mart december 2012

Volume 9 Issue 6 December 2012 Pages 68 `100

New energy chain for unsupported travels up to 50 m from igus

Total Chip Protection for Machine ToolsIntroduction to Additive Manufacturing (Rapid Prototyping and Manufacturing Technology)

Rapid Manufacturing of Aluminium Components

The HyPerformance series of HyDefi nition Plasma systems from Hypertherm

ON FACESoo Kam Tatt, Director, Hypertherm Asia

Cover Feature

CONTENTS

Introduction to Additive Manufacturing

20

24

38

42

46

48

32


COLOUMNSarvajith Singh

Quality ManagementCost of QualityP S Satish

Manufacturing Excellence Journey Towards ExcellenceVivin Agarwal

Responsible Business Greening your ResponsibilityA S Shetty

Machine Design Fundamentals Strength of Material Aspects

ON FACEFEATURE ARTICLE

12

50

56

58

58

63

NEWS MARTLAPP INDIA inaugurates state-of-the-art Cable manufacturing plant in Bhopal

FAIR MARTHannover to visit Delhi again after |its maiden Success

TECHNO MART Dassault Systèmes Unveils New Solid-Works Electrical Applications

PRODUCT MART Aluminum Precision Drawn tubes for Teliscopic Tube Application from Siddhi EngineersPRODUCT MART

THE LAST LEAF

Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, Bangalore – 560 043

Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed in the journal are not necessarily those of the Publish-ers.

Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither the Pub-lisher no any of its employees accept any responsibilities for any errors or omissions.

© All Rights Reserved

MTA2013_Industrial Business Mart Mag_Nov12_FA(PATH).indd 1 11/6/12 6:28:55 PM

Dear Readers,

We are winding up 2012 – the ups and downs we faced during the last twelve months would make a story in itself. We look forward and are preparing ourselves to do our best in 2013. There is no doubt 2012 has been a difficult time for all across the world, as a result of the global financial slowdown going on for the last couple of years. An emerging economy like India can get back on its growth path in no time, with result-oriented reforms from the Government.

Controversies apart, Foreign Direct Investment in Retail Sector was passed in both houses of parliaments in December. The whole world is watching the recent developments in India. The go-ahead given to FDI in retail sector will restore the Foreign Investors’ confidence of India as a safe, secure and promising market to invest.

Recent studies by trade associations state that FDI will lead to growth in the domestic manufacturing segment especially the SME sector, employment generation, supply chain efficiency and qualitative improvement in the branding of products. Concerns are that we will not be able to establish ourselves as a low-cost manufacturing country, forcing the international retailers to source products from other low-cost economies. This would hurt our already-challenged manufacturing sector and this has to be addressed with priority.

Rapid Prototyping (Additive Manufacturing) is a remarkable technology that is revolutionizing the way companies design and manufacture products. Rapid Prototyping enables quick fabrication of a physical model through additive processes. This technology employs various engineering and software techniques to produce a physical model through Layer Manufacturing in accordance with the geometrical data derived from computer generated 3D CAD designs. These processes are bridging the gap between design conceptualization and manufacturing. L Jyothish Kumar from this edition starts his regular column on Additive Manufacturing. We have also included two more articles on Rapid Prototyping.

In our ON FACE segment, we have included an interview of Soo Kam Tatt, Director, Hypertherm Asia, reviewing this year’s performance and also sharing their plans for the coming year. Hypertherm designs and manufactures the world’s most advanced metal cutting products for use in a variety of industries such as shipbuilding, oil and gas, heavy equipment, structural steel, and manufacturing.

We thank our readers for their reviews which help us to improve the quantity and quality of MART. With the inputs, we were able to bring a lot of changes in the magazine which resulted in substantial growth in our reach during this year. We are sure the substantial and sustained subscription growth would continue. We welcome your suggestions to improve.

Signing Off,

Hari ShankerManaging Editor

Foreward

industrial business MART12 December 2012December 2012industrial business MART12

LAPP INDIA, a 100% subsidiary of LAPP GROUP based in Germany and globally one of the leadingmanufacturers of cables and other cabling solutions, announced last month the completion of Phase 1 of its second manufacturing plant in India. A total of Rs 150-crores will be invested to set-up this 4-phased cable manufacturing plant in Pilukedi, Rajgrah District of Bhopal. With an initial investment of Rs 50 crores, Phase 1 of the plant will produce 1,000 kms of single core cables daily, catering mainly to the Building Cable Segment (BCS).

The inauguration ceremony had presence of special invitees including Shri Kailash Vijayvargiya, Honorable Minister of Commerce Industries and Employment, Government of Madhya Pradesh, Mr. P K Dash, Additional Chief

Secretary Govt. of Madhya Pradesh, Department of Commerce Industries & Employment among others. Also, key members from the global leadership team of LAPP GROUP namely Andreas Lapp, Chairman of The Board LAPP HOLDING AG and Honorary Consul of the Republic of India for Baden-Württemberg and Rhineland-Palatinate, Siegbert Lapp, Member of The Board LAPP HOLDING AG and Richard Lee, CEO, Asia Pacific at LAPP GROUP and acting Managing Director of LAPP INDIA Pvt. Ltd had travelled to Bhopal to attend this prestigious event.

The Bhopal plant is the second LAPP INDIA facility in India after Bangalore and is spread over an area of 1,17, 000 Sq m. The 4-phased plant construction is expected to be completed over a period

of 5 years and will be LAPP GROUP’s largest facility globally.

In terms of the location of the plant, Bhopal provides a strategic geographic advantage. Being centrally located in the heart of India, the facility in Bhopal will be well-equipped to meet the logistical requirements of the Northern and Eastern parts of India and cater to increased demand across India. Mr. Sriram Ganapathy, Vice President, Head– Building Connectivity Solutions, said that, “Geographically, the LAPP INDIA plant in Bhopal is well-connected, making it a key factor for us to decide on the location. Further, the Government of Madhya Pradesh has been extremely supportive towards LAPP INDIA, including providing required land approvals without causing any delays as

LAPP INDIA inaugurates state-of-the-art Cable manufacturing plant in Bhopal

Completed Phase 1 of the plant, with an investment of Rs 50 crores will have the capacity to produce 1,000 kms of single core cables on a daily basis. The 4-phased plant to be completed over a period of 5 years will have a total invest-ment of Rs 150 crores.

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“Expanding our operations in India has been a key focus for us at LAPP GROUP, mainly due to promising growth opportunities presented by the country. This year LAPP INDIA’s growth has increased to 23% compared to last year and the set-up of this new facility in Bhopal will help us cater efficiently to growing customer demands. The market size for single core wires (in the building segment) today stands at ap-proximately Rs 6,000 crores which indicates a large market opportunity in this sec-tor. With respect to LAPP range of products, the addressable cable market in India is currently being valued at Rs 1,000 crores. We, at LAPP, have identified this opportu-nity in India for single core cables and are strengthening our base accordingly.”

Andreas Lapp Chairman, LAPP HOLDING AG & Honorary Consul of the Republic of India for Baden-Württemberg and Rhineland-Palatinate

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industrial business MART 13December 2012

well as offering us uninterrupted power supply at the plant thus helping increase efficiency of production.”

The construction of the entire factory in Bhopal has been divided into four phases with the currently operational Phase 1 focusing on production of single core cable. The latter phases will focus on producing multi-core cables, aluminium cables and HT/LT aluminium cables respectively.

With the establishment of this plant, Mr. Richard Lee, CEO, Asia Pacific at LAPP GROUP and acting Managing Director of LAPP INDIA Pvt. Ltd is quite optimistic about LAPP INDIA’s future in terms of expected business growth and mentioned that, “We, at LAPP INDIA are extremely bullish on the opportunity for single core cables in the country, thus

making India the focal point for LAPP GROUP’s activities. Hence by setting up this facility, LAPP INDIA has great potential to grow and cater innovatively to the evolving needs of the industry as well as add to the range of products that LAPP INDIA currently has to offer.”

LAPP INDIA is a 100% subsidiary of the LAPP GROUP which manufactures Cables, Connectors, Cable Glands, Conduits and Accessories. They are the pioneers in introducing the concept of “Total solutions in Electrical Connectivity” in India, with an unbeatable range of products.

LAPP INDIA started its India operations in 1996 with a manufacturing unit in Jigani, Bangalore. Today, our Bangalore manufacturing unit is the third largest manufacturing facility of the LAPP

GROUP, producing about 100,000 km of ÖLFLEX® connecting and control cables and insulated single cores each year. LAPP INDIA has trained regional marketing organisations in Delhi, Kolkata, Mumbai, Pune, Bangalore and Chennai along with 23 sales offices and a strong network of dealers throughout the country.

Headquartered in Stuttgart, Germany, the Lapp Group is a leading supplier of integrated wire, cabling and connector products and solutions. Its offering includes electrical and fibre optic cables, industrial plug-in and screw connectors, cabling solutions, automation technology and technical accessories. Lapp Group’s core markets are in the mechanical and plant engineering and electronics manufacturing sectors, with rapid market expansion in the renewable energy, mobility and life science industries.

industrial business MART14 December 2012

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Fluke introduces ScopeMeter®

One day workshop on TPS by MBERG

New Fluke 190 Series II ScopeMeter® Test Tool is first handheld oscilloscope to achieve 500 MHz at 5 Giga-samples-per-second sample rate

Fluke Corp. introduces the Fluke® 190 Series II 500 MHz ScopeMeter®Test Tool, the first to achieve a 500 MHz at 5 GS/s real time sample rate in a handheld, sealed, rugged, oscilloscope, without compromising on safety rating, ruggedness or battery operating time.Now professional electronic troubleshooters have a high-performance scope with the bandwidth and resolution to capture virtually any signal while in the field.

The two-channel 190-502 model is the latest in the190 Series II with bandwidth from 60, 100, 200, - and now 500 - MHz.

High-tech electronics in today’s medical, communications, navigation and military devices routinely operate at high speeds

MBERG announces one day workshop on “Toyota Production System” on 19th December 2012 at Hotel Radisson, Gurgaon. With interactive sessions, presentations and case studies the workshop’s objective is to discuss Toyota Production Principles, concepts and terminology and the key elements of Toyota Production System.

The fundamental reason for Toyota’s success in the global marketplace lies in its corporate philosophy - the set of rules and attitudes that govern the use of its resources. Toyotta have succesfully penetrated global markets and established a world-wide presence by virtue of tis productivity.

The foundation of TPS lies on two very important factors:- Continous improvement or Kaizen, the basic approach and the respect for people.

requiring higher bandwidth. Correct display of waveforms with high frequency content such as clock pulses requires a bandwidth of at least five times the clock rate of the system under test. The 5 GS/s - or 200 pico seconds - sample rate of the Fluke 190-502 provides greater accuracy and clarity of shape and amplitude of unknown waveform phenomena like transients, induced noise and ringing or reflections.

The rugged 190 Series II ScopeMeter® test tools include innovative functions like ScopeRecord™, TrendPlot™, advanced triggering and automatic measurements functions you would expect to find in high performance scopes. The 190 Series II safety rating according to IEC 61010

standard is 1000 V CAT III/ 600 V CAT IV making it possible to safely measure from mV to 1000 V.

The Fluke 190-502 ScopeMeter®test tool is available from November 20th 2012. For more information, visit: http://www.fluke.com/190II. For information on Fluke tools and applications, or to find the location of your nearest distributor, call 1800 209 9110, e-mail [email protected] or visit the Fluke Web site at http://www.fluke.com/india.

This workshop is designed to guide participants about TPS principles in product delivery environment.

Millennium Business & Entrepreneurship Resource Group (MBERG) was formed by Late Shri K. K. Malhotra, formerly Deputy Secretary General at PHD Chamber of Commerce (PHDCCI) New Delhi and Senior Adviser at Asso¬ciated Chambers of Commerce & Industry of India (ASSOCHAM). To his credit he gave MBERG a rich experience of over 4 decades in Training, Finance, Administration etc. He was instrumental in organizing knowledge based work¬shops primarily to impart training to over 25,000 delegates with over 780 programmes involving around 3,000 training days since 1991 throughout the country.

For further details visit www.mberg.org

The faculty A K Vohra is a Graduate in Electrical Engg. from Punjab Engineering College, Chandigarh with a PG in Industrial Engineering and Advanced management course in Corporate and Strategic Planning from West Germany. He was associated with National Productivity Council for more than 33 years and Retired as Director and Group Head (Process Management) after holding positions like Director (Finance), Secretary, Dir. (Admn.), Dir. (HRD), Regional Dir., at Patna & New Delhi.

He has conducted numerous training programmes on TQM & Industrial Engineering subjects along with many consultancy studies / assignments in Industrial Engineering in India & abroad.

industrial business MART December 201214


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The anti-rotation feature on the inserts provides excellent stability for higher feed rates and cutting forces with an easy-to-index insert in the pocket.

The three variable topography styles of Rodeka inserts have robust cutting edges capable of covering any type of compo-nent and application. This design helps to achieve low cutting forces while consum-ing less power. The higher clearance of the bodies permits pocketing, profiling and 5-axis machining.

Each insert is marked so the user can easi-ly identify the insert topography and edge number for correct indexing in the tool pocket. For correct indexing, the dimple

in the edge of each number should be aligned with the groove in the cutter. To keep a fresh cutting edge and not lose performance, these inserts should be rotated counter-clockwise.

The three topographies of Rodeka inserts are engineered to take on different tasks and make these inserts diverse enough to handle a wide variety of indexable milling applications:

wThe LD style insert has a honed edge for light to medium machining and is the first choice for stainless steel and titanium operations. Rodeka -LD inserts can pro-vide up to 87% higher metal removal rates

Rodeka and Rodeka 8 - The Revolutionary New Indexable Milling Inserts from Kennametal

Kennametal introduces the revolutionary new Rodeka™ series of inserts for indexable milling. Based on the success of Dodeka™, Rodeka double-sided inserts have a unique design with twelve cutting edges for a more productive and cost effective cutting process.

than some high-feed cutters at equal tool life but with twice the effective cutting edges.

wThe GD insert style for medium to heavy machining has a 10° positive T-land and hone. This insert is the first choice for general-purpose applications and has been shown to offer increased metal removal rates when compared to similar cutters.

wRodeka HD inserts are designed with a 0° T-land and hone to take on heavy machining tasks and cast iron materials. These inserts also offer higher metal re-moval rates and can have a considerably longer tool life than similar milling inserts.

Though an insufficient negative clear-ance angle limits the ramping capabilities of Rodeka inserts, they are capable of taking on pocketing, profiling, face mill-ing, and blade machining at high metal removal rates with long tool life. Rodeka is available in a range of cutter styles and diameter sizes, including a 32–42mm diameter screw-on option, a 32mm diameter Weldon® style, 32mm cylindri-cal shank end mills, and shell mill cutters from 40–100mm in diameter.

Rodeka 8 is a variant of the double-sided Rodeka line of inserts with eight total cutting edges and specially designed tool bodies that are specifically engineered to take on turbine blade machining.

Rodeka 8 inserts have the same anti-rotation feature as Rodeka for a higher contact area with excellent stability for higher feed rates. Also, like Rodeka inserts, the seating dimple between tool


faces on Rodeka 8 eases insert rotation and improves second side edge per-formance. These inserts are offered in the same -LD and -GD styles as Rodeka inserts, with the Rodeka 8 -GD style being preferred topography for forged blades.

An advantage to the Rodeka 8 insert are the dedicated inserts developed to improve milling performance. PVD inserts have a polished rake face to generate better chip formation and increase tool life. CVD inserts have a thinner coating to avoid premature flaking on the insert and be better functioning in combination with sharper edges.

All Rodeka 8 inserts are made of a KC-MP30™ grade. This multilayered coated carbide with advanced post coat treat-ment has a wide application in general and rough steel milling that works best

in dry conditions. KCMP30 has improved edge toughness and reduces depth of cut notching. The grade’s toughness also avoids work-piece sticking and greater integrity at elevated speeds.

Rodeka 8 tool bodies are available in a shell mill cutter style with diameters from 40–80mm that are designed to improved blade machining, but also capable of pocketing, profiling, and face milling.

Kennametal Inc. (NYSE: KMT) delivers productivity to customers seeking peak performance in demanding environments by providing innovative custom and standard wear-resistant solutions. This proven productivity is enabled through our advanced materials sciences and application knowledge. Our commitment to a sustainable environment provides additional value to our customers.

Companies operating in everything from airframes to coal mining, from engines to oil wells and from turbochargers to construction recognize Kennametal for extraordinary contributions to their value chains. In fiscal year 2012, custom-ers bought approximately $3 billion of Kennametal products and services – delivered by our approximately 13,000 talented employees doing business in more than 60 countries – with more than 50 percent of these revenues com-ing from outside North America.

For further details visit www.kennametal.com

industrial business MART18 December 2012December 2012industrial business MART18

Grundfos Pumps India Pvt Ltd launched “No Compromise” yatra, an innovative mobile campaign on efficient sewage water pumping technology, introducing their new range of S-Tube embedded SE1 / SL1 range of Sewage pumps. This mobile exhibition will travel around the country to showcase, communicate and educate customers about this new range of S-Tube sewage water pumps. The yatra was flagged by Mr.Chandrasekaran, Sr. Business Director, Grundfos India on 1st of November at Pride Hotel, Gurgaon.

The new SE1 / SL1 range of sewage pumps are fitted with the new ‘S-tube’ impeller technology that avoids clogging problems unlike traditional Sewage pumps available in the market, said the company sources.With the S-tube impeller, the efficiency is higher compared to other wastewater impellers, as there are no edges, dead zones, or cutting functions that get worn over time. Furthermore the S-tube impeller features an innovative and patented labyrinth and sealing system, for years of trouble-free operation.

“The very name of the campaign is

derived from the benefits of using an S-tube impeller. No compromise literally means, that there is no compromise between pump efficiency and free passage inside the pump for better solids handling and greater non-clogging capabilities” said Mr. Ramanan, Head - Marketing, Grundfos India.

“The S-Tube impeller Pump is a trend

setting product in waste water market, and a boon to municipalities with medium and small sewage pumping stations, due to its high reliability with longer lifetime at lower maintenance cost. The S-tube impeller technology meets the challenges of Backflow, Vibrations, Abrasive wear and clogging. The unique and patented sealing system provides the highest possible reliability, as the hydraulic parts are kept clean during operation. The lowest possible

Grundfos launches ‘NO COMPROMISE’ campaign for efficient sewage water management technology

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Autonics unveiled KRN100 series, its brand new 100mm hybrid recorder following the launching of the KRN50 series in 2009, 50mm compact paper type hybrid recorder. KRN 100 series can

Hybrid paper type recorder, combines functions of paper recorder and paperless recorder

Autonics launches KRN 100 Series, A brand new Hybrid Recorder

both display a wide variety of industrial values on the LCD and print them on the paper.

It can save data at an external USB memory and also can print it through its data backup function (data logger function) of internal memory as well. In addition, it supports parameter setting on the PC through USB communication, Max 12 channel support due to its slot type input/ output cards and a wide variety of optional cards.

vibration level is guaranteed through the new static and dynamic balancing of S- Tube” said Mr.Chandrasekaran, Sr. Business Director, Grundfos India while launching the product.

Grundfos Pumps India Pvt. Ltd., a wholly owned subsidiary of Grundfos holdings was established on March 13, 1998. Grundfos India is responsible for sales of Grundfos products in India, Bangladesh, Bhutan and Maldives. Currently, Grundfos India has manpower of over 200 and operates with about 150 Distributors and Dealers with 13 offices across India.

Grundfos India provides pumps and pumping solutions for various applications – Heating and hot water service systems, cooling and air-conditioning systems, Industrial applications, Pressure is boosting and liquid transfer, Groundwater supply, Domestic water supply, Sewage and wastewater, Dosing, Chlorination systems, Disinfection systems and pumps running on renewable energy. For more information, visit http://www.grundfos.in/

Combines functions of paper recorder and paperless recorder, Enables to print the saved data of inner memory when run out of recording paper (Date logger function), Inner data backup with USB memory, Supports several communication (RS485,Etherner) to transfer real time data and High legibility and setting convenient by graph LCD.

For further details visit http://www.autonics.co.in


Godrej Locking Solutions and Systems (Godrej LOCKSS), the leader and innovator in the locks category has announced the launch of Knock N’ Lock - a unique invisible lock that is designed to provide the highest degree of security available for outdoor and indoor facilities.

This revolutionary locking unit is based on patented Knock Code technology that enables a concealed lock with no visible access point, thus preventing break-ins.

First of its kind in India, this unconventional product is designed with sophistication, embedded with smart technology, forged for superior security and programmed for greater convenience.

Knock Code Technology is a patented approach to locking that resembles no conventional system in the market. The

Godrej launches Knock N’ Lock locks are virtually invisible – they have no keyhole or external interface that can be tampered with. Unlike a conventional key, the KnocKey transmits a sequence of mechanical pulses to open the lock.

The user simply holds the KnocKey against the locking unit or an adjacent hard surface and enters the code, which passes straight through to the lock – even through solid metal, wood or glass. The system is extremely secure and robust, because it never uses the same code twice. So it’s impossible to imitate the key — even by recording the code.

The Knock N’ Lock versatile lock is ideal for securing all types of cabinets, containers and doors, defence vehicles, windmills, petroleum vehicles, commercial complexes as well as residential applications. Since the lock is fitted internally and has no exterior contact points, its presence and location

are invisible from the outside, providing maximum security. This lock is easy to install and has no wires. A mechanical unlocking button is fitted to the lock to allow quick opening from inside. The Lock can be operated by battery or adapted for an external power supply. A variety of strikes and mounting brackets makes this lock suitable for a wide variety of applications.


In today’s competitive world the

evolution of rapid prototyping (additive

manufacturing) technology has changed

the face of direct, digital technologies

for the rapid production of models,

prototypes, patterns, fit and functional

parts.

Since its evolution additive

manufacturing technology has changed

design, engineering and manufacturing

process within the aerospace,

automotive, electrical and electronics,

medical devices and consumer products

industries.

Because of its wide applications additive

manufacturing technology has become

a powerful and revolutionary field of

manufacturing.

Additive Manufacturing Technology

Known by many names such as-

• 3D Printing

• Rapid Prototyping

• Advanced Manufacturing

• Direct Digital Manufacturing

Applications of Additive Manufacturing

Technologies:-

• Automotive

• Aerospace

• Consumer Products

• Electrical and Electronics

• Dental and bio-medical

• Commercial and Industrial Equipments

An Important difference between AM

technology and conventional machining

Introduction to Additive Manufacturing (Rapid Prototyping and Manufacturing Technology)

Additive Manufacturing (Rapid prototyping-RP) can be defined as the layer by-layer fabrication of three-dimensional physical models directly from a computer-aided design (CAD) data.

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L Jyothish Kumar Founder &CEO, RAPITECH Solutions Inc. www.rapitech.co.in


process is that prototype or model

is obtained by layer by layer addition

process as opposed to removing

material from a ‘block’.

There are three main Rapid Prototyping

systems, depending on the form of

materials involved:

*Liquid-based RP systems –

The initial form of material is in liquid

state and, by a curing process, the liquid

is converted into solid state; the system

includes: 3D Systems’ Stereolithography


CASE

STU

DY

(SLA), Objet Inkjet Printing.

*Solid-based RP systems –

The initial form of material is in solid

state, except for powders (wire, roll,

laminates, pellets); this system includes:

Stratasys ‘Fused Deposition Modeling

(FDM).

*Powder-based RP systems –

The initial form of material is powder;

the system includes: 3D Systems’

Selective Laser Sintering (SLS) and

3D Printing, EOS Direct Metal Laser

Sintering (DMLS).

Benefits of Additive Manufacturing Technologies

• Prototypes, fit & functional parts are generated directly using 3D CAD data

• It is a cost effective and quick process for intricate parts

• AM technology eliminates tooling so that the cost and time of tooling is reduced.

• This would also reduce the lead times for new product development.

Direct Metal Laser Sintering Technology in Production Mould with inserts

Challenge:

• Series production tool for injection moulded plugs in PBT GF10%

• Tool availability as „quickly as possible“

Solution:

• 3-cavity mould in hybrid concept

• Machined aluminium tool base with inserts in EOS Maraging Steel MS1 (1.2709)

Benefits:

• Tool availability: 6 working days

• No need of pre-series tooling due to rapid delivery of production mould

• Reduction of tooling costs.

Production mould with inserts made from MaragingSteel MS1 (courtesy of FIT).

Source: EOS gmbH – www.eos.info

German based company FIT focuses on rapid fabrication of prototypes and small lot production on special parts. Examples of these parts range from unique structures for space vehicles to lightweight components for racing cars as well as customized biomedical implants.

• It produces fit and functional parts

• It reduces prototype/production time from months to weeks or days

• AM machines are small and

environmentally friendly and can be easily operated.

We will be continuing this article on Additive Manufacturing from next issue as a regular column. The author L Jyothish Kumar is the Founder and CEO of RAPITECH Solutions Inc., Bangalore. He completed his B.E., (Mechanical) from National Institute of Engineering, Mysore and M.Sc (Rapid Product Development) from De-Montfort University, UK.

He is also the President of Additive Manufacturing Society of India (AMSI). He is specialized in Additive Manufacturing , Technology, Application of Additive Manufacturing Technology- Aerospace, Automotive, Electrical and Electronics and consumer goods, Advanced Materials for Additive Manufacturing Technology, Process control and optimisation of Additive Manufacturing Technology and Research and Development in Additive Manufacturing Technology. He can be contacted at [email protected]


With the last nine years of networking and publishing of

MART, we were successfully made a place in the Indian

Manufacturing industry. Our growth was always triggered by

the changes undertaken as per the needs of the industry.

The contents of MART is unique, with regular columns by

industry experts in the diversified fields of engineering

manufacturing, technical features, news updates, interviews,

case studies, trade fair informations etc.

The guidance and support of the experienced industry

professionals through our Editorial Advisory Board have

helped us to understand the need of the Indian

Manufacturer better and produce a journal which is used by

the industry as an utility.

No: 217, 3B Main, OMBR Layout, Bangalore - 560 043, IndiaTel: +91 85530 12371/ 72 Fax: +91 80 25426934Email: [email protected] Visist www.martinfotech.in

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Traditionally Rapid Prototyping (RP) processes have addressed the need for plastic parts. Most commonly used RP processes are:

1. Stereolithography (SLA),

2. Selective Laser Sintering (SLS),

3. 3D Printing (3DP), and

4. Fused Deposition Modeling (FDM).

Since early 1990s, all RP processes, including above processes, have focused on creating plastic parts from a CAD data. Even amongst plastic materials, RP processes have had limited material choice.

SLA creates models from limited number of epoxy material. FDM creates parts out of ABS and Polycarbonate (PC), SLS out of nylon based materials. Recently some efforts have been made to develop

RP processes to create parts from metals. However, the success has been limited.

One such process is Direct Metal Laser Sintering (DMLS). Although DMLS can create parts from certain metallic materials, the choice of metals used in the process is limited and proprietary. One can not produce parts out of alloys of one’s choice.

Another major drawback of these RP processes, whether for plastic or metal, is their inability to produce parts in larger quantities fast and economically. In summary, Direct Rapid Manufacturing (DRM) of Metal Parts by RP has been limited. DRM by RP does not offer a wide choice of materials to customers.

The problem of obtaining larger quantity of metal parts from a choice of alloy is solved by combining traditional RP


Dr. Mukesh AgarwalTotal Prototyping Pvt LtdBangalore

This article will describe an ideal combination of traditional RP and an innovative lost-wax investment casting process to arrive at rapidly produced low-volume aluminium castings. The casting quality from the process is equivalent to those produced by Low-pressure Die Casting.

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with traditional Such Indirect Rapid Manufacturing (IRM) of metal parts is very common in the US

. In US, it is a common practice to produce a plastic or wax casting pattern or master model directly from CAD data using one of the above listed RP process. The wax or plastic model thus produced is used in conventional casting, sand casting or lost-wax investment casting, operation to produce fully functional metal components out of alloys of one’s choice.

This approach is so widespread that almost 25% of all models produced from RP machines in US are used as patterns for metal casting. Compare that to almost nil such application of RP plastic models in India.

Also, worth noting is that the total number RP machine installations in US is almost 30-50 times more than in India. So, total number of RP plastic models produced is that many times higher

and of which 25% are used as casting patterns/masters.

In fact, the revenues from such castings are much higher than the total revenues generated from sale of RP machines and sale of RP plastic models combined. To summarize, use of RP combined with traditional foundry operations to produce metal castings for product development has a long way to go in India.

One of the reason for this lack of appreciation of RP in foundry industry maybe due to the fact that Indian metal casting producers are doing contract manufacturing doing print-to-design work. As Indian emerges as a global hub for castings, to keep pace with global demands and maintain its edge, Indian Casting Companies are moving up the value-chain.

To do that, Indian Companies are engaging in New Product Development and not just remaining contract

manufacturers doing Print-to-Design. This new found zeal for value-addition will result in the need for Rapid Metal Casting.

This article describes one such innovative way of combining traditional RP with traditional lost-wax investment casting process to rapidly produce low-volume high-quality aluminium castings. The same approach is used for production of ferrous castings also; however, this article focuses on production of aluminium castings.

Lost-Wax Invstement Casting:

Lost-wax investment casting is a widely used foundry process for production of ferrous, especially stainless steel, components where near-net shape is required. The process begins with production of wax patterns. Figure 1 schematically demonstrates the whole process. Each wax pattern results in a casting at the end of the process. Wax patterns are produced by injecting

Wax Pattern

Casting

Ceramic shell with Pattern

Metal pouring

Ceramic shell

Figure 1: Schematic Showing the Steps in Traditional Lost-wax Investment Casting


molten wax into a machined steel die.

One or more wax patterns are then assembled together with sprues, runners, ingates etc to create a “tree”. The tree is then coated with a ceramic slurry by repeated dipping and drying process which takes 5-7 days. This is followed by melting of the wax and firing of the resultant ceramic shell.

Finally, molten metal is poured into the ceramic shell under ambient conditions. The shell is then broken manually to get the casting out. The casting is then fettled after which it undergoes machining operations to suit a particular assembly.

This traditional approach has three major drawbacks which render the process unsuitable for rapid, low-volume production during early-stage production development cycle. These drawbacks are:

1. A machined die for production of wax pattern is time consuming and costly affair, especially when low-volume components are required.

2. 5-7 days for ceramic coating a wax assembly is definitely not “Rapid”.

3. Molten metal pouring done under ambient conditions can result in poor quality.

This article describes an innovative approach of lost-wax casting process which overcomes the above drawbacks.

RAPID METAL CASTING:

The process begins with the components’ 3D CAD Model along with 2D drawings. After thoroughly studying the model and drawing for tolerances, accuracies, and machining provisions, necessary modifications are made to the CAD model to allow for metal casting shrinkage and machining allowances.

The modified 3D CAD model is then used to produce a RP Model, mostly out

of SLA due to its superior dimensional accuracy and surface finish. The RP Model is then used as a master pattern to produce a silicone rubber mould.

The silicone rubber mould produced is similar to those produced and used in RP process called vacuum casting of urethane parts. Silicone rubber moulds from such RP Master take no more than 1-2 days.

Wax Pattern Production:

Wax patterns by melting and pouring wax into the silicone rubber mould. The wax used is any conventional investment casting grade wax. The whole process of melting and pouring of wax is done in a vacuum chamber called Vacuum Casting machine.

Figure 2 shows such a machine along with a silicone rubber mould and the wax pattern. This process can produce 2-10 wax patterns depending on the size and geometry of the component. One or more wax patterns are then assembled with wax based gating system to create a “tree” similar to the one produced in traditional lost-wax investment casting process.

Ceramic Shell Production:

The wax tree is used to create a ceramic

shell just as in traditional investment casting. However, the process of repeated (3-5 times) dipping and drying of ceramic slurry is not used in this

Figure 2: Vacuum Casting Machine

Figure 3: Investment Mixer

process. The wax “tree” is placed inside a steel flask which is open from both ends.

The flask is then placed in a system called Investment Mixer. The investment mixer consists of two chambers – top and bottom. The flask with the wax tree is placed in the bottom chamber. The top chamber is filled with the required amount of ceramic powder and water.

A rotating stirrer blade in the top chamber creates a slurry which is then poured into the flask in the bottom chamber. This entire exercise is done under vacuum. This process results in the entire wax tree being encapsulated in the ceramic slurry inside the flask.

Within 2-3 hours the ceramic material hardens and then flask is then removed from the machine. Figure 3 shows the investment mixer with the flask kept in the bottom chamber.

Dewaxing and Shell Baking:

The flask with the wax tree embedded in hardened ceramic is placed in an autoclave oven. The oven is heated upto 700 C with various stages of holding at different temperatures.

This oven cycle results in completely ash-


free removal of wax and also in baking of the ceramic into a hard shell. Removal of wax from the ceramic structure results in a cavity into which molten metal can be poured.

Metal Casting:

The flask with the hard ceramic shell is removed from the oven and placed into the Metal Casting System. The metal casting system consists of two chambers – top and bottom. The top chamber consists of an induction furnace with a graphite crucible for melting aluminium alloys.

The bottom chamber is where the flask with ceramic shell is placed. Figure 4 shows the casting unit. Both chambers are closed after placing required amount of virgin alloy material in top and the flask in the bottom chamber respectively.

Both chambers are connected to a vacuum pump capable of evacuating

the system as well as to inert gas supply. The entire system is controlled through a PLC control panel.

The entire process of melting and casting is carried out under a combination of vacuum and inert gas pressure. Once the alloy has achieved molten condition and is at casting temperature, the molten material is poured into the ceramic shell by opening a valve between the two chambers. The molten material is thus filled into the ceramic shell cavity thereby completing the casting cycle.

Post-Casting Operations:

The flask is removed from the bottom chamber of the casting system and the ceramic shell is broken by a high pressure water jet system. The metal casting is removed and taken for traditional fettling operation to remove the gating system.

Finally, the casting is ready for any further operations such as pickling, sand blasting, heat treatment, and finish CNC machining.Figure 4: Metal Casting System

Figure 5a: Fuel Pump Component

Figure 5b: SLA Master, Wax pattern, and Casting

Case Studies:

The above described procedure has been used to carry out several complex aluminium castings, such as automobile cylinder head, intake/exhaust manifold, transmission housing etc. Figures 5 show many such examples of castings produced.

Conclusion:

This article has described an ideal combination of traditional RP and an innovative lost-wax investment casting process to arrive at rapidly produced

low-volume aluminium castings. The casting quality from the process is equivalent to those produced by Low-


Figure 5c: Aerospace Fuel Pump Castings

Figure 5d: HVAC Mounting Bracket

pressure Die Casting.

This entire process does not require any investment of time and money into machined dies or moulds. The process can produce 1-20 castings in 10-20 days depending on size and geometry of the component.

The process is ideally suited for initial prototype requirement during product development stage. Since the material

used is as per the requirement and the casting quality is comparable to LPDC components, the components from this process are also suitable for final use and not merely prototype for design validation.

Hence, this process is suitable for low-volume production during early-stage production while the production of die/mould is yet to begin actual production. Adoption of such a process can expedite product launch giving the manufacturer tremendous advantage of first-to-market.

The author Dr. Mukesh Agarwal, is an Entrepreneur, Scientist, Consultant, Author and a speaker. He is the Managing DIrector of 3D Product Development. He has more than 50 articles and technical papers published

as well as five patents in RP Technologies and material processing.

Dr. Agarwal has been a research scientist at some of the world’s most reputred universities. He has established a Six-University Consortium in Ohio, USA, to meet the aggressive needs of local industry and to conduct advanced R&D in RP. He can be reached at [email protected]


Construction of the part or assembly is usually done using 3D printing tech-nology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a much wider range of applica-tions and are even used to manufacture production-quality parts in relatively small numbers.

Rapid prototyping processes are a relatively recent development. The first machine was released onto the market in late 1987. While rapid prototyping is the term commonly applied to these technologies the terminology is now a little dated, reflecting the purpose to which the early machines were applied. A more accurate description would be layer manufacturing processes. An alternative term is free-form fabrication processes.

These processes work by building up a component layer by layer, with one thin layer of material bonded to the previous thin layer. There are several different processes. The main ones are:

• Stereolithography; • Laser sintering; • Fused deposition modelling; • Solid ground curing; and • Laminated object manufacturing.

In addition there are a number of newer processes, such as ballistic particle manufacturing and three-dimensional printing, which have appeared on the market.

All these processes essentially start with nothing and end with a completed part. This is in contrast to conventional manufacturing processes such as milling machines that start from a solid block of a substance and cut material away to form the finished part.

Rapid prototyping processes are driven by instructions which are derived from three-dimensional computer-aided de-sign (CAD) models. CAD technologies are therefore an essential enabling system for rapid prototyping. The processes use different physical principles, but essentially they work either by using lasers to cut, cure or sinter material into

Rapid Prototyping – An InsightRapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data.

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a layer, or involve ejecting material from a nozzle to create a layer. Many different materials are used, depending upon the particular process. Materials include thermopolymers, photopolymers, other plastics, paper, wax, metallic powder, etc.

The application of these processes is not restricted to supporting new product de-velopment activities C they can also be used to create production tooling. They can therefore be used to support one-off or small batch production runs. Thus the processes can be used to create models, tooling, prototypes, and even in some cases to directly produce metal compo-nents.

Many rapid prototyping technologies actually produce physical models. These models are then used to produce tooling using an indirect secondary process such as investment casting. The resulting tool

is then used to manufacture a com-ponent. However, new processes are beginning to appear that allow the tool-ing to be manufactured directly from the computer model, thus eliminating the physical model production stage.

In the future it is likely to be possible to manufacture components directly from the computer model, eliminating the need to produce physical models and tooling first, although these may still be required for other purposes.

The important point to understand is that, while rapid prototyping started out as an expensive tool for producing physical models for design engineers to visualise their component designs, this is now no longer an accurate description of the technologies or their application potential.

The potential different applications of

rapid prototyping technologies span the complete product life cycle from con-cept generation, through preparation of specifications and detailed design, to manufacture.

Director Technical & Operations with Pet Moulds, the author E D Balasubra-maniam is an Engineering graduate with specialization in Manufacturing with an overall experience of over 19 years in the Plastic Engineering industry. Right from beginning, he has experienced in the same platform of PET processing & Mould design & manufacturing. He has expertise in PET Packaging sector & Hands on experience in PET process-ing equipments. Apart from the vast experience in costing & Planning, he has sound knowledge in Material selection & process routing. He has also served as a Management Representative in ISO certification process. He can be reached at +91 98843 90666


FARO Technologies announces its first Asia Pacific 3D Documentation Conference

FARO Technologies, Inc. (NASDAQ:

FARO), the world’s most trusted source

for 3D measurement technology,

announced that it will host its first ever

3D Documentation Conference in Asia

Pacific from 25 – 26 April 2013 at Marina

Mandarin Hotel, Singapore. This will

be Asia Pacific’s largest platform for

the gathering of 3D documentation

professionals and practitioners from

various fields across the region. In line

with the event theme, “Connecting

3D Communities”, the conference will

encourage cross-vertical interactions

amongst 3D laser scanning communities

and stimulate industry integration and

cooperation.

“FARO Technologies envisions a

platform where the terrestrial laser

scanning community in Asia Pacific can

gather to share, learn and network.

Currently, we have a substantial pool

of users in the region and the timing

could not be better for the conference

to be held here,” said Joseph Arezone,

Senior Vice President and Managing

Director, FARO Asia Pacific. “Participants

can expect to benefit from the sharing

sessions chaired by industry experts

from around the world, the end-

user presentations, and the various

application workshops. This conference

will be an avenue where all stakeholders

related to 3D documentation can come

together to collaborate and expand the

market.”

This FARO 3D Documentation

Conference 2013 will feature keynote

addresses by renowned professionals,

power speeches by industry experts, and

exclusive networking opportunities.

At the same time, there will also be

an exhibition where 3D technology

and solution providers will showcase

their products and services to existing

and potential customers, as well as

business partners. FARO welcomes

participants from a variety of sectors

such as Architecture, Civil Engineering,

Surveying, Forestry, Forensics, Facilities

Management, Mining and Tunneling

amongst many others.

For more information about the FARO

3D Documentation Conference 2013, visit

www.3d-documentation-conference-

2013.com. Exhibition and sponsorship

opportunities are also available for this

conference.

FARO is a global technology company

that develops and markets computer-

aided coordinate measurement devices

and software. Portable equipment

from FARO permits high-precision

3D measurement and comparison

of parts and compound structures

within production and quality

assurance processes. The devices

are used for inspecting components

and assemblies, production planning,

inventory documentation, as well as

for investigation and reconstruction of

accident sites or crime scenes. They are

also employed to generate digital scans

of historic sites.

With FARO, 3D measurement and

documentation needs can be fulfilled

confidently. As a pioneer and market

leader in portable computer-aided

measurement, FARO consistently applies

the latest advances in technology

to make its industry-leading product

offerings more accurate, reliable, and

easy to use. The focus is on simplifying

workflow with tools that empower

customers, thereby dramatically

reducing the on-site measuring time and

lowering overall costs.

Worldwide, approximately 15,000

customers are operating more than

30,000 installations of FARO’s systems.

The company’s global headquarters

are located in Lake Mary, Florida, with

its European head office in Stuttgart,

Germany and its Asia-Pacific head office

in Singapore.

FARO has branch locations in Japan,

China, India, South Korea, Thailand,

Malaysia, Vietnam, Canada, Mexico,

United Kingdom, France, Spain, Italy,

Poland, and The Netherlands.

Further information:

www.faroasia.com/in

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What interesting or outstanding trends

did the metal cutting industry in Asia

display in 2012?

Within the global thermal cutting

industry, fiber laser made greater

inroads, as higher capacity systems

that can cut thicker materials were

introduced. This was a continuation of

the trend seen in 2011, which saw the

technology outpace CO2 lasers.

In the field of plasma, the industry

observed continued refinement of

cutting technology capability for both

mild and stainless steel. With increased

competition in these segments,

previously known applications were

reinforced, while new ones were

introduced.

Manufacturers of plasma systems

also introduced more accessories

and applications-based solutions that

enhanced the original equipment

manufacturers’ (OEMs) ability to

integrate plasma into their cutting tables

more easily. At the same time, this

increased the value proposition of the

final product.

What was the biggest challenge for the

industry this past year, or over the past

few years?

The greatest challenge in 2012 was,

in my opinion, the slowing economy

in Asia, and in particular in China. In

addition, the India market showed signs

of lagging later in the year, and other

Asian markets were also affected by the

downturn, leading to lower economic

output across the region.

On top of economic difficulties, demand

evaporation and heightened investor

“Sucessfull Implementation of FDI can attract investment, raise confidence in the Indian Market”

Hypertherm’s mission is to provide customers with the best cutting equipment and service in the industry. Hypertherm first entered Asia in 1991 by setting up a Singapore subsidiary. Since then, they have expanded across the region and now have a business presence in five Asian countries, namely China, India, Japan, Korea and Singapore.

Excerpts from an interview with Soo Kam Tatt, Director, Hypertherm Asia about industry in general and Hypertherm’s plan for 2013 in the region.

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cautiousness dampened the investment

climate of numerous key Asian countries.

Is there any silver lining for the metal

cutting industry in response to a poor

global economic outlook for 2013?

On the global front, it is difficult to

determine whether the metal cutting

industry will see an improvement as

the US and Europe economies are now

in different stages, and continue to be

exposed to various market challenges.

Although the US industry performed

generally well in 2012, the looming fiscal

cliff is a time-sensitive factor that may

throw the country and international

markets into disarray.

Closer to home, China hopes that its

new leaders will recognize the need for

continued growth. This comes alongside

expectations for measures that will

facilitate economic development and

growth that is sustainable. In India, the

government recently proposed credit-

easing measures and new regulations,

in order to attract foreign direct

investment (FDI). These, if agreed and

approved, should inject some confidence

into the sagging Indian market.

Apart from Asia’s two largest economies,

governments of other countries in the

region have also invested or plan to

invest large sums to upgrade business

infrastructure, in order to improve the

local economic climate. These measures

will be key to making 2013 a better year

for companies in general.

Please share with us the significant

milestones that Hypertherm witnessed

as a company in 2012?

Within the span of a single year,

Hypertherm reinforced further our

presence in two Asian markets – India

and China. In India, we incorporated a

new office in New Delhi, which also

Channel partners at a training session in Hypertherm’s India CTC.

houses our first local cutting technology

center (CTC). The CTC will serve as a

gathering point where employees of

over 40 channel partners can train up

their technical skills and sales expertise

to enhance their capabilities when

introducing Hypertherm products to

end-users.

As for our China operations, we moved

to a larger premise to accommodate the

growing associate base, and to have the

CTC and office located within the same

facility. This is in line with the growth

that we’ve seen in the country over the

years.

Hypertherm launched a few new

products in 2012, the most notable

being the Powermax 105®. This is a

new 105-amp air plasma system used

for handheld and automated cutting

and gouging. The system is designed to

comfortably cut 32mm-thick metals, and

sever metals up to 50mm-thick. It is the

toughest, most versatile system in its

class.

Another outstanding innovation was the

HyPro2000 torch, meant for retrofitting

onto existing MAX200 systems.

Compared to the standard torch, the

HyPro2000 cuts 25% faster and has

the potential to increase consumable

lifespan by up to 75%.

In which industries did Hypertherm

attain the most significant growth in

2012? What were the factors that led to

this?

2012 was a challenging year, and there

wasn’t a specific industry that stood out

for our Asia business. The leadership

transition in China complicated the

slowdown of the domestic economy

as the country normally doesn’t make

transition and implementation measures

during this changeover period.

Although signs of economic decline in

other Asian nations became evident

only after China experienced a drop,

the slowdown was already felt within

the industries earlier in the year.

Many markets in the region witnessed

decreasing GDP as we moved towards

the end of 2012. In India specifically,


inflation, government bureaucracy, the

weak Rupee and decreased agricultural

output due to low rainfall have lowered

the country’s GDP down to about 5% for

2012.

India’s government recently expressed

its openness towards FDI. Does this

have any impact on Hypertherm’s

business in the country?

New initiatives by the Indian government

to attract FDI have generally been

viewed positively by the business

community. In order to succeed,

however, these propositions have to

find traction within the complex web

of Indian democracy, the coalition

government, and the bureaucracy that

the country’s leaders plan to minimize.

Successful implementation of proposed

ideas is likely to attract investment in

the country, and should therefore raise

confidence in the local business climate.

Many organizations and governments

are now pushing for companies to

practice sustainable development. How

can the manufacturing industry answer

this call?

Sustainability is an inevitable call to

ensure that the incessant industry

pursuit of growth doesn’t come at the

expense of environmental degradation.

Many companies are aware that they can

play a part, and have started pursuing

efforts to reduce their impact on the

environment.

At Hypertherm, we have set long-term

goals to reduce waste and minimize our

carbon footprint. We continually hold

ourselves accountable to these targets.

As part of our efforts to reduce waste,

we are looking into ways to make every

component of our products recyclable,

reusable or reclaimable. Our target is to

produce zero waste by 2020.

In order to reduce our carbon footprint,

we hope to improve in the way we

transport our products worldwide.

Energy consumption is one area we are

looking at as part of our sustainability

efforts – we want our products to be

as electrically efficient as possible.

Another area is the way we transport

our products worldwide and here we

The Powermax 105® is the toughest, most versatile system in its class.

Hypertherm believes that business growth should not be at the expense of the environment.


will be optimizing and finding a blend

of reducing the carbon footprint and

serving our customer efficiently.

What are Hypertherm’s plans for its

business in Asia come 2013?

As I mentioned earlier, 2012 has been

a challenging year for Hypertherm in

Asia. China’s purchasing managers’

index (PMI) in October indicate that

the country’s economy may have hit

rock bottom, which seems to coincide

with the general view that recovery will

probably only occur in 2013. For India, if

the government’s measures to attract

FDI kick in, this would bode well for the

country’s business in 2013.

Although these factors may bring

about favorable conditions, growth is

unlikely to occur at the same pace as

it did previously as current domestic

issues in both China and India will crimp

exuberance to a certain extent. At the

same time, export prospects presented

by the rest of the world will not be as

bright as before.

Notwithstanding the economic climate,

at Hypertherm, we view the New Year

with vigor, as we always have. As a

company, we will focus efforts on

pursuing technologies and applications

that offer value to end-users and our

partners.

We have expanded our capabilities

in China and India in 2012 with larger

offices and incorporated new cutting

and training facilities. These will further

raise our support levels, and allow us to

serve our customers more efficiently to

minimize potential downtime .

The HyPerformance series of HyDefinition plasma systems was well-received by the Korea market.


The impact of quality on our business can be measured in terms of the Cost of Quality (CoQ). CoQ represents the total business cost in achieving quality. In other words, CoQcovers any and all costs that an organization incurs from having to repeat a process more than once in order to complete the work correctly.

CoQwas introduced by Juran in 1951 as a means of providing cost and accounting based justification to management for investments in process improvements. The goal of Total Quality Management is to reduce the cost of quality through continuous improvement of methods (processes) and other means such as error elimination, building in quality at product and process design stage, and improving methods – as shown in Exhibit 1. This involves failure analysis as well as

process analysis.

As seen in Exhibit 1, every activity done within a company can be categorised as either one of the following four:

1. Prevention – Activity to ensure work is carried out Right First Time (e.g. Training, developing systems standards and specifications).

2. Appraisal – Activity to check if work has been done Right First Time (e.g. Auditing, Checking, Inspecting, Supervising). Some of these can add value – e.g. audits; but most simply add cost.

3. Failure – everything that has to be done because something wasn’t Right First Time (e.g. Re-work, corrections, answering complaints, dealing with

Saravjit Singh

CEO, www.10xQuality.org

Cost of Quality“Quality is never an accident; it is always the result of high intention, sincere effort, intelligentdirection and skillful execution; it represents the wise choice of many alternatives.” —Will A Foster

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enquiries about problems, problem solving).

4. Base Workload – everything else, done Right First Time to meet a customer’s need. This requires continuously improving basic processes.

As seen in Exhibit 1, the sum of Prevention, Appraisal and Failure is the Cost of Quality. In service businesses, this often amounts to 40% of operating costs, with Failure and Appraisal accounting for most of that. In production work, CoQ is typically 25% of Sales Revenues, again with Failure and Appraisal being the biggest contributors to this cost.

In order to use the CoQtechnique, you should list all the activities in the

business thencategorizethese activities according to the four types as seen in Exhibit 1. Thenyou measure (or estimate when measuring is not possible) the amount of time and cost spent on each activity. Add up all this and calculate total time and cost spent on Failure and Appraisal. This is usually a big enough number to motivate management to want to take some improvement actions!

In order to better understand the CoQ we divide this into Cost of Poor Quality and Cost of Good Quality. This is shown in Exhibit 2.

Cost of Poor Qualityhas two components. These are:

1. Internal Failure Costs:These are those costs that are associated with

recognizing and correcting a poor quality characteristic BEFORE the product leaves the factory. The most common costs in this category are:

• Cost of scrap

• Costs related to all rework

• Costs incurred on analysis of failure

• Cost of crisis management to correct quality

• Re-testing costs

• Downtime and work stoppages due to internal failures

2. External Failure Costs:External failure is the worst of all possible situations. This includes failure of a product or service at the delivery point or when the product is being used by the customer. This is a bad situation because of two reasons. One, the product needs rectification and replacement of components or even full replacement. Second, company’s reputation is impacted. Costs associated with this are:

• Customer dissatisfaction and loss of repeat business

• Loss of new business

• Product and service support costs

• Cost of litigation and penalties

• Loss of reputation and erosion of brand image

Cost of Good Quality is associated with putting systems and processes in place to reduce the likelihood of a failure. The ideal condition is achievement of zero defects. Cost of good quality includes two components:

1. Appraisal Costs: Appraisal mainly includes inspection costs. Any activity we do that inspects the quality of the product or service falls in this category. Typical appraisal costs include the following:

• Allverification and validation costs

• Product and process review costs

Exhibit 1: Cost of Quality

Exhibit 2: Bifurcating Cost of Quality into its four components


• Costs towards product audits and compliance activities

• Products and services testing costs

2. Prevention Costs: Prevention costsare associated with preventing a quality problem from occurring in the first place. Typical costs that are included in this category are:

• Training costs

• ISO related costs, including quality management and continuous process improvement costs

• Tool evaluation and equipment automation costs

• Hardware and software up-gradation costs

• Costs towards defect prevention by incorporation of techniques such as

Exhibit 3: Costs vs. Defect Level

Exhibit 4: Six Sigma reduces Cost of Good quality

poka yoke.

How this affects a manufacturing company is shown below in Exhibit 3.

When a company uses Six Sigma initiatives to improve its processes there is a reduction in the Cost of Good Quality (Prevention and Appraisal costs). This is shown in Exhibit 4.

Lynda Byrne sees the Cost of Quality as shown in Exhibit 5. She suggests that each firm has an optimal quality level shown as ‘you want to be here’ point in Exhibit 5.

You will notice that this quality pointcoincides with the intersection of the cost of implementing quality (cost of

good quality) and the cost of rectifying defects (cost of poor quality).

This is the traditional view of quality and total cost of quality as practiced by most manufacturing companies.

Exhibit 6 illustrates costs associated with poor quality. The visible costs shown in this exhibit are obvious to everyone and most companies concentrate on reducing only these costs. However, there are many more other invisible costs of quality as shown in Exhibit 6.

Many companies when undertaking continuous improvement projects do not consider these costs. These invisible, hidden, costs of quality represent areas of big opportunity for reducing costs.They relate to all kinds of waste whichdirectly or indirectly contribute to the increase in the cost of developing, producing, delivering and servicing a quality product.

The concept of zero defect was first adopted by Japanese companies, ledby Toyota. This concept was seen to workand these companies were able to produce components and products having zero defects. Now many automotive multinationals and

Exhibit 5: Optimal level of quality


Exhibit 7: Cost of quality is minimum at zero defect

products at lower costs than companies in the western world.

Now that we know it is possible, we too can achieve minimum CoQ level at 100 % quality level through minimizing waste and achieving zero defects.

For this we have to become TQM compliant and use lean thinking methods to achieve continuous improvement of processes and productsby undertaking lean six sigma projects.

The main mantra followed by Japanese companies is continuous

quality improvement, mostly through small projects at shop floor and at all operational areas.

This initiative has beenled in Japanese companies by quality circles working on a large number of kaizen projects.

How increased profits are achieved through continuous quality improvement is shown in Exhibit 8.

The author Sarvajit Singh is the Chief Executive Officer of 10xQuality.org and he can be contacted at [email protected]

other companies have achieved zero defectmanufacturing and services.

The real advantage of zero defect production and services is that the cost of quality is minimum when quality is 100%, as happens when zero defect rate is achieved. This is seen in Exhibit 7.

Compare this to the traditional view as shown in Exhibit 5, where the optimal quality shown as being achievable is at a level well below the 100% quality level. It is no wonder that Japanese companies have achieved such heights and have been able to deliver better quality

Exhibit 6: Visible and Hidden Costs of Quality

Exhibit 8: Increased Profits throughContinuous Quality Improvement


8.0 Untold expectations

The customer has explicit and implicit needs. It is easy to understand explicit needs like quality standards, price, delivery, specifications, defining testing requirements, contracts etc. The challenge is to understand implicit needs which are not defined and if not met customer will be unhappy.

The chances of enhancing business is high if implicit needs like trust, relationship, satisfying ego, giving feeling of importance etc. are met. I call these implicit expectations as untold by Customer.

No checklist of Customer captures these points in assessing the supplier but are assessed in mind for decision to do business with supplier.

8.1 Understanding culture of Customer

I was heading international purchase of Robert Bosch Group in India to source from Indian Suppliers to Bosch plants worldwide. This involved close interaction between suppliers and customers and one of key task was to identify gap between customers and suppliers. These gaps were technical, commercial and typically cultural.

It was observed that business developed well when supplier made an attempt to understand culture of Customer. Each country and region has their own culture and many of our behaviour have come from our culture.

For example, Japanese takes time for a decision and it is done collectively. If we understand the reason for this could be that Japanese tries to a perfect job and

Journey Towards ExcellenceUnderstanding expectation of Customer – Part 7In the last six articles under the same heading, we dealt about SWOT analysis of sourcing from India and expectation from customer related to quality,technology,cost management,managerial ability and logistics. We will continue the topic further in this issue by focusing on those expectations that are not spelt out by Customers explicitly.

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P S SatishMentor and Consultant

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does not want any mistakes then we can adjust our interactions effectively. They believe in team. They will be happy if we understand this cultural aspect and respond suitably by way of a detailed and perfect job in a team.

It is equally important that customer as well understands culture of country and business at supplier. I used to tell overseas customers that if you want to do business in India better understand and appreciate why cows are seen on roads.

Companies dealing with foreign customers need to expose employees for proper understanding of culture of customers and link to the business. Bigger corporates are conversant with this and SMEs need to catch up.

Within India itself we find different cultures. The way business is done in

south India is different from that in north India.

8.2 Right attitude

In simple words, attitude is nothing but response to the situation. Customer expects right attitude by the supplier which is very difficult to measure. Right attitude and not the aptitude decide the altitude.

Many times approach to the problem solving is seen as more important than solution to the problem itself. Suppliers need to develop and demonstrate right attitude in all dealings with Customer. For example, business will not last long if the supplier demonstrates attitude of being opportunist.

8.3 Good behaviour

Demonstrating good behaviour during interactions with the customer including

that in video/telecom is important. Training employees especially marketing colleagues on etiquettes helps a lot. Talking loudly on phone is accepted as normal in one culture but not in the other.

8.4 Pro-active actions

Customer expects that supplier be proactive. He should be able to solve problems before they appear. Reactive approach will not help in long term relationship. Proactive actions like improvements of processes, cost reduction and improvement of products without being told goes a long way.

Typically customers are communicated when they ask for something. Pro-active communications without a reminder and follow up is also part of this. Some times over communication to customer are better if done structurally.


Muratec, a pioneer in AC Servo Sheet Metal machines has designed and developed a fully electric Green Press Brake BB 4013. BB 4013 is built with rigidity and a special offset frame to accommodate full length bending over full ram stroke.

Key Features include high speed ram movement (100mm/sec), stable high repeatability, oil-less environment and an advanced NC compatible with SD-simulation (option).

Meiban Engineering Technologies Pvt Ltd is a solution provider in the field of automation and turn key projects for manufacturing Automobile and Sheet metal components. Meiban Engg. supplies and services sheet metal machines which include CNC Servo Turret Punch presses of various

capacities, punching and shearing machines, and panel benders.Meiaban team also supplies the latest advance “CONIC” made in Japan, tools for sheet metal punching machines.

Meiban Engineering Technologies is based in Bangalore, with a Sales & Service office in Chennai and a Sales representative in Mumbai. All their sales & service engineers are factory trained to support the customer with technical and application information. For further details contact Tel: 98450 88605, E-mail: [email protected]

8.5 Building Trust and relationship

This is one of the foundation blocks for long term relationship. Japanese customers give lot of importance for this. Efforts needed here are high and takes time. Supplier need to develop patience.

8.6 Meeting Customer regularly

It is important for supplier to meet customer regularly even though there are no issues. This will build relationship. Supplier can ask pro-actively Customer about his feedback on performance and seek suggestions for improvement.

I have seen suppliers who have not met their customers for years. When asked, they say that there is no issue and hence no need. Voluntary offer by Suppliers for a meeting will make Customers definitely happy. Of course, this meeting has to be structured.

8.7 Customer orientation at all level

It is a wrong concept to think that only marketing colleagues who deal directly with Customer need to be customer oriented. In lots of companies managing director or CEO has no interaction with the customer. For a sustained business, CEO should ensure that all employees in the company are oriented towards customer.

8.8 Strategic thinking

One of the concerns of Customer is that whether the supplier has strategic thinking to ensure that his business is sustainable in long term. Suppliers seen to be doing for survival are potential dangers. Question to look at is if company has strategic approach of business involving senior management team

Other general expectations include

maintaining good housekeeping, visualization in the company,continuous improvement thinking, ability to do business using modern media like internet, safety at work, understanding law of the country where business is done, bench marking with competitors, understanding consequences of warranty and liability etc.

With these notes, I conclude this series of articles on understanding customer expectation. We will catch with some other topic in the next issue.

Please send your inputs, remarks, suggestions to P.S.Satish, Mentor and Trainer, M/s Saraswati Industrial Services, Q-103,Mantri Paradise Apartments,Bannerghatta Road, Bangalore-560076. Email : [email protected] . Wishing good day to you all.

The all new Ball Screw driven Electric Press Brake from Muratec



It is a fact that if you green your off erings, you diff erentiate. Green product development is a process which needs to be mastered. The compa-nies with innovative outlook can use “architect strategy”, for building green products from scratch.

Architecting eco elements in to a product may be a slower and costly process than acquiring or accentuating, but is most benefi cial in competitiveness.

On a larger scale is the example of Prius the more-fuel effi cient car by Toyota which dominates the fastest growing segment in car purchases. At a smaller level we have the example of Colorex developing household natural cleaner products to clean glass, bathroom ceramics & toilet bowl.

Both the products categories are now the best sellers in their domain.

The success of the product develop-

ment depends upon the quality of data accumulated about eco-conscious consumers’ knowledge and preferences.

First three steps that will infl uence the Green Growth Initiative.

Viability:-

Companies evaluate their assets along two dimensions: green-able attributes of their existing products and brands. Financial & organisational capabilities to handle the development process. It requires a careful analysis of greening benefi ts the proposed brand off ers.

Each product will have its own category- specifi c attributes, ranging from recyclability, to energy effi ciency, toxic reduction, lean consumption of raw materials etc... There are about 70 such performance indicator are listed in Global Reporting Initiative.

The second dimension involves apprais-ing the company’s Green resources and

Greening your Responsibility.Turning Eco Friendly practice into competitive advantage

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Vivin AgarwalProduct Architect & Social Entrepreneur


capabilities. Review of the process and priorities for innovation and new product development, supply chain management, the co-ordination of collaboratives among distributors and even partnership with environment organisations.

Willingness:-

Managers asses the strategic fit of each options with company’s objectives and the resources they can bring in the gambit of Green Initiative. They need to consider speed to market, the invest-ments, reputations and competencies that the initiative will require.

For a progressive company green growth may be part of an enterprise-wide sustainability initiative to retool options, shift of culture, ultimately repo-sitioning the organisation.

Execution:-

Taking action on all the points discussed above.

Following questions may help for for analysing Green Growth options,

1. What’s our strategic Goal?

To create a new Green solution.

To develop unique competency.

To respond to new market needs.

To gain green credibility.

2. Your brand portfolio:

How will this initiative affect the posi-tioning and resources of existing own brands?

Will the initiative provide wider abilities that can influence the other brands?

What will be the relationships of the existing and new brands?

3. Your customers.

What innovations and feature , consumers are expecting in greener alternative?

Does you parent brand have the permission to enter Green space?

Will this initiative will demand to create a new alternative, isolated brand?

Will this development will need to edu-cate develop the market and bring new customers into the category?

4. Your competitors.

Are we creating new green category?

Can we differentiate our brand?

How can we exploit the green weakness of our competitor?

Does the category already infested with competition?

5. Warning.

Do we have environmental skeleton in our current business model?

Will our initiative will be credible or we will be blamed for Green-washing?

The Sustainability Road Map:

The social forces have shaped the competitive landscape in past. Sustain-ability and greening are emerging as Megatrends, their courses are somewhat predictable. Our focus always be on the emerging business Megatrends which will lays new rules for the competition. Such transformations come from tech-nological transformation or from new ways of doing business.

So decide your own Green Responsibilty.

To be constantly innovative is a mandate of Responsible Business. You can join us in the search of innovative products, by responding to me at [email protected].

Most power distribution companies face major challenges in recovering electricity bills on time. ElMeasure has developed a unique Contactless Prepaid Energy Meter which acts as a direct revenue interface between power distribution companies and the consumers.

Unique featutres Include: User friendly

First time in the World from ElmeasureContact-less Prepaid Meter for Gas, Water & Electricity

Contactless Prepaid Energy Meter Solution, Remote Display Unit allowing customer to recharge and monitor consumption, Integration of Gas and Water with the electrical parameters thereby, extending the flexibility for the user to budget expenses.

Tripping of EB or DG consumption at

pre-determined set point for protection and effective use of energy, History of consumption for analysis and Direct current measurement up to 80A for Single or three phase measurements.

For further details visit www.elmeasure.com



4. Light Gauge Hot Rolled Sections:

In the case of pipes, channels, I sections and angle sections lower the thickness of the section, material utilisation is opti-mum. Hence for the same weight lesser thickness and deeper sections resist higher bending loads.

This principle is best illustrated in Fig.1. All the sections shown from 1 to 1e have the same moment of inertia. The saving in weight in the case of 1b is about 28%, in the case of 1c 53%, in the case of 1d 68% and in the case of 1e it is 78% which is the thinnest.

It is strange that in India practically all the steel plants concentrate on pro-ducing medium and heavy gauge hot rolled angles, T- sections, channels and I sections.

Light gauge hot rolled metal sections are available in technical tables only. Our steel plants should be motivated, persuaded and encouraged to produce

more of lighter gauge hot rolled sec-tions by the concerned government and professional institutions.

5. Torsteel:

Already in the case of building industries for concrete reinforcements mostly torsteel is being used instead of plain bars where there is considerable weight saving.

6. Stress Concentration:

Avoid stress concentration in machine elements. Failure of machine elements is mainly due to stress fatigue and it occurs in the area of stress concentration. By analysing the flow of stresses in machine elements a lot of material saving could be achieved. In any machine assembly identify the weakest link.

A machine assembly is only as strong as the weakest link and there is no point in making parts strong and heavy in several areas leaving one place the weakest

Strength of Material Aspects In this thirtyfifth series of article on machine design fundamentals on strength of material aspects let us continue with what we had already discussed in the thirtyfourth series of article.

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link. The failure occurs at the weakest link only. In machine design terminology it is called the factor of ignorance and not the factor of safety. The machine design taking into consider-ation of stress flow through the machine elements and taking measures to reduce the stress concentration requires a deeper understanding of the strength of materials, mechanics, different manufac-turing methods, kinematics etc.

7. Corrugated Tubes:

Wherever possible go for corrugated tubes/pipes instead of plain tubes. It is a well known fact that corrugation imparted to a plain sheet increases its strength many folds. The idea of convert-ing the corrugated sheets into pipes and culverts is a fairly new concept in India.

We are mostly used to plain pipes and curvatures of plain sheets. Bending the corrugated sheet into a pipe form gives an enormously higher strength pipe and there is a huge material saving. Other variations of corrugated pipes having lesser thicknesses are provided with lock-seams or rivetted.

8. Gusset Plates:

Another area where material can be saved is making use of gusset plates at the appropriate places where the stresses are high. Fig. 2 shows how a heavy plate for carrying load could be replaced by a thinner plate with ribbing and using gusset plates as shown in Fig. 2c. Fig. 2a & b show how material saving could be achieved by using gusset plates.

9. Sandwich Construction:

Usage of sandwich construction: It con-sists of generally three types of materials bonded together. The outermost lamina-tions are called skins or facings and the inner lamination is called the core. The skins or facings of a panel act very much like the flanges of an I -beam by taking the bending loads.

One skin is in tension while the other skin is in compression. The core material responds like the web of the I-beam. The core material resists the shear loads and increases the stiffness of the structure by spreading the skins apart. These are used as door /prefab panels. The core

High Quality Portable and On-line Instruments and Systems for applications and research in fluid mechanics, environment, aerosol, particles measurement, and customized systems are now available for use, at MEC Customer’s plants in India.

There are four different models that

Air Borne Particle Counters Portable & Online from Marvelconfirm to US FDA regulations, meeting fully international regulations and should be ideal for Pharma Units, Bulk Drug Production Houses, Drug Discovery Establishments, Electronic Components Making Facilities, Space Applications and the like.

In addition, continuous on-line systems

are there for meeting real time measurements.

For more details write to Marvel Engineering Company at [email protected] or call +91 44 28112297/ 28110582 or visit their website www.marvelco.in

materials most frequently used in sand-wich construction are honeycomb cores, foam cores and wood cores.

From the above cited examples it could be seen that by proper shaping the cross sections of the components material could be conserved and consumption re-duced ultimately leading to stable prices in the long run.

The author A.S.Shetty is the CEO of Sed-vik Industries, manufacturer of Rollform-ing machines, Bangalore and he can be contacted at +91 80-25452669 or E-mail: [email protected]



Hannover to visit Delhi again after its maiden Success India’s largest Industrial Trade Fairs of Hannover attracted more than 6,000 business visitors

With the first ever event in the North, Industrial Trade Fairs of Hannover made a mark in the city with 6,174 Business visitors during the 4 days of their five concurrent shows held in November 2012. The number of exhibitors have exceeded to 8% in comparison with the last year. Out of the same, had a combination of 60% Indian exhibitors and 40% international companies.

The fairs are expected to convert more than 400cr worth transactional business for the exhibitors. Owing to the success witnessed in Delhi NCR, the next edition will be organized from 17-20 December 2013 at Pragati Maidan, New Delhi.

The shows hosted more than 4000 products on display including the latest technologies from- Germany, Italy, China, Taiwan & Korea. The Industrial Trade Fairs of Hannover was the most sought after B2B event covering the manufacturing, automation, materials handling, surface technology & laser technology.

Gracing the occasion at the inaugural ceremony were Shri Ranajit Pratap Naraine Singh, Hon. Minister of State –

Home Affairs, Central Government, Dr. Jose B. Schulz, Minister Counsellor, Head of Economic and Commercial Division, Embassy of the Federal Republic of Germany, Mr. Deepak Sareen, Executive Director, Electronics and Computer Software Export Council (ESC).

The premier edition of the International Purchase Managers’ Summit – India 2012, saw more than 150 industrial Purchase managers understanding the trends of purchasing internationally. Mr. B. Narayan, Group President, Reliance Industries Ltd., inaugurated the event and was also awarded as “Distinguished International Purchasing Professional Award”. Live demonstration of E-procurement solutions was also a part of the summit to provide the complete experience to the delegates attending the summit.

On the other concurrent Seminars and conferences combined with the exhibition, the fair commenced with the CEO Conclave where the participating exhibitors interacted with each other and discussed new innovations in technology to Indian forefront. The

Laser Forum seminars with the onsite workshop and live demonstrations on Forklift Driving & Maintenance Practical Master Class were also inaugurated on the 1st day of the event. This was followed by the seminar for Surface Technology by SSPC. The day concluded with the stall awards and a high profile Exhibitor evening. The Day 1 of the event saw delegations like Chinese Surface Technology delegation and Industrial delegation from Ludhiana. The other days had important delegations from Mohali, Haryana, Chandigarh, Faridabad, Ghaziabad, Gurgaon and Manesar over and above the general Industrial Visitors.

On day 2, Hannover Milano Fairs and Deutsche Messe also unveiled their upcoming HANNOVER MESSE 2013 at a press briefing.

Industrial Delegations at the shows: AIM India, Chamber of Chandigarh Chambers, Derabassi Industries Association, Faridabad Chamber of Commerce and Industries, Ghaziabad Industries Federation, Haryana Chamber of Commerce and Industries, Industries Association of Chandigarh, Manesar

“As the premier meeting place for decision makers and investors from industry, business and government, HANNOVER Fairs India Pvt Ltd has shown time and again that it has the power and influence to kick off new trends and shape future developments. Our first venture in the North of India has been a resounding success. Our participants were able to create new business and new relationships in a professional trade focused setting. We look forward to coming back next year with a much larger and diverse set of innovations and new product launches. My team and I look forward to welcoming you back to WIN - World of Industry India.”

Mehul Shah Managing Director, HMFI


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Industries Welfare Associations and Mohali Industries Association.

Company Delegations at the shows: Maruti Suzuki India Pvt Ltd, Hindustan Aeronautics Ltd, Godrej & Boyce, Hero Moto Corp, ISRO, JCB India, Tata Motors, Titan Industries, JREW Engineering, Mahindra and Mahindra, New Holland Fiat India Pvt Ltd , Reliance Power

Transmission and Moser Baer India ltd.

About the Exhibitors from important Manufacturing Sectors:

MDA INDIA – ARGO-HYTOS, Bucher Hydraulics, EPE Process Filters, Fenner India, Janatics Kastas, KTR Couplings, Ringspann, Rotomotive Powerdrive, SKF India, Spareage Seals, W. Hunger Hydraulics, Windsor Exports

Industrial Automation INDIA - ACE Automation, BECKHOFF, Brainchild, Cognex, Daehan Sensor, Festo, ILME, Meyle, Pepperl+Fuchs, Pilz, Wago

CeMAT INDIA - Armsel Kito, Exide, Gandhi Automation, Giovenzana International, Grey Orange Robotics, Hercules Hoists, Hoffmann, Hormann India, KAUP India, Nilkamal Ltd., Roots Multiclean, Speed O Controls, STAKALL, Voltas Material Handling

Surface Technology INDIA - Arcraft Plasma, Brissa Enterprise, Daksh Scientific, DST Chemicals, Helm Hellas, Keepsake Engineering, LacTec, Mec Shot Blasting, NGL Cleaning, Progalvano SRL, Raj Systems, Rosler Surfacetech, Statfield Equipments, Technical Drying Services, WALTHER Spritz

LASER INDIA - Angel India Cad Cam, Coherent, Komastu NTC, Laser Science, Miyachi, Sahajanand Laser Technology, Scantech Laser, SEI Italy, SPI Lasers, World Star Technologies

Hannover Milano Fairs India Pvt Ltd (HMFI), is a wholly owned subsidiary of two of the world’s leading trade fair organizers Deutsche Messe AG, Germany and Fiera Milano, Italy. HMFI have been bringing world class trade fairs into the Indian market for Indian and international enterprises since 2007.

The strong international presence and the vast expertise and best trade fair practices of its parent companies are deployed in the fairs in India which is expected to boost trade which is the USP of fairs of HMFI. Exhibitors and visitors will gain from the professionalism of the international leaders.

Deutsche Messe - based in Hannover, Germany - is the world’s foremost trade fair company. Deutsche Messe develops, plans and runs trade fairs and exhibitions in Germany and abroad as Hannover Fairs International with a Turnover – 410 Million $. Deutsche Messe was established in 1947; own the largest Fair Ground in the world with Indoor capacity of over 4.5 Lac square meters of display area. It organizes World’s Largest Engineering Trade Fair – Hannover Messe and World’s Largest IT Fair – CeBIT

Italy’s largest Trade fair organizer owns the 3rd largest Trade fair venue with a Group Turnover – 150 million $.

www.vibrantgujarat.com 8-13 January 2013 Gandhinagar, Gujarat Organized by:-

K & D Communication LtdThe biannual event scheduled from January 8-13, 2013, at Gandhinagar, Gujarat, is jointly organised by the Government of Gujarat and K and D Communication Limited. It is a platform wherein the best of manufacturers and the best of innovations will come to showcase the latest advancements in manufacturing technology.

www.imtex.in24-30 January 2013BIEC, BangaloreOrganized by:-

IMTMAIMTEX series is the largest exhibition of metal-cutting machine tools and manufacturing solutions in South and South-East Asia. Concurrent event Tooltech 2013, the 15th International Exhibition of Cutting Tools, Tooling Systems, Dies, Moulds, Forming Tools, Machine Accessories, Metrology and CAD/CAM.

www.ietfindia.in15-17 February 2013Pragati Maidan, New DelhiOrganized by:-

Confederation of Indian IndustryInternational engineering and tech-nology fair was initiated in 1975, as a national event with participation of players from Indian Engineering In-dustry. Over the years, IETF enhanced its scope with presence of interna-tional players, and national pavilions of various countries showcasing their strength and capabilities. Partner Country: Korea

industrial business MART 51


Taking place at an incredibly exciting time for ASEAN metalworking community, the show attracted 65,216 manufacturing industrialists from across Thailand, ASEAN and 387 persons of Business Delegations from 13 countries (Australia, Austria, China, India, Indonesia, Italy, Japan, Malaysia, Philippines, Singapore, Sri Lanka, Turkey, UK) with strong intention to source the best-of-breed machinery and technologies as they were exposed to over 2,700 global brands from 50 countries and 8 officially international pavilions (China, Germany, Japan, Korea, Singapore, Russia, Taiwan and UK).

Some of the highlighted brands at the show included ABB, Agie Charmilles, Amada, Brother, Carl Zeiss, Chevalier, Davi, DMTG, Durma, Emuge, Erowa, Euromac, Fanuc, Guering, Haas, Haco, Hankwang, Hexagon, Hitachi, Hwacheon, Hyundai-Kia, ISCAR, Kawasaki, Komatsu, Kyocera, Matec, Mazak, Mitsubishi, Mitutoyo, Mori Seiki /DMG, Nachi, Nikon, Noritake, Okamoto, Okuma, Olympus, OTC, Renishaw, Rollomatic, SMT, Sodick, Sumitomo, Takamaz, Taegutec, Tornos, Toshiba, Toyoda, Trumpf, Tungaloy, Walter and

Yaskawa.

METALEX 2012 welcomed many key industrial figures visiting the show whose honorable presences underscored the show’s recognition and pivotal role for ASEAN’s

metalworking community.

Playing host to an unrivalled, record number of 160+ international speakers, the concurrent international conference and seminar tracks covered all aspects of metalworking, businesses and trends that matter to the industry with exclusive in-depth technical contents such as The 2nd METALEX Nano Forum (on nanotech for metalworking), Metallurgy Forum (for metal fabrication and construction), the 4th Thai-Japan Mould & Die Technology Symposium (on Japanese mould and die technology for ASEAN industries). Moreover, the development of new business partnerships and networks were constant and common with outstanding outcomes with business-inducing activities such as Business Matchmaking Program and BUILD Marketplace.

In summary, METALEX 2012

The Center Stage for Metalworking Community to Drive Regional Growth!

METALEX 2012, the flagship event of ASEAN metalworking community, won a great applause from over international visitors, exhibitors, supporters, speakers and delegates due to its solid contents, technology breakthroughs and out-standing business opportunities.

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represented a high-quality event where community members were able to meet, network, secure future business partnerships and discuss the positive results to date of those already engaged in their own moves towards the upcoming AEC in 2015.

The Pride of ASEAN on the Rise Next Year

Taking advantage of the growth of the industry and the event, METALEX 2013 will be even greater attractions for 68,000 international manufacturing industrialists who will discover the top-notch metalworking technologies by 2,700 brands form 50 countries along with more new contents and onsite activities will be developed to deliver more specialized, vertical presentations dedicated for the advancement of metalworking community in ASEAN. In addition, the business horizons will be expanded to get participants ready for the flourishing opportunities from the upcoming AEC in 2015.

METALEX 2013 will take place from 20 – 23 November 2013 at BITEC, Bangkok, Thailand.


Total Chip Protection for Machine ToolsNew energy chain for unsupported travels up to 50 m from igus

Metal chips are a problem for long travels and for when energy chains need to be used for gliding applications. Now the designers from igus GmbH, Cologne have developed a horizontal upper run guiding system called “Guidelok”. This new energy chain solution is ideal for longer travels up to 50 m and unsupported travel in the machining industry.

The new system carries the upper run of the energy chain on a swivelling roller bracket which moves away from the moving radius guaranteeing an unhindered ride. Guided in a lightweight aluminium trough, the energy chain passes through the roller

brackets first.

The roller bracket then moves out again behind the radius. Afterwards the upper energy chain run is supported on the roller brackets. Due to this construction no debris can settle between the sliding surfaces of the upper run and lower run of the energy chain.

With less material and energy, almost no wear.

Along with the main benefit of protecting cables and hoses against chips and debris, this design offers a number of other advantages. The enormous improvement of the free-supporting length allows users to choose a smaller energy chain for the given length, saving material and overall costs.

Secondly – by using a smaller and unsupported energy chain the required

New energy chain “Guidelok” for chip areas -from igus Gmbh, Cologne. Up to 50 m long unsupported travels are now possible. So no debris and chips can settle between upper run and lower run of the chain.

The energy chain passes the swivelling roller brackets (left), moves in and behind the radius then out again (middle). Then the upper run sets down again, and is supported by the brackets (right).

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drive force reduces. Thirdly upper run and lower run of the new “Guidelok” are separated from each other. This minimizes friction and wear, which increases the lifetime once again.

Already in service

Just introduced, the new energy chain system is already used successfully in an industrial application at a German manufacturer of machine tools. A heavy steel chain has just been exchanged with “Guidelok”. Changing the existing system for a gliding energy chain solution was out of the question.

Metal chips of a 1 Euro coin size would have settled in the inner radius between upper run and lower run, which could have caused damage. In contrast the new system for long unsupported

lengths is ideal for such applications.

The “Guidelok” energy guiding is - designed modular and with few parts, and is optional with or without side troughs - available ex works straight away. The company from Cologne is showing the product at www.igus.eu/guidelok; among other things, a movie illustrating the new principle of design.

The manufacturer igus can deliver within 24 hrs or at the same day. The program includes more than 70,000 energy chain, cable, plug and connector components as well as other accessories. www.igus.eu/machinetools

igus® operations in India started in the year 1998 with head quarters in Bangalore. Today igus® (India) Pvt Ltd, 100% owned subsidiary of igus® GmbH,

Germany has established it’s presence in the whole country with wide network of sales & service force with an aim to serve customers where ever they be.

igus® widest range of products that includes, E-ChainSystems®/ Cable drag chains, High-flexible Chainflex® cables, iglidur® polymer bearings, igubal® spherical bearings, DryLin® linear bearings & guide systems enable to serve the whole industrial establishments in the country from a small work shop to huge industrial establishments.

For more details write to Harish, Product Manager, E-ChainSystems® & ReadyChains® at igus (India) Private Limited, Tel : +91-80-39127809 (Direct), Email : [email protected] or visit them on www.igus.in


Dassault Systèmes (Euronext Paris:

#13065, DSY.PA), the 3D EXPERIENCE

Company, world leader in 3D design

software, 3D Digital Mock Up and

Product Lifecycle Management (PLM)

solutions, introduced new SolidWorks

Electrical applications during last month

at New Delhi.

These new offerings include an

innovative, system level 2D schematic

design tool and a powerful 3D electrical

modeling add-in to SolidWorks design

application that are linked in real time.

“Design professionals worldwide

endeavor to create accurate designs

with fewer mistakes and complications,

for faster time-to-market.Towards this

end, SolidWorks has introduced its new

offering- SolidWorks Electrical- a design

application that integrates electrical

and mechanical designs to speed up

complex design projects.This simple,

intuitive application simplifies electrical

system design with its intelligent design

tools, comprehensive parts database,

and allows real-time integration of

2D schematics and 3D models leading

to increased collaboration and

productivity.”said Manoj Mehta, Country

Manager, India and SAARC, SolidWorks.

When it comes to electrical system

design, organizations frequently look

for ways to improve the overall delivery

performance of their departments.

SolidWorks Electrical applications make

it easy for engineers and designers to

plan electrical systems and integrate

those electrical aspects into the overall

3D mechanical models.

These new applications pave the way for

mechanical and electrical engineering

teams to collaborate during product

development, streamline the design

phase, and reduce product delays,

resulting in more consistent and

standardized designs, lower costs, and

faster time-to-market.

“The full integration with SolidWorks

will make SolidWorks Electrical easy

to learn and will allow both our

mechanical and electrical departments

to collaborate on electrical system

and wiring design,” said Kyle Strong,

project manager at Getman Corporation.

“Our mining vehicles include complex

electrical wiring and need to have

consistent design -- the decision to

consider SolidWorks Electrical was

easy. By integrating our electrical and

mechanical design processes, we can

better document electrical requirements

and cable/wire paths, resulting in less

rework, higher product quality, and

faster time-to-market.”

SolidWorks Electrical provides new

capabilities with the following three

applications:

1. SolidWorks Electrical – a 2D schematic

design tool for electrical system

architecture and planning that:

• Simplifies electrical design with

a dynamic, context-sensitive user

interface, providing the ability to quickly

Dassault Systèmes Unveils New SolidWorks Electrical ApplicationsReal-time Integration of 2D Schematics and 3D Models Allows Mechanical and Electrical Teams to Better Collaborate and Deliver More Accurate Designs

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“Today, companies in industrial equipment, engineering services, high-tech, medical devices, and consumer goods are developing products that include more electrical content. More than half of our SolidWorks customers require a solution that streamlines collaboration between mechanical and electrical systems engineers. The addition of SolidWorks Electrical to our product portfolio moves us into this underserved market with a robust solution that upholds the SolidWorks focus on ease-of-use and makes close collaboration between mechanical and electrical design groups a reality.”

Bertrand Sicot

CEO, SolidWorks, Dassault Systèmes



turn concepts into detailed designs

• Identifies problems immediately with

real-time error detection which prevents

costly scrap and rework

• Allows for easier and more accurate

creation of schematics with a library of

more than 500,000 standard electrical

parts

• Enables multiple people to work on

the same project at the same time

2. SolidWorks Electrical 3D -- an add-in

to SolidWorks CAD application that

connects SolidWorks Electrical 2D

systems-level schematics to 3D models

designed with SolidWorks. It includes:

• Real-time, bi-directional updates

between 2D and 3D to synchronize

electro-mechanical designs so that

consistency is maintained throughout

development

• The integration of the 2D schematic

with the 3D model to help standardize

designs and unify BOMs to reduce

mistakes and delays

• Placement of the electrical system and

cables/wires in the 3D model to enable

planning of specific locations and paths

for consistent product manufacturing

3. SolidWorks Electrical Professional

– includes the functionality of both

SolidWorks Electrical and SolidWorks

Electrical 3D in a single application for

users working in both 2D and 3D areas of

electrical development.

The SolidWorks Electrical applications

are based on technology from Trace

Software, a company with more

than 20 years of experience in the

electrical design market. As a current

SolidWorks Gold Solution Partner,

Trace’s elecworks™ products are

integrated with SolidWorks, allowing

engineers to stay within the familiar

SolidWorks environment to optimize

electromechanical designs.

The first release of SolidWorks Electrical

will be available in North America,

Europe, and the Middle East in August

2012, with other regions and countries

to follow. For more information about

SolidWorks Electrical, please visit:

http://www.solidworks.com/electrical/


Ahmedabad based Siddhi Engineers, a TUV certified ISO 9001-2008 & ISO- 14001-2004 TUV NORD certified Company, engaged in manufacturing of Close Tolerance, Precision Aluminum Redrawn COIL tubes.

Aluminum redrawn Coil tubes by its process have various advantages, over extruded tubes as mentioned below:

1. Advantages of Aluminum Precision Drawn Tubes over Extruded Tubes

Very close dimensional tolerances +/-0.02, Very good surfaces finish Ra 0.4μ, Added mechanical/physical properties, Accurate straightness 1: 1000, Very small (from 1 mm diameter) & very thin (from 0.2 mm) section is possible, Very precise quality and eccentricity.

Special shapes with high accurate in dimension.

2. Siddhi Engineers are able to supply Precision Drawn Coil Tubes & Profiles in Various Types of

Aluminum wrought alloy like 19500, 19700, 19000, 31000,52000, 24345, 62400, 65032, 63400, 64430 as per IS standard.

They are being supplied for various reputed brands.

Please inform us about your size, OD, ID, Length, Alloy, Tolerances, with drawing so that we can supply you the best sample for your evaluation. Please also inform us about what process you would like to carry out Our product so that SUITABLE alloy and critical dimension can be supplied accordingly.

Please refer website www.siddhiindia.com for more information. For further details do contact Siddhi Engineers Tel: +91 79 40244300/ 27542909 Email: [email protected], [email protected]

Aluminum Precision Drawn tubes for Teliscopic Tube Application from Siddhi Engineers

1050, 1070, 1100, 3003, 3103, 5052, 2014, 2219, 6005,6061, 6063, 6351 as per EN standard.

3. While processing product Siddhi Engineers give the product in exact length or multiple length, which eliminate wastage, which may be to the extent of 15 to 20% in case of extrusion.

Presently, they cater to Heat Exchanger application, Fin Tube application, Radiators, Space Application, Telecommunication, Blood Bang Rings, Aluminium foil, Defense, Pneumatic Cylinder, Refrigeration industry, Air-conditioning Industry, Automobile Industry and Aluminum Rollers.

Siddhi Engineers manufacturer of drawn close dimension precision Aluminium tubes of various shapes for traveling bags. The tubes of shapes like round, square, rectangular elliptical are produced for variety of bags.

The strolly bags, heavy luggage, computer laptop bags, school bags use same.

The tubes are made for single tubes as well as telescopic applications.

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High operating efficiency, Space saving compactness, Easier Mounting, Wide range of Reduction Ratios, Robust

Planetary Geared Motors from PowertekPOWERTEK offers a wide range of Planetary Geared Motors. The Precision Geared Motors ranging from 0.16HP to 500HP. Output 0.1RPM to 450RPM and torque range upto 90,000KGM.

Designs, Virtually Maintenance Free operations are some of advantages associated with Planetary Geared Motors. Special Designs to meet individual drive requirement.

They can also supply Geared Motors such as Variable Speed

Geared Motors, Multi Speed Gear Box, Electromagnetic Brake Geared Motor,

Helibevel Geared Motors, Flameproof, Shaft Mounted Gear Box, Custom Built Geared Motors, Agitator Duty Units.

The Planetary Geared Motors find applications in Plastics, Rubber Textile, Machine, Tools, Papers, Cement, Printing, Wire Drawing, Cables, Pharmaceuticals, Leather & Sugar Industries.

For further details contact Powertek Equipment Company, Tel: +91 22 25905333 / 25905324, Email: [email protected]/ [email protected] or visit www.powertekindia.com


Some of their prototypes have been tested in rigorous environment & passed with flying colours. Through these services we help our clients ensure that there are no bottle necks in tool development, no inadequacies left in assembly & aesthetics & in some cases even those in function. It provides them enough confidence to move ahead with investments in further development of their projects.

IDE can provide exact replica of your designed 3D models parts in special polymers. The direct methods used are

StereoLithography Apparatus, Selective Laser sintering, Fused deposition modelling and Cast Polyurathane.

•SLA : (StereoLithography Apparatus)

This method provides prototypes with excellent finish & is suitable for parts having intricate details as well as those having excellent surface finish requirement . The Masters for vacuum casting process are made using this process. These prototypess are pricier than those made with SLS. Also are slightly brittle than SLS protos.

•SLS : (Selective Laser sintering)

This method provides prototypes with slightly coarse finish but with better strength than those done with SLA. Especially suitable to check snap fitting & even live hinges with special grade resins. Though the as obtained prototypes have coarse finish, they can be post processed with sanding/laquering & finally spray painting to get desired colours & finish.

•FDM (Fused deposition modelling)

This involves laying of layers of fused strand of material(ABS or PC) to get required form. It produces prototypes with coarse finish , but with much better strength & heat resistance compared to other processes.

•Cast Polyurathane

Short batch production by vacuum casting : A master made by SLA is utilized to get a rubber mould by vacuum casting & the cast protos are obtained by using special PU based polymers. Depending on intricacies / simplicity of profile one rubber mould can produce many copies of prototypes.

For further details do write to Infotrans Designs And Engineering, Mumbai, C V Kushe (CEO), Email: [email protected], [email protected] or call him at Mobile: +91 9821246012 Tel: +91 22 42666019

Rapid Prototyping Services from Infrotrans Designs & Engineering

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Mumbai based Infotrans Designs & Engineering provides end to end services for Plastics product development of which prototypes are a very important part. They not only select the right prototyping process considering the development stage , but deliver a completely finished, well assembled product proto.


Mysore based Ferro Foundries offers “TIGER” Hydraulic Scissor Lift Table can be smoothly taken up or down and can be stopped at any intermediate position

Power Operated Hydraulic Scissor Lift Table from Ferro Foundries

by operating the push button or pedal switch. This equipment brings table to the most convenient working height for panel feeding and receiving to process

machines and it helps in increase of production.

It is being used in wide range of applications in engineering, Paper, Textiles, Chemical, Plywood, Glass, Asbestos sheet, Industrial Laminates and other industries. Standard models are

also available and the equipment can also be custom built.

Available in different capacities and in different heights catering to the specific application the industry needs, these equipments will be ideal in improving efficiency and also takes care of safety of men and material.

For further details and specifications please visit www.ferrotiger.com or contact Ferro Foundries Pvt Ltd, Tel: +91 821 2402376 / 4282101,3048000-04, Email: [email protected]


Panasonic of Japan brings a range of compact yet powerful PLC’s in a wide range of models to suit a diverse set of applications. These Micro to Medium range of PLCs have class leading memory capabilities and scan times. The PLCs follow industry standard IEC 61131 standards of programming and can be programmed in Ladder, FBD, IL, ST and SFC styles.

The PLC software has dedicated function blocks for Motion control rendering programming of stepper and servo motors very simple and quick. The PLCs support upto 4 axes of control with linear interpolation. The PLC also supports upto 8 high speed counters simultaneously. The software also has options of creating customised function blocks giving OEM customers the option of creating their own IP and protecting the same.

The new FPOR PLC has dedicated function blocks for Electronic gearing and Print mark registration control which are very useful in packaging, labelling,

bag cutting applications. The FPX PLCs have upto 8 high speed counters useful for applications such liquid filling. The FP Sigma and the FP2 series complete the range of PLCs.

Options exist to connect these PLCs to industry standard networks like Profibus, Devicenet, CANOpen, CCLink, Slink etc. A wide range of communication options also exist on the CPU which includes RS232, USB, RS485 and Ethernet.

A wide range of high brightness and high contrast touch screens are also available to complement the range of PLCs from Panasonic. These PLCs have CE and UL certification and wide range of models are available

in an Industry leading warranty of 3 years. Applications abound in Printing, Packaging, Pharmaceutical, SPM, Machine controls, Building Automation and Process automation.

For further details contact Strategi Automation Solutions Pvt Ltd, Tel: +91-80-32489798/32467879, Email:[email protected], Visit www.strategiautomation.com

Panasonic PLC from Strategi Automation

Servo Insert Couplings from Rotolinear

Rotolinear Systems offer Servo insert couplings . These servo insert couplings

are with

features like

, pluggable,

damp vibration,

compensation

of misalignment

& backlash-

free etc. Servo

insert couplings

are available

from 0.5Nm

upto torques of

525Nm.

Different models like stud/set screws

clamping, Collet clamping, Outer

conical hub, split hubs, compact version,

Expanding clamps etc are available.

Some of the applications include linear

slide, machine spindle, screw jack

units, servo drive, printing machines,

packaging machines ect.

For further details contact Rotolinear

Systems, Tel: +91 80 23572855

Mobile: 9845196751,

Email: [email protected],

Visit: www.rotolinearindia.com



Dear Readers,

Leadership is all about the vision and direction to a team of people. It is about raising the confi dence and aspirations of the followers. It is about enthusing the team with a hope and desire to conquer and reach the far away. In other words, a leader is an agent of change, aimed at accomplishing progress and growth, inspite of tough times. Leaders do something, and in doing so, combat the forces of entropy and evil that can so quickly and easily take over, like weeds overcoming an untended garden. (Courtesy : Jeff Janssen, Janssen Sports Leadership Center)

A name which comes to mind when we talk about leadership is Jeff Bezos - founder & chief executive of a $100 billion empire built on books. Amazon. He was recently named 2012 businessperson of the year by Fortune. A person with clear thinking & a cohesive vision, Bezos is an ultimate disrupter. He has upended the book industry & displaced electronic merchants. He remains zealous about delivering a good customer experience. In fact, in absence of Steve Jobs, he has become the new undisputed role model for founders who want to keep control of their companies. The stock of his company is up 10-fold in the past six years. The one thing that I liked about Bezos is his act of innovating by starting with the customer & working backwards. Customer focus is a cultural issue, that distinguishes Amazon from other companies. Bezos uses the concept of ‘distributed innovation’ to add businesses under the Amazon roof. The three big ideas at Amazon are long-term thinking, customer obsession & a willingness to invent - all of these coincide with the skills of a leader. When you consider the greatest business minds of past 100 years, the two people who would top the list would be Steve Jobs & Sam Walton. Both created businesses that helped change the way we buy, shop & interact thereby creating a societal revolution, in a true sense. Hence, both of them are extraordinary business leaders. They were both extreme charismatics. (Courtesy : Fortune)

Quietly, with little advertising, the Philippines has surpassed India as the number one call center in the world. Now, this South China Sea nation of 7,000 islands, 39 million people workforce, and 470,000 English-speaking college students graduating every year, is going to overtake India in non-voice (back offi ce) business process outsourcing (BPO) by 2015 (Courtesy : The Epoch Times).

As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions.

Till then, Happy Technology !

Manoj KabreMember, Editorial Advisory Board (EAB)

THE LAST LEAF

mart december 2012

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