Krishnan adds, Make in India is an idea and a campaign. In order to realise this vision, we need to do several reforms starting from ease of doing business, competitiveness, land availability and labour reforms. From the governments side, the push in the defence & aerospace sectors will certainly accelerate the Make in India campaign. However, we must realise that we are in for the long haul.

Highlighting on the optimistic budget, Ramesh adds, The budget is silent on Make in India; we have to wait for the future announcements, because reforms can happen at any time. Further adding, Kelkar says, It is difficult to do this quickly & one should not expect dramatical results in one year. The budget is one instrument, but the reforms will depend on passing the bills for amending the acts. The honble Prime Minister has met most of the CEOs of top 500 companies worldwide to promote Make in India and it shows hard work & commitment towards this campaign. Industry believes that this initiative will give boost to the Indian economy.

Boost for manufacturing

The budget has a proposal to correct inverted duty structures & incentivise local manufacturing by correcting anomalies. Sharing his thoughts on this, Krishnan says, This is welcome move. In the medium term, government will have to look at these aspects on an ongoing basis to correct anomalies and incentivise local value addition. Stating her point, Kelkar believes that this is a logical step in globalisation. This will provide level ground to Indian industry to compete worldwide & the weaker players will have to shape up or phase out, she says. Adding further, Raghavan says, Capital goods sector can look forward to reducing input costs as duties on essential imported parts have been slashed to 2.5% from 7.5%. Higher import duties on tax in SUV segment will help automotive manufacturing.

Speaking on the benefits to the machine tool industry, Ramesh averred, This is much a long awaited move, reducing import duty from 7.5% to 2.5%, particularly for inputs of CNC machines. This will directly benefit the machine tool industry.

PARAMETERS CONVENTIONAL HIGH SPEED MACHINING

Spindle speeds, rpm 4,000 8,000 ~ 50,000

Axis feed rates, mm/min 10,000 2,500 ~ 60,000

Rapid feed rates, mm/min 20,000 20,000 ~ 60,000

Accelerations, g -- 0.5 ~ 2.0

Inputs from Dr Nageswara Rao Posinasetti, Professor, Department of Technology, University of Northern Iowa, on the comparison of conventional and HSM parameters


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It helps in improvising cost price and will help in the direction of demand.

Infrastructure development

The budget intends to permit tax-free infrastructure bonds for the projects in the rail, road and irrigation sectors. Jaitley has laid out plans to boost infrastructure, relying on public investment, as private investment remains week. Krishnan believes that the governments allocation of ` 70,000 crores towards rail and road infrastructure development will go a long way in giving a fillip to infrastructure development in India. He says, Governments promise to clear new plug-and-play projects with all clearances in mind will dramatically improve project execution and management efficiencies, as well as help to build investor confidence. Sharing similar views, Kelkar says,

The budget clearly spells out investments in roads, bridges and port facilities. It seems they want to take it from 6 7 km per day to 30 km per day of road construction. The emphasis is on concrete roads and not the tar roads. This shows that the government has long-term views and is looking at building road network of good quality.

Further elaborating, Raghavan says, Higher allocation of funds for urban development & rural infrastructure will create demand pull for commercial vehicles and interest rate sensitive 2-wheeler segment. Thrust on agriculture infrastructure could help tractor segment, which is currently in significant stress. All these measures will create pull for auto and other manufacturing segments. In medium term, manufacturing segment will have positive impact due to boost to construction segment 100 smart cities, FDI in realty, income tax concessions on home loan interest, etc. Defence and railways have received good attention in budget. Proposals such as 49% FDI in defence, 5,000 crores additional allocation of defence budget entirely on capital account will spur public & private investments. The budget for plant machinery and modernisation has been

enhanced by over 700 crores and will result in demand for machines. According to Ramesh, the outlay for infrastructure development has not significantly increased. Revitalise the public private partnership (PPP) mode of infrastructure development would be welcome, he adds.

The budget way

According to Krishnan, the machine tool industry looks forward to stable, predictable growth of manufacturing sector.

We believe that it is some distance away. However, we realise that medium to long term opportunities are exciting, and the industry is preparing for the same, he says. Indeed, the budget is promising for the machine tool industry. Highlighting this, Kelkar opines that the import of machines has become easier and duty barrier is not there now. She asserts, Indian machine tool manufacturers will face a stiff competition. They have to seriously review the input material cost, manpower cost, etc. Apart from this, they have to offer technologically superior products, which are also designed for high production volumes. Machine tools companies will have an opportunity to supply machines to MNCs who are setting shops in India.

Taking the idea forward, Raghavan believes that the budget shows a positive sign from the GDP growth perspective, especially for the manufacturing sector. We are upbeat about the growth prospects and getting ready to serve the demand pull, which the budgetory proposals will generate, he adds. Looking ahead to a productive manufacturing sector, on a concluding note, Ramesh believes that, specifically, for machine tool industry, the significance is with the reduction in the rate of import duties that is the step in the right direction. But for machine tool industry to do well, there must be stimulus in the other industries like white goods, automotives, infrastructure spending & general industry. Indications are good, we are waiting for the action to start, he says.


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FORM-3-4.indd 1 3/13/2015 7:49:36 PM

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MAN AGE ME N T | S T RAT EG I E S

Technology is the backbone of every business. It is an enabler, playing a signicant role in protability and growth. e article analyses the critical role that it plays in addressing the modern business challenges and leveraging the adoption of business soware solutions

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MAN AGE ME N T | S T RAT EG I E S

Various technologies may be applied to the running of an organisation, but none are as critical to business success as

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TRANSFORMING MANUFACTURING MODEL

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36 EM | Ma r 2015

MANAGE ME N T | S T RAT E G I E S

BusinessDrivers

Managing achange inbusinessmodel

Newcustomer

recruitmentand

retention

Expansioninto newmarkets

CIOs ranked their top three business drivers as expansion into new markets; managing a change

in business model and new customer recruitment and retention

efficiencies and ultimately boosting profitability.

There is a clear link between successful manufacturers and their understanding & use of ERP as a strategic tool for delivering a superior customer experience. The real winners are the businesses that shift their focus from inward to outwardmoving beyond better price and availability to improved service levels, reliability and relationships. The most successful manufacturers choose ERP solutions that enable an easy evolution through the customer experience maturity model.

New levels of agility, flexibility and ease of use in modern ERP systems make it possible for businesses to transition without having to reinvest heavily as their needs change. Competing by lowering costs and increasing product functionality doesnt hold in the long term. Modern businesses have to combine technology and processes that embed a customer-oriented culture at all levels of the organisation to ensure they improve customer experience and stay ahead of the market.

Technology is business critical

Earlier, business leaders focused on

the product and the resources needed to manufacture it where technology played a transactional role. Now, its clear that without technology to facilitate the manufacturing process; profitability, growth and expansion are virtually impossible.

Technology is critical to globalisation, resulting in aggressive adoption of business software solutions as companies leverage the power of IT to manage multinational operations, drive workplace productivity and efficiency.

The economies of emerging markets like India, the Middle East and Africa are growing at a significant rate and represent significant opportunity. Globalisation driven by trade and investment is aided by technology, which paves the way for multinational businesses to make their mark by taking advantage of opportunities in largely untapped markets that may offer cost effective labour, untapped resources and uncluttered markets.

Strong competition from low cost economies threatens many manufacturers in mature economies by challenging them on various levels, including price and time to market. This is where customer service and innovation become differentiators. An ERP system that is

flexible, agile and responsive is critical to achieve this.

A proven ERP system evolves with a business, supporting expansion by acting as an enabler. The business impact of these solutions, applications and underlying technologies make or break a business. This has led to a significant change for the CIOs role.

The role of CIO

Around 79% of surveyed CIOs and other senior executives agreed that the role of the CIO changed within the last five years. The most prominent change noted was the transition of the CIO from being an improver to being an influencer. Improvers are hands on, controlling costs, increasing efficiency, optimising processes and making sure the business gets the IT that it needs. Their focus is on doing things better. Influencers are tomorrows transformers - they do things better by using technology to solve business challenges and alleviate pain areas.

The new role of modern CIO

CIOs ranked their top three business initiatives as transforming IT function


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to support the need for business agility, improving IT user experience for employees and improving IT infrastructure for enterprise connectivity. Non-CIOs ranked what they perceived as being the top initiatives for their CIO colleagues as improving the IT user experience for employees; optimising, streamlining and the supply chain; and improving IT infrastructure for enterprise connectivity.

Business initiatives for CIOs

CIOs ranked their top three business drivers as expansion into new markets; managing a change in business model and new customer recruitment and retention. Non-CIOs ranked the top business drivers for their CIO colleagues as expansion into new markets, managing a change in business model and getting products to market faster. It is interesting to note that new customer recruitment and retention & getting products to market faster go hand in hand when it comes to profitability.

With all of these factors considered, it is clear that the role of the CIO is increasingly important to forward thinking businesses who want to gain a competitive edge. He is becoming responsible for the most critical areas of adaption that, if done correctly, will take the business to another level.

Addressing challenges of modern businesses

Speed, reinvention, agility and innovation are critical to the success of any organisation. Serious about optimising performance and gaining competitive advantage, a staggering 90% of respondents to the survey agreed with this statement. The enterprise application market in India, the Middle East and Africa is growing as organisations explore the benefits of investing in such solutions. Small & medium enterprises are now aware of the fact that investing in enterprise applications such as ERP will help them to streamline and integrate their business processes enabling operational efficiency. This can ultimately catapult them on a path to become a global player.

According to CIOs and senior executives surveyed, a clear understanding of the direction of the business has had the most significant impact on the role of the CIO. Second to this is investing in IT infrastructure to improve agility and responsiveness, followed by sourcing technologies that accelerate business processes.

Other senior executives felt that investment in IT infrastructure that supported decision making and more efficient processes are a direct result of the need for speed, reinvention, agility

and innovation. This shows that both parties, in their respective roles, are focused on the same objectives. Here, these factors are more critical than in markets where competition is fierce and growth is imminent for those who go above, when it comes to meeting customer needs and ensuring excellent customer service.

By incorporating best practice for integrating lean strategies to enhance workflows, reduce waste, and nurture problem-solving approaches, ERP systems have been gaining traction due to their ability to harmonise and optimise many parts of the manufacturing chain and thereby improve the customer experience.

ERP critical to business success

Around 76% of CIOs and other senior executives agreed that best in class companies perform better because of their use of business systems, and that their ERP system is the enabler of their businesses. It is the most significant tool in their pursuit for optimum performance and profitability.

65% of CIOs and 38% of non-CIOs agreed that ERP had reduced the complexity of and sped up key operational processes. 46% and 43%, respectively, said that ERP enabled better visibility into their business. These were

Improvesproductivity

of employees

Reduces thecomplexity of,and speeds up

key operationalprocesses

ERP Criticalto Business Success

Helps to reduceoperational costs

Enables bettervisibility

into business

According to CIOs and senior executives surveyed, a clear

understanding of the direction of the business has had the

most significant impact on the role of the CIO



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followed by helping to reduce operational costs and improving the productivity of employees

This provides further evidence of how modern ERP system is perceived as increasingly critical to business success and has an increasingly significant impact on the performance.

Looking towards future

When asked to rate the technological enablers in order of importance for future investment, respondents ranked mobile applications, software as a service (SaaS), social applications and platform as a service (PaaS) highest. Mobile solutions have opened up new opportunities for cost savings, employee productivity, market reach and engagement, streamlined operations, responsiveness and service quality, among many others. Corporate trends such as bring your own device (BYOD) and mobile enterprise apps attest to strong industry-wide recognition and appreciation of the huge impact of mobility

According to the Aberdeen Group, the need for instant access to ERP stems from the need to cut costs through efficiency and visibility. Instant access to ERP improves efficiency, especially in organisations with operations in multiple geographical locations or with employees out in the field. Instant access to data also enables decision makers to react to problems without delay and facilitates a quick response to the needs of its customers.

Choosing an ERP solution developed by an industry leading provider who takes a visionary approach to business software is critical for all manufacturers.

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ERP providers must invest heavily in research and development (R&D) to ensure that their solutions can keep

abreast of change.


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EFFECTIVE APPROACHES FOR MACHINE TOOL UTILISATIONTo maximise the utilisation of a machine tool within the limits of its capabilities requires an intelligent, balanced approach in the development of cutting parameters. This article talks about the important components of effective machine utilisation by maximising the required timeline for metal cutting, and quicker and easier ways to manipulate cutting tool application parameters that helps to achieve optimum performance with the existing machine.

Patrick de VosCorporate Technical Education ManagerSeco [email protected]

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Achieving maximum productivity and profitability in machining operations result from optimisation of the entire metal cutting process. The foundation of that effort is intelligent application of cutting tool parameters in combination with full utilisation of machine tool capabilities. There are two main

components of effective machine tool utilisation. The first involves finding ways to maximise the amount of time the machine is available to cut metal, and the second includes tactics to make the most productive, reliable, and profitable use of that time.

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MACHINE TOOL UTILISATION

Costs, k

k

k

k

Production costs are determined by productivity and machine tool utilisation (machine tool downtimes and wrongly produced workpieces).

Production rate

Rejections Downtimes

Machine tool utilisation

Maximising available time Full utilisation of a machine tool must begin with

maximising the time it is available to cut metal. Even though a machine is on the shop floor 365 days, its productive availability is much less. In the case of five-day, single shift work weeks, and counting time lost to holidays and other interruptions, there are approximately 1,300 or 1,400 machine hours per year available for production. Programming and setup consume a certain amount of time. To make that non-productive period as short as possible, manufacturers employ strategies that include offline programming and modular setup methods. Tool magazines and automatic tool changers expedite tool handing, another time-consuming necessity. Robotic work handling and pallet changers help reduce the time required to load raw workpieces and unload finished parts. Every hour saved via improved programming speed, faster setup methods, and streamlined tool handling and work handling is another hour that is available to machine parts.

Using time efficiently

After implementing strategies to maximise the amount of time available to cut metal, manufacturers are challenged to use that time efficiently and produce as many parts as possible at the lowest cost. The key is to fully utilise the capabilities of the machine tool while the cutting edge is in contact with the workpiece material. Recognition of the machine tools limitations plays a role as well.

When planning to best use the time available, it is clear that some elements of the machining process cannot be changed. The end application of the machined part determines the choice of workpiece material, and the materials machinability dictates initial cutting parameters. For example, the poor thermal conductivity of titanium alloys demands use of low cutting speeds and feed rates to minimise build up of heat. Machine tool capabilities are also a given, because changing the machine

is not usually an immediate option. Manufacturers recognise these factors when estimating production costs. However, significant differences between estimated and actual costs can result from inaccurate evaluation of machine tool characteristics and application of cutting conditions that cannot be sustained.

There are common requirements when establishing initial cutting parameters for any machining operation. Depth of cut and feed rates must be chosen to avoid tool breakage, assure formation of desirable chips and limit generation of heat. Cutting speeds that are too high will cause tools to wear out too quickly, and speeds that are too low will not allow tools to function productively.

Cutting faster generally will produce a workpiece in less time. But while the machining time is shorter, tool life also is shorter and tool costs will increase. More tools will be required to do the job and worn cutting edges must be indexed or replaced. The downtime resulting from tool changes boosts the costs of the operation overall. In effect, there is a trade off between faster and more expensive machining and slower and less costly operation. Consistent productivity and process stability lie in between the two approaches: insufficiently aggressive cutting parameters reduce costs until the tool no longer functions efficiently and productivity is lost, while increasingly higher parameters raise productivity until the tool wears too rapidly or breaks.

In addition, the choice of cutting conditions depends not only on the characteristics of the cutting tools but also, in a large number of cases, on the capabilities of the machine tool. Different machine tools have differing limits of power, torque, rpm, and stability. The clearest limitation is power.

Power ratings alone do not determine a machines capability for a specific application. A 60-kW machine tool would appear to offer more than adequate power, but if the intended manufacturing operation is, for example, producing 12 m-long, 3 m-diameter forging rolls, 60 kW is not as impressive. The power required to cut a specific workpiece depends on the workpiece material and size, the depth of cut, feed rate and

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not a simple, fast or inexpensive solution. It is quicker and easier to manipulate cutting tool application parameters to achieve optimum performance with the existing machine. And even if investment in a new machine tool is feasible, the relatively long operating lifetime of the equipment is an important consideration. A company may buy a machine tool with capabilities that match or exceed its present needs, but factors such as part workpiece material, size and volume can and will change significantly over the five, 10 or more years that the machine will be in operation. To cope with the changes it will be necessary to alter cutting conditions, but that must be done in an intelligent way.

After finding ways to maximise the amount of time a machine tool is available to cut metal, the preferred path is to select tools with substrate material, coatings, and cutting edge geometries that are best for the workpiece materials and operations involved. The next step is to apply the minimum cutting speeds at which the tools will work well. Then, feed rates and depths of cut should be as high as possible, while recognising the power and stability characteristics of the machine tool. Mathematical formulas have been developed that can help determine the best match between machining parameters and machine capabilities. If possible, a shop may prefer to run practical tests to get similar results. Fairly often, the formulas only confirm rea

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