advanced machine engineering technological innovations
TRANSCRIPT
www.industr.com/en
EM - Interview
Seenivasan Balasubramanian,Chief Executive Officer, Indian Aerospace Manufacturing Private Limited (IAMPL) (p. 24) Industrial Maintenance P. 38
Cutting Tools P. 28
Electric Vehicle P. 32
Coolants & Lubricants P. 36
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
EFFICIENT MANUFACTURING
VOL 12 | OCTOBER 2021 | `100
ADVANCED MACHINE ENGINEERING Technological innovations driving change
7410009435/36
CUSTOMER SATISFACTION
With reliable manufacturing processes
VOL 10 | OCT 2019 | ` 100
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
EFFICIENT MANUFACTURING
www.industr.com/en
EM - Interview
Petr Novotny,Managing Director Scania Commercial Vehicles India (p. 30)
FOCUS Cutting Tools P. 38
SPECIAL FEATURE Industrial Maintenance P. 54
3EM | O c t 2021
ED ITOR IAL
This would be my last Editorial note, as I decide to move on to explore other opportunities. It was an absolute pride and honour for the past more than a decade to work for the Indian subsidiary of the German media house, and develop the brands for the global market. The magazines A&D India (Automation & Digitisation) and EM (Efficient Manufacturing) are well established brands in India now, both in print and online. I have had many wonderful opportunities to learn as a professional and as a person during this period. I have had several occasions of engagements, deliberations, and interesting conversations with who’s who in the manufacturing industry, from India and other countries that I will continue to cherish. The journey was very exciting and challenging. Looking back on my time at Publish Industry India, we have confronted seemingly insurmountable business challenges along with unprecedented times and circumstances where I tried responding with the best of my abilities. I take this opportunity to thank everyone who contributed in this success journey, our partners from India and abroad, readers, customers, editorial advisory board members and contributors, and the colleagues, past & present.
Today, the arrival of India as a shaping force on the global markets is clearly picking up pace. As Indian industry strives to be globally competitive, it has realised the importance of investing in advanced technologies. Also, as the industry grapples with the lingering effects of the downturn and anticipates recovery, manufacturers have a once-in-a-generation opportunity to leverage on their strategic initiatives and efforts put in to survive in the challenging times. Our magazines are here to facilitate manufacturing enterprises identify and implement new strategies to restart growth and move their business forward to a brighter future. The magazines will continue to provide refreshing insights into the advanced technology in terms of the latest and the most appropriate business information.
Wish you all the very best and the exciting times ahead!
Shekhar Jitkar Publisher & Chief [email protected]
EDITORIAL ADVISORY BOARD
Raghavendra RaoCEO, Kaizen Hansei LLP
Dr N RavichandranFormer Executive Director,Lucas-TVSChief Mentor,UCAL Fuel Systems
Dr Ravi M DamodaranChief Technology Officer, Greaves Cotton
Dr P N RaoProfessor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Ramesh T KMD & CEO, Micromatic Machine Tools
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Vineet SethManaging Director,Mastercam India
Sonali KulkarniPresident & CEO,Fanuc India
Dr Wilfried AulburManaging Partner,Roland Berger Pvt Ltd
Satish GodboleVice President, Motion Control Div,Siemens Ltd
Overseas Partner:
China, Taiwan, Hong Kong & South-East Asia
“As the industry grapples with the lingering effects of the downturn and anticipates recovery, manufacturers have a once-in-a-generation opportunity to leverage on their strategic initiatives and efforts put in to survive in the challenging times”
Looking back…!
EM | O c t 2021
4 EM | O c t 2021
ELECTRIC VEHICLESDownstream aluminium: Meeting the EV demand through innovation in production
CONTENTSMARKET 08 NEWS
10 “Bringing alignment to a company’s goal & an individual’s goal”Interview with Dr Jairam Varadaraj, Managing Director, ELGi Equipments
12 “Preventive maintenance has become predictive maintenance”Interview with Suchitra Raibagi, Designated Partner – Zimmer Automation LLP
START-UP
14 “We build manufacturing capacities and integrate them with manufacturing capabilities”Interview with Srinath Ramakkrushnan, Co-founder & COO, Zetwerk
V IEWPOINT
26 Boosting clean technology vehiclesThe Viewpoint digs deeper into what makes the $3.5 billion incentive to the automotive industry different and how it promotes electric vehicles & hydrogen fuel-powered vehicles
WORLD AFFAIRS
15 XR extending the dimensions of Indian manufacturingThe opinion feature analyses how extended reality or XR posses the quality to integrate the manufacturing floor & take it to new heights and why it is a need of the time
MANAGEMENT INTERVIEW
24 “Technologies are evolving at a much faster rate today”Seenivasan Balasubramanian, Chief Executive Officer, Indian Aerospace Manufacturing Private Limited (IAMPL)
FOCUS CUTTING TOOLS
28 Advancing cutting tools through titanium machiningThe article explains how the choice of the right tools helps in overcoming challenges associated with complex machining of titanium, a preferred material in aircraft manufacturing
16COVER STORYAdvanced machine engineering: Technological innovations driving change
CUTTING TOOLSAdvancing cutting tools through titanium machining
28
32
5EM | O c t 2021
INDUSTRIAL MAINTENANCEIndustrial maintenance – Embrace the digital approach
38
A&D India – the leading industrial magazine in India, on Automation & Digitisation, that offers a three-dimensional perspective on technology, market and management aspects of automation
EM – the leading industrial magazine in India, on Efficient Manufacturing, that offers a three-dimensional perspective on technology, market and management aspects of manufacturing
www.industr.com/[email protected]
AUTOMATION & DRIVES
Jun-Jul 2018 I VOLUME 11
www.industr.com/en
Advt
VOL 11 | J
UN-JUL 2
018 | ` 100
AUTOMATION & DRIVES
Also
ava
ilabl
e in
Chi
na, T
aiwan
, Sin
gapo
re, M
alays
ia, T
haila
nd &
Hon
g Ko
ng
www.industr.c
om/en
CULTIVATING GREEN PATCH IN BROWNFIELD
A practica
l way
to get
starte
d in manufac
turing IIo
T
In association with
FOCUS
A&D - Intervi
ew
Rebecca Liebert,
President &
CEO,
Honeywell
UOP
(p.30)
VIEWPOINTCollaborative
Robots P. 32
Power & Energy P. 4
0, 42
AUTO
MATIO
N &
DR
IVES
Aug-Sep 2018 I VOLUM
E 11
ww
w.industr.com
/en
VOL 11 AUG-SEP 2018 ` 100
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
www.industr.com/en
Advt
In association with
FOCUS
VIEWPOINT Sensors in
Automation P. 36
Automotive &
Machine Tools P. 42
A&D - Interview
Rolf Najork
President of Executive Board,
Bosch Rexroth AG (p.32)
A&D - Interview
Hans Bangert
Managing Director,
Bosch Rexroth India (p.32)
A&D - Interview
Marc Jarrault
Managing Director,
Lapp India (p.34)
SMART OPERATIONS
Recipe for success AUTOMATION & DIGITISATION
AU
TOM
ATION
& D
RIVES
O
ct-Nov 2018 I VO
LUM
E 11
w
ww
.industr.com/en
VOL 11 OCT-NOV 2018 ` 100
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
www.industr.com/en
Advt
In association with
VIRTUAL COMMISSIONING
Scope in the Manufacturing Industry
AUTOMATION & DIGITISATION
A&D - Interview
Akilur Rahman,Chief Technology Officer,
ABB India (p.28)
FOCUS
VIEWPOINT Technology adoption in the Indian
automotive sector P. 30
Food & Beverage Processing P. 34
AUTO
MATIO
N &
DIG
ITISATION
Dec’18-Jan’19 I VO
LUME 11
ww
w.industr.com
/en
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
www.industr.com/en
Advt
In association with
OT & IT COLLABORATIONUshering new business models
AUTOMATION & DIGITISATION
A&D - InterviewIndraneel Chitale,Partner – Chitale Group
(p.22)
FOCUSVIEWPOINT Collaborative approach for success P. 24
Aerospace & Defence P. 28
VOL 10 | DEC’18-JAN’19 | ` 100
GET AUTOMATED NOW!GET AUTOMATED NOW!
GET EFFICIENT NOW!GET EFFICIENT NOW!
AUTOMATION & DIGITISATIONAUTOMATION & DIGITISATION
SUBSCRIBE TOSUBSCRIBE TO
SUBSCRIBE TOSUBSCRIBE TO
publish-industry India Pvt LtdPune - 411001, Maharashtra – IndiaTel: +91 7410009435/36
www.industr.com/en
Also
ava
ilabl
e in
Chi
na, T
aiwan
, Sin
gapo
re, M
alays
ia, T
haila
nd &
Hon
g Ko
ng
EM - Intervie
w
Vijay Kalra
,
Chief of
Manufac
turing
Operatio
ns,
Mahindr
a & Mahi
ndra [A
S] (p.
34)
EFFICIENT MANUFACTURING
VOL 08 | O
CT 2017 | ` 100
FOCUS
SPECIAL FEATURE Industrial M
aintenance P. 58
Cutting To
ols P. 40
Lean in automotive m
anufacturin
g
ROADMAP FOR IMPLEMENTATION
www.industr.c
om/en
VOL 09 | MAY 2018 | ` 100
www.industr.com/en
EM - Interview
Viraj Kalyani,
Founder & Chairman
Kalyani Studio (p. 28)
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
FOCUS Automotive Plastics P. 34
SPECIAL FEATURE Shopfloor Management P. 54
PRINCIPLES, APPLICATIONS AND DIRECTIONS
Sustainable Manufacturing
EFFICIENT MANUFACTURING
OPPORTUNITIES & CHALLENGESEV manufacturing in India...
VOL 09 | AUG 2018 | ` 100
www.industr.com/en
EM - Interview
Dr Nagahanumaiah,Director,CMTI (p. 28)
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
FOCUS Defence Manufacturing P. 30
SPECIAL FEATURE Industrial Parts Cleaning P. 48
EFFICIENT MANUFACTURING
What drives the sector
MATERIAL HANDLING INDUSTRY IN INDIA
VOL 10 | MAY 2019 | ` 100
Also
ava
ilabl
e in
Chi
na, T
aiw
an, S
inga
pore
, Mal
aysi
a, T
haila
nd &
Hon
g Ko
ng
EFFICIENT MANUFACTURINGwww.industr.com/en
EM - InterviewSanjay Chavre,Sr Development Officer, Dept
of Heavy Industry – Ministry
of Heavy Industries & Public
Enterprises, Govt of India (p. 30)
FOCUS Automotive Plastics P. 40
VIEWPOINT Industry Associations – Bringing the sector closer P. 32
TECHNOLOGY COVER STORY
16 Advanced machine engineering: Technological innovations driving changeThe Cover Story outlines the trends, technologies and processes in place that are driving advanced machine engineering
ELECTRIC VEHICLES
32 Downstream aluminium: Meeting the EV demand through innovation in productionThe article talks about how aluminium is making the EV story a success, their benefits and how it is an automaker‘s dream metal.
COOLANTS AND LUBRICANTS
36 Big saving potential for gear technology for liquid toolThe case study elaborates how with the solutions from Blaser Swisslube, an Indian customer was able to reduce the cut time, lower smoke & mist and achieve overall cost saving
SPECIAL FEATURE INDUSTRIAL MAINTENANCE
38 Industrial maintenance – Embrace the digital approachThe article explains the nitty-gritties of AI and how it can one-up industrial maintenance for the manufacturing sector
New Products42 Clamping element for unpressurised
fixing of rotary axes; 43 Lightweight polymer linear bearings;
Battery module housings for EVs; Fine boring heads
Columns03 Editorial 04 Contents 06 Guest Editorial44 Highlights – Next Issue44 Company Index
6 EM | O c t 2021
GUEST ED I TOR IA L
Over the years, we have seen procurement functions of the manufacturing industries undergo certain changes owing to computerisation and adaption of ERP systems. Today, with the growth of the internet and digitisation, the purchasing is heading towards e-commerce.
In a typical manufacturing industry in India, the inputs & material costs account up to 50% of the manufacturing cost. Hence, the key target of the purchase function is to keep reducing the buying costs. The purchasing function has to ensure good quality, timely availability & lowest price, and often while leveraging the combination of the three, end up in conflicting situations.
The emergence of B2B e-commerce is a boon to purchasing functions as the choice of quality, exact stock status and multiple brands with price options will help the industries meet the procurement targets and improve profit margins. With the internet and smart phones becoming affordable to commoners, internet users are estimated to be 876 million by 2025. This has been a boost for the commercial phase of India, and e-commerce has become viable. Plus, advancements of
CO
MM
ENTS
& C
OM
MEN
TAR
Y
various technology platforms, like Artificial Intelligence, Virtual Reality, Augmented Reality, etc. have also been supporting the growth of the e-commerce space.
Many Indian start-ups are trying their best to digitise the whole supply chain in India. And with more small business owners joining the tools offered by e-B2B players, like digital cataloguing, online payments and logistics, the segment will continue to grow.
The benefits derived by the industry by adapting to B2B e-commerce are many. Below is the partial list of important ones:
1. Wider choice. 2. Artificial Intelligence-enabled
technical selection and assessment of products.
3. Real-time stock availability status. 4. Transparent pricing eliminates
middlemen and corruption. 5. Reduced sales costs due to short sales
channel and optimised service costs leading to lower prices, which will be beneficial to the industry.
6. Reverse auction process can provide an equal and transparent opportunity to all participants.
7. Simplified purchase process resulting in reduction of efforts from the indirect functions like purchase stores, etc will improve the operating efficiencies.
8. Single source of supply for multiple brands can vastly improve financial management process.
9. Online requirement definition involvement of end-users, purchasers and finance.
10. Easy linking to ERP systems & ready MIS for the top management to monitor the procurement process.
11. Easy return policy and ticket-based complaint redressal will help reducing post-sale issues resolution.
COVID-19 hastened the development of B2B e-commerce, and many sectors have realised the advantage of this model.
As the manufacturing industry embraces Industry 4.0 standards, where the interactions based on AI and AR will be more between the machines (computer systems), B2B e-commerce will play a major role in ensuring seamless supply chain management. ☐
“B2B E-COMMERCE IS A BOON TO PURCHASING FUNCTIONS”
S Ravishankar,CO-FOUNDER,TOOLKART
YOU HAVE THE APPLICATION.WE HAVE THE PERFECT SOLUTION.
THE KNOW-HOW FACTORY
Gripper TechnologyHighlights+ Up to 30 % more gripping force than the Benchmark+ 10 % higher static forces and torques than the Benchmark+ Gripper fingers up to 10 % longer than the Bench- mark+ Optional with IP40/ IP64/ or IP67 sealing+ Protected against corrosion+ Up to 30 million cycles without maintenance+ Over 30 years of experience and branch knowledge+ 2.000 standardized grippers, swivel-units, and robot-accessories+ Custom made system solutions
ZIMMER AUTOMATION LLP19, Commerce Avenue, Mahaganesh Colony, Paud Road, Pune 411038,Maharashtra, India
E-Mail: [email protected] http://www.zimmer-group.com
8 EM | O c t 2021
Cyient enhances its Additive Manufacturing solutions with implementation of SLM®280Cyient recently installed a new SLM®280 system following international support from SLM Solutions. It is integrated into the company’s first metal Additive Manufacturing facility in Jupiter, Florida. Referring to the new development, Rajendra Velagapudi, SVP & Global Operation Head – Design Led Manufacturing, Cyient, asserted, “The new SLM®280 enables us to offer manufactured components directly to our customers in aerospace, defence, medical and energy. This is a key milestone on our road to becoming an end-to-end Additive Manufacturing solutions provider.” Commenting on the partnership, Sam O’Leary, CEO, SLM Solutions, stated, “SLM Solutions and Cyient share synergies across geographies and industries, which will allow us to take a global approach in supporting their growth. SLM Solutions has established expertise and customer base across aerospace, defence, medical, oil & gas and energy, which are also critical sectors for Cyient. We actively consult and support from our Indian and US offices as Cyient integrates into strategic manufacturing supply chains worldwide. We are thrilled to work together as it grows its product offerings with selective laser melting.”
Balkrishna Tyres inaugurates new production plant in MaharashtraBalkrishna Tyres (BKT) recently started the trial production at the company’s new state-of the-art site in Aurangabad, Maharashtra. The result of a $56 million investment, the plant’s annual production capacity is around 30,000 MT of off-highway tires. The plant will employ approximately 500 people when it’s at full capacity and will manufacture medium and small diameter tires, designed for machinery operating in the agricultural and industrial industries. The project focused on the construction of a cutting-edge plant from both a structural and mechanical point of view and on the reorganisation of departments and work flows for maximum efficiency. With the foundation stone laid in June 2019, this site arose during the pandemic. BKT was determined to ensure the safety of all those working on the project before continuing with its realisation. However, the health emergency did not curb their desire to move forward, with a positive message to the market that “it can be done” while of course fulfilling all the due safety requirements.
TVS Motor ties with Tata Power for electric 2-wheeler charging infrastructureTVS Motor Company recently signed up a strategic partnership with Tata Power for comprehensive implementation of Electric Vehicle Charging Infrastructure (EVCI) across India and to deploy solar power technologies at TVS Motor locations. The partnership aims to create a large dedicated electric two-wheeler charging infrastructure to accelerate electric mobility in India. Elaborating on the partnership, Sudarshan Venu, Joint DM, TVS Motor Company, mentioned, “TVS Motor is extremely excited and proud to be the pioneering partner with Tata Power, which is leading the way in creating a wide and sustainable charging infrastructure in the country. Fitting to TVS Motor’s vision of electrification, we envisage a wide and reliable charging infrastructure for two and three-wheeler EV customers across India, powered by renewable sources of energy such as solar.” Further, Praveer Sinha, CEO & MD, Tata Power, added, “Through this collaboration, we will further leverage our expertise to enhance synergy between sustainable mobility and renewable energy integration resulting in the creation of a robust EV charging ecosystem across India.”
AGEL completes acquisition of SB Energy India for $3.5 billionAdani Green Energy Ltd (AGEL) recently acquired SB Energy India in an all-cash deal for which definitive agreements were signed on May 18, 2021. With this deal, SB Energy India is now a 100% subsidiary of AGEL. The transaction pegs SB Energy India at an enterprise valuation of $3.5 billion (~₹26,000 Cr) and marks the largest acquisition in the renewable energy sector in India. Just last week, Gautam Adani, Chairman, Adani Group had announced that the Group would invest over $20 billion over the next 10 years in renewable energy generation. Expressing his views on this transaction, Vineet S Jain, MD & CEO, AGEL, elucidated, “The addition of the high-quality, large utility scale assets from SB Energy India demonstrates Adani Green Energy’s intent to accelerate India’s efforts to transition towards a carbon neutral future. Our renewable energy foundations will enable an entire ecosystem of new industries that can be expected to catalyse job creation in multiple sectors.”
MARK E T NEWS
9EM | O c t 2021
Dormer Pramet celebrates 20 years of Dormer A002Dormer Pramet recently celebrated 20 years of launch of the Dormer A002, which helped in keeping High-Speed Steel (HSS) the go-to option for machine shops around the world. Its distinctive TiN tip coating resists flank and crater wear with low friction. This promotes increased cutting speeds, extending tool life and improving performance. Its self-centring split-point provides positional accuracy and hole-quality, giving an efficient cutting action and reduced axial forces. The A002 drills up to 4xD in steel, stainless steel, cast iron, plastics and many other materials, making it a worldwide hit for its flexibility and ease of use. From cordless drills to five-axis machining, A002 has changed the way people perceive HSS drills. Speaking at the occasion, Sharad Kulkarni, National Sales Manager, Dormer Pramet, averred, “By widening the spiral groove & its unique self-centring split-point, the A002 became a game changer in drilling applications. Its design enabled light cutting and gave excellent chip evacuation, which makes it versatile and incredibly easy to use. In addition, it saves times and offers consistent performance.”
Dynamatic Technologies to manufacture aerostructure assemblies for Boeing’s F-15EX Eagle II fighter aircraftDynamatic Technologies recently has been awarded a contract for manufacturing assemblies for Boeing’s newest tactical fighter, F-15EX Eagle II. The company will supply the F-15EX aerostructure assembly requirements from FY 2022, which will be manufactured in their manufacturing facility in Bengaluru, Karnataka. Dynamatic Technologies is also partnering with Boeing to help grow the Indian aerospace and defence ecosystem with advanced manufacturing capabilities, training and skill development in alignment with the ‘Skill India’ initiative of the Government of India. Expressing his views, Udayant Malhoutra, CEO & MD, Dynamatic Technologies, cited, “The award for manufacturing aerostructures for the F-15EX Eagle II to Dynamatic is a testimony of our partnership with Boeing.” Further, Salil Gupte, President, Boeing India, added, “We see tremendous potential for India to contribute to the global aerospace industry as an industrial and technology partner. The award of aerostructure assemblies for the latest and most advanced version of the F-15 aircraft family is a reflection of Boeing’s focus on Aatmanirbhar Bharat and a testimony to the world-class capability of our industrial partners in India.”
NEWS MARKET
DMG Mori receives development order for digitisation of tool manufacturingDMG Mori and Schaeffler intensify partnership to develop a fully integrated system for cost-efficient and sustainable manufacturing. The basis for this is an AI-based work plan creation, automatically generated work preparation and reconfigurable workflows. The aim of the new collaboration at development level is, for example, to significantly shorten quotation time by up to 80% through optimised processes and systems. Hitting the ball straight, Andreas Schick, COO – Production, Supply Chain Management & Purchasing, Schaeffler AG, conveyed, “I am convinced that our development project will benefit not only both companies, but first of all customers and users. Together, we want to create completely new, digital solutions and redefine the future of the industry.” Further, Christian Thönes, Chairman of the Executive Board, DMG MORI AKTIENGESELLSCHAFT, added, “Our cooperation is the perfect fit. With Schaeffler as an important strategic partner, we are setting new standards in the digitisation of tool manufacturing. 3D CAD data are the basis for highly automated, digitised processes and thus sustainable manufacturing.”
Dassault Systèmes’ Solidworks 2022 launchedDassault Systèmes recently introduced Solidworks 2022, the latest release of its portfolio of 3D design and engineering applications used by millions of innovators worldwide. Featuring an array of customised and flexible solutions, Solidworks 2022 enhances the capabilities & workflows used every day for design, documentation, data management and validation. Solidworks 2022 also opens up possibilities for the users to leverage the collaboration capabilities of Dassault Systèmes’ 3DEXPERIENCE platform & increase their competitive advantage by connecting to the 3DEXPERIENCE Works portfolio of solutions. Solidworks 2022 includes:• New workflows and feature enhancements in assembly and part design, drawing detailing, simulation and product data management • New features in parts• User interface enhancements to shortcut bar, configuration management, geometric tolerancing and more• Quality and performance improvements when working with large assemblies, importing STEP, IFC & DXF/DWG files, detailing
drawings and managing product data • Automatic assembly performance optimisation • Fastest graphics to date with improved display response and quality• Access to the 3DEXPERIENCE platform’s collaborative digital environment• Access to the cloud-based 3DEXPERIENCE Works portfolio of expanded applications
10 EM | O c t 2021
MARK E T I N TERV I EW
Being the first largest is not going to happen in the time frame that we have planned; the time till
2027 is too short to have that kind of an aspiration – the aspiration has to be large, but it also has to
be realistic. We’ll first get to the targeted milestone and then calibrate ourselves because the strategy
to get to number two is going to be very different from the strategy required to get to number one.
ELGi Business System is to achieve ELGi’s goal of becoming the world’s second-largest air compressor manu-facturer by 2027. Why not the first?
“Bringing alignment to a company’s goal & an individual’s goal”
...says Dr Jairam Varadaraj, Managing Director, ELGi Equipments, one of the global leaders in providing sustainable compressed air
solutions. In this confab with Juili Eklahare, Dr Varadaraj throws light on what made the company win the Deming prize, how it aligns individual
goals with the company‘s goals and explains its goal of becoming the world’s second-largest air compressor manufacturer & not the first. Excerpts…
What do you attribute the success to when ELGi won the Deming prize? What makes your company different?
The Deming prize is the recognition of the way we conduct our business. The fact that we
have been recognised as a Deming company means that our processes in every function are
extremely customer-centric & employee-friendly. But I can’t make the statement that another
company that is not Deming is not focused on customers. However, the fact that we are
recognised as Deming means that we have that centricity in our processes.
How do you align individual goals with the company’s goals? Can you give examples?
Let’s say, the company’s goal is to increase the market share for a particular product in India. So,
we take that overall productivity goal and consider that if we have to increase the market share for
this product in India, then in which geographical region is our market share low compared to other
geographies. Once we identify that geographical region, we will go further into that region and
consider which city/district in that geographical region is there where the opportunity is the highest
and our share is the lowest. Once we have identified the district, the sales manager & the sales
engineer responsible for that district will have a target that reflects our aspiration of increasing our
share. That’s an example of how we bring alignment to a company’s goal & an individual’s goal.
You are expanding your company’s focus globally, which was primarily Italy and France to a certain extent. Can you tell us about your company’s global expansion?
Our strategy is to define clearly where we want to play in a very focused strategic manner.
So, when we did that exercise about five to six years ago, we identified Australia, Indonesia,
Thailand, India, Europe and North America as the strategic markets that we will focus on. We
do business in a hundred countries and these six strategic markets is where we will invest
disproportionate amount of leadership time, money & people in building these markets.
Coming to Europe, we made the acquisition of Rotair in 2012, which gave us the focus in
Italy, and we were already doing some business in France. Our limited attention was these two
regions. But by virtue of the success we had in Italy, we decided to expand our presence.
How do you think the demand would be for your products post-pandemic?
I can only make a hypothesis here. Many companies have hit the bottom and are now coming
back up; the economy is going to start climbing back up and the governments’ programmes
for revitalisation of the economy are all going to result into more investments. So, I see this
pattern across the world, which means this is good for our business as well.
CYLINDRICAL GRINDING WITH SPEED
+91 20 27293403
Office No. 805, Deron Heights
Baner Road
Pune 411045
India
JUNKER PREMIUM-SERVICE:
Guaranteed servicing
www.junker-group.comErwin Junker
Maschinenfabrik GmbH
India Branch Office
The Lean Selection speed is an extremely effi cient high-speed The Lean Selection speed is an extremely effi cient high-speed grinding machine, perfect for grinding small and medium-grinding machine, perfect for grinding small and medium-sized production series in single or multiple-shift operation. sized production series in single or multiple-shift operation. When it comes to grinding shaft-type parts, including blanks When it comes to grinding shaft-type parts, including blanks for cutting tools, the Lean Selection speed is a very cost-for cutting tools, the Lean Selection speed is a very cost-effi cient solution and is both highly fl exible and effi cient.
Lean Selection speed
Fast and competent
24 hours a day, 7 days a week
Worldwide servicing network
12 EM | O c t 2021
MARK E T I N TERV I EW
Due to new & accurate sensor technology and vision systems developments, it has made us
think and embed them in our EOAT solutions. Applications such as ‘handle in the box’, ‘tracking’
& the ‘handling flexible parts’ have been automated in a procedurally stable manner.
A fundamental aspect of this is that the front end, which is the gripping system, has become
the decisive element for the success of various applications. The gripper or the gripping system
is a part of the digital chain of a value-added process. Earlier, end of arm tooling was fixed to
robots or gantries working in cages for safety. Now, robots are working with humans.
Nevertheless, there still are areas where a human, due to his sensory, tactile & cognitive
abilities, and empirical experience, is superior to any automation solution. Humanoid robots are
not far away and Zimmer is thinking about it.
The smart factory of the future is flexible, highly efficient and communicative. What is Zimmer Automation’s smart factory implementation roadmap?
“Preventive maintenance’ has become ‘predictive maintenance”
...says Suchitra Raibagi, Designated Partner, Zimmer Automation LLP – a part of Zimmer group – in this interview
with Juili Eklahare. She mentions how humanoid robots are not far away, how the company has its own solar park which
supports production requirements and its next step. Excerpts…
What are the current innovations from Zimmer Automation LLP’s technology areas?
Working unmanned in three shifts with improved availability is the main trend in recent
production plants and hence, ‘preventive maintenance’ has become ‘predictive
maintenance’. Sooner or later, cobots will be everywhere; man, machines and cobots will
work together. This means developing end of arm tooling for cobots. We have a complete
series in the range and are working with many reputed robot builders.
How do you work towards top quality, speed and reliability simultaneously for the production components you manufacture?
Remote maintenance and preventive maintenance are important measures to prevent the sudden
failure of components and functional assemblies in production facilities and to make maintenance
intervals more predictable. As we guarantee the unrestricted functionality of our Gripping Systems
up to thirty million maintenance free gripping cycles, few might argue that it might be fancy or might
be expensive. But they are an absolute must for Plant Operators who produce round the clock
or for a manufacturer who is producing in mass quantities. Soon this feature of maintenance-free
gripping cycles will become must-have specification as we upgrade to industry 4.0.
How are you working towards bringing in maximum sustainability through your manufacturing processes?
Our manufacturing is in Germany and our factory is built taking lot of care and with all
acceptable environment norms. We also have our own solar park which supports our
production requirements.
What is your next step for the company? From all that I have said so far, all I can say is that we are helping build reliable, smart &
agile function packages apart from EOAT to all line builders.
“The best coolant I’ve ever used.”
Do you know that proper use of the correctmetalworking fluid has an extraordinary leverageeffect on stability, quality, performance andtherefore on the costs of your production?Our machining experts can help you turn yourmetalworking fluid into a key success factor.
Test us. It‘s worth it.
blaser.com/testus
Titan GilroyTITANS of CNC: Academy, USA
MB_Titan_A4_en_CLAIM.indd 1 16.11.20 16:01
“The best coolant I’ve ever used.”
Do you know that proper use of the correctmetalworking fluid has an extraordinary leverageeffect on stability, quality, performance andtherefore on the costs of your production?Our machining experts can help you turn yourmetalworking fluid into a key success factor.
Test us. It‘s worth it.
blaser.com/testus
Titan GilroyTITANS of CNC: Academy, USA
MB_Titan_A4_en_CLAIM.indd 1 16.11.20 16:01
14 EM | O c t 2021
I NTERV IE W S TA RT-U P
We operate across two sectors – capital goods and consumer goods. In capital goods, we are
trying to plug in the gaps in the supply chain through which we solve supply chain transparency
issues for all the stakeholders, eliminate negative surprises throughout the transaction with on-
time delivery and ensure no quality escapes. In consumer goods, we are solving a combination of
capacity creation whilst creating a digital ecosystem across the country.
What problems of the manufacturing industry does Zetwerk offer solutions to?
“We build manufacturing capacities and integrate them with manufacturing capabilities”
…mentions Srinath Ramakkrushnan, Co-founder & COO, Zetwerk, a global manufacturing network for custom
manufacturing. In this tête-à-tête with Anvita Pillai, he discusses the business model & USP of Zetwerk, their new line of business,
the $150 million funding and more. Excerpts…
What sets apart your startup in the market in comparison to competitors? What are your USPs?
Zetwerk, contrary to its competitors, is not offering a product to the customer. We are building
manufacturing capacities and integrating them with manufacturing capabilities. We, across
different manufacturing processes, such as sheet metal, injection moulding, typecasting,
extrusion, etc identify people with good capacities, who have good capabilities and integrate them
with the stakeholders on our platform.
Your startup recently bagged a $150 million funding. Can you elaborate on what the funds would be used for?
We are channelling the funds majorly towards our international expansion. We are building out
manufacturing supply chains in the US and SEA countries like Vietnam, Taiwan, Bangladesh and others.
We are also focusing on strengthening our product and technology footprint. Simultaneously, we are
aggressively recruiting folks into our technology so that the core agenda of our product intake function will
be to build a digital operating system that integrates all the stakeholders of the manufacturing industry.
Lastly, we are entering newer capabilities & supply chains, for example, the aerospace & defence sector.
About your entry into the aerospace and defence sector, could you tell us the reason for entering this relatively high-risk sector and about the services you would be offering?
The aerospace sector is not new to us. Even as early as 2019, we were doing machining jobs and
serving in small volumes. We also picked up a certification called AS9100, which is required to
participate in the aerospace supply chain. Now, we are partnering with many manufacturers who
have the skills and capacities to fulfil the country’s Make in India requirement. We currently have
Zetwerk Kinetics and Zetwerk Aerosystems; our focus will be metallic systems sub-assemblies
for different aerospace and defence entities through the Zetwerk Kinetics entity and composite
systems manufacturing through the Zetwerk Aerosystems entity.
What are your plans for the Indian market? How do you plan on staying ahead of your competitors in both, manufacturing & aerospace sector?
We believe we are already pretty diversified in India, and our business is growing rapidly. We have built
sizable capabilities at scale in capital goods, where we see the capex cycles are turning back. We
are now focusing on building capabilities in sectors such as infrastructure, oil & gas, renewables and
green hydrogen. We plan to build the complete technology suite in the consumer goods segment to
essentially do backward integration and create a more holistic supply chain footprint.
15
WORLD ANALYS I S OP IN ION
EM | O c t 2021
XR extending the dimensions of Indian manufacturing
Despite the pandemic and interim global slowdown, the manufacturing industry is thriving on the path of revival. An IHS Markit study shows that India’s manufacturing PMI for September increased from 52.3 in August 2021 to 53.7 points. In addition, Trading Economics forecasts the sector to touch 55.0 points by the end of this quarter. The growth can be partly attributed to the adoption of digitalisation since the onset of COVID-19. While only 10% of industrial enterprises adopted digitalisation in 2020, industries have been picking pace when it comes to using technology to replace repetitive, tedious work on the shop floor. It is now expected that by 2025, over 50% of industrial enterprises will make IIoT-based platforms a part of their enterprises.
While various digital technologies are making their way into the industry, XR, aka extended reality displays the potential to offer plenty of value to the manufacturing sector. An amalgamation of Artificial Intelligence (AI), Augmented Reality (AR), Virtual Reality (VR) and Mixed Reality (MR), XR is poised to surge into a $125 billion market in 2026 from its current market valuation of $33 billion, as per a Markets and Markets study.
The gaming industry is considered the biggest consumer of XR – a classic example being the game Pokémon Go. Although gamers had a comparatively easier learning curve than what
the manufacturers could have, the technology can help the industry streamline its complex assembly, maintenance process, logistics, safety training, etc. For instance, Boeing improved the dynamics of its complex assembly system by introducing smart glasses, which provides voice commands and information that reduced the company’s wiring production time by 25% and the error rate to near nil.
Besides lack of general awareness and the Indian market’s rather reluctance to adopt new technologies without international use cases, delay in data readiness and understanding its potential for quick ROI have been few reasons why XR has been limited to only the gaming and entertainment industry so far. But now, the benefits incurred by the early adopters of the technology, such as Siemens, Boeing, Airbus, Ford, Volkswagen, among others, are setting a key trend for the manufacturing sector throughout.
The growing competition in the manufacturing sector calls for innovation such as XR. The technology isn’t just a medium of entertainment but also a mode of collaboration. It has the potential to improve ones manufacturing floor and ensure effective end-to-end collaboration throughout. Despite the slow growth in terms of technology adoption, India can catch up, similar to how it picked up the pace while adopting other Industry 4.0 technologies and grow manifolds faster.
Anvita Pillai, Assistant Editor
16 EM | O c t 2021
COVER STO RY T EC HNOLOG Y
Innovative technologies are rapidly advancing machine engineering processes, driving positive change in the industry, prompting companies of all sizes to meet the challenges and trends facing machinery manufacturers towards these evolutionary approaches, thus enabling machine manufacturers to take advantage of industry trends to drive the adoption of new technologies. The Cover Story outlines the trends, technologies and processes in place that are driving advanced machine engineering.
ADVANCED MACHINE ENGINEERING Technological innovations driving change
16 EM | O c t 2021
COVER STO RY T ECHNOLOG Y
17EM | O c t 2021
TECHNOLOGY COVER STORY
It is an intimidating mission to design, validate and manage modern-day manufacturing and assembly machines to achieve first-class quality while optimising cost. Advanced machine engineering marries the development of the digital twin with the collaboration of the many disciplines to develop the machine into a complete solution suite. These are complex, multidisciplinary designs – combining mechanical electrical and fluids – requiring a single source of truth in design to address the back-and-forth process that exists between engineering silos. In addition, because nearly all machines require automation code, advanced machine engineering enables virtual machine simulation, testing out the PLC code in a virtual world with a digital machine, before testing it on a physical machine. This addresses the need to validate what the machine will do before installation on the factory floor, only to discover errors. Therefore, anything that was tested physically in the past can now be simulated virtually.
Industrial machine industry – Trends
Industry megatrends are affecting customers operating machines within their respective industry audience. Technology advancements are driving industrial machinery companies to realise Industry 4.0, with some staggering implications. Consider the following trends that are reshaping the engineering, manufacturing and service operations for most machinery suppliers:
• Consumer driven customisation – Machines automate processes to help companies lower costs & expedite delivery of their goods to the end-user. Hence, trends in the broader consumer market ultimately end up defining what machinery customers need. A typical consumer product’s development cycle is compressing – lot sizes are smaller and product life spans are shorter. So, machinery customers need machines that are more flexible and adaptable to an ever-changing product mix, often with customised features or functions that require machine builders to innovate more quickly.
• Smart machines - Machinery component suppliers have
completely embraced IoT enabled devices. Thus, machinery manufacturers are on a steep learning curve in knowing how to take advantage of the available information. The number of I/O (input/output device-driven) channels and different communication protocols (wired networks, and wireless 5G) provide an order of magnitude increase in information flow compared to recent years. Therefore, automation code developers are forced to choose which channels to use while building more intelligent machines.
• Hyper automation – Discrete programming is enabling machine users to gain insights from all the IoT information. The hyper-automation trend requires vast amounts of data & cloud-based analytics to accelerate learning about machine behaviour and performance to automate machine functions. Also, hyper automation is enabled by the emergence of low-code tools that help machine users mine data analytics for many business processes, including manufacturing optimisation, engineering reliability and cost reductions.
• Global innovation and competition – Global, highly innovative competition has always existed, but now the challenge comes from more flexible, agile start-up companies that begin from the basis of machine learning and are not encumbered by existing business processes or legacy customer engagements. Some offer Production-as-a-Service (PaaS) and other innovative software-enabled service monitoring tools and machine optimisations – even on competitor’s machines.
Advanced machine design – Customisation and simulation
Therefore, the above listed trends are driving consumer-driven customisation, thus resulting in immense changes in machinery. People expect to get what they want when they want it. This equates to a shorter lifespan for these products. Manufacturers need to ramp up very quickly to rapidly produce sophisticated products while supporting more variants. Advanced
Manufacturers need to ramp up very
quickly to rapidly produce sophisticated
products while supporting more variants
18 EM | O c t 2021
COVER STO RY T EC HNOLOG Y
machine design is being impacted by this dynamic towards customisation and escalating the pace of change. Consequently, machines need to be more adaptable in reacting to changing consumer trends. Performing simulation earlier in the design is enabling the generative design movement in CAD. Instead of designing first and then simulating afterwards to uncover problems with the design, the generative design uses forces, kinematics and the constraints in the design to assist in shaping it. Also, this is useful even when not using Additive Manufacturing technologies. Simultaneously, there is an increase in collaborative multi-discipline design, with much electrification in advanced machinery that it is difficult and challenging to simulate without a way to validate the PLC and automation code that governs the machine. The technology and tools are now in place to significantly drive change and exponentially increase efficiency, giving a true competitive advantage to machine builders, helping them to deliver machines into the market faster.
These advanced machine engineering capabilities enable a truly comprehensive digital twin with multidisciplinary design, virtual machine simulation & commissioning and a multi-disciplinary bill of materials. Let’s discuss these differentiators in further detail.
Key differentiators – Multi-disciplinary design, virtual commissioning and multi-configuration management
The following solution differentiators are separating Variant Configuration (VC) and multi-configuration Bill of Material (BOM) management:
• Multi-disciplinary design – Machine manufacturers are leveraging a multi-disciplinary design to make their manufacturing more efficient. Multi-disciplinary design is defined as assessing the complexities of building a machine, including engineering the design and manufacturing. Traditionally, most machine manufacturers focused on CAD and manufacturing parts within tolerance for everything to function mechanically and the mechanical arrangement and
assembly related to the machine. The machine was primarily a mechanical piece of equipment, like yesterday’s automobile or airplane. Therefore, the mechanical design was in one area with the electrical design, while the schematics and software development were in their separate silos. However, the industrial machinery paradigm is changing. For example, the electrical motors and rotary equipment to move camshaft gears are driven by software and PLC codes, thus accelerating performance-based programs in recent years. The software is adaptable to conditions on the floor and the machine reacting to real-time sensor readings. Even something as simple as a cylinder extending and retracting can be based on a pressure differential and flow regulation that were unavailable to small- and medium-sized businesses a few years ago due to prohibitive cost. As a result, more mechanical capabilities and features are being replaced by software. It’s a game-changer for every machine designer. Multi-disciplinary design is a blending of capabilities and skill sets in a more collaborative environment. This scenario pays dividends in quality output of the machine design – everything works together and has its place. It is more of an art form than bolted on electrical, sensors and cable-runs – it is an integrated solution. Therefore, it is creating harmony in the multi-disciplinary design that did not exist when disciplines were in silos, thus transitioning into advances in simulation.
• Virtual machine simulation and commissioning – A second differentiator provided by advanced machine engineering is virtual machine simulation and commissioning. This refers to how a machine proves or validates the software code in the virtual world before physically operating on the factory floor. The behaviour of the machines is being driven by software, which is why simulating the code running on a virtual twin of the machine generates substantial dividends in time and resources. With virtual commissioning, the PLC software validates in a managed environment with a full modular product development strategy. Now, machine builders have the simulation upfront and can link the software to the modules. This set up is a ground-breaking achievement for
Instead of designing first and then simulating
afterwards to uncover problems with the design, the
generative design uses forces, kinematics and the
constraints in the design to assist in shaping it
Projekt2 03.07.17 10:34 Seite 1
20 EM | O c t 2021
COVER STO RY T ECHNOLOG Y
companies to be competitive in this space.Moreover, virtual simulation provides a physical safety
aspect because if the machine collides in the virtual world, it is substantially safer and less costly to fix than on a physical machine. Virtual commissioning drives the behaviour of the motors, integrating that into the kinematics. This is powerful because a mechanism on a machine might move faster than expected, leading to an actual impact load greater than what was anticipated. Replicating the kinematics in virtual commissioning uncovers potential hazards leading to a swift resolution. Furthermore, by embracing virtual commissioning and visualisation, machine builders bring customers into a virtual reality wall to interact with the machine in its digital form. From a financial perspective, this pays huge dividends because no one purchases a machine sight unseen. Also, they will not purchase it merely on a claim of virtual simulation via running software code. Therefore, a customer needs to substantiate that a machine works before it is shipped to their plant.
Many software integrations and safety factors are necessary to run a machine, and this becomes a stressful and monumental task to perform physically with the customer in attendance. Therefore, the virtual world is ideal for turning a machine on and carrying out commissioning. There is less pressure for both the machine builder and its customers. It brings together the engineering upfront in the design, with the collaboration of various disciplines for testing the machine code.
• Bill of Materials (BOM) – A third differentiator of advanced machine engineering is the multi-disciplinary BOM for machine builders as they create more sophisticated, smart machines. It gives manufacturers greater flexibility to respond to customer demands for customisation. Every machine and every order that a machine builder receives is often a new project. Consequently, machine builders need a way to track the diverse options and variants, for integrating requirements along with project and change management, while managing the entire BOM throughout
the product life. This means from the original engineering design, through manufacturing and then managing that machine bill of materials throughout its service life, a level of planning capability is required for every engineering discipline, providing a more agile approach. Also, there is a need for traceability of customer requirements, engineering requirements and activity that is performed by the design engineer, electrical engineer and controls engineer for executing the project. This includes the journey from high-level customer requirements specification document through the BOM structure and attaching it to the actual task that is necessary for the deliverable. This process provides a level of capability for ensuring and reducing the risk in meeting customer requirements, leading into the topic of the sophisticated software solutions that are implemented into every machine.
Industrial machinery – Advancing software solutions for smarter machine
Advanced software is a necessity for machine manufacturers facing competitive globalisation, shrinking margins, rapidly expanding customisation, environmental and government regulations, as well as Industry 4.0 and other smart factory initiatives. In the face of these significant challenges, machines must be smarter. If a company is unable to address the complexity that comes with adding software to their machines or developing an advanced machine from customer requirements to compete aggressively on a global basis, their days of profitable growth are limited. Essentially, the core requirement is becoming machine design innovative in the operation and development process. The difference between a company being good and great comes down to the quality and innovation in their automation code. Great code provides intuitive user interfaces, promotes ease of use and takes advantage of new hardware capabilities and software algorithms to help machines move faster, more safely and with less wear and physical stress on components. However, writing great code is not enough, as the lines of code in machines today
Advanced software is a necessity for
machine manufacturers facing competitive
globalisation, shrinking margins, rapidly
expanding customisation, environmental and
government regulations, as well as Industry
4.0 and other smart factory initiatives
HELICAL DRILL THREAD MILLING INTO SOLID MATERIAL UP TO 66 HRC
MTMH3-Z
Guhring (India) Private LimitedPlot No. 129 l Bommasandra Indl Area l Phase IV l Bangalore : 560099
Tel: 080 40322500 - 09 l Mobile: 0 8861007723 l Fax: 080 40322510 l [email protected] l www.guhring.in
22 EM | O c t 2021
COVER STO RY T ECHNOLOG Y
have an increased magnitude of complexity. Therefore, it is critical to test that code in the virtual world and run it through all the use cases before loading it on the physical machine.
Companies are under pressure to deliver more customised machines faster with added complexity. It’s no longer possible to rely on and safely physically validate the machine. Every machine is released to the customer with a set of binaries that represent the compiled machine operation and UI code. With conventional practices, programmers scramble to get last-minute changes to the code locked in before the machine ships. In this chaotic environment, it is imperative to retain a locked version of the final code to use for several purposes – service, catastrophic backup, lessons learned for future machines and upgrades to previous machines in the field. Having a code repository is not enough. Each software variant must be traceable and retrievable to the serial number machine as part of the machine bill of material. Through the machine life, future upgrades in both hardware and software need a traceable system record, representing the living digital twin of the machine.
Industrial machinery – Digital twin
The digital twin holistically is a representation of the physical machine – its performance and recipe for manufacturing it. It corresponds to everything that constitutes the machine: mechanical, electrical, hydraulic, fluid, pneumatics, design domains, performance, simulation and automation code. Moreover, the digital twin encompasses the manufacturing and service life, basically having a digital version of the as-maintained, as-serviced machine from the point of origination through to end-of-life, when it gets recycled. There is a blurring of lines between mechanical, electrical and software, so there cannot be a digital twin of the machine without representing all the domains. Also, a comprehensive digital twin is imperative because every function a machine performs depends on an integration of mechanical, electric, pneumatics and software domains. Therefore, these domains must be included in the digital twin to assist in creating and maintaining the most comprehensive digital twin.
As machines become more complex and machine builders create more variants that requires a digital twin of each machine built, there needs to be traceability of the machine’s serial number at the point it is released through manufacturing and into service life. Advanced machine engineering innovations, like digital twin, impact all areas of manufacturing to affect the operations of a plant positively.
Expediting next-gen virtual simulation into manufacturing
The market is ripe for proficient experts uniquely positioned with capabilities for providing customers with the solutions by serving the product improvement process. The next generation of software is advancing beyond current versions. The methods for engineering are transitioning and becoming exponentially more proficient than a decade ago. The technology and tools are driving change to significantly increase efficiency to create true competitive advantages for machine builders and suppliers by expediting the delivery of machines into the market via advanced machine engineering.
Advanced machine engineering solutions are emerging today that address the challenges and trends that are driving the machinery industry today. These include multi-discipline design, virtual machine simulation & commissioning and multi-disciplinary BOM and configuration management. Multi-disciplinary design enables collaboration between the various disciplines, including mechanical, electrical, software and fluids, all within a single design environment, thus, the need to build an accurate digital twin that supports these disciplines. Furthermore, virtual machine simulation and commissioning is enabled by tightly integrating the simulation solution supporting parallel product development. Finally, there are now advanced capabilities for managing the entire BOM for all the options and variants required to advance machine builder support throughout its product life, from the original engineering design through manufacturing, and into service life. ☐
Courtesy: Siemens Digital Industries Software
A comprehensive digital twin is imperative because
every function a machine performs depends on an
integration of mechanical, electric, pneumatics and
software domains. Therefore, these domains must be
included in the digital twin to assist in creating and
maintaining the most comprehensive digital twin.
UNLEASHTHE CUTTING POWERESTRAMET S 77 – THE COOLANT REVOLUTION
Oemeta India Pvt. Ltd . | 710 Indo-German Chamber of CommerceNucleus Mall, 1 Church Road | Camp, Pune - 411001 | Tel.: +91 204 10 47-112 | [email protected]
Headquarter: Oemeta Chemische Werke GmbH | Tel.: +49 (0) 4122-924-0 | [email protected] estramet.com
• Based on synthetic ester oils
• Increases tool life by up to 100 %*
• Low consumption * based on trials conducted at PTW Darmstadt
24
MANAGE ME N T I N TERV I EW
EM | O c t 2021
“Technologies are evolving at a much faster rate today”
…says Seenivasan Balasubramanian, Chief Executive Officer, Indian Aerospace Manufacturing Private Limited (IAMPL), a joint venture (JV) between Rolls-Royce and
Hindustan Aeronautics Limited (HAL) in Bangalore. In this interview with Juili Eklahare, he discusses how in commercial aerospace the immediate priority is to understand how
the business is going to evolve, the digital initiatives at IAMPL and how we need to keep in view the benchmarks of excellence that are going to be at play in the future. Excerpts…
high-precision machined, special processed parts, including rings, casings, shrouds, seals for the technologically advanced civil and defense aero-engines. Today, we have integrated machining technologies and special process capabilities under one roof which makes us competitive in terms of delivering zero-defect parts faster.
Presently, having gained the experience in the global quality and supply chain requirements, we are also ready to explore opportunities with other engine manufacturers in the industry.
Over the past 60 years, Rolls-Royce and Hindustan Aeronautics Limited (HAL) have produced engines together for military applications. Can you tell us how this collaboration has helped in nurturing the capability of the Indian aerospace industry?This collaboration has worked in three primary ways – firstly, implementing the best practices and standards of quality for aerospace & defence across the industry. Secondly, implementing efficient production systems. And thirdly, hand-hold in developing methods, skills needed in the industry with the many years of their experience.
What do you think of the forecast for India becoming a global aerospace hub? Is it bright?With our attractive civil and defence market, the availability of engineering capability & talent and competitiveness in cost, there is a bright opportunity for Indian aerospace to be a global hub. All the stakeholders need to work together, including the customers, suppliers and the government. We need to understand that technologies are evolving at a much faster rate today. Ten years from now, the job description of our engineers
You have a ‘Make Things Happen’ attitude. With a long experience in the automotive & aerospace verticals, what do you think are the priorities for the industry right now and actions that must be taken at the soonest, for making the Indian industry a global manufacturing destination?Understanding the changing customer and market needs is very important in the present situation. With the technology expecting to change to electric & hybrid in automotive, sustainability commitments are becoming a priority. Infrastructure development is also a key for moving forward.
In commercial aerospace, the immediate priority is to understand how the business is going to evolve and how that will be facilitated across the world. This is the time for
the industry to improve the performance to ‘best
in class’ levels for customers and to demonstrate the trusted partnership.
Can you tell us more about the
capabilities IAMPL has and the services
it offers?We manufacturer
more than 160 different
25
I N TERV I EW M ANAGEMENT
EM | O c t 2021
will be very different from what it is today. We need to keep in view the benchmarks of excellence that are going to be at play in the future.
IAMPL was one of the suppliers to Rolls-Royce which got nominated for Rolls-Royce Global Supplier of the year recently. What do you attribute this success to? Can you give us more details on this?I attribute this to the ‘power of people’ in understanding the requirements to be a globally competitive player, working with a focus and doing things right the first time and every time. Rolls-Royce expects excellence in everything. Over the last ten years, we have trained our people to be the best and continue to implement that culture here at IAMPL. Also, Rolls-Royce helped us in training our people for its production systems. It is a step-by-step approach implemented right from the stage of process design up to the point of product shipment.
With digital/ smart manufacturing becoming the buzzword for the manufacturing sector, what are the initiatives at IAMPL in this area?Digital has helped us to reduce, and wherever possible, eliminate manual intervention. This is helping our engineers to focus more on process improvement. We have done a pilot project of developing a system-designed quality plan, where the alpha-level accuracy matches or betters the manual effort. This will help us pursue excellence further. We have to demonstrate our capabilities on these parameters because Rolls-Royce continuously evaluates the performance of a vendor and rates
vendor performance on quality, delivery, cost and management initiatives. To be a class-leading vendor, we need to score 90% or more and we are there. We have developed a digital-twin based Manufacturing Execution System (MES) with an integrated inspection system for every operation. We started this digitally empowered MES from 2018-2019.
We can proudly say that, in our industry, we have pioneered the digital twin-based manufacturing execution system in terms of integrating it with the production system and using its data for further improvements. Going forward, we aim to use our performance data for designing processes.
We are working on an AI-based system which can provide decisions on control plans and ensures that the processes are in control. We have also adopted IoT techniques for further savings of power. That is a part of our digital drive. We use IoT-based devices for improving our efficiency in power consumption.
How is IAMPL / Rolls-Royce placed in supporting India’s ‘Make in India’ campaign? How are you implementing the same in growing the Indian Armed Forces?We have demonstrated our integrated capabilities of machining, special processes and how they all are coupled with our digital manufacturing execution system, all available under one roof. Our constantly evolving capability is a natural advantage shared with HAL in all our joint programs. At the same time, there are certain other manufacturing techniques where we have learned from them. It’s a synergy. I see this as supporting our industry ecosystem where we can become class-leading vendors to the global aerospace industry. ☐
THERE IS A BRIGHT OPPORTUNITY FOR INDIAN
AEROSPACE TO BE A GLOBAL HUB
‘‘
Seenivasan Balasubramanian is a Mechanical Engineer with a post-graduation in Manufacturing Management from BITS Pilani and an Executive Post Graduate Diploma in Business Management from Symbiosis International University. His experience spans across manufacturing, supply chain, procurement, program management and multi-location plant management. He has handled SAP implementations and transferred multiple programs from Europe, Asia and the US to India and led green-field projects.
26 EM | O c t 2021
V IEWP O IN T MA R K ET
India will be giving about $3.5 billion in incentives to auto companies over a five-year period under a revised scheme to boost the manufacturing and export of clean technology vehicles. With a lot of incentives that have come up for the automotive sector, the Viewpoint digs deeper into what makes this incentive different and how it promotes electric vehicles & hydrogen fuel-powered vehicles.
Boosting clean technology vehicles
Juili EklahareAssistant [email protected]
“ This scheme will definitely speed up investments done by global companies in India”
The intention is clearly for the government to push strongly for clean fuel technology. CNG, ethanol, etc, as far as my understanding goes, are definitely not included in this scheme. But technologies like fuel cell, hydrogen, etc are definitely very much involved. In my view, this scheme focuses on two aspects – one aspect is the investment done from the company into these kinds of technologies and the other aspect is the mechanism of incentive that is based on additional stage realised year after year. The global manufacturers are very much present in the Indian automotive space – most automotive players are doing business here. So, I think this scheme will definitely add a benefit in order to speed up and accelerate the investments done by global companies in India, which I think is one of the government’s intentions to launch this scheme i.e. to make India a global hub for production of vehicles exported also outside of India.
Diego Graffi,Managing Director & CEO,Piaggio Vehicles
“Recent policies are broader in spectrum in terms of technology & people it affects”We surely observe a firm commitment of the government towards cleaner technologies this time.
Previous schemes under FAME-1 were perhaps a little ahead of their time, while recent policies are broader in spectrum in terms of both technology and the people it affects. The EV technology value chain is still young but is certainly evolving at a phenomenal rate. EV companies can be assured that the Indian government is willing to offset the cost of development of a superior and safer electric drivetrain. EV companies and their ancillary units like BMS/battery manufacturers can and rightfully should invest more in better functionality, control and design. The scale at which this scheme applies certainly calls for global players apart from Tata, Mahindra, such as Audi and Porsche, to announce their plans of launching and manufacturing in India. Minimum investment over five years and 10% growth in sales each year can yield incentives of up to 8-18% of the sales value of the vehicles or components.
Harshawardhan Wadikar,Head of Innovation – Product & Quality,Kosh Energy Technologies
27EM | O c t 2021
MARKET V IEWPO INT
“The goal is to create global manufacturing champions in the country”It is envisaged that there will be a net savings of ₹200,000-250,000 crores on account of oil
import bill reduction during the period of this programme due to EV adoption. Advanced Cell Chemistry (ACC) batteries manufactured under the programme is expected to accelerate EV adoption. The production linked scheme for ACC batteries is technology-dependent and varies with the cycle life of the battery. With higher energy density and higher cycle life, the incentive amount will be higher. These factors make this scheme very different from other schemes for auto companies. Plus, the goal is to create global manufacturing champions in the country and attract firms exploring a China-plus-one strategy for production. The plan is to set up a 50-Gigawatt hour (GWh) manufacturing capacity for advance chemistry cell batteries by attracting investments totalling ₹45,000 crores. The incentive will be paid out on the basis of sales, energy efficiency, battery life cycle and localisation levels. Such battery storages will cater not only to electric vehicles but also to the consumer electronics industry and electricity grids.
“ This incentive will promote local manufacturers to foray into the development of new technologies”
This scheme primarily focuses to benefit EV manufacturers and low emission vehicle manufacturers, unlike previous schemes that were launched. This is in line with the government’s strategy to promote a clean and environment-friendly transport industry. The new scheme can help EV companies reduce the initial cost of vehicles to make them more competitive to fuel vehicles and can be utilised in R&D to develop cheaper, more charge-efficient batteries and can also be used in developing charging infrastructure in the country. I believe the idea here is that this incentive will promote local manufacturers to foray into the development of new technologies and parts as the demand for EVs rises. It will also momentarily serve as a temporary relief to EV manufacturers for the high import charges on parts. This is good news for global manufacturers as it is an economical relief for them.
“ Localisation is important to get the maximum benefit of this scheme”The key difference I see between this scheme and the policies that have been brought
up in the past is that the previous schemes announced were more consumer-driven – they were more beneficial to end-consumers in terms of subsidy and other benefits. This scheme is leveraging renewable energy & electric vehicles. It has a direct benefit to the manufacturers; so, it is definitely a great move from the manufacturers’ standpoint. It’s going to attract all the global manufacturers as well as the local. Besides, it will boost the confidence of OEMs. Plus, localisation is important to get the maximum benefit of this scheme. All manufacturers will start eyeing India while the government is supporting to the fullest. So, even for the global players who are looking to invest in India, this is the right time.
Maneesh Singh,VP - Strategic Development, DAO EV TECH
Akihiro Ueda,CEO and President,Terra Motors
Venkat Rajaraman,Founder& CEO, Cygni
28 EM | O c t 2021
CUTT IN G TO O LS F OCUS
Advancing cutting tools through titanium machiningIn spite of its demands on machining, titanium’s acceptance across manufacturing segments cannot be overlooked. A fitting selection of cutting tool design and machining strategies is tremendously vital for machining titanium and its alloys. This article explains how the choice of the right tools helps in overcoming challenges associated with complex machining of titanium, a preferred material in aircraft manufacturing.
Imag
es c
ourt
esy:
shut
ters
tock
As commercial aircraft OEMs seek to make airplanes lighter and more fuel-efficient, the technologies deployed by the aerospace industry have undergone a radical transformation. One of the major factors that have influenced the performance of commercial aircraft is the evolving dynamics of material science – yielding changing composition of metals used. Comprising high strength to weight ratio, corrosion resistance, fatigue resistance and capability to work in high temperature zones, titanium is one of the primary materials for aerospace structures and engines. Yet,
its low modulus of elasticity, poor thermal conductivity, high chemical reactivity and hardening properties, together, make it one of the toughest materials to machine. Therefore, an appropriate selection of cutting tool design and machining strategies is extremely important for machining titanium and its alloys along with proper machine, coolant and work holding capabilities in order to maximise productivity & optimise costs.
To design the right machining solutions, it is important to understand the metallurgical properties of titanium.
FOCUS CUTT ING TOOLS
29EM | O c t 2021
Titanium alloys & their properties
Titanium undergoes various phases, from α to ß and depending on these phases, titanium alloys are classified into four main groups:
• Unalloyed/untreated titanium – excellent corrosion resistance, but lower strength properties
• Alpha structure (α alloys) – great creep resistance and low to medium strength
• Beta structure (β alloys) – high strength and high density, but the most difficult to machine
• Alpha beta structure (α-β alloys) – medium to high strength and includes alpha and beta stabiliser elements
The commercially viable alloys are ß and (α-ß). ß alloys contain transition metals, such as V, Nb, Ta and Mo that stabilise the ß-phase. Examples of commercial ß alloys include Ti11.5Mo6Zr4.5Sn, Ti15V3Cr3Al3Sn and Ti5553. Beta alloys are readily heat-treatable, generally weldable and have high strength. Excellent formability can be expected in the solution treated condition. However, they are prone to ductile-brittle transition and thus, are unsuitable for cryogenic applications. Beta alloys have a good combination or properties for sheet, heavy sections, fasteners and spring applications.
In comparison, α-ß alloys contain both α and ß stabilisers. The simplest and most popular alloy in this group is Ti6Al4V, which is primarily used in the aerospace industry. Alloys in this category are easily formable and exhibit high room temperature strength and moderate high temperature strength. The properties of these alloys can be altered through heat treatment.
Associated challenges
Some challenges associated with machining comprise high-
chemical reactivity of titanium alloys, which causes the chip to weld to the tool, leading to cratering and premature tool failure. In addition, the chip-tool contact area is relatively small, resulting in large stress concentration due to these higher cutting forces and temperatures, resulting in premature failure of the cutting tool.
The machining of flight critical components (engine rotatives) at optimal production rates requires reliable, high precision tooling for semi-finishing and finishing turning operations. The entire process needs to be secured to avoid any damage to the part that requires advanced chip breaker technologies.
The requirements include:• Tool stiffness/stability• Heat management• Coolant flow• Grade toughness (chipping resistance) • Heat resistant coating• Chemical wear resistance• Micro geometry that promotes low cutting forces• Stable machines and conditions that promote higher Metal
Removal Rates (MRR)
Stages of titanium machining and choice of the right tooling solutions
Titanium is typically produced in the shape of plates and bars, as well as forgings and castings. The buy-to-fly ratio is typically between 10 and 16, meaning a raw material of 10 kg titanium ends up being a finished part with the weight of one kg.
Typically, titanium machining is carried out in three stages – pre-machining, roughing and finishing, as illustrated in the diagram on the next page.
To design the right machining solutions,
it is important to understand the
metallurgical properties of titanium
30 EM | O c t 2021
CUTT IN G TO O LS F OCUS
1. Pre-machiningFlat bottom drilling is ideal for the pre-machining of high
temperature alloy airframe structural parts. Quickly removing large amounts of material remains a challenge for these types of components. Traditionally, the first step of the process is to enter the material by using ramping techniques, which is time-consuming and leads to low metal removal rates.
Speeding up the machining process requires a tool that combines the advantages of a flat bottom drill and a z-axis plunge mill. The flat bottom design eliminates radial forces, while four effective cutting edges provide increased feed & speed rates, leading up to 200% higher metal removal rates than traditional ramping techniques and freeing up capacity for aerospace manufacturers.
Once the drill has shaped the basic structure of the component, it progresses for the roughing and finishing steps.
2. Roughing The Buy-To-Fly ratio requires efficient removal of the
excess material achieved through titanium roughing applications, which causes the cutting edge to be exposed to extremely high temperatures for a long time. A recommended roughing solution for a large structural part is helical shoulder milling that addresses the high metal removal needs in aerospace machining. To achieve lowest possible cost per edge, tool makers have come with up to eight cutting edges per insert in Helical Milling Cutters. Such designs can reduce power consumption up to 50% and can deliver the highest MRR, especially in high-temperature alloys.
If the work holding is weak and tool overhang is high,
another technique that can be used is High Feed Milling (HFM). With low entering angles, these cutters provide optimum cutting forces with maximum stability. Also, in materials like titanium, which has an extremely low thermal conductivity (thermal conductivity of Ti6Al4V is ~ 7.2 W/m K), it is prudent to work with higher feeds than speeds.
An array of new generation PVD coatings with alloyed substrates are available, which provide resistance to thermal cracks, least co-efficient of friction and prevent chip welding in roughing applications. The cutter body should be constructed of higher-quality steel for improved stiffness and rigidity to withstand the high cutting forces. The variable helix design helps to break the harmonics that lead to chatter, further improving tool life, part quality and throughput. Positive cutting action reduces vibration, minimising the cutting zone temperature and prevents work hardening tendencies.
3. Finishing Finishing operations are mostly performed with solid
endmills. Some unique design features include unequal flute spacing, variable helix configuration to minimise chatter & vibration, eccentric reliefs, twisted end face for increased stability & ramping along with the most optimised geometry and flute design for titanium machining. In some advanced designs, endmills come with positive clamping technologies (safe lock) which prevent tool pull-out and ensure high process security. High performance endmills will also have features like chip gashers for smooth chip evacuation and lower cutting forces. ☐Courtesy: Kennametal
32 EM | O c t 2021
ELECT R IC V E H ICLE S T ECH N OL OG Y
The thrill around electric vehicles (EV) has put the aluminium industry in the limelight. Electric vehicles are set to increase demand for aluminium tremendously, with modernisation in products being the downstream aluminium sector’s emphasis. The article talks about how aluminium is making the EV story a success, its benefits and how it is an automaker’s dream metal.
Policy incentives and technological advancements are going to guide the manufacturing and adoption of EVs (or Electric Vehicles) in a big way, as India witnesses a sea-change in its attitude towards the segment. Electrified and efficient are the words often used to describe the future of the automotive sector, which is also set to push the demand for aluminium exponentially, with innovation in products being the focus of the downstream aluminium sector.
A bright spot
In the early days, Godrej’s evaluation of accuracy was difficult to obtain. National Aerospace Standard NAS979 tests (standardised cutting tests for CNC milling machines) were performed by a highly skilled expert as part of machine commissioning. These tests were problematic and time-consuming to carry out. In 1996, Godrej purchased Renishaw’s
RK Jain, Sr Vice President – Commercial,Jindal Aluminium Limited
Downstream aluminium: Meeting the EV demand through innovation in production
Imag
es c
ourt
esy:
shut
ters
tock
7410009435/36 aandd -
34 EM | O c t 2021
ELECT R IC V E H ICLE S T ECH N OL OG Y
EVs are a bright spot in the Indian automotive segment as they are a key element of the transition to cleaner energy. The Government of India data released earlier in the Parliament has a promising story to tell. India saw 69,012 units of electric vehicles being sold in 2017-18.
These numbers went up to 143,358 units in 2018-19 and to 167,041 units in 2019-20. The growth in units includes sales of two-wheelers, three-wheelers and buses. Two-wheelers have led this growth. With the government having its eyes set on selling only electric cars in India after 2030, the sector is poised for the biggest renewable energy revolution the country has seen.
Making it drive
Making the EV story successful is aluminium, both used in the manufacturing of electric vehicles and also in creating the necessary charging infrastructure. A higher performance metal, the push for EVs is adding importance to the role that this light and sturdy metal will play as it brightens prospects for the downstream aluminium segment as a whole.
From the challenge of helping vehicle manufacturers in reducing vehicle weight to improving the efficiency of conventional vehicles or to better the range of electric vehicles, aluminium extrusions are an increasing part of the solution.
Customisation in production
The shift to electric vehicles is no longer just an option – it is a must. India, China, many European countries and the United States have all already decided in favour of electro-mobility, supported by R&D programmes, charging infrastructure and buyer incentives.
This is an opportune moment for the downstream aluminium sector – which is an old partner of the automobile industry and finds its use in the making of a vehicle body, doors, trunks, hoods, bumpers, crash boxes, brakes, cables, wheels, etc – to increase its overall usage.
However, bringing about innovation in production is the need of the hour for the Indian downstream aluminium manufacturers if we want to meet the EV demand. Innovation in production is also crucial to raise the average quantity of aluminium used per vehicle from India’s average of 29 kg per
vehicle to global usage standards of 160 kg or 250 kg as predicted for use in EVs in the time to come.
The challenge
Automobiles, whose bodies are made of aluminium, are costlier than their other metal counterparts. This poses as one of the major obstacles to aluminium’s market appeal in India. This will be addressed once the demand for EVs picks up and costs are lowered. As consumers get environmentally conscious and the government introduces policies that require vehicles to bring out variants that are to be more fuel-efficient than before, fuel saving, carbon emission, costs, including repair, are areas where the downstream aluminium sector will have an important role to play.
New applications of downstream aluminium
Innovation is needed and is already being done at various levels. For instance, in meeting the EV demand, the automobile industry is looking at major changes in vehicle manufacturing that will focus on improved combustion, calibration, injection and cylinder pressure. Downstream aluminium suppliers are meeting the needs through extrusions and rolling by using technology and innovation.
New applications of downstream aluminium include lightweight battery casings and heat exchangers, besides overall structural integration. Offering a higher strength-to-weight ratio compared to other metals, the ability to absorb a larger amount of crash energy and ensuring that vehicular performance enhancements do not come at the cost of safety is what downstream aluminium offers to the automobile industry, especially in meeting the EV demand.
Aluminium – the automaker’s dream metal
All this, and the ease with which aluminium fits into creating simple & intricate shapes giving an elegant finish to the vehicle, make it an automaker’s dream metal. Thus, not only will this innovation in material supplied lead to lightweighting, lowered costs and meeting the commitments of going green but through EVs it will now also offer a higher per-unit usage of downstream aluminium products in automobiles. ☐
36 EM | O c t 2021
COOLAN T S & LUBR ICAN TS T E CH N OL OG Y
Big saving potential for gear technology with liquid toolGear technology can profit from the leverage effect of the optimal cutting and grinding fluid. With increased focus on environmental health, the smoke and mist produced during gear cutting and grinding applications have become one of the main concerns. This case study talks about how with the Blaser solutions, smoke and mist are significantly better controlled. For an Indian customer, the metalworking experts from Blaser Swisslube were able to reduce the cut time by 24%, lower smoke & mist tremendously and achieve overall cost savings per produced component – a result which is promising for the Asian gear hobbing and grinding production.
In terms of new gear hobbing and grinding technologies, Blaser Swisslube offers solutions to its customers and addresses their challenges for improved efficiency, increased tool life and reduced cycle times. These can be accomplished with higher parameters, which cause higher machining temperatures.
“We aim to improve these points in cooperation with our customers,” Punit Gupta, Managing Director – West Asia, Blaser Swisslube says and goes on, “As higher parameters produce more heat in the machine, we have to find the optimal cutting fluids. With our product range of cutting fluids, we
want to deliver an added value where higher cutting parameters in combination with lowest risk of smoke formation are achievable. The focus to reduce smoke production is a need in the area of environmental health which the top management needs to focus on.”
Blaser Swisslube has already created optimal conditions to run machining tests in its technology centre at the headquarters in Hasle-Rüegsau, Switzerland years ago. The technology centre is unique in the industry and allows Blaser to test recently developed cutting and grinding fluids of an
37EM | O c t 2021
TECHNOLOGY COOLANTS & LUBR ICANTS
incredibly diverse range of materials, as well as conduct close-to-reality simulation of production situations. Customers also benefit from those findings.
Holistic approach to reach productivity increase
A customer in the Indian automotive segment (Tier 1 supplier for gears and crank shafts assembly) was looking to improve his gear hobbing production situation. The goal was to reduce the cut time of forged steel components and lower smoke & mist in the facility. “We take a holistic view on the production process before we recommend a cutting fluid solution to the customer,” explains Manoj Verma, Application Manager, Blaser Swisslube, and continues, “I’ve analysed the given parameters at the customer site and realised that there is room for improvement in regards to cutting speed.” The Blaser Sales Engineer, in close collaboration with the customer, switched during a test phase a conventional cutting fluid to a Blaser ester oil-based cutting oil and increased the
cutting speed by 20% with convincing results. The cut time was reduced by 24%, the advent of smoke and mist was reduced by 51% and lowered the overall costs per component. Sandeep Bhat, Regional Sales Manager, Blaser Swisslube, conveys, “Our customer is very happy with the achieved results, as he did not expect that a change of the cutting fluid could have such a big impact on productivity. With tremendous reduction in smoke and mist, we have received a big thumbs up from the operators.”
Already reached maximal parameters?
“There is a hidden potential in the machines in gear grinding and gear cutting applications. We have experienced that not every machine is working on its maximal possible parameters yet,” Punit Gupta says. “We would be extremely happy to set up the joint projects with our customers to explore the possibilities and make our customers win,” he closes. ☐Courtesy: Blaser Swisslube Solutions
Advt
www.industr.com/en - a website, designed with a fresh new look and user-friendly navigation, updated with the latest information on the manufacturing technology world
Available on all digital devices globally, www.industr.com/en is an umbrella portal that integrates content of our two magazines – EM (Efficient Manufacturing) and A&D India (Automation & Digitisation).
Click and be a part of our online community!
publish-industry India Pvt LtdOffice No. 302, Sarosh Bhavan, Near BMW Showroom, Dr. Ambedkar RoadPune - 411001Maharashtra – [email protected]
www.industr.com/en
38 EM | O c t 2021
I NDUS T R IAL MA IN T E N ANC E SPE C I AL F E AT URE
Industrial maintenance – Embrace the digital approachTechnology has been evolving and changing the face of how we live and conduct business activities. In technology, Artificial Intelligence (AI) has played a crucial role in transforming manufacturing industries and has brought ease of business to various levels. The article explains the nitty-gritties of AI and how it can one-up industrial maintenance for the manufacturing sector.
The way technology has revolutionised the world in every aspect would have been unimaginable just a decade ago. Over the past few years, especially, technology has become an integral part of our lives – both from a personal and a business standpoint. Technology has become the centre of our lives to the extent that the term ‘smart living’ has indeed been implemented, right from our home appliances to vehicles and even industrial premises are now equipped with new-age technologies to make life easier, seamless and more convenient.
Out of all the novel technologies, Artificial Intelligence
(AI) has by far been the biggest game-changer. And with the pandemic accelerating the adoption of technology, AI has only further taken centre stage in our lives. Today, most businesses would cease to exist without AI; such has been its impact and the manufacturing sector is no exception. Combining human experience and expertise with AI-enabled systems, businesses are not only building innovative solutions for the real problems but also significantly reducing the costs involved while enhancing the operational efficiency. Be it customer support, monitoring, facial recognition or other
Imag
es c
ourt
esy:
stoc
k-ph
oto
Atul Rai, Founder, Staqu
BORINGDRILLING
REAMING BURNISHING THREADING SPECIALS
Contact us today to test the newest T-A Pro insert
The T-A Pro HSS (X) insert geometry provides improved tool life, high process security, and excellent
chip control in the most challenging applications.
T-A Pro®
HIGH-SPEED STEEL (X) INSERTØ 11.1mm - 47.8mm
New
Email: [email protected] | Phone: +91 11 41827044Holemaking Solutions for Today’s Manufacturing
www.alliedmachine.com
40 EM | O c t 2021
I NDUS T R IAL MA IN T E N ANC E SPE C I AL F E AT URE
video analytics-based processes, AI has been instrumental in enabling efficiency in the manufacturing sector.
AI-enabled video analytics – Revolutionising the manufacturing industry
Companies that invest in AI-based video analytics solutions have adopted novel technology-driven solutions quickly, upskilled their staff, generated high-value products more efficiently, increased their ROI and gained new prospects/opportunities overall. By integrating AI-powered video analytics, players in the manufacturing industry can initiate a new wave of efficiency without heavily investing in manpower or incurring other costs repeatedly. When it comes to visual inspection, AI has been multi-functional and has enabled businesses not just to build effective solutions but also to resolve issues quickly.
Contrary to common misconceptions, video analytics solutions, such as CCTV, go above and beyond simply capturing an incident. Video analytics, in fact, makes the entire surveillance infrastructure smarter and more efficient, not just in terms of the security aspect but by providing real-time alerts for nearly every division of operations in the business, thereby adding immense value in the long run.
Major challenges that are faced by manufacturing companies are optimising conveyor belts and workers’ safety. AI-enabled video analytics solutions enable constant, automatic monitoring of the conveyor belts at manufacturing premises to streamline the productivity analysis. Right from counting the exact number of pallets loaded and unloaded to detecting if the pallets are filled or empty and sending real-time alerts to enable staff to segregate the damaged products from the rest of the inventory, video analytics assists businesses in every function. Furthermore, in areas where CCTVs cannot be installed, AI can facilitate remote viewing through mobile camera feeds.
Workers safety & AI
Manufacturing plants often have several types of heavy machinery that can be a major hazard to work around, making businesses prioritise worker safety. In this case, too, AI comes to the rescue since deploying manpower to ensure worker safety would mean more resources are at stake. Through AI-led video analytics, monitoring aspects like whether safety precautions are being adhered to, any dangerous situation, faulty machinery that may put workers at risk of injury or death, etc, become far more seamless, convenient, cost-effective and accurate. Smart video analytics can also enable floor safety by tracking staff movement and offer quick alerts in case of potential hazards.
AI outside & inside manufacturing periphery
Manufacturing plants often have multiple vehicles carrying supplies entering and leaving throughout the day. But how do businesses recognise or flag vehicles? Employing human resources will prove not only expensive but also time-consuming and inaccurate at times since there’s always the possibility of human error. However, with AI and video analytics, Automatic Number Plate Recognition (ANPR) and vehicle analysis become quicker, more accurate and cost-effective. The AI technology’s analysis can scan vehicle number plates to integrate or cross verify this information into the manufacturing plant’s security logs. Additionally, the AI’s analysis can also be used to open automated gates fitted with sensors or keep a record of the in and out times of the vehicles.
Intrusion or theft are also major reasons of concern in manufacturing sites. Manufacturing sites tend to be sprawling with multiple aspects of operations and several different processes being carried out simultaneously at different areas in the premises. This makes the deployment of manpower to
Through AI-led video analytics, monitoring aspects like whether safety precautions are being adhered to, any dangerous situation, faulty machinery that may put workers at risk of injury or death, etc, become far more seamless,convenient,cost-effective and accurate
SPEC IAL F EATURE I NDUSTR IAL MA INTENANCE
41EM | O c t 2021
SPEC I AL F EATURE I NDUSTR I AL M A INTENANCE
prevent theft or pilferage an expensive affair. Leveraging AI, manufacturing sites can install CCTVs that can analyse, monitor and alert authorities at the site in case of any suspicious activities, such as intrusion, theft or pilferage of goods. AI will send alerts to authorities in real-time, enabling them to act as quickly as possible.
AI enhancing the quality of productivity in employees & products
Although manufacturing processes have become more reliant on technology, the need to supervise employees or track productivity hasn’t diminished. Appointing a supervisor would only mean that more manpower is required, thereby increasing the costs. However, with AI, players in the manufacturing sector can seamlessly and accurately track employee productivity, making monitoring more cost-efficient and less time-consuming. Apart from this, AI-based video analytics can also scan and analyse a product when it’s being assembled or manufactured, detecting even the smallest of faults. This kind of detailed analysis provides in-depth insights into the manufacturing process, helps avoid production bottlenecks and boosts the efficiency as well as the quality of the products.
The COVID-19 perspective
The pandemic has indisputably transformed our lives, and businesses, especially the ones that didn’t integrate AI and other technologies into their operations, have had to adapt quickly to survive in the volatile yet highly competitive market. Even as human contact became the most feared, with the apprehension continuing after nearly two years since the outbreak, AI-led technologies have become a one-stop solution for businesses across verticals. For the manufacturing industry, too, the scenario isn’t different. Video analytics can monitor whether the staff is adhering to COVID-19 safety protocols through facemask detection, social distancing violation, sanitisation, etc. These will ensure the premises are safe and greatly curb the risk of transmission.
Utilising AI-enabled solutions such as video analytics is imperative for efficient, cost-effective and seamless operations. Considering the rate at which technology is evolving and being integrated into business operations, we can safely say that AI is here to stay and will further augment the manufacturing industry’s processes and infrastructure, thereby driving growth. ☐
SPE C I AL F E AT URE I NDUS TR IA L MA I NTENANCE
EM | O c t 202142
TECHNOLOGY NEWS
The Zimmer Group, recently presented the DKHS1000 series, which is a
clamping element for unpressurised fixing of rotary axes. The new series
provides the highest angular accuracy under torque absorption whilst
simultaneously maintaining high dynamic ability due to closing times
exceeding those in the market.
In machine tool applications, the demands on machine dynamics and
accuracy are continuously increasing. For example, in rotary axes, angular
accuracy has more of an effect as the radius increases. In addition, swivel
bridges can quickly add up to several hundred kilograms, including the
weight of the component, which must also be held in position under
process forces with high rigidity.
Meeting the highest requirementsThe new DKHS1000 hydraulic clamping element series meets these
requirements. It has been designed for highly rigid and precise fixing of
rotary axes with high angular accuracy whilst under torque absorption.
Thus, the holding torques to be achieved are already specified at a
deflection of less than one angular second. To date, this accuracy can only
be resolved by a few high-end angle encoders available in the market. The
accuracy achievable is higher than what would be possible with an axis
under closed-loop control. The increased rigidity and the better dissipation
of oscillations and vibrations result in an improved milling pattern.
High dynamics and service lifeWhen used in combination with highly dynamic torque drives, the
DKHS1000 series can show off the advantages of its fast closing time of Email: [email protected] | Tel: +91-9130 083 828
less than 30 milliseconds. To put this into perspective, closing times are
almost 10 times faster than with pneumatic solutions. The short closing
and opening times are achieved by the high preload of the housing in
combination with the low absorption volume.
Based on extensive testing during development and in cooperation
with early test customers, the B10d value is over five million cycles under
application conditions. This service life, which exceeds that of the market,
means that the DKHS1000 can be used for the majority of the entire
‘machine life’ without replacement; this enables the greatest possible
planning reliability and high system availability.
Innovative and proven active principles used beneficiallyCombined with the large piston area, holding torques of up to 8000 Nm can
be achieved utilising the preload of the housing material. The one-piece
housing expands slightly in the elastic range under hydraulic pressure and
releases the shaft connection and therefore the axis of rotation.
The preload also offers the customer an integrated emergency function,
which ensures that moving components are held securely in the event of
pressure loss or failure of the entire system.
Accuracy and holding torque for different requirementsThe holding torques are specified in each case as a function of the stiffness
at one angular second for use in machining processes and at five angular
seconds for design under safety requirements.
To illustrate the achievable accuracy: One angular second, or arc
second, describes the 3600th part of a degree. It is equal to the angle that
represents a drop of five millimetres over a lever arm of one kilometre. For
the DKHS1460 size, this angular accuracy is maintained when under load of
a full-grown racehorse over a lever arm of one meter, which corresponds to
a holding torque of 6000 Nm.
Novel condition query - added value via material stressIn line with the new principle of operation in the area of the rotary axes,
the company offers a new condition monitoring option. A strain gauge is
applied to the housing, which determines the material stress. This enables
high-resolution and permanent status monitoring. In conjunction with the
already short closing time, the cycle time is reduced to a minimum.
The choice between IO-Link or digital control enables simple and fast
commissioning. For further simplification, PLC modules that are easy to
implement are provided.
Zimmer Group | Pune
Clamping element for unpressurised fixing of rotary axes
DKHS1000 series
Hydraulic clamping
EM | O c t 2021 43
NEWS TECHNOLOGY
Lightweight polymer linear bearings
igus recently showcased its new, cost-effective, durable and lightweight
drylin W linear bearing that ensures fast, lubrication-free movements. The
slim bearing, just 10 gm at installation
size 10, has several advantages for
those new to linear technology who
need a simple linear guide for
applications, such as adjusting
tabletop devices, cameras, sensors or
monitors. The bearing is made of
iglidur JB, a tribologically optimised
high-performance polymer, so it
needs no lubrication or maintenance
and is durable & resistant to dust & dirt. The black material is remarkable for
its very low co-efficient of friction in dry running and very low stick-slip
tendency. It is also impact-resistant and robust while remaining elastic and
damping so that it can absorb & dissipate vibrations. The new bearing can be
installed very easily on any drylin W single rails or double rails. If the user is
looking for a cost-effective linear guide, igus’ clear anodised drylin W WS-CA
aluminium rails are a good choice. Combining the two materials – silver
aluminium and black bearing material – gives the user a complete solution
with a simple, elegant design.
Email: [email protected] | Tel: +91-93411 36381igus India | Bengaluru
Lightweight drylin W polymer bearing
Battery module housings for EVs
LANXESS recently developed a battery module housing for electric vehicles
(EVs) in association with INFAC. The battery housing uses Durethan BKV30FN04
from LANXESS to satisfy stringent mechanical
and chemical property requirements for latest
EV components. The halogen-free, flame-
retardant & glass-fibre-reinforced polyamide
6 (PA6) is characterised by its excellent
flame-retardant and electrical properties. The
material is highly processable and enables
the integration of complex functions required
for housing components, resulting in smaller number of parts and simplified
assembly process as well as lighter weight. For the battery module housing,
shock absorption and thermal management are critical in order to protect the
battery from external shock. Durethan BKV30FN04 is not only mechanically
robust but also boasts high-voltage insulation, is resistant to up to 800 V and
effectively blocks high-voltage current. With strong flame-retardant properties,
it prevents or delays flames from spreading in case of a fire. The glass-fibre
reinforced Durethan BKV30FN04’s durability to mechanical loads is superior to
unfilled PA6. Furthermore, it maintains excellent strength and stiffness when in
contact with electrolyte or cooling media and has chemical resistance to
suppress chemically induced damage.
Fine boring heads
Wohlhaupter India recently announced the expansion of Wohlhaupter boring
tools offered with the launch of the 464 (465) series of fine boring heads.
These internally balanced fine boring
heads include 3ETECH digital adjustment
as well as an analogue vernier scale
adjustment. One 3ETECH digital readout
can be used on multiple adaptable
3ETECH boring head tools including
VarioBore, 537 (538) large diameter
cassettes, 464 (465) fine boring heads
and custom tooling solutions. The new
464 (465) fine boring heads have a full diameter range of 50–205 mm
(1.968”–8.070”) with the lightweight aluminium Alu-Line boring heads
ranging from 65.00–205.00 mm (2.559”–8.070”). Featuring the standard
Wohlhaupter MVS connection, these boring heads provide the capability to
adapt to any machine. With the digital diameter adjustment located externally
rather than internally, maximum coolant pressure can be utilised with no
concern of damaging digital components inside the tool during operation. In
high production settings like that of the aerospace, automotive and heavy
equipment industries, the user will only need one 3ETECH module for all
adaptable heads, which reduces machining costs.
Email: [email protected] | Phone: +91-22-2587 1000
Email: [email protected] | Tel: +91-11-4182 7044
LANXESS India | Mumbai
Wohlhaupter India | New Delhi
464 (465) fine boring heads
Durethan BKV30FN04
Advt
44 EM | O c t 2021
H IGHL IGH T S CO MPAN Y INDEX | IMPR INT
» Blockchain Technology in Manufacturing
Blockchain is essentially a new model of product traceability, supply chain transparency, compliance monitoring and auditability. The upcoming edition will explore how it may accelerate the supply chain management, advance product customisation options, reduce counterfeiting and more.
Highlights - November 2021
COMPANY INDEXName . . . . . . . . . . . . . . . . . . . . . . . Page
Adani Green Energy Ltd (AGEL) . . . . . . . . 08
Balkrishna Tyres (BKT) . . . . . . . . . . . . . . 08
Blaser Swisslube Solutions . . . . . . . . 13, 36
Cygni . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cyient . . . . . . . . . . . . . . . . . . . . . . . . . 08
DAO EV TECH . . . . . . . . . . . . . . . . . . . 27
Dassault Systèmes . . . . . . . . . . . . . . . . . 09
DMG Mori . . . . . . . . . . . . . . . . . . . . . . 09
Dormer Pramet . . . . . . . . . . . . . . . . 09, 35
Dynamatic Technologies . . . . . . . . . . . . . 09
ELGi Equipments . . . . . . . . . . . . . . . . . . 10
Ervin Junker Maschinenfabrik . . . . . . . . . 11
ExxonMobil Lubricants . . . . . . . . Back Cover
Guhring (India) . . . . . . . . . . . . . . . . . . . 21
Name . . . . . . . . . . . . . . . . . . . . . . . Page
ifm electronic India . . . . . . . . . . . . . . . . 19
igus India . . . . . . . . . . . . . . . . . . . . . . . 43
Indian Aerospace Manufacturing
Private Limited (IAMPL) . . . . . . . . . . . . . 24
Jindal Aluminium . . . . . . . . . . . . . . . . . . 32
Jyoti CNC Automation . . . . . . . . . . . . . . 01
Kennametal . . . . . . . . . . . . . . . . . . . . . 28
Kim Union Industrial Co . . . . . . . . . . . . . . 43
Kosh Energy Technologies . . . . . . . . . . . 26
Lakshmi Machine Works . . . Front Inside Cover
LANXESS India . . . . . . . . . . . . . . . . . . . 43
Lien Chieh Machinery Co . . Back Inside Cover
Oemeta India . . . . . . . . . . . . . . . . . . . . 23
Piaggio Vehicles . . . . . . . . . . . . . . . . . . 26
Name . . . . . . . . . . . . . . . . . . . . . . . Page
Quaker Houghton . . . . . . . . . . . . . . . . . 31
QVI India . . . . . . . . . . . . . . . . . . . . . . . 41
Schaeffler . . . . . . . . . . . . . . . . . . . . . . 09
Siemens Digital Industries Software . . . . . . 16
Staqu . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tata Power . . . . . . . . . . . . . . . . . . . . . 08
Terra Motors . . . . . . . . . . . . . . . . . . . . 27
Toolkart . . . . . . . . . . . . . . . . . . . . . . . . 06
TVS Motor Company . . . . . . . . . . . . . . . 08
Wohlhaupter India . . . . . . . . . . . . . . 39, 43
Zetwerk . . . . . . . . . . . . . . . . . . . . . . . . 14
Zimmer Automation LLP . . . . . . . . . . . . . 12
Zimmer Automation . . . . . . . . . . . . . . . . 07
Zimmer Group . . . . . . . . . . . . . . . . . . . 42
» Automotive ManufacturingTo match pace with the ever-innovating technologies in the automotive industry, one has to understand the convergence of disruptive technology driven trends that could revolutionise automotive manufacturing. The following edition helps one to gain perspective of the evolving technologies and trends in automotive manufacturing.
Publisher / Chief Editor Shekhar Jitkar [email protected]
Assistant Editor Juili Eklahare [email protected]
Assistant Editor Anvita Pillai [email protected]
Senior Content Developer (Online & Print) Namrata Singhania [email protected]
Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 [email protected]
Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 [email protected]
Alok Kumar (Sr Manager – South) Bangalore Contact: +91 8861009443 [email protected]
Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) [email protected]
Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 [email protected]
Design & Layout Tarun Kumar Pyne Design Head (Print & Web)
Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: +91-7410006435/36
Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Shekhar Jitkar (Publisher / Chief Editor)
Subscription Cover Price: `100 Annual Subscription Price: `1000 [email protected] Tel: +91-7410006435/36
Printing Sneha Arts, Near Maha Nagar Bank, Wadgav Shinde Road, Lohegaon, Pune - 411047, Maharashtra
Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of the magazine contents is only allowed with written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.
Internet https://industr.com/en/
Digital edition https://www.industr.com/en/e-paper
IMPRINT
» Industrial BearingsAs demand for durable, smart and cost-efficient bearings has increased exponentially, the bearing industry is becoming more intensive technologically. Growth in this industry is linked to the growth of the automotive and other industrial sectors. The next issue focuses on the major growth drivers, latest trends and challenges faced by the bearing industry.
» AR/VRIn the recent years, Augmented Reality (AR)/Virtual Reality (VR) have gained a great impetus for driving the transformation and upgradation of core components, extensive smart devices, network transmission devices, cloud computing devices, telecom services & software and industry information services. The subsequent issue throws light on the industry ecosystem and development trends resulted from the adoption of AR/VR.
RNI No. MAH/ENG/2010/34603