mart december 2013

www.martonline.in 1December 2013

Volume 10 Issue 6 December 2013 Pages 52 `100

Made in India for IndiaEvolution of Eco 40

“Superior Quality of our products keeps us ahead of the competition”Chandmal Goliya, Managing Director, Kusam Meco

The Global Power Leap

www.martonline.in2 December 2013


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Hi Readers,

Wish you all a Merry Christmas.

2013 is becoming history, and we are just counting days to welcome 2014. The current year was a mix of ups and downs and without losing or gaining we are sailing towards another year of optimism and expectations. Share market rose to its peak in the beginning of this month after the results of the four assembly elections. The people of Delhi created history by electing an infant political party who identified with the challenges faced by common man. The market is looking at a change in guard at the centre and the victory of BJP in the three states triggered the share market rise. India will go for poll during the beginning of the next financial year and the industry is looking forward to a constructive leadership to take the economy forward.

The New Year starts with two major fairs for the Indian manufacturing industry. Elecrama 2014, the biennial exhibition organized by IEEMA is coming to Bangalore for the first time at BIEC from 8th to 12th of January and IMTEX 2014, the forming segment of IMTMA’s premium show from 22nd to 28th of January with Tooltech 2014. In this edition of MART we are coming out with a special feature on Elecrama - one of the oldest manufacturing fairs - which was kick started in Kolkata in 1948, just a year after our independence. Over the last 64 years Elecrama evolved as the one-shop destination for electrical equipments and industrial electronics. This edition of Elecrama will witness more than 1000 exhibitors using 65,000 Square meters across six different halls. The organizers are expecting more than a lakh of business visitors, and the exhibitors are gearing up to offer their best to the growing challenge.

Chandmal Goliya, the man behind 30-year-old Kusam-Meco always uses Elecrama as a platform to introduce their latest innovations. In this edition at Bangalore too, Kusam-Meco is launching a couple of new products, and looking forward to take the services to the global platform. We had a talk with him about his future plans and it is featured for you in the On Face Column. In my last editorial I mentioned about the meeting I had with the Valmova Global team and their launch of Eco 40 Directional Control Valve at Excon 2013 exhibition in Bangalore last month. The Valmova Indian team developed this innova-tion within just eight months’ time, and this was the first ever product initiated and produced outside the Valmova headquarters at Brazil. We decided to feature this story to you, and thanks to Akanksha Lal we give you the Evolution of Eco 40.

We at MART also had a challenging year and was able to place ourselves better than last year. 2014 is very much promising, and we are coming out with a lot of new innovative initiatives which will be offered to the industry within the next couple of months. MART is looking positively towards ELECRAMA and IMTEX exhibitions, and the outcome of these two shows will ensure the manufacturing sector to set its pace for the next two years. We take this opportunity to wish all our readers Merry Christmas and a promising New Year.

Do write to us to make MART, SMART!


Saravjit Singh Manoj Kabre P S SatishA S Shetty LD Bhakre Mahesh R P Siji NairJ R Mahajan

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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 Publishers. RNI No: KARENG/2004/13614

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PARI Succeeds in Eliminating Errors with EPLAN

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Volume 10 Issue 6 December 2013

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SCHUNK’s SDH hand rings the NASDAQ Closing Bell for Launch of ROBO-STOX™

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8 Made in India for IndiaEvolution of Eco 40

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Startup Management Best Practices: Managing Monkeys

Journey Towards ExcellenceP S Satish

Tomasz Tunguz

Perception of QualityGorur Sridhar

The Global Power Leap 20

On Face

Case Study

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31

Chandmal Goliya, Managing Director, Kusam Meco


32 Cost-Effective Technology of MIM

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36Commercial Vehicle

Production: Aiming to Reduce Component Costs

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MART FEATURE


Made in India for India

Evolution of Eco 40

As a member of the globally renowned Danfoss Group, Valmova designs and manufactures brake valves in Pune, India and continue to invest in this growing region. Valmova India launched Eco 40 Directional Control Valve globally at Excon 2013 exhibition last month in Bangalore. Akanksha Lal shares with the readers of MART, Valmova India journey of producing the first innovation outside its headquarters at Brazil.

Valmova has received good response in Indian Market. We now have an entire product range to offer to our customers. As I see it strategically, India is the right place to be, and we want to make products in India and export it to all major locations in the world. We see as the construction, agriculture and earth moving requirements grow we shall grow at the same pace. Also, with growing awareness for safety with hydraulic equipment’s Indian market is booming.

Domenico Traverso VP Stand Alone Businesses, Danfoss Power Solutions India Pvt Ltd

Valmova has always recognized the importance of engineering innovation as a competitive advantage and as a driver for capturing growth. As a member of the globally renowned Danfoss Group, Valmova designs and manufactures brake valves in Pune, India and continue to invest in this growing region. With a strong people culture that places the pursuit of customer value and product excellence at the forefront of their activities, their engineering teams

are geared for success in a competitive market.

The vision of the company is to be its clients’ local partner providing Valves with More Value. And for that the strategies in place are ‘having unique application knowledge’, ‘providing technology and features at affordable price’ and ‘be cost effective through operational excellence’.

Eight months - from conception to launch

Akanksha Lal

[email protected]

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My team had to actually put this assembly in place in a short span of time, that’s when I realized that the strength of my team’s performance came from their coordination and dedication. It was our team that was focused on ensuring that we get the right product at the right time. But, the real excitement was witnessed during the testing phase. As the quality people checked that all the parts and components for working correctly we were hoping it all goes right. It was a moment to cherish when we finally got news of the quality tests.

James Emanuel Production In-Charge, Valmova India

It was an experience any sourcing professional would love to have. With a fixed time line and demands from design it was challenging and exciting. The best part about the entire project was when we could deliver all required parts and they were tested to be fit for use and commercial scale.

Nilesh Bhoir Manager – Sourcing, Valmova India

It all began with Mr. Domenico Traverso, Vice President of the Stand Alone Businesses of the Danfoss Group deciding to reinvest in India to augment current production facilities in addition to the Valmova, Brazil. Valmova represents affordable technology products locally

made with superior standards and unique technology features that are usually limited to the very high-end range. Mr. Traverso was confident of the potential of the product, his people and the market and this led an empowered leadership team led by Mr. Rinaldo Fernandes, General Manager of Valmova

(located in Caxia du Sul, Brazil) creating an organization in India spearheaded by Mr. Sanjay Bakle.

With the increased investments to India, the Pune location started developing new parts through a phased

What are the benefits of your Eco platform Directional Control Valves?

Eco platform directional control valves will give our customers more value through operational excellence. They are a family of products and can have multiple sections with same spare parts. Also, this product line can be customized as per customer’s needs. However, this product can be used as it is for most of its application areas.

What are the application areas of this directional control valve?

The Eco 40 Directional control valves can be used in many applications; some of them being, cranes, drill rigs, combined harvesters, Motor graders fork lifts and Truck mounted cranes. And we are still discovering new applications for these valves.

What is the max flow of Eco 40?

It is 45 LPM, with a maximum pressure of 250 bar, this is exactly what we feel will be the

most popular size for both India and Brazil

Does the Eco 40 have only Mechanical actuation?

No, Eco 40 can come in Mechanical, Electrohydraulic, Pneumatic, Hydraulic and Cable operated actuations. This capability is something Valmova is very proud to present to our customers in our markets, demonstrating our commitment to value.

Can this product be customized?

Yes it can, depending on the customers’ requirements we can customize the product. However, it is operationally perfect even if used as it is.

What was the most challenging part of the project?

We were getting live inputs from the Sales team here in India, and we had to make a product that could be best fit in this market. Working through this process really helped our ability to adapt to the market and the wants of our customers.

How has your experience been in India so far?

I am very happy with the way the product has evolved and I’m also very optimistic. I look forward to some great sales news here in India.

What would be your concluding words to our readers?

India is a great place to be, I’ve had a wonderful experience as a professional in this country. The workforce approach to innovation is encouraging and as a result, I hope the Eco 40 does great in India.

process. In the first phase of the internal strategy, India was to produce all Valmova variants of hydraulic brakes for the global market. All brakes produced in Brazil were moved to India too. Thus, under the leadership of Mr. Sanjay Bakle a new product line was introduced

Adriano Nunes Garcia Director, Engineering & Product Development

- this line was called the Cecilia Valve line. The parts made on this line were Single Bore Master Cylinder, Dual Bore Master Cylinder, Equalizer, Slave Valve and Selector Switch.

The swiftness of the venture was such that the sales team was able to sell finished products within 8 months since the creative thinking of Valmova, Brazil and its top management. With an

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As Valmova team is located in our facility, I had a chance to see the team work on this project. It was wonderful to see the excitement and dedication of this team, their coordination and support to each other was remarkable. I would like to mention that design team in India did a remarkable job. I am as excited as the team about this product launch in India and I wish this team Good Luck with Eco 40.

Upinder Razdan Managing Director - Danfoss Power Solution India Pvt Ltd

established Cecilia Valve line, it was time for another step forward. And decision was taken to take up the next phase of the strategy.

In January 2013, Eco Platform was introduced in Inia and design director Mr. Adriano Nunes Garcia visited India and appointed three young expert design engineers to support him in this Herculean task. The team put all their

Mr. Khanna is the project going to be accepted in the Indian market?

As you are aware we launched the Eco 40 Directional Control Valve at Excon 2013 in Bangalore. It was a definite attention seeker. We have a couple of great inquiries already. This gives us great confidence for the immediate and long-term future.

How does the Eco 40 fit into the Indian context?

In India we basically use lower Hp applications, this product is absolutely suited for the same, I am more hopeful as this product can be used as it is and also customized as per the requirements of our customers.

What is your sales strategy in India?

Our focus is primarily on OEM’s; however, we also have a very strong network of distributors which we share with our parent company Danfoss Power Solutions in India. Therefore, we are open to both segments.

Varun Khanna Sales Head , Valmova India

This project was accomplished only because we began with end in Mind. Our strength, our Indian design team, put in their heart and soul and made us all proud of their capability. The entire coordination between design, sourcing, manufacturing, quality and sales has been amazing. I am proud of my team and now confident that they can make the impossible possible.

Sanjay Bakle General Manager, Valmova India

I am as happy as the team is, but as you’re aware, my job is the most critical as we have to be fact based and not let the excitement hamper our job. Thus, as an individual and as a team member I was very happy to declare the results. I think most of the credit goes to the team for keeping their focus and ensuring that they deliver nothing but the best.

Kiran Ahire Engineer QA, Valmova India

resources and hearts into developing a product that was completely ‘Made in India for India’ - the Eco 40. Working under such a tight time frame meant that the design team worked relentlessly throughout the project whilst the Sales team in India was constantly providing feedback regarding the dynamic Indian market situation. November 2013 saw the launch of Valmova’s Eco 40 Directional Control Valve at Excon ’13 held in Bengaluru, India.

It was a great learning experience for the highly skilled team at Valmova to develop a product in such a short span of time. Industry responses the Eco 40 has been overwhelming.

The clear vision and sound strategy that is implemented by Valmova on a global basis has formed the foundation of this success story. Valmova has yet again clearly demonstrated their unique application toward a challenging project that delivers on quality, speed and above all – value.



ROBOTICS


The SDH hand attached to the UR5 robot arm from Universal Robots rang the NASDAQ Closing Bell on Tuesday, November 12 to mark the launch of the ROBO-STOX™ Global Robotics and Automation Index ETF (Ticker Symbol: ROBO). The robotic bell ringing marks the first time a non-human performs this prestigious task.

SCHUNK’s SDH hand rings the NASDAQ Closing Bell

SCHUNK has been chosen by ROBO-STOX to ring the bell along with Universal Robots to represent the rapidly increasing robotics industry. On Tuesday, November 12 at 4pm EST, the SDH 3 finger gripper from SCHUNK attached to Universal Robots’ UR5 robot arm pressed the button activating NASDAQ’s closing bell. The bell ringing celebrates the launch of the ROBO-STOX™ Global Robotics and Automation Index ETF (Ticker Symbol: ROBO), the latest exchange-traded fund to begin trading through Exchange Traded Concepts’ accelerated, low-cost, private-label ETF platform.

About The “Bell Ringer” In the NASDAQ bell ringing application, the UR5 robot arm has been integrated with a three-fingered SDH gripper by the manufacturing company SCHUNK with the assistance of the SCHUNK and Universal Robots’ distributor, Cross Automation. The six-

axis UR5 weighs only 40 lbs. and handles payloads of up to 11.3 lbs with reach capabilities of up to 33.5in. Repeatability of +/- .004” allows quick precision handling of even microscopically small parts. Programming happens through an intuitive 3D tablet touchscreen — or by simply grabbing the robot arm to demonstrate desired movement.

The SDH hand from SCHUNK enables the form-fit and force-fit gripping of a wide range of objects and can be used both in areas of service robotics and in industrial applications. Two of the three fingers can change their positions, making it suitable for many different gripping scenarios and features high flexibility. The pressure and surface are monitored by an optional tactile sensor system. This means it is possible to detect whether the object has been optimally gripped or whether a correction must be made

during the gripping process. The high maximum gripping force, which conforms approximately to the force of the human hand, can be sensitively monitored by the integrated sensors and adjusted.

ROBO-STOX LLC is the creator of the first benchmark index to track the global robotics and automation market. Through the expertise of its leadership team and strategic advisors, ROBO-STOX looks worldwide to find new innovations in the robotics space, from companies of all sizes and verticals, to deliver the growth of robotics to investors — from individuals to institutions.

SCHUNK is the worldwide competence leader for clamping technology and gripping systems. Totaling more than 60 years of experience, SCHUNK is a family owned operation and a global player in one. For further details visit www.schunk.com


AUTOMATION

Ramji Singh

[email protected]

PARI Succeeds in Eliminating Errors with EPLAN

Precision Automation & Robotics India Limited, known as PARI is a global automation solution provider based at Pune. It was during 2004 PARI switched to EPLAN software and the transition bought desired results and eliminating errors.

Precision Automation & Robotics India Ltd. is a global automation solution provider of robotic products and technologies. With over 850 employees and 6 facilities worldwide, PARI provides a complete range of automation solutions including conceptualizing, designing, manufacturing, implementing and supporting of advanced factory automation systems. The company began its operations in 1990, and has since grown at an amazing rate of 50% each year. Serving global customers in 4 continents, and with operations and markets in over 12 countries, PARI serves various market segments including Automotive, Industrials, Transportation, Infrastructure, Farm Equipment, Energy, Food & Beverage,

Pharmaceuticals and Life Sciences.

PARI operates in three business verticals - Automated Manufacturing & Robotic Solutions, Automated Car Parking & Automated Logistics, serving these sectors. The company operates through deploying well-engineered automation solutions through mass customized technologies and system to achieve the global needs of its customers.

PARI’s success lies in the fact that the company strives to provide excellence in every step of the process from sales to commissioning and ensuring that this excellence is reflected in its products, people and solutions. With a wide range of innovative solutions and focus on complete customer satisfaction combined with a fast growing global presence, PARI aims to be among the top 10 global automation companies.

PARI switched to EPLAN in 2004 and since then has never looked back. With a large market base in India, Europe and the US, PARI felt the need for an error-free design system to help cater to the high standards of quality expected. However, the software that was being used by PARI required that the work be done manually, which held a potential risk for errors at every step. Switching to the current solution gave PARI a host of advantages including generation of various reports, at click of button, generation of Bill of Material (BOM) automatically based on the schematics, automatic assignment of device ID’s and

wire numbering and easy error detection (for example, not allowing two different voltage wires to be connected).

The change also helped in the provision of different standard symbol libraries, customization when following different drawing standards, uniformity in the presentation of the wiring diagrams (the look is independent of the engineer), and in the creation of the internal component layouts of panels by using footprints from a library.

“EPLAN is a well-designed user friendly software. It has reduced the engineering time by at least 40%. The quality and data consistency over the documentation is very good,” says Atul Patil, VP (Control Systems Engineering), PARI, on the effectiveness of the change.

The transition brings desired results

PARI experienced a smooth transition from the existing software to the use of the present solution. Before the launch of EPLAN, all engineers at PARI were trained to work on EPLAN through a series of training workshops that were conducted. The faculty especially focused on providing adequate training to all the engineers associated with hardware design. The result was a successful setting up of standard part’s database, macros, templates, etc. making it easy for the engineers at PARI to do a better job in lesser time.

PARI enjoys a decade of enhanced quality, production and documentation with EPLAN



Commenting on the significant amount of savings in time, Vice President Patil says, “We had not set any target in reduction of project turnaround time, when we switched over to EPLAN. Our focus then was to generate good-looking error free drawings of international level. We did not set any specific goals in this regards, but yes, it has reduced the engineering time by at least 40%.”

Execution of a typical project at PARI

PARI uses EPLAN in its design phase. In a typical project, the designing starts with the creation of a platform based on customer requirement. The engineering solution is used in designing plot frames, forms, symbol libraries, schemes, database, etc. Based on this, the wiring diagram is created after which auto-ferruling, device numbering and PLC numbering is done to optimize time. PARI designs schematics in-house for the panels along with the field wiring.

The production team at PARI use terminal/wire/cable reports and the wiring schematics during the production phase of the project, to wire up the panels/ boxes and the field wiring. After the design phase, the clients of PARI continue to use EPLAN schematics for maintenance purposes. For clients who wish for their schematics in software other than EPLAN, PARI further uses the engineering solution to produce an output in editable format as required by the client.

Impact on PARI’s engineering productivity

Although PARI’s primary reason to change its design software was to generate impressive and error free drawings of international level, EPLAN has in turn provided a positive impact on PARI’s overall engineering productivity. PARI reports a reduction in engineering time by a massive 40% by reducing the engineering

hours for wiring diagram preparation, checking and associated re-work. PARI is also planning to directly import the bill of material (BOM) generated via the software into their home grown ERP system – hence reducing the errors in ordering material and saving time in entering the BOM into the ERP. Overall PARI is very happy with the excellence in quality and data consistency in documentation.

PARI succeeds in eliminating errors

The successful launch of the engineering solution has encouraged best practices

“We have significant improvement in quality of project documentation using EPLAN. Many times our wiring diagrams are superior than our international competitors and some customers have expressed this view.”

Atul Patil Vice President (Control Systems Engineering Precision Automation & Robotics India Ltd.

in PARI in four different areas, namely through the provision of standardization of recurrent content, through faster and more reliable generation of documentation, through the reduction or elimination of errors and easier error-checking and through faster integration of data corrections and customer-specified changes. At PARI, the control design engineers use EPLAN mainly for schematic generation. 1500+ macros have been created, including DIN and ANSI type macros and corresponding parts database. The product has also enabled PARI to use DIN based modularization using the HLA+LOD concept. Engineers at PARI further use associated products like EPLAN Data Portal to pick up parts. The high quality wiring diagrams produced by PARI are also found to be far superior to their international competitors, a fact that has been widely expressed by PARI’s various clients.

PARI is extremely satisfied with EPLAN

PARI’s extreme satisfaction has resulted in them rating the service and support at a high 4, on a scale of 1 to 5. This stems from the fact that the product has not only made it possible to increase production even further, but has also provided a full range of services to fall back upon. For example, thanks to Unicode, the integration of their international locations was made easy for PARI. Extremely satisfied with the current engineering solutions, PARI also recently purchased EPLAN Fluid to aid in other areas of design and production.

Overall, PARI found EPLAN as a reliable tool, especially since it contributed towards significant improvements in areas such as project documentation, error reduction, content standardization and document generation. Visit www.parirobotics.com and www.eplan.in to find out more about PARI and EPLAN.



Elecrama, the biggest power showbiz hosted by IEEMA at Bangalore from 8th to 12th Jan, 2014 is beyond doubt the most highlighted exhibition in the world of electrical transmission and distribution equipment industry ever since 1990. Held biennially in India it has changed from time to time to become the one-shop destination for electrical equipment and industrial electronics. The expedition that initially started almost 64 yrs ago in Calcutta in 1948

The Global Power Leap

As the power showbiz Elecrama dons the electrical and power industry, India is expected to see a potential growth in the manufacturing and the power sector. Held biennially it is a catchall for all- the domestic and the countries abroad. Hence Indian industry is expected to measure a potential growth.

has come with the catch line ‘Powering India’ with its 11th edition.

The exhibition will have a stretch of more than 65000 sq. meters in a covered ground over 6 halls with 1000 exhibitors and more than 1, 25000 visitors from India and 130 countries. Encouraged by the Ministry of Power, Ministry of Heavy Industries and public enterprises and Ministry of Commerce and industry, Govt. of India it is

supported by BESCOM, the distribution utility power and KPTCL, the transmission utility power. The coming Elecrama ‘Go Global’ mission waits to foresee the newly launched technology through the platform of Trafotech. The field of Engineering on the platform of Elecrama has subject related electrical issues to necessitate the scope of engineering infinite. For the power of the future, the next Go Global mission will be held in Mumbai.

The industry is measuring a potential growth in terms of better environment, new market, and world class facility and globally accepted goods as termed P. Gupta, one of the dignitaries of Elecrama. To Mr. Bhaskar Sen, Chairman, Eastern region the 18000-65000 crore projects is the basis of development. Now the preparation is in respect of transmission. “The CEOs are putting money in our team from UAE, Arab Emirates and other

foreign countries as part of the overseas utility. And that’s the big fat thing”.

The time has reached to such an extent when India tends towards the international market. Running with 450 buyers the country aims for 1200 kilo watt energy. Collaboration is the will force whereas achievement is the landmark. “The capacity is to generate 1200 kilo watt but the objective is to generate more as we aspire after big. Powering India has such a big pull that India can now acquire foreign plot. Incentive in terms of Govt. investment is praiseworthy so crisis of fund is a no no”-said Mr. Sen.

IEEMA is the sole organizer to associate the power industries on one podium and to buck up the utility of power growth in India in cooperation with MNC Power Houses.

“Apart from a world class exhibition, ELECRAMA will also play host to a slew of concurrent events that will broaden the perspectives for a modern business person and will offer a strong interface with the key decision makers like Governments, Electrical Utilities, Funding Agencies, Technical Specialists, EPC Contractors, Electrical Consultants and Academic Communities.”

Sanjeev Sardana Chairman, Organizing Committee Elecrama 2014

Debolina Dutta

[email protected]



The organization IEEMA, the Indian electrical and electronics manufacturers association is the corporate association of both the private as well as the public sectors --large as well as medium and small industries running with a large variety of companies as its members. As its name the sector has a multiple functions to catch the customers as of now the chief objective is to create a better environment consisting of various acts, laws and status to provide new market excess with new products, new technologies and to create a market for them not only in India but also in overseas countries with an object of gaining ample opportunities to showcase the products to the target audience.

According to Mr. G P Gupta Chairman, Managing Director, Techno Group and also a member of IEEMA after being sluggish for many years the total export is of 5 billion dollar. The ground reason speaks something else as the present trend in the IT sector is downturn. The current market is facing the onslaught of Chinese product that captures mostly of 45% of the Indian market. In a press conference Mr. Sanjeev Sardana, Chairman ELECRAMA-2014 said, “Recently Indian electrical goods hover round the market of U.S.A and U.A.E, U.K, Germany, Australia and Canada Nigeria and Kenya and Australia. The viability of the

Indian product is experiencing a potential growth in the overseas countries”.

India is exporting almost 15%-20% whereas the scenario in the global trade has a sharp touch of U.S 4.6 billion in 2011-12.The estimated growth of business is over 200 crores with a 500 crores eagerly awaiting in the pipeline as per the Broadway research work of RBSM (An association of The Reverse Buyer seller meet). India’s exports of electrical equipment were around US$ 4.6 billion in 2011-12. “The target is to touch upon 25billion dollars. And there is no reason why the Indian industry cannot achieve this. The top three ambassadors who are the leading in the power sector are thumbing up the issue. Among them Cyber Electrics with 1.5 billion dollar investment, Gem, a French multinational on setting up manufacturing belt and the third is Psycho Electrical from U.S.A have already tied the notch for Indian market”-said Mr. Sanjeev Sardana, the chairman of the organizing committee, Elecrama 2014.

“India is most competitive when it comes to the transmission sector” said Mr. Bhaskar Sen, Chairman Eastern region. The average utilization of plants is more than 70%. The growth rate in the transmission sector from 2004 to 2012 has been quite phenomenal with an initial from an 18,000 crore to a 64,000 crore –and “the summit is not a mere child’s play.”

The opportunity is a challenge for people allied with the industry. The interaction with the power bigwigs through Cigre, RBSM, IEEMA Trafotech session could sum up a successful buyer-seller coalision.

Therefore what is the future of the power sector in India? How can the business foresee the growth of this sector? Will it be a bulk difference in terms of export between the present and the past scenario? Or will it be a trifle stingy? According to Navin Goliya, the director of Kusam Maco, the trend is the measurement of change from the analog to the digital and as the company has successfully paced with the modern digital edition, their strong motto is the after sale service on which the company is firmly stick to.

Even it was not easy at all for the giant power companies to face the toughest challenge despite the recession in the Indian and the global economy. There was for a span of four years when the Indian and Global Economy saw decline in the Electronic Testing & Measuring Instruments. The come back was very hard. However, in spite of recession, due to the superior quality of the products and strong marketing efforts Indian industry is successfully keeping pace with the global trend. Such is the surge for business that Kusam Maco has now over 250 instruments in their portfolio.

“At the past Elecrama Exhibition we got a chance to meet many customers not only from India but also from Overseas. We provide all the visitors a detailed knowledge of our better quality products so that they can contact us for their requirement when need arises. And this way in the Elecrama exhibition we get close to our Customers & understand their needs & provide them the products as per their requirement. This has resulted in introducing customer need instruments. We now have over 250 instruments in our portfolio.” Naveen Goliya added.

For Basavaraju, the Managing Director of Trishul Engineers Bangalore, Elecrama is the platform & the opportunity for Indian small and medium enterprises to showcase their innovative products & technological superiority to the global market. The Electrical industry’s share of exports is about 1.5% of the country’s total exports. Asia-Pacific and Europe together account for more than 70% of the global market, with the Asia-Pacific region’s share being 45% and is expected to see the strongest demand, India will be playing a major role in supplying generation and distribution equipment’s in the coming years. He is gearing upto launch new programmable foil winding machine in Elecrama 2014.

“Elecrama 2014 will showcase the global competitiveness

“ELECRAMA 2014 is much awaited, every alternate year, with hopes of new qualified & serious visitors to view our latest products, more new serious enquiries leading to new business opportunities & long lasting business relations. Our vision is to make ‘KUSAM-MECO’ the most trusted brand nationally as well as internationally.”

Naveen Goliya Director, Kusam Meco

“Elecrama is never limited to the four squares of the stage that restricts the benefit of booking orders during the fair but it always helps to interact with the customers from all around the globe, understanding their requirement. It provides the scope to meet directly the potential customers and interact with different manufacturers of electrical components and machinery.”

Arijith Basuray Managing Director Neo Teletronix Pvt Ltd



of Indian products and local manufacturer’s capability to develop world class engineering products at competitive costs. The capacity addition target in the 12th Plan is expected to be 88.5 gigawatts and Close to 100 GW of capacity addition is envisaged in the 13th Plan. ELECRAMA being one of the biggest trade show in this domain. Participating in such events of high degree provides a company global exposure, product visibility, interaction with customers, consultants and people from the export market under one roof. It will also help us build Brand Image”, he added.

In this ELECRAMA 2014 Kolkata based Arup Saha of A K Power Industries Pvt Ltd are expecting to expand their business in the developing countries like Middle East, Central Asia, West Asia and Africa who are undertaking electrification vigorously through funding from multilateral agencies like the World Bank, African Development Bank and IMF. A K Power Industries manufactured products like Transmission, Substation & Distribution Line Structure, Insulator Hardware Fittings, Conductor & Earthwire Accessories, Pole Line Hardware; Connectors have immense opportunities for capturing these markets. The Indian government has also

realized the huge potential for exporting to Africa. Africa has about 54 countries with a combined population of around 6.5 billion people. However, electrification in these countries is barely 30% which means there is scope of the rest 70% to get electrified. Arup Saha is confident that there will be deals and contracts signed even in this ELECRAMA thereby boosting significantly the exports of their products.

“During ELECRAMA 2012, the footfall of the foreign buyers was near about 5,000 and contracts worth more than US$ 200 million were finalized. For the first time reverse buyer-seller meet (RBSM) was organized in 2012 elecrama, and based on the experience gained from the previous version of Elecrama, IEEMA is preparing themselves for the same in 2014.This RBSM gives us the opportunity to meet one-to-one with the foreign giving them a good idea about the capabilities of the Indian electrical industry”, commented Mr. Saha.

The Global Trend peeps for a quality goods under the wrap of economy budget and so trading from the offshore countries like India and China

Global market is shoring up. The needs for the testing and the manufacturing instruments are rising up. So it is not far off when the

increased demand of new technology-the Manufacturing Test & Measurement market is about to see a high growth in this field. India’s high grade technology at an easily salable price leads her in the global list in the power sector. Needless it sends ripples among the quality-driven, price sensitive developing nations who value the product much rather than its price.

The Indian electrical equipment industry of US$22.5Bn in 2011-12 saw the variable combination of generation equipment (boilers, turbines, generators), transmission & distribution (T&D) and allied equipment like transformers, cables, transmission lines, switchgears, capacitors, energy meters, instrument transformers, surge arrestors, stamping and lamination, insulators, insulating material, industrial electronics, indicating instruments, winding wires which surely shows a sign of narrow growth but standing at that economic scenario is not it a major challenge?

The expectations are high. Like every alternate year the stage of Elecrama is roused with an arrival of qualified and serious visitors to come up with serious new enquiries to sum up in lasting business relations. The trade summit can equally be revolved both nationally

and internationally. Latest technology adaptation & its certification to many quality standards is the surest way for a corporate house to survive the challenge. Its license to the quality certification props it up to face the changing face of the world.

This year the biggest powerbiz will get under its wings the multifunction power analyzer, solar power meter with orientation & tilt angle, low frequency field intensity meter, high voltage insulation tester with 15 kilo volts output volts, vibration meter with sensor probe, infrared thermometers, high voltage detectors, temperature & humidity transmitters, digital multi meter with insulation tester, air purifiers etc.

Every business has experienced ups & downs in the journey. But how to set objective to win over the customer? Do the good quality products, reasonable prices & after sales service achieve the alma mater of a business or is it something else? Nonelse can deny these facts-They exist and will continue to be a part of the India’s biggest showbiz. Till then hope for the best.

“ELECRAMA-2014 is a great initiative by IEEMA to bring global and local technologies to customers to make informed choices thus providing the industry to play a major role in driving India’s economy at 8-9% GDP if not more. India’s electrical equipment industry is expected to play a critical role in improving its power infrastructure. The next 10 years will be crucial for the Indian electrical equipment industry as it gears up to meet domestic demand as well as major player in the global electrical industry.”

Basavaraju Managing Director, Trishul Engineers

“The main theme of ELECRAMA is ‘go global’. Each year IEEMA plan to promote international business and for this, they gather decision makers from various power utilities across the globe including West Asia, Latin America, ASEAN countries, SAARC countries and Africa. For last consecutive three versions of ELECRAMA we have participated. It’s a very rich experience we have gathered. This edition we are going to show 765kV & 1200 kV Hardware fitting in ELECRAMA 2014.”

Ayan Mallick Managing Director A K Power Industries Pvt Ltd


www.martonline.in24 December 2013www.martonline.in24 December 2013

In the 80’s 90% of the Multimeters & Clampmeters used in the industry were Analog meters. Established in the year 1983 KUSAM-MECO introduced & pioneered the use of Digital Multimeters & Clampmeters in Indian industry. KUSAM-MECO has a proven track record of offering products which have surpassed industry standard certification such as UL, CE, ISO 9001 : 2000 Quality Assurance Certification. The company has testing facilities traceable to NPL standards to provide good quality instruments to the customers. Chandmal Goliya the man behind this success shares his journey and future plans to the readers of MART.

“Superior Quality of our products keeps us ahead of the competition”

ON FACE

Kusam-Meco completed 30 years of its service to the industry. Entering the New Year with Elecrama 2014, can you please sum up your last 31-year success journey?

As Digital Instruments were newly introduced, in the initial years we had to change the mindset of the customers to change their measurement needs from Analog to Digital Instruments. Because of the price factor, customers were reluctant to changeover, but slowly by our strong efforts the usage of Digital Instruments increased and we were able to get a strong foothold in the market. Our strong point was our after-sales service. Thereafter, there was no looking back and our company increased the product range multifold year after year. Today we have one of the largest ranges of T&M Instruments in India.

Elecrama is one of the important

exhibitions where one can see the latest and vast range of the Electronic Testing & Measuring Instruments. Every alternate year umpteen number of participants participate to display the world of Electronic Testing & Measuring Instruments. Every business in the Testing & Measuring Instruments has experienced ups and downs in the journey. But ‘Kusam-Meco’ managed to win over the customer with their good quality products, reasonable prices and after-sales service.

For the last 4 years Indian and Global economy has been going through a rough patch. How did Kusam-Meco face this tough situation?

Yes, in the last 4 years not only Indian economy but Global economy too saw a decline in the Electronic Testing & Measuring Instruments. However, in spite of recession, due to the superior quality of

our products and strong marketing efforts we were able to improve upon our sales over the previous years.

You are always a regular part of Elecrama exhibitions and launched several products during Elecrama 2012. How has the exhibition benefited to the growth of Kusam-Meco for the last 2 years?

At the Elecrama exhibition we meet many customers not only from India but also from Overseas. We provide all the visitors a detailed knowledge of our better quality products so that they can contact us for their requirement when need arises. And this way in the Elecrama exhibition we get close to our customers and understand their needs and provide them the products as per their requirement. This has resulted in introducing instruments that the customer need. We now have over 220 instruments in our portfolio.

Which are the new markets Kusam-Meco developed within the last 2 years?

In the last 2 years ‘Kusam-Meco’ introduced Digital Clampmeter, LCR Meter with USB, AC/DC TRMS Clamp-on Multimeter, 4-Wire Earth Resistance Tester, Combustible Gas Detector, Laser Distance Meter, etc. We have also upgraded some of our existing products with better features and


specifications. This has led to introducing our products to various new users whom we were unable to cater to earlier, thereby increasing our presence in those fields.

What are your expectations from Elecrama 2014?

Our expectation from Elecrama 2014 is more qualified and serious visitors, more exposure for our products to the visitors, more serious enquiries, and more business opportunities both national and international.

Which are the latest innovations Kusam-Meco would be offering at Elecrama 2014?

The latest innovations to be displayed at Elecrama 2014 includes Multifunction

Power Analyser, Solar Power Meter with Orientation & Tilt Angle, Low Frequency Field Intensity Meter, High Voltage Insulation Tester with 15 kV output volts, Vibration Meter with sensor probe, Infra Red Thermometers, High Voltage Detectors, Temperature & Humidity Transmitters, etc.

Can you brief about your production facility and the quality control to produce zero tolerance error products?

To provide our customers timely service and superior quality products we have our separate R&D department who checks each and every instrument thoroughly, so that our customer is satisfied with the quality of our products. And for the quality and service of our product we have

been rewarded with the ISO 9001:2008 Certificate.

We have a team of qualified engineers who are responsible for maintaining the quality standards at ‘Kusam-Meco’. We have high quality calibrators and other standard instruments to ensure proper quality to the customer.

There are a lot of industry supportive initiatives by state and union governments. Has any of these helped Kusam-Meco in its 31-years’ journey?

After 67 years of Independence our country still lacks a manufacturing supportive atmosphere. More than supporting to set up a new manufacturing facility, there are hindrances in running an ongoing industry. If measures can

be brought in removal of these hurdles and harassments we can expect more and more people strengthening the manufacturing in India.

Which are the major areas you feel the government should attend to support the industry?

Government should attend the areas of taxes (of local and national, direct and indirect) and provide good infrastructure like other modern economies. Also there should be no red tapism and rules should be as less and simple as possible for the growth of the industry.

Can you tell about the people behind the success of Kusam-Meco?

With four people we initiated the

operations of Kusam-Meco during 1983. Today we have a team of more than 30 experienced professionals in different departments with the able leadership from Mr. Navin Goliya and Mr. Pradip Goliya.

Your future plans?

The future plan of ‘Kusam-Meco’ is to make its reputation not only in the local market but also to achieve success internationally by promoting its products all over the world as per the needs and requirements of the customers. And to innovate and develop its products by improving the quality and design for the customers. Our Vision is to be the top company to provide the best products to the customers’ satisfaction. ’Kusam-Meco’ should be the most trusted brand in the T&M Industry.

KM 2100 Power Analysert

KM 7010IN Insulation Tester


QUALITY

Gorur Sridhar

[email protected] of QualityQUALITY, the moment one hears about it, it sends shivers down everybody’s spine. Why is it so? On close examination it reveals that we are simply unable to meet our ever-changing customer’s expectations. It’s an irony that on one hand we wish to add more customers& retain them but not able to meet their expectations.

It is true that Quality cannot be 100% but tending towards that is striving for perfection. Any of the certifications or regulations like ISO9000, AS9100, MIL, FDA, FMVSS, CMMI, 6 Sigma etc. are only the vehicles helping to drive towards achieving that goal.

The moment we try understand those, the bigger question that arises is ‘How do we weigh Quality’? ‘How do we quantify Quality’?

In order to address the above, let us now try to answer the question ‘How do we identify ourselves in the value chain of the product’?

Is Quality paramount in some specific type of industry or is it supposed to be given equal importance in all domains? Why do we perceive that Quality is important in Aerospace & belittle other domains viz. Industrial, Marine, Automotive, Medical etc.?

Let us examine the cost of some of the failures associated with the ‘Poor Quality’ in the above mentioned domains:

Aerospace and/or Space &defense:

• NASA used the metric system while Lockheed Martin used the English system when building a satellite

Cost of the lost orbiter: $125 million

• Flawed design of the foam

shield causes the Columbia to crash while re-entry

Lost in 2003: $13 billion was the cost of building the space shuttle. All seven crew members died in the crash.

• Faulty equipment causes a B-2 stealth bomber to crash on take off

Loss in 2008: $1.4 billion

• Faulty O-ring sealing joint causes the Challenger to explode on lift off

Loss in 1986: $5.5 billion was the cost of building the Challenger. All seven crew members on board died in the explosion.

Industrial:

• Faulty equipment causes nuclear meltdown at Three Mile Island

Loss in 1978: $836.9 million in repairs and clean up

Marine:

• Weak cement around the well results in BP’s deepwater horizon drilling rig explosion. Leading to the largest environmental disaster in US history.

11 dead and $10 Billion loss & Inestimable environmental loss

• Safety inspectors forget to replace a valve at the Piper Bravo Oil Rig

Lost in 1994: $3.4 billion in repairs. The explosion killed 167

of the 226 men working.

Automotive:

• Problematic floor mat & defective brakes leading to unintended acceleration in Toyota.

Recall of 9 million cars. Stopped the sales & production of 8 popular models. 52 dead and 38 injured. Incurred a loss of $5.5 Billion.

Medical:

•Wrong foot amputated, due to wrong case history filing.

Patient lost both the feet and sued the hospital for damages.

• Wrong healthy fetus aborted in twins, due to negligence.

Patient lost both the kids and the hospital compensated with a hefty sum.

• Wrong side of the brain operated, due to mix-up.

Patient died and the hospital was sued for an undisclosed amount as damages.

Analyzing the common thread between all the above failures Quality is not restricted to a particular domain rather it is a universal language. The standards, requirements, specifications etc. would vary among domains but the underlining factor is that Quality is inseparable. Irrespective of the domains “Quality always remains as Quality” and can never be undermined.

Flawed design of the foam shield causes the Columbia to crash while re-entry. Lost in 2003: $13 billion was the cost of building

the space shuttle. All seven crew members died in the crash.


The questions that would still remain unanswered are ‘What is it that we can compromise on’?

‘Where can we draw a line to differentiate between acceptable, desirable & non-negotiable’?

‘Is deploying those extra resources in terms of manpower and time justified’?

(Gorur Sridhar is Quality Manager for an aerospace company. The views expressed in this article are purely personal thoughts and do not contain the views of the company.)

Gorur N Sridhar is a Mechanical Engineer and Six Sigma Black belt with more than 26 years of experience in Manufacturing, Quality and Design fields. He has been instrumental for substantial cost savings through Value Engineering, Process Improvements & Failure Analysis. He has got major achievements to his credit including filing of 6 Patents.

He is a MBB practitioner and mentored more than 100 Six Sigma projects. He is a Qualified Internal Auditor for ISO9000, QS 9000 & AS9100 Systems. He is also associated with the Implementation and Sustenance of CMMI L5 activities. He is also equally contributing in EHS and Community development programmes. Located in Bangalore he can be reached at [email protected]

Every industry has its own way of handling quality issues and addressing them appropriately and is not a ‘one fit all’ solution. The cycle time of qualifying a part may take relatively a longer time in an Aerospace industry since it has to undergo a greater number of cycles compared to its counterpart in an Automotive industry. This in no way makes it superior to other industries.

As a matter of fact most of the quality systems originated from the Japanese Automotive industry and deployed horizontally across the other countries &domains.

The simple 7 QC tools and PDCA cycle gave rise to the universally accepted 6 Sigma, Corrective & Preventive action concepts. SAE standards formed the baseline for the Aerospace (AS) standards. ISO became the de facto standard for all industries& service sectors as well, etc.

Though Quality is defined as:

“Quality means doing it right when no one is looking.”

“Quality is everyone’s responsibility.” etc.

Whether it is a beauty salon or dressing a chicken for serving or tailoring a bridal wear

“Always know who your client or customer is - no matter what your job is.”

I would simply put it this way:

“Working to your conscience and discipline in following a procedure is Quality”.

“Quality means doing it right when no one is looking.”

“Quality is everyone’s responsibility.”


P S Satish

[email protected]

MANUFACTURING EXCELLENCE

As a continuation of last article, we will discuss on few more points to manage SME’s better in India

Journey Towards ExcellenceManaging a SME in India - Part 12

24. Understand change of ground rules

The way we were running the industries say 15-20 years back will not hold good now. We need to understand how many of ground rules have change over years first before we try to address them.

This article attempts to explain what changes are seen and few tips on addressing the changes.

•Extent of market:

Earlier focus was to see market area as a particular region or at the most a country. See now. The world is your market. With improved communications like Internet you have access to Information of world. Boundaries between nations which were restricting exchange of trade are slowly vanishing. Logistics have improved drastically. With these opportunities have improved tremendously.

China has exploited this very well. Many industries there have put up facilities with final aim of supplying to whole world. At the same time, competitions for us from global players have increased. Our competitor is no more from next street but could be from china, Philippines, east Europe or Mexico. The way opportunities have increased, challenges are also increased. Let us extend our focus to think at global level. It is apt to mention here, ‘Think global, act local’

•Focus:

There is a change in the way our focus was on Customer. Earlier the focus was on price to customer. The efforts were to reduce it at the cost of quality or service. Now there is a shift of focus. Now emphasis is on value more than just price. Value is nothing but what customer perceives as return for the money he pays. Increasing quality, service, satisfaction, and comfort without increasing price or cost will enhance the

value. Customer is ready to pay higher as long as he perceives higher value.

See the example of Micromax mobile phone in the market. In India, they are in 3rd position after Samsung and Nokia in a short time. They focused on price and offered mobiles at relatively competitive price. Their service level is that of other global players and they are trying to focus on that to retain competitive position for longer time.

•Regulations:

Earlier there were many government regulations to start and run an industry. The era was called licence Raj and

industries had to seek permission of Government for many things. The control of government on import, foreign interactions was very high. Old players know that even to visit a foreign country the permission of RBI had to be sought to get a limit on foreign exchange. With era of so called liberalization, privatisation and globalization (LPG), policies have slowly changed and hold of government is coming down. This is a process still ongoing

•Market dominance:

In earlier time, manufacturer was defining the market. There was like a push of product to market. The choices of

In a short time by focusing on price Micromax grabbed Indian mobile phone market and now they are in 3rd position after Samsung and Nokia



customer were limited. Look at the time of Ambassador and Fiat cars. The customers did not have choice and had to buy what manufacturers offer. See now. Customers have problem of plenty. It is a pull market. They define what type of product market should have. Now there is a need to understand well what customer wants and develop products suitably.

Just having a good product does not mean that there is a customer. We need to change our perspective from production centric to Customer centric. This change is being seen in service industries also. Take an example of hospital. They are realizing importance of not having best facilities but also on mind set of serving patients with care.

•Capital Investment:

Earlier focus was on physical manufacture and on tangible things. The investments emphasis was high on land, buildings and machineries. Now there is a realization that these capital investments are enough to take company to a higher level. The focus

is shifting to investments also on intangible things like branding of the company, enhancing reputation of the company, improving know-how, spending on R&D & innovation etc.

The investment on human capital and on training is viewed as one of best return in the long range. This is an area our MSMEs need to work on in changing their thinking only on investment of machines. Enhancing ethics of the company to improve the brand image as a part of corporate social responsibility is the topic of the day. Another area of investment is on information like the way Data is managed, preserved and analysed. Let us think of investing on soft things as well as hard things.

•Business:

The concept of was to run companies in isolation and as independent. There is a change of thinking towards collaboration or alliance. Workings with other companies including competitors in some area will make both of them win. Strengths of

companies can be synergised to address the market. Interdependency is the order of the day. Japanese companies have achieved this to a great extent. They have a concept of networking of businesses that own stakes in one another as a means of mutual security. It can be horizontal like banks or vertical with suppliers and dealers. The word used for this concept in japan is ‘Keiretsu’. I will give another example. Aerospace is seen as promising area of growth in manufacture next to automotive. Investments required here is relatively high for an individual MSME. Collaboration together by few MSMEs to take up a project could be an answer.

I will continue the series of article in the next issue. Please send your inputs, remarks, suggestions to P.S.Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services,

Q-103,Mantri Paradise Apartments, Bannerghatta Road, Bangalore-560076. Email : [email protected] ; www.satishps.com. Have a good day.



Tomasz Tunguz

[email protected]

Startup Management Best Practices: Managing Monkeys

You’re walking down the hallway at work from one meeting to the next. A colleague or report stops you en route, asks for a minute and presents an important problem. It’s easy to respond with “let me think about it” and duck into the meeting. In that half-second, all the responsibility of the decision has been transferred. Unlike a minute ago, you have the monkey on your back.

The challenge with these situations is two-fold. First, you’re unlikely to have enough information to make a decision. Second, no time has been allocated to solving the problem.

Multiply this event by 3 or 4 times per day, every working day, and it’s easy to see why these hallway conversations create massive bottlenecks in organizations. Everyone is talking but no one is deciding or acting. Organizational inertia sets in and

Tomasz Tunguz, a venture capitalist at Redpoint Ventures, an IT venture fund with offices in Silicon Valley, China and Brazil continues his column in MART. You can follow him on twitter @ttunguz.

TOMASZ’s CORNER

the company’s rate of execution grinds to a halt.

William Oncken, Jr, who founded a management coaching company, developed a strategy to help managers handle monkeys.

When faced with a monkey, a report has five choices:

1. Wait for instruction

2. Ask for help

3. Suggest an action and ask for permission

4. Act, but inform immediately

5. Act and wait until the next 1/1 meeting to inform

Oncken reasoned that the first two options are the worst because they encourage monkeys to propagate through hallway

conversations like the one above. Instead, managers should trust their reports to pursue options 3 through 5. Each of these three options requires a follow up meeting and a schedule of updates that should allocate enough time to discuss how best to deal with the monkey. Ultimately, enforcing this practice builds trust among the team, empowers team members to evaluate and resolve problems, develops employees’ skills, all while increasing a manager’s effectiveness, a win-win outcome.

Oncken’s technique for managing monkeys ensures continuity in business processes, preventing managers from becoming bottlenecks and empowering reports to act quickly and effectively. It’s a good technique to maintain top execution speed.

Source: www.tomtunguz.com



Wireless Technology in Oilfield Production Plant

In the past, hundreds of man-hours were required to check device running conditions and to analyze oil production data. Katlax established in 1993 with commitment for offering latest in Sensors & Automation to Indian and Global industry offers

Wireless Automation enabling remote monitoring and management capabilities for the Oilfied Production Plant.

Wireless Products in Oilfield Production PROCESS

The Oilfield production plant consists of oil wells, metering stations, manifold valves, oil transferring stations, a joint station, a crude oil transmission system and other distributed facilities spread across hundreds of square Meters. All the devices’ working conditions and oil output data (mainly temperature, pressure, flow, etc) are very important for production.

In the past, hundreds of man-hours were required to check device running conditions and to analyze oil production data, which greatly impacted the ability to measure conditions in real time with accurate data. With help of Wireless Automation now it is possible to have remote monitoring and management capabilities as described below.

In Oilfield Production Plant, many units are located with hundreds of meters distance

among them, which are listed below:

• Control Centre

• Oil Refinery

• Pump Jack

• Tank Farm

• Pipeline System

Here Control Centre which collects all the data from different units and controls the process, is connected with all the units through Wireless Devices.

• Pump Jack Lift is controlled through Control Centre using Wireless Transceiver.

• For Pipeline management, I/O mirroring RTU unit is used which supports RS485 communication. Here RTU unit is connected with Control Centre through RS485 to Wireless Converter.

• At Tank Farm,

There are two main processes which are controlled & monitored through Control Centre : Liquid Level Monitoring and Plunger Lift Control. Liquidlevel in each tank is monitored and plunger lift control data is communicated through Wireless Transceiver.

• On Oil Refinery Side,

Flare stake monitoring and Pressure monitoring is done by Control Centre with the help of Wireless Converter and Wireless Differential Pressure Transducer respectively.

Note : Above case study diagram is artistic representation only. Any resemblance to any company’s products or corporate article is purely coincidental.

For further details visit www.katlax.com

CASE STUDY



VALUE ENGINEERING


India has been at the forefront of automotive development and manufacturing. The increased interest of all the automotive manufacturers in expanding their manufacturing footprint in India, can be seen by the new plants that they have been putting up in various regions – new plant of Ford in Gujarat, new plant of Honda in Karnataka, and so on. Leading the technology revolution in the component manufacturing field is Indo-US MIM Tec Pvt Ltd. (branded as Indo-MIM) at Bangalore. They are engaged in the field of providing cost-effective solutions through manufacturing of complex shaped steel and stainless steel parts as per customer drawings, using the emerging technology of MIM. They have reached the status of World’s largest company in this field, as per information provided in the International Conferences.

Indo-MIM has always believed in Open Innovation, i.e. open approach to sharing of capabilities and technical know-how thereby bringing technical information to the doorstep of the global customers. This has been accomplished through participation in various global exhibitions across Asia, Europe and USA, as well as being a speaker at various symposiums and conferences, to take lead in disseminating

Cost-Effective Technology of MIM

Leading the Innovation Bandwagon, through Concurrent Engineering and Value Engineering, Indo-MIM has set new milestones in the field of Metal Injection Molding (MIM) across the global automotive industry

information about this innovative and emerging technology.

Our services range from Concept Creation, Product Development, Prototyping, Small Batch Production, Mass Production, Sustainability, Quality and Reliability. Specific area of expertise include mold flow analysis, generating high surface finish using lapping and honing, post-MIM surface treatments, gauge and fixture design for ease in qualification and sustainable quality, specialty grinding, welding, sub-assembly processes. This can further extend to managing a lean and efficient supply chain for exports from India. A dedicated Innovation Cell at Indo-MIM supports global customers 24 x 7 to assist in new product design, concept finalisation and MIM feature discussions, thereby enabling make the MIM experience easy and fast.

Customers have access to Indo-MIM for support on prototypes, mold flow analysis and samples. Furthermore, this can then scale up from this development phase to frugal engineering and the subsequent result could be a low volume production or the large scale production.

Indo-MIM has Quality Certifications like ISO 9001, ISO/TS 16949, ISO 13485, AS

9100 Rev C and also has an ISO Class 8 Clean Room for specific applications as per customer requirements. It practises Lean manufacturing and Six Sigma methodologies at both its manufacturing plants, wherein there are more than 20 ASQ certified Six Sigma Black Belts who work on various projects throughout the year.

The culture of six sigma is inculcated into the people working at the shop floor, owing to which the working style is unique and different. There are 5 Kaizen projects that run at each plant every month, thereby enhancing the working atmosphere as well as the employee culture in the company. The result is that the customers getting a leaner process designed for their components that result in several cost benefits and sustainability.

A particular highlight is a fitting recognition of Indo-MIM at the recently held MPIF Annual Powder Metallurgy Design Excellence Awards at Chicago, Illinois, by being awarded three prizes in the automotive design category.

For further details, contact Indo-US MIM Tec. Pvt. Ltd., Plot No: 45, KIADB Industrial Area, Hoskote, Bangalore: 562114; Phone: 080 22048800; Email: [email protected]


HMS Industrial Networks now introduces the Netbiter EC350 – a new communication gateway which makes it easier to monitor and control industrial equipment remotely. The gateway comes with enhanced performance and connectivity making

it ideal for remote management and configuration of power generators, cooling systems, UPSs, wind turbines or other industrial machinery.

Enhanced connectivity.

The Netbiter EC350 is the first in a new generation of Netbiter gateways. It connects to industrial machinery via Modbus (serial or Ethernet), SNMP, EtherNet/IP or I/O and sends data to the cloud-based Netbiter Argos server via Ethernet or cellular communications.

3G Communication

While previous generations of Netbiter gateways have been able to communicate via GSM/GPRS, the new Netbiter EC350 is enhanced to also communicate over 3G networks. The 3G communication provides increased performance compared to GPRS and also increases the geographical cellular coverage as it is possible to install the gateway where 3G is the only available network. With support for 5 different 3G bands, the Netbiter EC350 is a product suitable for the global market.

Enabling Remote Access

The Netbiter EC350 will support “Remote Access” functionality. This means that users can open up a secure connection to remote machinery and configure or operate it from any location using standard software applications. Remote access provides a secure data tunnel to the remotely located equipment. For example,

with a Netbiter connected to a PLC, it is possible to perform remote debugging or programming of the PLC from any location, using the same PLC configuration software as usual. Remote access functionality will be available as of Q1, 2014.

“Netbiter is one of the pioneering solutions on the remote management market and we have taken advantage of our long experience when developing the EC350,” says Henrik Arleving, Product Line Manager, Remote Management at HMS. “With more connectivity options and increased performance, Netbiter definitely takes the lead as one of the most versatile and powerful remote management

solutions on the market.”

Technical enhancements

From a technical point-of-view, the new gateway has about 20 times more processing power than the previous gateways and an extended memory capacity supporting up to 512 MB Flash and 1024 MB RAM. Two fully separated Ethernet Interfaces (WAN and LAN) makes it possible to provide secure communication to the field installation. A built-in GPS receiver makes it suitable for mobile fleet management applications and the increased number of analog and digital I/Os allow signals and sensors to be directly connected to the Netbiter gateway. Six status LEDs also provide detailed diagnostics.

HMS Industrial Networks is the leading independent supplier of embedded network technology for automation devices. HMS develops and manufactures solutions for interfacing automation devices to industrial networks. For further details write to UL Electrodevices Pvt Ltd, S.NO. 6/9/6, Bhairavnath Nagar Nahre Gaon, Tal Haveli Pune - 411 041 Tel: +91 20 269 60040 Email: [email protected] Visit: www.ulepl.com

New Netbiter Gateway Simplifies Remote Management of Industrial Equipment

The Netbiter EC350 communication gateway provides communication to field installations using Ethernet or the cellular networks to a cloud-based service called Netbiter Argos (located at http://www.netbiter.net).

NETWORKING


Mekaster have been pioneer in introducing various types of torque wrenches including Mechanical (upto 2700 Nm), Torque Multipliers (upto 13,000 Nm), Hydraulic (upto 38,000 Nm) & Electrical / Pneumatic Torque Wrenches (upto 13,000 Nm). To compliment the existing range of Steel Body Hydraulic Torque Wrenches, Mekaster has also recently introduced a lightweight range of Hydraulic Torque Wrenches.

Mekaster lightweight Hydraulic Torque Wrenches are ideal for tightening and loosening at various locations with operating torque range from 40 Nm to 27,000 Nm in Square Drives as well as Ratcheting Hex Wrench (Hydraulic Cassette type) models. These torque wrenches are with high torque to weight ratio, providing high degree rotation, maximum repeatability with an accuracy +/- 3% & ease in operation.

The Square Drive wrenches can be supplied with either square drive or Allen Key drives with Push-button drive release where no tools needed to reverse. Similarly the ratchet hex wrench (Hydraulic Hex Wrenches) is provided with quick exchange

cassette, which do not require any tools for changing. These flat hexagonal cassettes are optimized for smallest radius and are suitable for tightening and loosening in confined spaces.A range of Electric and Air operating Power Console is also available for use with these torque wrenches. These consoles incorporate a German made Hydraulic Unit with high flow pumps with 2&3 stage operation for faster cycle time & continuous pressure torque setting with fine adjustments. Features such as system over pressure, safety release valve, auto retract, oil level indicator, oil temperature gauge are standard. The electric models are also equipped with timed control for automatic shutting off the motor in case of ideal run and forced air cooling over a large area in high air life conditions. A 6 m long twin line hose is included with console.

Industrial tools are indispensable parts in any manufacturing unit. Any compromise on the quality of the tools will result into the wastage of both time and resources. Mekaster has been pioneer in introduction of heavy-duty industrial tools in India since 1970s. Mekaster Tools Limited as a separate entity was incorporated in the year 1991 with the only motive of providing world-class industrial tools.

The impeccable quality of the products, wide distribution network and capability to feed bulk demand has helped us extend our clientele base across the globe. The organization works on sound management principles to satisfy the varied demands of the clients. Since its very inception, the concern has been providing tools known for cost effectiveness, durability and reliability. The Tools, Console and Hoses are equipped with high pressure, quick coupler designed with non-drip connection / disconnection and a safety ring for

locking sleeve to prevent the accidental disconnection.

For further details write to Mekaster Tools Limited, 10168, East Park Road (KCP), Karolbagh, New Delhi – 110 005 Tel: +91 32908029 Email: [email protected] or visit www.mekastertools.com

Mekaster Light Weight & Cassette Type Hydraulic Torque Wrenches

HYDRAULICS



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MACHINE TOOLS

Commercial Vehicle Production: Aiming to Reduce Component Costs

The market for commercial vehicles is experiencing a lively development. For example, emerging economies have a great need for new technologies in the production of HGVs or agricultural machines, to enable them to achieve the desired growth in construction industry and agriculture. At the same time, competition is hotting up. New manufacturers from, for instance, China intensify the price war. Against this kind of background today’s production planners are coming under considerable pressure. The future of commercial vehicle production lies in being faster, more energy efficient and more flexible. For the turning experts at EMAG these are very familiar conditions. With their vertical pick-up turning machine VL 8 for workpieces of up to 400 mm diameter they offer a highly efficient solution for the production of commercial vehicle components.

Large vehicles = large constituent components. This is the simplest way to describe commercial vehicle production. However, the manufacture of especially large and heavy components (for instance for the powertrain of HGVs, earthmovers or buses) poses a particular set of questions. How can a large clamped component be machined economically and, at the same time, at the highest precision? Does the demanding workhandling of such components not result in endlessly long production processes?

The vertical pick-up turning machine VL

8 from EMAG’s machine builders provides the answer. They have transferred all the advantages of their VL series directly to a machine specially designed for the handling of large components, where a number of different turning and milling operations are carried out within the framework of a single close-loop production process, with integrated automation providing the speed required and a vertical layout ensuring a high degree of process integrity where chip flow causes no problem.

The results achieved with this design often become apparent within a very short time. Subcontractors and component suppliers benefit from short idle times, high component quality and sinking unit costs. The VL 8 is rapidly becoming a true “cost-killer“ in the production of commercial vehicles.

Tried and tested basic construction – optimal price-performance ratio

The basic design of the VL 8 closely follows that of the successful VL series. Sturdy machine construction, dynamic axes and simple operation are the main characteristics of these machines. They are also based on a completely new machine concept that allows for a variety of production technologies for soft and hard machining to be combined to achieve a very attractive price-performance ratio. The following major components ensure the production process on the VL is also highly efficient:

• The corner stone is a machine base in the polymer concrete MINERALIT that guarantees vibration resistant processes, providing for an excellent tool life and an outstanding machining quality.

• The front of the machine base features a compound slide carrying the vertical main spindle that traverses the Z- and X- axes with great dynamic.

• With a chuck diameter of 500 mm the pick-up spindle accepts workpieces of up to 400 mm diameter.

• The machining process uses a main spindle with 60 kW rating, a torque of up to 1,220 Nm and speeds of up to 2,850 rpm.

Highly efficient: the VL 8 vertical turning centre provides a step-up in performance when it comes to the machining of

large workpieces, such as components for HGV powertrains.

Well equipped: up to 12 turning or, optionally, 12 driven drilling and milling tools allow for the application

of a variety of machining processes in a single setup.



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• The turret accommodates 12 turning or, optionally, 12 driven drilling and milling tools.

• The workpieces are loaded into the carrier prisms of a conveyor belt and positioned via NC axis.

The pick-up spindle collects the workpieces from the lateral conveyor belt and takes them to the machining area. It is here that short travels ensure short chip-to-chip times. The machining process is a highly flexible one that allows for the use of a large variety of tools. It is also possible to link up two machines and a component turnover station to create a flexible production cell – for instance to machine the first and second sides of a workpiece complete in one cycle. Furthermore, the integration of a Y-axis in the turret allows for the “off-centre” machining of more complex geometries.

Precision is built in

Other features ensure the precision of the machining process. There is – for instance – the, where short distances

between the bearings, the use of high-precision separable bearings in a tandem-O-tandem arrangement and support bearings with length compensation, at the spindle end, provide for a particularly sturdy construction – an important basic condition for micrometre-precision turning processes.

A further help in maintaining precision is the integration of an inspection process into the cycle sequence. The required probe is installed outside the machining area and checks the workpiece while it is still clamped. Any corrective data is sent to the CNC control and the process adjusted accordingly. This guarantees consistent

high precision even during automatic operation. Other pluses in the production of components for commercial vehicles are the ease of operation and control of this machine. All service units are easily accessible, with tool changes just as easy to carry out, as the distance from operator to turret is just 400 mm.

The machine builders at EMAG have always put their trust in tried and tested components that are considered standard in manufacturing circles. This ensures that the VL 8 can be available within a few weeks – and at a very attractive price-performance ratio. In short, the VL 8 combines all the factors that make it possible to reduce component costs in commercial vehicle production: low investment costs, flexible and fast production processes and a sturdy machine construction.

For further details write to EMAG India Pvt Ltd, Technology Centre, No:17/G/46-3, Industrial Suburb, 2 nd Stage, Yeshwantpur, Bangalore - 560 022 Tel.: +91 80 4254 4400 or visit www.emag.com

Effortless: The workpieces are transported to the pick-up station in flexible carrier prisms mounted on the conveyor belt, making the resetting effort to accommodate workpiece diameter changes a minimal one.


“Today’s manufacturing scenario of commercial vehicle

production the key factors are - reduced component cost,

lower investment cost, flexible and dependable production

processes. To cater all these, a sturdy machine construction

is required without compromising the desired Q’s The Quality

and Quantity. Our VL 8 will address all these factors”

Krishna Prasad National Sales Manager, EMAG India

Auro offers FieldScout Light Meters from Spectrum Technologies

Spectrum Technologies, Inc., developer of 14 AE50 award winning products, is proud to introduce their new line of handheld Field Scout Light Meters.

Measure the energy that drives plant growth. Glass or plastic materials used in greenhouses may only allow 50% to 90% of the sun’s light to reach your plants. Field Scout Light Meters measure UV radiation

(250-400nm); Quantum light/ photosynthetically active radiation (PAR) from 400-700nm, and light levels in Foot-Candles.

For further details do write to Auro Electronics (India) Pvt, Ltd, 3749 Hill Road, Ambala Cantt. 133001 Tel: +91 171 2630970 Mobile:+91 9315101170 E-Mail: [email protected] Visit: www.auroindia.net


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AUTOMATION

Flat and Powerful: Igus Showcases the latest Generation of linear axes

Spindle-driven linear axis drylin SLT-BB and spindle linear module drylin SLW-25120 at the drinktec 2013

Vinayak Shetty

[email protected]

At the drinktec 2013 in Munich, igus GmbH is presenting the drylin SLT-BB, a spindle-driven linear axis with an even smaller installation height, and the drylin SLW-25120, a spindle linear module for high loads. Both models have been specifically designed for machines and plant used in the food industry, having to fulfil specific requirements concerning installed size and load-bearing capacities.

drylin linear axis SLT-BB: Innovative design for restricted design space

A minimum linear axis installation height of only 20 mm and an installation width of only 45 mm can be achieved thanks to the innovative lateral positioning of the spindle next to the linear guide system. The compact design weighs only 0.15 kg with a manual or motor drive both being possible.

With a maximum rotational speed of 1,000 rpm and a maximum linear speed of 1.5 m/min, movement can be fast as well as effortless and smooth. The ball-bearing spindle is available with trapezoidal or steep thread. Different thread gradients are available ex stock.

The bearing clearance can be adjusted seamlessly using the drylin T-miniature slide TWE-04-12. The high capacity, compact design size and lubricant-free operation of the drylin linear axis SLT-BB makes it ideal for automation applications in beverage

and food machinery including vending machines.

drylin SLW-25120: The Atlas among linear modules

The drylin SLW-25120 is a new product in the igus linear module range which combines compactness and an enormous load-bearing capacity. This spindle linear module can transport up to 1,000 kg radial load. An axial load of up to 250 kg is possible.

Despite this high load-bearing capacity, the module has a flat and compact design and is therefore easy and flexible to install. It is suitable for manual format adjustments as well as for electrical adjustment. It is connected to a motor either using a flange or coupling.

Equipped with a torsion-resistant aluminium double-shaft profile, a hard-anodised rail and thermoplastic high-performance plain bearings, this linear module guarantees high stability and a maintenance-free drive. The low-profile

and sturdy design make the drylin SLW-25120 ideal for demanding positioning tasks.

The drylin range for lubricant-free drive engineering

Since all the bearing spots of the drylin products manage without lubricant and are characterised by outstanding wear-resistance, they are simply ideal for use in soiling-sensitive applications such as those found in the food industry. In addition, their maintenance freedom guarantees significantly lower operating costs.

For further details visit www.igus.in

The “drylin SLW-25120” for high loads up to 1,000 kg. The new dry-running linear module from the SLW range is extremely sturdy and yet requires

little space thanks to its compact design height. (Source: igus GmbH)

The “drylin SLT-BB” from the new “slim line” generation of flat, lubricant-free linear axes. The lateral po-sitioning of the spindle makes a particularly small design height possible. In addition to the steep thread

shown, a version with trapezoidal thread is also possible. (Source: igus GmbH)


www.martonline.in40 December 2013www.martonline.in40 November 2013

AUTOMATION

Smart solution with frequency sweep technology – A level switch for all media

Fill levels must be recognized in countless storage, buffer and holding tanks in the process industry, food industry, and even in wind power plants or other fields. The level switches used are normally as different as the various media being monitored. With the CleverLevel LBFS/LFFS switch, Baumer has developed a true all-rounder that uses frequency sweep technology.

Figure 1: Level control in a container.

Figure 2: The CleverLevel series of level switches use frequency sweep technology and can reliably detect extremely different media. The readings

are not affected by adhesive substances or foam.

This method capitalizes on the fact that every material, regardless of its consistency, has a dielectric constant specific to that medium. This makes the new level switch suitable for practically all media, including liquids, granulates and even electrostatic media. At the same time, it is unaffected by adhesive substances or foams that may lead to switching errors with other technologies.

Furthermore, it can distinguish between different media. This makes the CleverLevel more than merely a replacement for the traditional vibrating fork used in level control. Configuration is possible using Teach-in. It is more convenient with Flex Programmer software, which enables visualization at the same time. The displayed information can be communicated to a higher-level controller if required and interpreted there in accordance with the operation

phase. Level detection is of great importance in the process industry. They monitor maximum and minimum values of material fill levels in tanks or as protection against overflow or dry operation. A number of limit switches are available, based on different technologies. The specific application determines the selection, because until now it was not possible to cover all applications with one level

switch. Things are different now. A new level switch that uses frequency sweep technology now proves to be a practice-oriented all-rounder for almost every conceivable medium.

The demands on level switches can vary considerably, depending upon application. There are therefore numerous application-specific factors to consider, such as foam formation, aggressiveness or flammability of the media to be

detected, adhesive substances, unfavorable installation conditions, the speed of the filling process and, naturally, the accuracy required. The widely used vibrating forks do not necessarily offer the best conditions. Some have quite large components that extend far into the material being measured.

Measuring errors can arise, since high viscosity materials tend to stick to these forks. Coarse granular media can

easily become lodged between the forks and also cause measuring errors. The forks and difficult to clean and liquid and powder substances require different versions. It was impossible to cover all applications with one level switch, until now.

Versatile sensor with elegant configuration

Now the Baumer CleverLevel series of level switches fill this gap. They are based on frequency sweep technology.

Figure 3: Supported by the FlexProgrammer, the CleverLevel series can perform even complex filling level detection tasks.



The sensor analyses the resonance frequency of the oscillating circuit affected by the dielectric constant of the medium below the sensor tip. This allows adhesive substance on the sensor tip or foam to be suppressed. High sensitivity over a large measurement range for dielectric constants from 1.5 to over 100 enables limit detection for all sorts of powders, granulates and liquids. And setup is easy.

The default setting already recognizes most media. The Teach-in function helps in case of doubt and more complex configuration becomes child’s play with the FlexProgrammer software, because the user can practically “see” the same thing as the sensor. The switching range can be adjusted as required to ignore foams in maximum or minimum monitoring, for example. The same applies if the sensor needs to ignore adhesive substances.

Tanks with liquid chocolate are a typical example. Even when empty, the sensor and container walls are coated with chocolate. When configured accordingly, the CleverLevel still switches only when the tank is really full or empty. Electrostatic adhesion, which must frequently be taken into account in the detection of powdery substances, can also be ignored by appropriate definition of the

switching range.

The simple, graphic configuration software really adds to the user-friendliness. For example, it is possible to observe the sensor’s internal signal while the thresholds are adjusted by mouse click within the graphic representation. This not only makes the configuration method intuitive and thus easily learned, but also considerably improves the reliability of the results, because they can be checked graphically at any time. This is also possible with extended setting methods that take medium conductivity into account, even if two media have the same dielectric constant.

Even different media in the same process line or process tank can be detected in order to differentiate the end product. For example, different types of fish sauce, different beers, etc. For this purpose a measuring signal can be output so that different dielectric constants through different media, foams or adhesive substances can be differentiated in the control. This makes it possible to detect if a medium is polluted with another medium, e.g. oil polluted with water.

Assessment of measurement results and maintenance planning

The information that is visualized with the help of software can also be transferred to the higher-level controller. It can then evaluate the measuring signal. It ultimately knows if the position of the switching point shifts because another medium is in the tank during flushing, for example. Dirt in the tank can also be detected in this way and cleaning can be scheduled accordingly.

Today, many application areas are dependent upon

this information. Wind power plants are a typical example of this, because “spontaneous” maintenance of lubricant containers is extremely costly and can only be carried out at unjustifiable expense. The same applies to locomotives, ships or mobile implements in agriculture, for example.

A further strength of the level-monitoring sensor is particularly evident in mobile tanks. It normally works with a response time of 0.1 sec., which permits high-speed filling processes and the precise maintenance of filling levels. However, this becomes a disadvantage if the tank is in motion and the contents slosh around. In such cases, a switching delay of up to 10 sec. can be set to avoid false signals due to tank movement.

Robust, hygienic, with ATEX approval

But the new CleverLevel series offers even more. The level switches can be installed in any position, even in rather inaccessible locations. The LED that signals the switching process is highly visible in all directions. The sensor works silently, compliance with protection class IP67 requirements is standard, and it is suitable for ambient temperatures between -40°C und +200°C.

Operation is also unaffected

by vibrations. For example, the latter is important if the level switch is placed close to a pump as protection against dry running. The small penetration depth of only 15 mm is also a positive feature in these circumstances. Flow and pressure are hardly affected. In addition, thanks to gap-free installation and the smooth tip, nothing can adhere to the sensor.

In addition to the industrial process connections, there are also versions with EHEDG approval and an ATEX version for Ex areas for applications with stringent hygiene requirements. There are countless application possibilities for this all-rounder level switch. The food and beverage industry can benefit from its possibilities as much as every other industry, from pharmaceuticals, chemicals, petrochemicals, and process engineering all the way to the water supply and wastewater fields. Further areas of application are found in wind power plants, mobile machinery, cereal mills or cleaning facilities and pumping systems.

For further details visit www.baumer.com/cleverlevel. You can also write to Baumer India Pvt Ltd, 201, C3-Building, Saudamini Complex, Bhusari Colony, Paud Road, Kothrud, Pune – 411038 Tel: +91 20 25286833 Email: [email protected]

Figure 4: Using the Flex Programmer software, the switching range can be adjusted as required to ignore foam during maximum or minimum monitoring.

Figure 5: There are countless areas of application for this fill level sensor all-rounder, such as filling liquid

chocolate.



MACHINE TOOLS


Kennametal to supply breakthrough KM4X Spindle Connection to Sumitomo Electric

Kennametal and Sumitomo Electric have signed a licensing agreement under which Sumitomo Electric will provide and support Kennametal’s new and advanced KM4X spindle connection solution to Sumitomo Electric customers globally. Sumitomo Electric, a leading global supplier of electric wire, optical fibers and cutting tool products, sees significant benefit for its manufacturing customers.

“The KM4X spindle connection is the most rigid system in the world today. This design enables manufacturing companies to maximize their capital investments. KM4X enables higher metal removal rates, which facilitates higher machine tool utilization and reduced cost per part, while increasing the manufacturer’s available capacity,” says John R. Tucker, Vice President and President of the Industrial Business Segment for Kennametal Inc. “Having an innovative technology partner like Sumitomo Electric supply the KM4X connection will create a powerful production advantage for manufacturing companies around the world.”

The spindle connection, the interface between the machine tool’s spindle and toolholder, has to provide the torque and bending load capacity compatible with machine-tool specifications. Cutting forces, particularly in roughing or machining high-strength materials, generate bending moments that will exceed the interface’s limits prior to reaching torque limits. By combining high clamping force and optimized interference levels, KM4X provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in

machining high-strength alloys and other materials. This means extremely high metal removal rates and more completed parts per day.

Advanced Materials Require Advanced Manufacturing

The continuing development of high-strength, lightweight materials such as titanium alloys, Inconel, and new aluminium alloys are eagerly sought by manufacturers in many industries, including aerospace and defence, energy, and transportation. These new materials present significant machining challenges in themselves. Add the competitive pressures in these global industries, and finding advanced manufacturing solutions becomes a top priority.

Machine-tool builders have responded with milling and turning centers that feature improved stiffness and damping on spindles and sizable machine structures and motors, all to provide the significant horsepower, torque and thrust forces required while minimizing undesirable vibrations that deteriorate part quality and tool life.

“In most cases, the tool-spindle connection determines how much material can be removed on a given operation,” says Doug Ewald, director, global product management, tooling systems at Kennametal. “This is because this interface must withstand high loads and yet maintain its rigidity. With the ongoing advances in cutting tools and machining centers, a spindle connection that makes the best utilization of available power possible is an important consideration to investigate early in production planning.”

“This is a full-system partnership between companies,” says John Jacko, vice president and chief marketing officer at Kennametal. “With the KM4X spindle connection and Sumitomo Electric’s innovative technology, there is no reason why companies should hold back investigating high-torque, high-speed machining capabilities for both existing and new equipment. This means achieving the maximum potential of your machine tools.”

For further details write to [email protected] or visit www.kennametal.com.

By combining high clamping force and optimized interference levels, KM4X™ by Kennametal provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining high-strength alloys and other materials.


Slimline: new AKD-N distributed servo drives

Legend: Out of the cabinet and hygienically pack-aged directly on the machine: The new distributed

AKD-N servo drives significantly reduce cabinet volumes and cabling effort.

AKD-N is the new distributed servo drive generation from Kollmorgen. The drive system comprises robust IP67-rated controllers, which are positioned in close proximity to the motor and supplied by a central power module located in the switchgear cabinet. The 11 mm diameter hybrid cable perfectly delivers the power as well as the fieldbus communication to the AKD-N. The controllers can therefore be operated directly in series via DC bus connection without an additional supply, covering power ratings of up to 4 kW. Safe Torque Off is integrated into the range as standard and can be deactivated on an individual or collective basis. Typical fields of application of the new devices include packaging machines and production systems in the food and beverage industry.

Out of the cabinet and hygienically packaged directly on the machine, the distributed AKD-N servo drives significantly reduce cabinet volumes and cabling effort - depending on the application in question, savings of over 80% can be achieved. In this case, Kollmorgen has opted against hybrid motor controller

units. The improved thermal properties of the controllers positioned in parallel but spatially separate prevent derating and, in comparison to directly combined solutions, offer 100% power. Furthermore, integrated combinations are predominantly focused on the motor type, which actually restricts the optimum design of an application, especially as these units are less flexible in terms of installation due to their design features. As the AKD-N is able to connect to rotary servomotors as well as direct drive linear and rotary types, there is maximum scope for design where performance and power are concerned.

Indeed, the distributed servo technology can be combined with the centralized format just as easily. Background: when it comes to distributed use, the only differences to be seen on the well-established AKD devices are on the outside. As such, there are no real surprises in terms of their function, programming and integration into the engineering system. Rather, Kollmorgen has fully converted the IP20 switchgear cabinet series into to a system offering a high protection class

– combined with intelligent AKD PDMM servo drives, as well as integrating drive-based PLC and motion control. Single cable technology is also available between the servo controller and the motor.

The advantages: reduced cabling, a high degree of flexibility through use of single standard cable for power and control across all feedback devices for overall decreased hardware costs as well as improved cleaning options for machines.

For more information visit: http://www.kollmorgen.com/hi-in/home/

Kollmorgen: single-cable connection technology further developed – resulting in 80% less cable required


www.martonline.in44 December 2013www.ibmart.in44

MART UPDATE

ELMEASURE Unveils Its New Company Logo

The world of energy management is changing and Elmeasure is evolving with it. It has been close to a decade since the journey of Elmeasure started and a lot has changed over those years. ElMeasure’s business has grown and evolved, through this process they have learned not to limit themselves. To reflect this new direction ElMeasure changed their logo to express who they are today and symbolize their dynamic future.

ElMeasure’s new look symbolizes a vibrant and growing enterprise with a clarity of purpose, a set of core values and consumer trust as their foundation. ElMeasure’s latest range of solutions inspires their new tag line “possibilities ... Infinite” because that is what they do at Elmeasure “provide infinite possibilities to meet each customer’s specific need”. ElMeasure’s

brand new logo is built around this theme and is going to be the new face of the company to signify their new identity and direction. A strong and more pronounced “E” symbolizes their renewed focus built on the strength of their past as they move to the future. The blocks moving out of the “E” and leaving a trail represent new and innovative solutions that are moving from a wired architecture to a wireless one.

In order to achieve lasting change in the field of energy management, ElMeasure must deliver solutions that are based on innovation and technology at an unprecedented speed and scope. ElMeasure is moving in different direction; wired to wireless, innovative solutions like BEMS. This prompts the change of logo to reflect them in the changed scenario.

Renishaw to co-chair India-UK Advanced Manufacturing Group meeting

Rhydian Pountney, Renishaw’s General Manager – ROW Sales Division, will co-chair the Advanced Manufacturing Group of the India-UK Joint Economic and Trade Committee (JETCO) which takes place in New Delhi on 9th December. The meeting is part of a wider JETCO programme that involves Dr Vince Cable MP, UK Secretary of State for Business, Innovation and Skills, the Indian Minister for Commerce & Industry Anand Sharma, and a trade delegation of UK businesses.

Mr. Pountney is responsible for business development in 10 of Renishaw’s overseas subsidiary operations, including India where he has overseen considerable expansion of the sales and marketing operation. He also recently won the Ambassador of the Year Award at the Insider South West International Trade Awards.

He said, “Renishaw is a highly successful UK exporter of high technology products

for the engineering sector with its own sales and manufacturing operations in India. I look forward to drawing on this experience to positively contribute to the JETCO Advanced Manufacturing Group which I will co-chair, and where we will discuss important areas of collaboration with our Indian partners, on specific projects in the Indian manufacturing sector, manufacturing skills and collaborative research.”

In addition to The Advanced Manufacturing Group (AMG), there will also be concurrent JETCO joint working groups discussing Education and Skills Development, and Innovation. All three groups will feedback to a plenary session attended by Dr Cable and Anand Sharma,

with Mr Pountney reporting on discussions from the AMG.

The India-UK JETCO was established on 13 January 2005 to further develop a strategic economic relationship following the Joint Declaration ‘India-UK towards a new and dynamic partnership’ between then Prime Ministers Manmohan Singh and Tony Blair in 2004. It was also conceived as a mechanism to develop business led vehicles to enhance bilateral trade and investment through business to business relationships.

Rhydian Pountney at Renishaw’s facility in Pune, India


“The world of energy management is changing and Elmeasure is evolving with it. Part of this process is a new logo design that is going to be the face of the company to signify our new identity and direction. Our new look symbolizes a vibrant and growing enterprise with a clarity of purpose, a set of core values and consumer trust as our foundation. Our latest range of solutions inspires our new tag line “possibilities ... Infinite because that is what we do at Elmeasure “provide infinite possibilities to meet each customer’s specific need”. We hope you will agree that change is necessary to grow and we envisage your continued support as we journey together in a world where the possibilities are truly infinite”. Babu T K CEO, Elmeasure India Pvt Ltd

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New FX15 series of flashing signal lights for use in Ex zone 1/2 and 21/22

R. STAHL is introducing a new signaling solution that withstands extreme environmental conditions, e.g. a wide operating temperature range of +70 °C down to -¬55 °C. FX15 beacons feature an enclosure manufactured from corrosion-resistant glass-reinforced polyester (GRP) that is designed to provide IP66/IP67 protection. All fixings are stainless steel. While the standard finish is natural black, painted units with epoxy coatings in red, yellow and blue are also available.

The beacons are supplied with a robust stainless steel lens guard as standard to protect the flame-retardant polycarbonate lens. The light source is a xenon tube providing a high light output. FX15 beacons flash at a rate of one per second. Lenses are available in seven colours (red, amber, green, clear, blue, yellow, magenta). The Fresnel lens that covers the well glass and houses the xenon tube produces a flash energy of 5 Joules, which ensures an

Flashing beacons for rugged conditions in hazardous areas

excellent luminous intensity of 49 cd for the clear version.

The beacons are suitable for use in a variety of onshore and offshore applications and environments, notably including marine use, the oil and gas sector, and skid packages. Operating voltages range from 24 and 48 VDC to 115 and 230 VAC. All units feature 3 x M20 cable entries that enable a variety of wiring and mounting options. FX15 flashing beacons are ATEX- and IECEx-certified, with other relevant approvals (GOST, PESO, Inmetro and North American listing) to follow soon. Essential installation material such as mounting brackets, straps, glands, tag and duty labels, along with replacement parts are

Robust flashing beacons from R. STAHL’s new FX15 series are suitable for rugged conditions in Ex zone 1/21 or 2/22 environments

also available at launch.

For further details do visit www.stahl.de or write to R Stahl Pvt Ltd, 9 Arcot Road, Lakshmi Nagar, Porur, Chennai - 600 116 Tel: +91 44 24766674 Email: [email protected]


Hitachi Variable Speed Drives from StrategiHitachi of Japan brings a wide, rugged range of AC drives upto 400 Kw ratings. These are available as simple v/f drives and also sensorless and flux vector drives.

Simple v/f drives (L300 and X200) are suitable for fan, pump, compressor applications and are available upto 132 Kw. Variable Speed drives offer significant power savings when used in such applications with paybacks in many cases being within a year. These drives also incorporate a special Hitachi algorithm to ensure higher energy savings in fan/pump applications.

The SJ700 series vector control drives have a industry leading starting torque of 200% at 0.3Hz in the SJ700 series. It can maintain 150% torque at 0Hz also. These drives can be used for position control applications with the addition of a feedback option card. The SJ700 series has an inbuilt braking circuit upto 22Kw and a built in EMC filter upto 55Kw. These drives have a

built in Over current and Over Voltage suppression.

The new latest WJ200 drives has many class leading features such as 200% starting torque. It has special algorithms to improve low speed regulation. It can be used for simple positioning applications with encoder feedback without the use of any add on card. It can be controlled with a pulse train input also. It incorporates a built in USB port for programming. The same drive can be used for both induction motors as well as brushless motors. All the drives are compliant with International ratings such as CE, UL, C-UL etc.

For further details write to Strategi Automation Solutions Pvt Ltd , Plot #

25/B, Doddanakundi Industrial Estate, Off Whitefield Road, (Behind Graphite India), Bengaluru – 560 048 Tel: +91 80 32329798/ Email : [email protected] Website: www.strategiautomation.com

www.martonline.in46 December 2013www.ibmart.in46 www.martonline.in46 September 2013www.martonline.in46 December 2013

The Industrial Visit to Explore the Standalone Discovery of Japan

Recently Japan, the wireless wonders planned to generate solar energy and so for building a solar power array on the lunar equator. The new exploration is to utilize the solar energy as the renewable energy on earth. Most of the countries are eagerly waiting to have a sneak peek at the future development that the country is going to open up before us.

India is believed to be one of the main benefactors of this project as it plans to generate electricity at a cheaper rate. Setting the target limit of 20 GW power by the year 2022, India is trying to encourage the small industries. Moreover the Govt. initiative in providing various subsidies is an upturn issue for the Indian industries.

An industrial visit from India is planned to introspect the growing technology in the solar project causing the enhancement of the bilateral trade issue between India and Japan. The group maximizes the limit of 30 members extendable by 3-4 members.

The project Luna Ring developed by Shimizu Corporation, a construction company is the unique one to invent this outbound technology. The panel project will place a solar power system on the array of lunar equator capable of

generating 13000 terawatt during the process and will send back the power to earth. The construction work is expected to be ended by the beginning of 2035 as that would initiate the project – as said on the company’s website.

The solar cell will hover round almost 11,000k.m as a belt on the lunar equator. The belt will have width having the distance from few kilometers to 400k.m. The robots run by the transmission wire for 24hrs will play a major role as ground leveling and excavation of hard bottom strata. The concrete would be covered with solar panel which will be connected through cables via wave. The energy beams directed from the moon will catch the station on earth to receive them directly.

The high potential cable will convert the electric power from lunar solar cells to the transmission facilities. High- energy-density laser will be beamed to the receiving facility. The 20k.m diameter antenna will be in used for transmission at the receiving end. For obtaining the accurate transmission a guidance beacon

from the earth would be in function. Materials needed for the construction as well as maintenance of the solar belts, will be transported along this route. The electric power cable will be directed by this transportation route. The auto operative plants will have the capability to resource itself from the lunar body and installing them. The cutting edge technology will necessitate the increase of energy thus reducing the utility of oil. After the massive destruction in the Tsunami and the earthquake that happened in the year 2011 it is a successful surge for alternate way to power.

The tour is jointly organized by Saraswati Industrial Services, Bangalore, India and CoCoRo World Co Ltd, Tokyo, Japan. For further details do write to [email protected], [email protected] or call Mobile 9845043202 .

HARTING’s successfully introduced Ha-VIS preLink® technology is now complemented by another product, the Ha-VIS preLink® Extender. This component of the innovative Ha-VIS preLink® cabling system enables the simple extension of transmission paths in data network cabling. In addition, it allows fire zones to be bridged and subscriber ports to be directly connected to the terminal block connector without the need for intermediate patching. It offers particular benefits for Broadcast TV Studio, Theatre, AV Multimedia or Theme Park installations.

Even unused cables can be reactivated and extended to the next required connection. The installer simply assembles the Ha-VIS preLink® termination module onto both ends of the cable to be extended. The terminated cable ends are then inserted

The Ha-VIS preLink® Extender enables simplecable extension for up to 10Gbit/s network cabling

into the Ha-VIS preLink® Extender. A flexible shield clamp transmits the cable shield potential. The Extender itself can be directly mounted on walls, in cable ducts or in a switch cabinet via two Ø 3.2 mm fixing holes. The small 15.6 x 13.2 x 65.7 mm (W x D x L) design permits installation even in cramped spaces.

The Ha-VIS preLink® Extender meets the transmission performance specifications for Category 6A pursuant to ISO/IEC 11801 Ed. 2.2 (2011-06). As a result, the structured cabling run can be used

for applications up to 10 Gbit/s, up to the maximum link length.

For more details write to www.HARTING.in

Torsten Ratzmann (center), Senior Vice President Production and Logistics, receives the award from Dr. Inga Michler (right), business correspondent

at the WELT Group, and Marc Schneider of Axel Springer Media Logistik, sponsor of the sustainability award.



HaasTEC India 2014 to Demonstrate Haas Cutting CapabilitiesPreregister for a chance to visit Haas US Facility

Haas Automation India is pleased to announce the next HaasTEC Open House will be held from 16th-19th January 2014, in Navi Mumbai. In keeping with previous HaasTEC events, the company will present several of its innovative, affordable CNC Machine tools, such as the dual spindle DS-30Y turning centre with Y axis, and the ever popular DT-1 Drill Tap machine.

All the Haas machines on display will be fully operational – In fact, the theme for this latest HaasTEC will be ‘Innovative Demos’: Haas machines cutting parts you haven’t seen before.

“At this HaasTEC, we want to demonstrate to visitors the power and versatility of Haas CNC Machine tools and their outstanding performance to price ratio. As our customers already know, it’s no longer necessary to spend a small fortune if, for example, you want to machine hard metals and complex shapes in 4 and 5 axes. Haas machines enable companies to cost-effectively produce high-precision parts, either in small batches or in production quantities.”

Terrence Miranda Managing Director, Haas India

Guests who pre-register on the company’s website http://www.haascnc.com/openhouse/ will be entered into a free draw, and the lucky four winners will be invited on an all-expenses paid trip to visit the Haas factory in Southern California, USA. As with previous HaasTECs, Haas Automation India’s industry partners will also support this event.

Easy-to-assemble shaft couplings for torques up to 110,000 Nm

Hard labour made easy

High screw tightening torques can become a real challenge during installation of large shaft couplings – especially where space is restricted. Mayr power transmission has therefore equipped the ROBA-DS disk pack coupling for high torques with an easy-to-assemble, positive-locking conical connection which operates at extremely low tightening torques. The five construction sizes in this series cover a nominal torque range from 22,000 to 110,000 Nm.

The handling of large couplings is hard labour, and should therefore be made as easy as possible for the technicians. Furthermore, ease of assembly for large couplings also represents an economic aspect. Many hours and unnecessary costs can be saved thanks to simple and fast assembly. In the case of the ROBA-DS with a conical connection, the flexible disk pack is connected, positive-locking and backlash-free, with attachment components such as hubs, flanges and sleeves.

Externally-conical bolts are pulled into

the conically-shaped bores of the attachments using tensioning screws, and the collar bushings of the disk packs are tightened. Due to this conical shape, forces are generated which radially, flexibly expand the collar bushings and attachments, and in this way guarantee the backlash-free connection of the disk pack.

Screw tightening torques drastically reduced

The new conical connection reduces the screw tightening torques to a fraction compared to conventional, frictionally locking designs, and this significantly simplifies installation and disassembly. Furthermore, the aggregates do not have to be moved for installation and deinstallation.

ROBA-DS disk pack couplings are extremely robust, resistant to high and low temperatures, and are torsionally extremely rigid and maintenance-free. They transmit the torque backlash-free and without wear, and compensate for axial, angular and radial shaft misalignments. On double-jointed designs, this component

permits extremely flexible variations in length between the two disk packs for adjustment to the shaft clearance. Disk pack couplings are extremely well-suited to applications with high torques thanks to their outstanding characteristics, and customer-specific hubs and sleeves ensure a high level of flexibility

For further details write to National Engineering Company, J-225, MIDC Bhosari, Pune – 411026 Tel: +91 20 27474529 Email: [email protected]

The positive-locking conical connection of the ROBA-DS disk pack coupling requires significantly lower screw tightening

torques compared to frictionally locking designs.


Robust RFID data carrier with extra-large memoryBalluff has presented a new generation of data carriers, up to eight times faster than the standard, with extra-large memory of up to 128 kBytes at the SPS IPC Drives trade fair. These drives work up to eight times as fast as the standard ISO 15693, making them the ideal choice for track-and-trace applications with high data volumes such as those used in assembly lines in the

automotive industry.

Built with FRAM technology, the data carriers are maintenance-free, require no

external energy supply and have virtually unlimited read/write cycles. Thanks to their high degree of protection (up to IP 68), they offer especially trouble-free communication with a high level of data security, even in difficult environments.

Powerful RFID controller BIS-V

Once the user has decided on a RFID controller from Balluff, the powerful Balluff signal processor BIS V is an ideal choice. It not only supports all the features found on new data carriers, but also significantly simplifies hardware and installation for users. The controller in the metal casing with IP 67 protection fulfills all requirements for industry-oriented design and comes equipped with USB as a service interface to PCs.

Balluff offers the device with a choice of Profibus, EtherCAT, Ethernet/IP or CC-Link

interface. Especially positive for users: up to four HF read/write heads (13.56 MHz) in accordance with ISO 15693 and ISO 14443 or LF read/write heads (125 kHz) can be connected in the front with plug-in connectors and are then automatically recognized. In addition, the RFID controller is the only device on the market to offer an IO-Link master port for direct connection of IO-Link-compatible sensors or actuators.

For further details visit www.balluff.co.in

Data carrier

Stainless Steel Cable Junction Boxes tested for Intrinsic Fire Resistance up to 50mm²

Today, an emergency power supply is required in many areas in addition to the general power supply for safety reasons. This includes buildings with public traffic, such as tunnels, airports, train stations, sports facilities, hospitals, malls, etc.

Particularly high demands are placed on the emergency power supply and the components used for it. In case of fire, they must ensure that functionality of the circuits is maintained over a defined period of time. Emergency lighting, lifts, smoke extractors, and alarms must remain operational for at least 30 or 90 minutes according to requirements so that people can leave the building and rescue forces can work.

Conformity with IEC 60670-22 must be verified for cable junction boxes. For example, this includes environmental requirements – moisture, protection from dust and environmental temperature, corrosion and mechanical stress – as well as electrical testing conditions. In order to meet fire protection requirements, electrical installation systems must operate for 30 or 90. They must resist temperatures of up to 1000°C.

Tunnel box: Intrinsic fire resistance E90 in XXL

Hensel has, once again, proven its expertise in electrical distribution systems with its tunnel box. Hensel is the only company to provide a solution for the connection of cables up to 50mm² with E90 intrinsic fire resistance. The so-called tunnel box was designed as a connection box for conductors from 16 to 50mm². Its field of application is where cables must be laid over long distances with intrinsic fire resistance, as is the case in tunnels, for example. By using cables up to 35mm², the tunnel box can also be used as a junction box. Connecting terminals consist of high temperature resistant ceramic in accordance with IEC 60 998-2-1.

The stainless steel boxes are powder-coated in RAL 2003 Pastel Orange and meet degree of protection IP 65. Attachment occurs via external keyhole drillings which facilitate wall mounting.

Communication junction box with E30 intrinsic fire resistance

The E30 communication box from Hensel is also new. The empty box is intended for the installation of connecting device for

telecommunications and equipped with cable entries on 4 sides. The mounting brackets for attaching the connecting device are already included in the scope of delivery. The connecting device for telecommunications are available as accessories for 10 or 20 pairs with both LSA connection technology and screw terminals. Cable entry is via elastic sealing membranes.

The robust fire protection box is impact resistant in accordance with IK 10 and meets degree of protection IP 55. Screw anchors for concrete, lime sandstone, bricks and clinker are included in the scope of delivery. The communication junction box is powder-coated in RAL 2003 Pastel Orange just like the tunnel box.


THE LAST LEAF

Dear All,

“Willpower is the key to success. Successful people strive no matter what they feel by applying their will to overcome apathy, doubt or fear” - Dan Millman.

I am reminded of these lines after viewing the video by Sandeep Maheshwari, which is quite inspiring. He is doing an exercise “Asaan Hai” in a very interesting way, that could bring in hope for the entire community and give direction to all who have lost one.

The recognition of Tarang Jain of Varroc Engineering as the Next Generation Entrepreneur at the recent ceremony of Forbes India Leadership Awards (FILA) was a fitting acknowledgement of his efforts to take India to global heights by virtue of foreign acquisition of manufacturing units across Mexico, Czech Republic, & China plants, signifying a BIG leap. Varroc plans to become a $ 4 billion size company by the year 2020. FILA also awarded Entrepreneur with a Social Impact to Ranjan Sharma - Founder & Director, IKSL for building a for-profit model that provides farmers with valuable information through voice messages. Sharma’s IKSL now covers the entire country and has a subscriber base of 20 lakh farmers. This could happen only through an approach of Innovation and Willpower.

I recently learnt about a company called Values Centered Innovation (VCI) – www.vcihome.com - run by William and Debra Miller. This couple from Dallas, Texas has migrated to India during the year 2000 n their sixties, and settled at Puttaparthi, near Bangalore. Their research is based on Creative and Innovative Thinking, and enabling everyone to innovate. This company is a global innovation enablement enterprise. They elicit the highest capacity of people at all levels to identify opportunities to make a meaningful difference, generate creative ideas, and produce beneficial, sustainable results. Their idea of Co-innovating with others is very unique and can indeed come handy in today’s industrial scenario, when simple solutions do not help to solve complex problems. Innovation means much more than just new products, services, technologies, and processes. To view innovation from a holistic perspective, they’ve identified 5 domains of innovation, each with a different aim. Often, an innovation in one domain requires complementary innovations in other domains “to make the whole thing work.”

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 Kabre Member, Editorial Advisory Board (EAB)


RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012-2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month

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