WPP license no MR/TECH/WPP-74/North/2019 License to post without prepayment Postal Registration No MCN/154/2017-2019 Published on 5th of every month Posting date: 7th & 8th of every months Posted at Patrika Channel Sorting Office, Mumbai-400001 Registered with Registrar of Newspapers under RNI No MAHENG/2011/37959 TOTAL PAGES 58 VOLUME | ISSUE | MARCH 2019| `50 WPP license no MR/TECH/WPP-74/North/2019 License to post without prepayment Postal Registration No MCN/154/2017-2019 Published on 5th of every month Posting date: 7th & 8th of every months Posted at Patrika Channel Sorting Office, Mumbai-400001 Registered with Registrar of Newspapers under RNI No MAHENG/2011/37959 TOTAL PAGES 58 VOLUME | ISSUE | MARCH 2019| `50 CUTTING TOOLS SHARPER EDGES AEROSPACE & DEFENCE FLYING HIGH THE INSIDE STORY SANDEEP SINHA, MD, CUMMINS INDIA, ON HOW HE IS BALANCING THE BS VI DEADLINE, WHILE SETTING THE COMPANY ON AN EXPONENTIAL GROWTH PATH Published by ITP Media (India) SpeedCore CARBIDELINE ChamferCut THE BEST FOR YOUR GEARS In gear production, high cutting speeds, precise geometries and extreme robustness are key aspects Our gear hobs and gear cutting systems have represented this for 100 years There is exactly one best solution for your requirements www.lmt-tools.com marketing@lmt-tools.co.in CONTENTS 16 THE INSIDE STORY SANDEEP SINHA, MD, CUMMINS INDIA, ON HOW THE COMPANY IS BALANCING THE BS VI DEADLINE, WHILE SETTING THE COMPANY ON AN EXPONENTIAL GROWTH PATH 26 CUTTING TOOLS: DRILLING & BORING THE INDIAN CUTTING TOOLS SEGMENT IS SEEING AN ENTIRELY NEW RANGE OF TOOLS WITH BUILT-IN SENSORS AND OTHER NOVELTIES 38 AEROSPACE & DEFENCE LANDMARK DEALS MARK INDIA'S AEROSPACE AND DEFENCE SECTOR AS MORE OEMS ANNOUNCE PLANS TO SET UP MANUFACTURING OPERATIONS IN INDIA 42 DIGITAL TRANSFORMATION SIEMENS AND MANUFACTURING TODAY SOUGHT TO ADDRESS SOME CRITICAL QUESTIONS ABOUT HOW SMBS CAN MOVE UP THE VALUE CHAIN 48 HEAVY ENGINEERING WITH CAPITAL EXPENDITURE ON THE RISE ACROSS MEGA INFRASTRUCTURE AND INDUSTRIAL PROJECTS, INDIA’S HEAVY ENGINEERING UNITS HAVE MUCH TO CHEER FOR MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com EDITOR'S NOTE BROADENING HORIZONS Jayashree Kini Mendes Mitalee Kurdekar MARCH CELEBRATES TWO MAIN EVENTS: SAFETY Week and Women's Day Both can be related to the manufacturing sector Safety is seeing an increasing focus as no company/plant would like its manpower to retire hurt It also tarnishes the image of the company, a blot that cannot be erased for a long time to come More manufacturing companies have gone to great lengths to increase safety measures at their site Besides training employees and insisting that they follow rules to stay safe, there are intricate algorithms devised to ensure they are followed These are not restrained to your usual safety hats and shoes alone They are elaborate methods to stay alert for any sudden event that could cause an unforeseen catastrophe And rightly so The second event, Women's Day, is celebrated the world over In the world of manufacturing, women have stormed the shop floor—hitherto a stronghold of men It's not uncommon to find women working shifts and doing the same kind of jobs that men did for many years (they could, however, be excluded from heavy lifting) Women holding engineering degrees and diploma holders are increasingly seeking jobs in manufacturing, not because it's lucrative, but because it offers a sense of satisfaction that they have entered a domain that, wittingly or unwittingly, kept them away for eons And believe me, they are proving to be an asset They are found to be more diligent, enterprising, and disciplined I second that Both these events should be celebrated with much fanfare in the manufacturing sector Safety Week and Women's Day should be encouraged and companies that so should be given a hearty pat on the back On our part, we heartily support both these days and will strive to write more detailed reports on them going forward Jayashree Kini Mendes Editor jayashree.mendes@itp.com ManufacturingToday DECISIVE TOOL FOR MANUFACTURING EXCELLENCE Volume | Issue | March 2019 ITP MEDIA (INDIA) PVT LTD Notan Plaza, 3rd floor, 898, Turner Road Bandra (West), Mumbai - 400050 India T +91 22 6154 6000 MANAGING DIRECTOR: S Saikumar GROUP PUBLISHING DIRECTOR: Bibhor Srivastava EDITORIAL EDITOR: Jayashree Kini Mendes T +91 98905 33061 jayashree.mendes@itp.com EDITOR: Mitalee Kurdekar T +91 22 6154 6040 mitalee.kurdekar@itp.com ADVERTISING DIRECTOR: Sanjay Bhan T +91 98457 22377 sanjay.bhan@itp.com BUSINESS HEAD: Hafeez Shaikh T +91 98331 03611 hafeez.shaikh@itp.com STUDIO HEAD OF DESIGN: Milind Patil SENIOR DESIGNER: Vinod Shinde CONTRIBUTOR: Sanjay Bandre PRODUCTION DEPUTY PRODUCTION MANAGER: Ramesh Kumar ramesh.kumar@itp.com CIRCULATION DISTRIBUTION MANAGER: James D’Souza T +91 22 6154 6032 james.dsouza@itp.com COVER IMAGE: Studio Amir DISCLAIMER The publishers regret that they cannot accept liability for error or omissions contained in this publication, however caused The opinions and views contained in this publication are not necessarily those of the publishers Readers are advised to seek specialist advice before acting on information contained in this publication, which is provided for general use and may not be appropriate for the readers’ particular circumstances The ownership of trademarks is acknowledged No part of this publication or any part of the contents thereof may be reproduced, stored in a retrieval system or transmitted in any form without the permission of the publishers in writing An exemption is hereby granted for extracts used for the purpose of fair review Printed and Published by Sai Kumar Shanmugam, Flat no 903, Building 47, NRI Colony, Phase – 2, Part -1, Sector 54, 56, 58, Nerul, Navi Mumbai 400706, on behalf of ITP Media (India) Private Limited, printed at Indigo Press India Pvt Ltd., Plot No 1C / 716, Off Dadoji Konddeo Cross Road, Between Sussex and Retiwala Ind Estate, Byculla (East), Mumbai-400 027, India, India and published at ITP Media (India) Private Limited, Notan Plaza, 3rd Floor, 898, Turner Road, Bandra (West), Mumbai - 400050 India EDITOR: Jayashree Kini Mendes WRITE TO THE EDITOR Please address your letters to: Editor, Manufacturing Today, 898 Notan Plaza, floor, Turner Road Bandra (West), Mumbai - 400050 or send an email to jayashree.mendes@itp.com rd Please provide your full name and address, stating clearly if you not wish us to print them The opinions expressed in this section are of particular individuals and are in no way a reflection of the publisher’s views 10 MARCH 2019 | Manufacturing Today Published by and © 2019 ITP Media (India) Pvt Ltd RNI No: MAHENG/2011/37959 www.manufacturingtodayindia.com Perfect as a whole And in every detail With CNC machining centres and turnkey solutions from CHIRON With the concentrated development know-how of the Precision Technology Center For µ-accurate dreams made of stainless steel, titanium, gold or platinum CHIRON India Machine Tools Private Limited Bangalore, India Tel +91 80 4905 6490 info@chiron-india.com www.chiron-group.com ADVISORY BOARD Our distinguished advisory board has been assembled to help guide Manufacturing Today to become even more representative of its community Members have been invited from the highest levels of the industry to ensure that the magazine continues on its path of success Kishore Jayaraman, President, Rolls-Royce South Asia Manish Kulkarni, Director – Strategy & Business Development BDB India N Tarachand Dugar, President, All India Manufacturers’ Organisation (Also chairman, Dugar Group) Pradeep Bhargava, Director, Cummins India Raj Singh Rathee, Managing Director, KUKA Robotics India Rajesh Nath, MD & CEO, German Engineering Federation (VDMA), India Robindranath Som, President, Nickunj Eximp Enterprises Sandeep Balooja, Managing Partner, S&L Consultants Satish Jamdar, Chief Mentor and Advisor, American Vision SM Bhat, Managing Director, Ador Welding Suresh KV, Country Head, ZF India Dr Wilfried G Aulbur, Managing Partner, India, Chairman, Middle-East, Head, Automotive Asia, Roland Berger Strategy Consultants Subscription form Duration You Pay year (12 issues) Rs1000/- Please use BOLD / CAPITAL LETTERS ONLY Mr/Ms: _ (First name) (Middle name) (Last name) Designation Company Address1 Address2 Address3 City: _Pin code: State: Tel: Fax: Mobile: _ Email: _ Cheque/DD No _ Dated Favouring ITP Media (India) Pvt Ltd Drawn on Bank Please use bold & capital letters only l The mode of payment should be cheque/demand draft favouring ‘ITP Media (India) Pvt Ltd’ Please write your name and address on the back of the cheque/demand draft l Orders once placed will not be terminated or transferred l Please allow a minimum of weeks to process the order Subscribe to MANUFACTURING TODAY by completing the form and sending it to: Subscription Department ITP Media (India) Pvt Ltd, Turner Road, 898 Notan Plaza, 3rd Floor, Bandra (W), Mumbai-400 050 India For further queries write to: james.dsouza@itp.com | Tel:+91 22 6154 6006/6000 l l 12 MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com DIE & MOULD “The company has diversified its product portfolio and is continuously increasing its market penetration in domestic as well as international markets.” – Manav Kapur Products made in India are not only technologically advanced but also made of good quality enormous potential in the coming years Talking about our company AMPL India, high quality and high precision are the two pillars which we strongly abide While the changing technology trends in the vertical, integrated approach in the overall production, improved tool room management systems are the key factors for speeding up the growth status of this industry.” Manav Kapur, managing director, Steelbird International, says, “The company has diversified its product portfolio and is continuously increasing its market penetration in domestic as well as international markets with its innovative auto components, and Steelbird’s tyres and tubes are already doing well in entire north India, including UP, MP, Punjab, Haryana, Delhi-NCR, Kerala and Northeast Also, Steelbird International already complies various quality standards such as ISO/TS 16949:2009; OHSAS 18001:2007; ISO 14001:2004; ISO 9001:2008, now, it is working in collaboration with Japan’s leading manufacturer of rubber components and industrial materials, Fujikura Rubber As Fujikura is competent with R&D facilities, marketing and sales is the core strength of Steelbird, which mean the two brands are the best fit for each other This strategic partnership is a big boon for the market as well.” RESEARCH & DEVELOPMENT In the past decade, there has seen substantial growth of Indian companies not just nationally but also globally Products made in India are not only technologically advanced but also made of good quality “Currently we at AMPL India not have a formal R&D setup, while through R&D we firmly believe that great products are created We are focusing to develop a stateof-the-art R&D setup in house in the company itself to turn up more progressively to consistently deliver the right kind of product at right price while scaling up the production and meeting the expectations and delivery for our customers Additionally at this point of time, we follow standard parameters such as 5S, Sigma, Kaizen, and various other lean management parameters to ensure that we the right justice with our customers serving them premium quality plastic furniture,” adds Aggarwal Moiz Gabajiwala, CEO, Zephyr Toys, avers, “We not have a period-specific budgeting mechanism on the R&D part but instead focus on a product and product line based budgets for R&D Certain periods demand higher revenue pumping into the R&D team over others To reach an R&D budget we consider the value per unit and units of expected sales along with the sales channel and the competition Another factor that comes in play is the gut feel A product and numbers might not support the budget provided but instead, the expectations and length of product life cycle might be a bigger factor Rounding off we first 44 MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com DIE & MOULD ECONOMIES OF SCALE REDUCE THE COST, BUT WHEN MARKETS DEMAND A LARGER VARIETY THEN THE PRODUCTION LOTS ARE SMALLER decide a certain value that we want to spend on a product/range or and then go ahead from there.” COSTING CUES Cost competitiveness through shorter run times and productivity improvement are key deliverables Geared toward continuous improvement, the agile methodology can greatly increase prospects for cost competitiveness and success Increased flexibility, productivity, transparency and higher quality deliverables through better technology always kicks in to deliver the best results in the shortest amount of time Citing examples from AMPL India, high tech driven machines efficient in terms of electricity consumption as well as productivity enhancement, right kind of mould, skilled labourers give benefits of better and timely output, cost effectiveness and a quality product so that they can sustain and grow meeting their customers’ expectations “Shorter runs have now become the norm This is due to the fact that today we have a lot of options and alternatives With shorter runs, the production becomes more expensive and ultimately this impacts the cost to the end consumer Thus the product has less value and the cycle continues In our industry the run lots or the pieces per production lots are small, that is why the similarity of products is extremely important Of course, economies of scale reduce the cost, but when markets demand a larger variety then the production lots are smaller,” explains Gabajiwala However to keep costs down and to gain the benefits of economies of scale, they focus on keeping the production process similar There is a quick and as minimalist change as possible to a production line for a changeover This gives them a little bit more productivity for a slightly lower cost over a complete www.manufacturingtodayindia.com “AMPL focuses on innovation tapping growth prospects with government’s focus on manufacturing for the die and mould industry.” – Sushil Aggarwal Die and moulds are crucial to industries that have quick turnarounds Cost competitiveness through shorter run times and productivity improvement are key deliverables Manufacturing Today | MARCH 2019 45 DIE & MOULD change of production style and process For example, they have multiple sets of MECHANIX, like MECHANIX 1, MECHANIX 2, MECHANIX Basic etc Each share similar parts and similar production process, this enables us to make smaller lots of each set and still be able to make multiple sets And we manage to retain the benefits of Economies of scale purely due to the fact that the inventory is interchangeable and the production process is either extension or reduction of another item with almost no change Make in India will surely open investment doors 46 MARCH 2019 | Manufacturing Today MAKE IN INDIA Today, India’s credibility is stronger than ever as the country has a huge density, demographic dividend, huge consumption capacity and increasing market demand etc Initiatives in alignment with GOI's agenda towards the push for 'Make in India ' initiative encourages private initiatives and MSME Entrepreneurs to deliver sustainable products that are inclusive of meeting the global standards and make globalization a positive force to tentatively move and encourage the capital-goods imports In the coming years, there is visible momentum, energy and optimism Make in India will surely open investment doors and according to me world’s largest democracy is well on its way to become the world’s most powerful economy Manufacturing currently contributes just over 15% to the national GDP The aim of this campaign is to grow this to a 25% contribution as seen with other developing nations of Asia In the process, the government expects to generate jobs, attract much foreign direct investment, and transform India into a manufacturing hub preferred around the globe “The make in India campaign will lead to an increase in exports and manufacturing An increase in exports will improve the economy and India will be transformed into a global hub of manufacturing through global investment using the current technology It will lead to the creation of many job opportunities It will welcome more FDI Since the government had promised to improve the ease of running businesses in India, it is going to attract many FDI Through Make in India more companies are looking to set up factories, a unit known as “Invest India” is in the process of being put to place This unit will be under the department of commerce and will be available any time to make it easy to carry out regulatory clearance within the shortest time possible ensuring that businesses are run in India easily,” says Gabajiwala With industries looking at CNC machining, rapid tooling, high speed machining and super smooth surface technology in manufacturing and focusing on quality it certainly seems that the future of this industry is indeed bright And therein lies India’s competitive edge www.manufacturingtodayindia.com a i d n I n i t n i r p t o o f r Ou 018 Pub 2016-2 N/146/ ai-400001 mb No MC ation Office, Mu Registr Postal nnel Sorting ment Cha t prepay Patrika ST RY t withou Posted at IN DU TIO N e to posry months 387 UC ens TR eve 18 Lic 008/33 CO NS RTH/203rd & 4th of MAHENG/2 TH E 77/NO FO R e: No NC E CH/WPP- ting dat under RNI LL IGE s MR/TE nth Pos IN TE nse no vious mo Newspaper ES S BU SIN WPP liceevery pre istrar of TS & 30th of red with Reg OJ EC IS, PR Registe ALYS of number Total 84 pages HED PUBLIS 68 es of pag ` 50 ber 18 | ST 20 num Total GU 20 | AU 018-20 ue 08 N/99/2 mbai-40000Vol 10 | Iss Mu n No MC istratio ting Office, Sor tal Reg nt Pos Channel rika payme hout pre ted at Pat post 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is d building velopmens an tige Gr ip of de D, Pres t locations l aspects and townsh CM , SEZs ominen to nove Razack Irfan oosing pr ered him ch parks, to ch ct has ve hotels, te il, in ta st This in such as re SMALL E H T O T TE BIG SALU tion innova m and ia) ia (Ind idealis ITP Med ed by iration, Publish g insp bratin licitations le ce of dition sions and fe tra e us th inued tations, disc 18 cont en rum 20 rough pres th sign Fo en De The iG G SETTIANGENDA TH E A CLO SER THE K AT LOO d by ITP Publishe SU S CCES IE STOR INDU S OF STRY PION 8-2020 Office, 42/201 ting MCN/2Channel Sor n No istratio at Patrika ted tal Reg nt Pos month Pos payme us hout pre ry previo /46040 post wit st of eve HENG/2012 to nse h &31 No MA e: 30t 18 Lice RNI orth/20 Posting datpers under P-76/N CH/WP vious monthar of Newspa MR/TE pre istr nse no of every with Reg WPP liceed on 27th Registered Publishai-400001 Mumb ng Aligni d ess an busin in care health Total (India) Media FAR Y SO E N R JOU THE IS DIGITAL OF EROS NT ON GH, CEO STME N LULLA SIN LLION INVE WI RISHIKA THE $50 MI LP EROS NOW NT HE CONFIDE SHOWS WILL ALLS L EB ORIGINA TTLE FOR EY T BA THE OT • Vol 48 pages om india.c otelier www.h URE L FEAT SPECIAALLENGES LITY QUA KAIZEN ATION OF APPLIC N OPINDIIOCARE OF MO IMPACT India 70 PAGES TOTAL | `50 201 | AUGUST RING FACTU MANU CENTRES TECH EDGE S RING L BEA RY O STRIA INDU NEW TERRIT TECH INTO 18 st 20 Augu • `50 11 Issue UE E | ISS VOLUM 84 20 18-20001 98/20 | `5 MCN/ mbai-400 st 201 Mu n No |Augu istratio Office, Issue tal Reg l Sor ting e 10 | nne nt Pos Volum payme rika Cha hout pre ted at Pat post wit s Pos ense toevery month /34648 Lic /2009 h/2018 7th of /Nort date: 6th & MAHENG PP-73 I No CH/W Posting under RN rs MR/TE month nse no of every Newspape WPP liceed on 4thRegistrar of Publish red with Registe EERS of number Total pages 019 2017-2 00001 N/154/ ai-4 n No MCOffice, Mumb istratio tal Reg l Sorting ment Pos Channe t prepay at Patrika t withou Posted to pos ry months 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AHEA PRESEN INDIA, O, MD,TATION, IR RA SUDH TRANSPORMPANY’S RDIER HIS CO SING A BOMBA ATES ON LE IN INFU ERN OD OR M ELAB ARRING RO TUM IN URNEY ST MOMEN RAIL JO OUS WED RENE A’S AMBITI INDI Published E SIGN TALE D N U O R A TURNA D LLEGE AN ICAL CO STAINABLE SU JALI MED , GEETANHOSPITAL SELF OR CT 0-BED IVE DIRE , EXECUTAKING THE 1,15 ARWAL M ANKIT AGEPS TOWARDS ON ST L, ITA s month 013/52810 HOSP ry previou HENG/2 RUL ed by Publish Media (India) guide finitive The de Volum ISE G PREM TIN THE CO-CREA OF SION, S, OFES CT THE PR ARCHITE T S OF ABLE R AT CN INDIA NE LIVER G IN RE DE GING PART EVOLVIN NA THE ME E IS YOND RK AR, MA ITECTUR BE GOING CHANDAVA HOW ARCH PREM LIGHT ON S SHED IONAL’S TERNATNIOR IOTT IN SE MARR L WANG, OF GLOBAL MICHAE ENT HEAD PACIFIC IN CONT N FOR ASIA T HOW OU SIG LS IS DE TELS , SPEL REGION TURE OF HO THE FU REDEFINED BEING ES R U O Y R E ORD NOW Y P O C today’s re for furnitu ; Office kspace g wor changin ient AV g ing effic at gr -workin Inte ? oes co D s; offices system itional al pages 56 Tot ge trad | `50 2018 challen gust 12 | Au t emen manag ilities and fac spaces ercial comm essful cc su to ) (India Media ia) dia (Ind ITP Me MA h of eve on 25t under RNI No lished s spaper 019 Pub 2017-2 istrar of New Reg N/265/ No MC istered with Reg istration tal Reg ai-400001 nt Pos payme Office, Mumb pre out ting post withChannel Sor nse to 18 Lice ted at Patrika orth/20 Pos P-75/N s month viou CH/WP MR/TE of every pre th nse no WPP licedate: 29th &30 Posting d by ITP Publishe MI D by ITP Issue e5| Publish dia ITP Me ed by (India) For subscriptions, please contact: James Dsouza Tel: 022-61546006 Email:james.dsouza@itp.com GOING STRONG WITH CAPITAL EXPENDITURE ON THE RISE ACROSS MEGA INFRASTRUCTURE AND INDUSTRIAL PROJECTS, INDIA’S HEAVY ENGINEERING UNITS HAVE MUCH TO CHEER FOR BY MITALEE KURDEKAR 48 MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com SPECIAL FEATURE HEAVY ENGINEERING THE HEAVY ENGINEERING INDUSTRY IS IN A buoyant mood With a spate of mega projects on the anvil, capital expenditure – particularly with regard to infrastructure building and capital intensive manufacturing sites including metro rail, highways, expressways, seaports, airports, refineries, and oil & gas installations – is on the rise Naturally, the positive impact of this is being seen across the heavy engineering industry, with demand growing at a steady pace And heavy engineering manufacturers are responding rather well More importantly, the industry has matured a great deal in recent years Traditionally viewed as the barometer of any vibrant economy, the Indian heavy engineering industry feeds the demand of many critical, growing sectors of our economy Over the past five years, it is said to have grown at an average rate of 12% due to a variety of factors like a steady rise in infrastructure development, growing industrial production, as well as a slew of government initiatives like liberalisation of FDI participation to 100% in select industries, and rationalisation of the indirect tax structure and customs levies Favourable conditions have attracted many foreign players to this industry, with the purpose of meeting unfulfilled or new domestic demand, in addition to taking advantage of India’s ideal location when it comes to exporting their products to other markets around the world This has also encouraged local players to diversify and also engage in new technological developments Further, the appointment of the Engineering Export Promotion Council (EEPC) as the nodal agency to spearhead the export efforts of Indian engineering units, coupled with a comparatively weaker rupee, has helped increase the exports of engineering goods Even more encouraging is the The Indian heavy engineering industry feeds the demand of many critical industries such as oil & gas www.manufacturingtodayindia.com Manufacturing Today | MARCH 2019 49 SPECIAL FEATURE HEAVY ENGINEERING fact that more than half of such exports are to developed countries like the US and others in Europe “The heavy engineering industry has graduated to a level where we, as a country, have created the capability to manufacture heavy engineering equipment required for all the core strategic sectors.” – GK Pillai “India’s engineering R&D market is expected to increase from $28 billion in FY18 to $42 billion by FY22.” – Vikram Amin India’s heavy engineering industry is expected to grow by around 25% in the next few years 50 MARCH 2019 | Manufacturing Today OPTIMISTIC OUTLOOK Key players in India’s heavy engineering industry are optimistic about future growth prospects This is evident from the intent of most units to invest in R&D, in turn adding value to customer projects These investments have only increased with the entry of international players, who bring their global technologies into play, forcing domestic players to indulge in quality improvement initiatives and diversify with new production capacities, rather than stay behind in this competitive race There are examples of domestic majors leading this way with the likes of L&T and Thermax entering the power equipment and power utility segments With so much happening, India’s heavy engineering industry is expected to grow by around 25% in the next few years, capitalising on the favourable investment climate within the country GK Pillai, MD & CEO, Walchandnagar Industries, states, “Over the last 40 years or so, the heavy engineering industry has graduated to a level where we, as a country, have created the capability to manufacture heavy engineering equipment required for all the core strategic sectors like defence, power, nuclear power, automobile, steel and mining Various critical manufacturing technologies have been indigenised coupled with countless advances in metallurgy and we are near the goal of self-reliance.” Sounding upbeat about what the future holds, Pillai adds, “In the coming few years, the demand for GOING FORWARD, STAKEHOLDERS ARE EXPECTING THE ECONOMIC CLIMATE TO BE CONDUCIVE FOR ROBUST GROWTH the heavy engineering industry is expected to have double digit growth, primarily driven by the localisation of more items in the strategic sectors like defence, nuclear and aerospace The Government’s push for Make in India is going to bear more fruits in the coming few years.” FAVOURABLE CLIMATE Going forward, stakeholders are expecting the economic climate to be conducive for robust growth The steady flow of demand coming from most user industries is a definite indication of the same Leading the way is the infrastructure segment, with fresh investment coming in industries like petrochemicals, automotive, power, mining etc As Vikram Amin, executive director (sales & marketing), Essar Steel India, says, “The turnover of India’s capital goods industry is expected to in- www.manufacturingtodayindia.com PAIRED WITH POSITIVE POLICIES During 2016, the Government announced the National Policy on Capital Goods with the laudable intention of trebling the production of capital goods and raising employment opportunities in this industry by 2025 This is closely linked to other major Government initiatives like Make in India, Heavy Industry Export and Market Development Assistance Scheme, and Skill India, and has proved to be a tremendous encouragement for the heavy engineering OEMs The above has not only benefitted domestic players, but also attracted global companies to make investments with regard to the setting up of production facilities in India Alluding to this, Rao suggests, “Bombardier is actively collaborating in the Make in India programme by delivering rail vehicles, products and solutions that are developed locally, for both Indian and foreign markets Bombardier also supports the Indian Government’s vision on Skill India with locally-grown talent now delivering projects for both India and export, as well as supporting the Clean India Movement by regularly arranging clean up drives in Vadodara, India.” Export promotional policies are another form of encouragement for the industry Pillai states, “Though the Indian engineering industry has opened up for the global markets, the scale of operations is still very low The exports are yet to ramp up However, with more foreign companies coming to India and setting up manufacturing bases in the country, the possibilities of exports increasing from these manufacturing companies is definitely going to rise At Walchandnagar Industries, we are equally buoyant about this www.manufacturingtodayindia.com SPECIAL FEATURE HEAVY ENGINEERING crease to over $115 billion by 2025 This remarkable growth in the last few years has been driven by increased investments in infrastructure and industrial production In addition, the Make in India policy is being carefully pursued to achieve greater self-sufficiency in the area of defence equipment including aircrafts India’s engineering R&D market is expected to increase from $28 billion in FY18 to $42 billion by FY22.” Explaining that favourable conditions like robust demand and encouraging policy support have created an environment for a higher investment in the heavy engineering space, Sudhir Rao, MD, India, Bombardier Transportation, professes, “Bombardier aims at investing in India with a long-term perspective in manufacturing facilities, local talent, developing local supplier base, new technologies as statutory in the projects which Bombardier is pursuing in the Indian market We believe in the Indian workforce and continuous training and share our indepth, cutting-edge knowledge and global expertise with our partners in India.” development and are hopeful of getting into reputable partnerships, which will enhance the manufacturing capability, quality and, in effect, increase our export potential for heavy engineering products.” FACING CHALLENGES In order to take advantage of emerging opportunities in the market, and also to meet their own as well as various stakeholders’ targets, OEMs in the heavy engineering industry have to face many challenges First and foremost on the list is adapting to new technologies and process automation, which foreign counterparts are working with and eager to introduce in India These are vital for achieving internal targets of cost reduction, risk management and, more importantly, for profit enhancement, which is necessary for further R&D and investment High cost of financing is another challenge that the industry is faced with, and the Government – with various fiscal and monetary measures – would like to support the players Product development is time consuming, yet an important challenge that needs to be addressed in the wake of all of the above However, with the assistance of computer-aided design solutions and simulation techniques, time involved in product development has been cut down and early market in- “Bombardier aims at investing in India with a long-term perspective in manufacturing facilities, local talent, developing local supplier base, new technologies as statutory in the projects which Bombardier is pursuing in the Indian market.” – Sudhir Rao The favourable climate has attracted global companies like Bombardier to make investments with regard to the setting up of production facilities in India Bombardier is developing certain products – like the MOVIA Maxx – in India Manufacturing Today | MARCH 2019 51 SPECIAL FEATURE HEAVY ENGINEERING DOMESTIC PLAYERS HAVE STARTED CONSIDERING PARTNERSHIPS, WHILE ALSO DIVERSIFYING THEIR PORTFOLIOS High cost of financing is a major challenge that the industry is faced with 52 MARCH 2019 | Manufacturing Today troductions are possible Speaking about the product development cycle, Pillai points out, “Certain projects for core sectors such as defence take longer due to developments, try-outs, establishing the process parameters, etc However, once the development is complete, the cycle time is established for repeat orders Through continual improvement in processes, augmentation of resources, and close project management, the cycle time reduction is achieved.” Acknowledging the contribution of their standard processes and skill-sets, Rao proclaims, “Our employees in India, which is our biggest strength, are fully trained on special tools and processes to ensure standard quality across Bombardier What started as rail engineering experts from across the globe moving to India to set up a manufacturing site, has rap- idly evolved into a truly Indian production and engineering hub with high international standards.” Amin makes a point about the importance of the right materials by saying, “The steel industry has undergone a major metamorphosis over the last decade While, on one hand, it has to meet the changing demand of the customers, on the other, it has to contend with the competition from the alternative materials set to replace steel Hence, it is a continuous challenge for the steel industry to continuously evolve and remain ahead in the learning curve.” THE ROAD AHEAD With the entry of many foreign players, the heavy engineering industry is surely getting crowded Therefore, it is encouraging that domestic players have started considering partnerships, while also diversifying their portfolios Also, it may prove to be profitable for OEMs to acknowledge each other’s relative strengths in these partnerships, so as to consolidate their product platforms in a manner that will bring value to their customers The Government, on its part, could certainly help OEMs with tariff benefits like indirect levies, SEZ and FDI policies, so that they can take their businesses to the next level Given the heavy engineering industry’s importance to the economy at large, this would be a welcome move Having said that, all the concerned stakeholders seem to already be doing their best to keep the current momentum going As a result, things are certainly looking up for this all important industry www.manufacturingtodayindia.com INTERVIEW WALTER TOOLS MAKING A MARK KIM SEIDELMAN, APAC REGIONAL PRESIDENT, WALTER, AND BRAJESH KUMAR, MD, WALTER TOOLS INDIA, HAVE BEEN WORKING QUIETLY AND STEADILY TO BRING IN ADVANCED TOOLS, NOT TO FORGET THE INTENSE R&D THE COMPANY IS INVOLVED IN What are some of the recent innovations to happen in cutting tools globally? Seidelman: I would like to talk about Tiger·tec Gold range, which has is an innovative coating technology using ultra low-pressure CVD coating process Globally there are a lot of companies, including Walter that are working on various SMART and/or connected tools using sensors to gather data and transmit or talk to machine tools or other devices We are working on various research projects with a university in Germany on such connected tools Another innovation is our X·treme Evo/DC160, which is a range of solid carbide drills This can be used universally in three different ways: In all ISO material groups It is designed for a variety of applications such as inclined entries and exits, drilling holes close to the edge of the workpiece or convex and concave surfaces It is also intended for use with all machine concepts As a first step, Walter is bringing out the X·treme Evo in variants and × Dc without internal coolant and 5, and 12 × Dc with internal coolant There's a lot going on that is not related to products but more about innovation in data We’ve got an entire selection of standard products, around www.manufacturingtodayindia.com 45,000+ of line items of standard tools now available with fully attributed data available for our customers and for our channel partners You have introduced a new range of milling tools, Xtra·tec XT How different are they from earlier ones? Will this be made available in India too?? Kumar: The Xtra·tec is a successful product from our products basket We regularly fine tune our products to cater to the challenges our customers are facing XT is extended technology Along with carbide coating, we also look into the design and that makes a huge difference to performance of the tool We always keep the global market in mind when developing a new tool Xtra·tec tools are a completely new generation of milling cutters Walter is initially launching shoulder milling cutters and a face milling cutter from this generation – for virtually all requirements in shoulder and slot milling, in all common material groups The most striking design feature of the new milling tools is the installation position of the indexable inserts: At a greater incline and with a larger contact surface This reduces the surface pressure in the seat while increasing the stability The larger screw hole cross- Manufacturing Today | MARCH 2019 53 INTERVIEW WALTER TOOLS How you look at R&D within Walter Tools? Seidelman: R&D is the heart and soul of our company Our founder, Richard Walter, was an innovator He held some of the earliest patents for cemented carbide cutting tool materials for metal cutting and we look back at our history and invest heavily in R&D - substrate, coating, edge prep, pre-coating treatment, and post-coating treatment section stabilises the indexable insert and the longer screws which are now available hold it in place more securely The cutter body has also been made more stable, as it now has much more material behind the insert seat With demand from aerospace and defence increasing, how are you catering to them?? Seidelman: There are a number of initiatives from us for this sector alone We are offering an extended range of services that includes complete parts processing and 5-axis CNC programming We are well attuned with CATIA, which is the software system that most aerospace manufacturers use and starts with Airbus and Boeing and driven through sub suppliers Walter also has a couple of seats of CATIA in Asia and we continue to develop that We work directly with machine tool builders and aerospace manufacturers to develop cutting tools for cutting aluminium, lithium, titanium, etc Most of this happens at our state-of-the-art tech centre in Tübingen In terms of your own manufacturing, what are some of the processes followed considering that quality and precision is your hallmark? Seidelman: We are proud of ourselves when it comes to delivering quality and continue to invest in developing employee skills and we develop latest technology at our manufacturing units As a rule, we don't buy commercially available equipment for carbide manufacturing, but instead develop the machine tools, inspection processes and invest in automation Much of the automated inspection processes introduced into the production units are things we're doing to limit variability and assure high quality 54 MARCH 2019 | Manufacturing Today What is the various kinds of training you offer customers to prolong tool life? Kumar: Though we are tooling suppliers, we call ourselves as solution providers We ensure that we pass on the knowledge to our channel partners, our customers and each and every technician using our products, so that they can understand the technology and engineering we put into the products We have a different kind of training programme One is the competency development of our own employees, and we have a good concept at Walter We have a full-time technical trainer and that trainer is certified from the Walter Academy Across the globe, we impart the same training to our customers We first train the trainers who then train their colleagues which are our own employees, and then they train the customers and their technicians Training is first given on metal cutting processes, and after that product training It's the reason we invested in the technology centre and train people quarterly Going forward, what is your prognostication for the cutting tools industry? Seidelman: I think we are going to see supplier consolidations, mergers & acquisitions, and an increase in near net shape parts That means less rough machining, which can affect the cutting tool supplier We're going to see a lot of lightweight but difficult machining material, mainly in automotive The same will happen in aerospace and energy Data and digitisation will play a larger role in cutting tools selection, application and analysis Going forward, entire new skillsets will be required for our sales and engineering employees and end customer involved in metal cutting It's no longer going to be the art of machining but taking a scientific approach with data and digitisation Farther down the road, AI will play a big role, and that might affect our younger employees On the commercial side, I think it will be data driven decisions and less relationship-based decisions made during the cutting tools selection process Many markets depend on human relationships, but survey results show that 53% of the cutting tool decisions are made before the engineer meets the supplier Much work happens online and upfront and there's little need to call a sales engineer www.manufacturingtodayindia.com Power Build has been in the business of gearboxes, geared motors and other power transmission since 1972 Having its own manufacturing facility in Vallabh Vidyanagar, Gujarat, PBL have been the pioneers in the mechanical power transmission industry in medium torque Shaft mounted speed reducer or SMSR are kind of very simple gear box used in mechanical power transmission It is available in the market with limited variety of ratios, and input power will be given through pulley belt arrangement, and hollow shaft gearbox will be mounted directly on solid shaft of machine Rotation degree of freedom w.r.t output shaft axis will be fixed through torque Arm The beauty of the product and when application required different output RPM, it will be achieved by setting up a ratio in pulley arrangement RADICON POWERBUILD is one of the leading manufacturer and supplier of shaft mounted speed reducer These gearboxes are used in construction machinery where single machine needs number of belt conveyors e.g Batching Plant PRODUCTS TECHNOLOGY TRENDS SHAFT MOUNTED SPEED REDUCER (SMSR) X•TREME EVO SOLID CARBIDE DRILL With the X•treme Evo solid carbide drill from the Advance product range, Walter AG is launching the new DC160 product type This can be used universally in three different ways: In all ISO material groups It is designed for a variety of applications such as inclined entries and exits, drilling holes close to the edge of the workpiece or convex and concave surfaces It is also intended for use with all machine concepts: In machining centres, horizontal or vertical, or in lathes, rotating with driven tools, axial and radial (with an- www.manufacturingtodayindia.com gular head), or stationary As a first step, Walter is bringing out the X•treme Evo in variants and × Dc without internal coolant and 5, and 12 × Dc with internal coolant In addition to the DC160 variant, the drill from the Advance range is also available as the DC260 Advance step drill with and without internal coolant The greatest strengths of the X•treme Evo lie in its long tool life and high levels of productivity and process reliability The WJ30ET (full coating) and WJ30EU (point coating) grades are new to the X•treme Evo: A highly tough micrograin substrate combined with Walter's own TiSiAlCrN/AlTiN multi-layer coating on an AlTiN base layer Extremely wear-resistant for a long tool life – even while maintaining high cutting parameters Another innovation is the thinner web with steep approach angle, along with the fourth land that lies close to the drill tip The steep approach angle reduces the feed force and increases the positioning accuracy The deep-seated fourth land is engaged even quicker and consequently optimises drill guidance, particularly for inclined entries and exits The new type of face geometry on the X•treme Evo creates plenty of room for the chip in the centre and therefore improves chip removal, particularly in soft material Manufacturing Today | MARCH 2019 55 2019 THE WESTIN GURGAON th edition 11+ Hours of Networking 30+ Industry Speakers 100+ Interact Ideate Innovate FOR SPEAKING OPPORTUNITIES: FOR BRANDING ENQUIRIES: ROHAN PATEL Sr Conference Producer rohan.patel@itp.com +91 9985 31797 BIBHOR SRIVASTAVA Group Publishing Director bibhor@itp.com +91 98204 39239 FOLLOW US ON Senior Delegates SANJAY BHAN Director sanjay.bhan@itp.com +91 98457 22377 HAFEEZ SHAIKH Business Head hafeez.shaikh@itp.com +91 98331 03611 AN EVENT BY http://www.manufacturingtodayindia.com/smartmanufacturingsummit/ ... ENGINEERING UNITS HAVE MUCH TO CHEER FOR MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com EDITOR'S NOTE BROADENING HORIZONS Jayashree Kini Mendes Mitalee Kurdekar MARCH CELEBRATES... TRANSPORT CORPORATION Manufacturing Today | MARCH 2019 15 PHOTOGRAPHS: STUDIO AMIR COVER STORY CUMMINS INDIA Powered by 16 MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com THE INSIDE... 050 India For further queries write to: james.dsouza@itp.com | Tel:+91 22 6154 6006/6000 l l 12 MARCH 2019 | Manufacturing Today www.manufacturingtodayindia.com Got it? Why encrypt our conversation