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Manufacturing News 2014 Feb

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A leading magazine on manufacturing activities around the world and in India, published by IIPE, india's premier institute fostering growth of manufacturing sector. Check article "Manufacturing in a Vectorial Space' on pg 10 to know how to add the vectorial edge to your manufacturing system..

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Manufacturing News 2014 Feb

  1. 1. ‘Bangalore ln. '<> national EXhIb. ‘liC7l Centre ! . Fl 31 '‘‘‘''—': T ‘O ‘ lrvle rials av’-:7 lgrsc nclngy Ex _ Cr‘ Stepping into the 45th year of celebration, IMTEX FORMING 2014 and Tooltech 2014 was inaugurated on 22 January 2014 in the midst of several celebrated industry professionals who graced the occasion with their presence at Bangalore International Exhibition Centre (BIEC). The USP of the show, termed as IMTEX Forming 2014, was its focus and the exhaustive range of forming technologies in all engineering applications. It was a greatly expanded exhibition that included all forming technologies in metals, plastics, ceramics, composites and exotic materials the manifestation of which had one objectiveto enable manufacturing excellence through world—class productivity and cost- competitiveness. The show also laid the latest developments in machine equipment, processes, tools, accessories, software and raw materials besides feed stocks required to manufacture formed parts in diverse engineering applications. According to the organisers, the forming technology is an integral part of manufacturing in Integrated punching, shearing, automatic loading and component exit from Prima Power Italy various industries and has contributed in the development of many new processing technologies, processing methods, machineries, tools and solutions to design and f a b r i c a t e e n d products/ finished goods. Apart , from this, the organisers also , . held ‘Tooltech 2014‘, the 16th edition of which displayed metal working tools, tooling systems, machine tool accessories, metrology and CAD/ CAM at the same venue. The event featured innovations in tooling technologies for precision finish as well as cost competitiveness in all metal working operations. Carl ieiss - Axio Imager “The key user industries such as the automobile, auto components, defence, aerospace and power are set to fuel the growth of the Indian machine tool industry, ” said L. Krishnan, President of the Indian Machine Tool Manufacturers‘ Association‘s (IMTMA) and Managing Director of TaeguTec India P Ltd. The industry‘s current market size stands at $2.05 billion of which the domestic production makes for around 33 i ' per cent of the total consumption. The exhibition catered to 440 exhibitors who displayed 500 machines tools in an exhibition area of 30,000 sqmts. The participation other than India came from 24 countries including 4 group participations from China, Germany, Czech Republic and Taiwan. The show was visited by up to 45,000 visitors during the 6 days at BIEC. i I ‘Qrrion 3015 Plus - LASER CUTTING from LVD Belgium The six—day exclusive forming exhibition was inaugurated in the presence of Mr. Vikram Kirloskar, President, SIAM, Mr. ‘ Jamshyd N. Godrej, C h a i r m a n Exhibitions, Mr. L. Krishnan, President IMTMA and P. G. J a d e j a , V i c e president IMTMA.
  2. 2. The I2th Indian Auto Expo held at New Delhi in this month has been a flagship event of the Society of Indian Automotive Manufacturers (SIAM). Despite the fall in sales of automotive vehicles due to economic downturn in 2013, the event attracted all the major players from world over like Mercedes Benz, Audi and Volkswagen, Ford, General Motors, Maruti Suzuki, Hyundai, Honda Motors, Nissan Renault, Mahindra and Mahindra, Tata Motors and many other players. Two wheeler makers including Harley Davidson, Hero Honda, TVS and Bajaj Auto along with their competing products. 9 new models were launched and I 5 global unveilings took place during the expo. Major highlights were the unveiling of global concept car by Ford, Compact cars by Hyundai, clutchless car by Maruti Suzuki deriving automatic manual transmission technology from F-I, 4th generation City Sedan by Honda and two new I00 cc bikes by Hero motors. Unlike last year, the Expo was split and held at Greater Noida for the vehicles and at Pragati Maidan for auto components with convenient transport arrangements between both the venues. The expo witnessed an unprecedented I,2I,000 visitors and business visitors had their sessions well planned. The show will help in reviving the demand for automotive products once the economic situation improves soon. In this context one has to take note of the increasing demand for quality Ford Figo Concept Hero Motocorp Honda auto components for reconditioning the 5-6 year old vehicles. While the customer wants to go in for a new vehicle slightly later he wants to have the car he has which might have done I00,000 kms in shipshape. This has brought a new boom in "after sales market" for the vehicle manufacturers as well as component suppliers. Tata Motors has set up exclusive TOP line for such service and others are also coming up with such initiatives. Companies supplying harness, lighting and other safety equipments are also seeing increasing business as reported by industry bodies. This is a welcome sign for the industry waiting for demands to pick up for new vehicles. The Bajaj Auto RE60 Ouadricycle is getting government approval for operation on Indian roads soon. It is powered by a 200 cc petrol engine which can also run on CNG and will compete with three wheelers effectively with A better stability and ride comfort. It may possibly meet fuel efficiency and emission standards I‘ __ V. _ M better. In addition to Bajaj Re6O — U—Car meeting the Indian market demand, it may be exported to Asian countries as well as African and South American countries. This will make a "Made in India" product become an example of Indian innovative frugal engineering, next only to Tata Nano. Let IIPE fraternity explore pathways to make world class products and make Indian engineering second to none! Let India become a hub of innovative, cost effective and eco friendly transportation systems for the whole world! Prof. R. M. Vasagam Hyundai SANTA FE Maruti Suzuki
  3. 3. _I"-: I_‘gIfiy-. _Irv 'J| "‘-Al 1 % The General Index for the month of December 2013 stands at 178.3, which is 0.6% lower as compared to the level in the month of December 2012. The cumulative growth for the period April-December 2013-14 over the corresponding period ofthe previous year stands at (-) 0.1%. % The Indices of Industrial Production for the Mining, Manufacturing and Electricity sectors for the month of December 2013 stand at 133.0, 188.0 and 169.4 respectively, with the corresponding growth rates of 0.4%, (-) 1.6% and 7.5% as compared to December 2012 (Statement I). The cumulative growth in the three sectors during April- December 2013-14 over the corresponding period of 2012-13 has been (-) 1.8%, (-) 0.6% and 5.6% respectively. % In terms of industries, eight (8) out of the twenty two (22) industry groups (as per 2—digit NIC—2004) in the manufacturing sector have shown negative growth during the month of December 2013 as compared to the corresponding month of the previous year (Statement II). The industry group | |r‘£ , ,, ‘Radio, TV and communication equipment & apparatus‘ has shown the highest negative growth of (-) 35.7%, followed by (-) 26.1% in ‘Furniture; manufacturing n. e.c. ‘ and (-) 22.1% in ‘Office, accounting & computing machinery‘. On the other hand, the industry group ‘Wearing apparel; dressing and dyeing of fur‘ has shown apositive growth of 19.7% followed by 13.5% in ‘Chemicals and chemical products‘ and 12.9% in ‘Electrical machinery & apparatus n. e.c. ‘. % As per Use-based classification, the growth rates in December 2013 over December 2012 are 2.4% in Basic goods, (-) 3.0% in Capital goods and 4.5% in Intermediate goods (Statement III). The Consumer durables and Consumer non- durables have recorded growth of (-) 16.2% and 1.6% respectively, with the overall growth in Consumer goods being (-) 5-3%- / Some of the important items showing high negative growth during the current month over the same month in previous year include ‘Polythene Bags incl. Hdpe & Ldpe Bags‘ [(-) 58.4%], Aluminium Conductor‘ [(-) 55.9%], ‘Telephone Instruments (incl. Mobile Phones &Accessories)‘ [(-) 39.0%], ‘Boilers‘ [(-) 38.9%], ‘Earth Moving Machinery‘ [(-) 38.2%], ‘Gems and Jewellery‘ [(-) 33.3%], ‘Polyester Chips‘ [(-) 31.9%], ‘Molasses‘ [(-) 30.3%], ‘Pens of All Kinds‘ [(-) 29.2%], ‘Computers‘ [(-) 25.9%], ‘Wood Furniture‘ [(-) 25.7%] and ‘CommercialVehicles‘ [(-) 25.3%]. / Some of the other important items showing high positive growth are: ‘Vitamins‘ (198.4%), ‘Sugar Machinery‘ (78.8%), ‘Ayurvedic Medicaments‘ (62.7%), ‘Cable, Rubber Insulated‘ (59.8%), ‘Air Conditioners (Room)‘ (47.2%), ‘Steel Structures‘ (38.5%), ‘Leather Garments‘ (27.4%), ‘Transformers (Small)‘ (26.7%), ‘Stainless / alloy steel‘ (25.0%), ‘Cashew Kernels‘ (23.4%) and ‘Antibiotics &its preparations‘ (20.1%). Inflation Eases in January roviding relief to the common man, inflation in January ased to an eight-month low of 5.05 %, helped by a moderation 'n food prices. J anuary‘s inflation rate is the slowest since ay 2013, when wholesale prices increased 4.58 %. nflation in food articles in January came down to 8.8 per cent s against 13.68 per cent in the preceding month. Data released showed retail inflation declined to a two—year low 0 8.79 per cent in J anuary, while industrial output in Decembe shrank 0.6 per cent, prompting calls by industry for a interest rate cut to boost growth. "We must and very urgentl concentrate on reviving growth for the manufacturing secto and lay special emphasis on resolving problems of the MSM sector also, " Ficci President Sidharth Birla said. MIXED SIGNALS Exports grew only 3.8 per cent in January, thethird consecutive month of single-digit rise Lr. ..'. lT. E'uI. I.“" 3112': II]: 2.‘: ‘ ibllllull _wr. irrge Firstlo monthsin absolute Firstio monthsin absolute Z00 “N '30 numbers numbers “,0 . , _ 50 ‘ Stirllron —"arlI. irr; -2 ’ Sbrllrun —°/ u(li. irr<; e no 20 Int) 28.08 in 30 “D so (I Z55 20 “‘° . 1.0 Bi -20 Z50 W0 p. ‘ zus ‘0 “W I) .2. :2 , 4.0 . I . -11-12 '12-I3 -ii-it no ‘*7 L‘ _ 0 If’: SbrllronrnlHS: °/«(lunacy-o-y 235 E _ p -4» [.10 , 1 Souru-: (ornIIer(L-daparilnenl -11-12 12-1; ~1g—1r. “"’ Exports for January were $26.75 billion (Rs 1.7 lakh crore); cumulative exports touched $257 billion in the first 10 months of the current financial year against $243 billion in the corresponding period of 2012-13. This means the country will have to export $67 billion of goods in February and March to meet the export target for 2013-14. Imports contracted 18.1 per cent in January over the same month a year before, to $36.7 billion compared to $44.75 billion in January 2013. This narrowed the trade deficit for the month by almost half over a year, to $9.9 billion compared to $19 billion. Some items rose among the export basket. Engineering goods rose 37 per cent , rice 22.9 per cent, marine products 13 per cent, iron ore 18 per cent and readymade garments by 17.4 per cent. “The engineering sector is clearly leading the rebound in India's overall exports. We have remained cost-competitive, " said Anupam Shah, chairman of the Engineering Export Promotion Council. Eb‘. i3‘. 0): ; lfrlr tl ll_. ‘Jg I1; ‘iii 3: W13;
  4. 4. lII1i= lt‘I= I'I'L€‘ | |r‘t / HIM / cc-QRM 2014 PREVIEW / / A Brief Look at IIPE’s Forthcoming / National Conference-2014 at Mathura / It is quite some years since IIPE had organised an independent major event at the national level. But, plans were just in place, when the enthusiastic UP State Centre offered to make it a reality this year. Thanks to the large hearted team at the GLA University who are sponsoring this event in a big way, GC-QRM 2014 will be held in a sprawling scenic campus during 18th to 20th April, 2014 at Mathura. THE THEME: GLOBAL MANUFACTURING COMPETITIVENESS is the cry of the hour, both at the national and individual firm’s level. One of the strategies employed for this is QUICK RESPONSE MANUFACTURING or QRM. The main principle of QRM is to serve the customer in the shortest time possible, at the lowest cost and best quality. QRM is not a readymade strategy with pre-formulated steps for implementation. It requires a thorough understanding of the business environment, the firm’s current products, technology, skills of the manpower, and its capacity to innovate and take calculated risks. Innovation and entrepreneurship are the keys for identifying the right tools for implementing QRM. Talking of QRM Tools, there are a number of them being used already in Indian industry, but without conscious focus. We are getting experts from industry and academics to expound these tools through many case studies and work shops. A brief schedule of events will be as follows - 18.04.2004 2:00 - 5:00 PM Inauguration of the conference by our National Chairman, Prof. R. M. Vasagam; Keynote address by Chief Guest (being decided); Briefing on Conference Programme by Prof. Surender Kumar, Chairman of IIPE UP State Centre. 19.04.2014 9:30 - 11:30 AM IIPE’s 37th Anniversaryfunction - Progress so far; Future Plans; Question Hour; Annual IIPE Awards for Centres and Members. 12:00 - 1:30 PM Paper presentations 2:00 -5:00 PM QRM Implementation Workshop: This is a realtime strategy development session on live cases from industries. We welcome industries to send their executives with real life problems, so that they can be analysed, debated and QRM methodologies can be developed appropriately. 20.04.2014 9:30 - 11:30AM Conference Papers Presentation 12 :00 - 1 :30 PM Valedictory of the Conference We are also planning parallel sessions as theme workshops, discussion forums etc. The final programme will be ready by mid March 2014. People who couldn’t find time to send in their paper abstract, kindly work on the full paper straightaway, and ensure that it reaches the panel before 10th March 2014. Please come in large numbers, to taste the hospitality of Mathura, specifically of the IIPE—UP Team at the GLAU. 'oiu, r=. I.iv guwil 1"? ‘ IIPE 37TH 4 lllllll VER84 1? Y MGE7‘ c UM i~! ATIOi~! AL COi~! FEREi~! CE oN lil. l23E': l. l}i2I. iI'E'II'Ill". 'lEi! F:SS THROUGH 0lIIl; 'II0£. S'I'0I‘. '.S‘[fliflI1'lIf4£'TlIM1'6‘ CHALLENGES AND OPPORTUNITIES FOR INDIAN MANUFACTURERS HOSTED BY IIPE UP STATE CENTRE, MATHURA SPONSORED BY Research Promotion Cell, University Polytechnic GLA UNIVERSITY, MATHURA During 18th to 20th April 2014 SCOPE OF THE CONFERENCE The conference is a forum for the discussion on the role of engineering and technology to achieve the excellence for global competitiveness in the manufacturing era to have improved customer response. The important areas to be covered are: / ’ Global competitiveness & Manufacturing Excellence / ’ Industrial Ecology, Manufacturing Tribology / ’ Tools and Techniques for Maximising Customer Response / ’ Network Based Manufacturing / ’ Green, Lean, Agile and Legile Manufacturing / ’ Micro/ Nano Manufacturing, Industrial Robotics and Flexible Automation. .. Etc IMPORTANT DATES Submission of Abstract: 07 February, 2014 Acceptance ofAbstract: 15 February, 2014 Submission offinal paper: 08 March, 2014 Registration Details Corporate Participants Rs .4,000/- Academicians Rs. 2,000/- Students Rs. 600/- (25% discount will be given to IIPE Members) For Further Information, Contact Dr. Surender Kumar, kr. surender@gmai| .com R. Chandrasekar, rc1947@gmai| .com Special Call to Industries and Educational Institutes GC-QRM 2014 aims at exchange of proven techniques to develop the competitive edge in the Global arena for all manufacturing businesses. The Conference will focus on interactive sessions with the participants, from which they will carry knowledge about strategies for successful implementation at their workplaces. Institutions will get to know the current industrial practices, which will enable them to build a relevant curriculum for the students. Students who participate are exposed to real life industrial situations, which helps them to prepare themselves by seeking knowledge outside their regular syllabus. ‘ Jfigg-. our
  5. 5. J‘-dl. x.'E/ dlldyvl gin-£1 Institutions ~: delivered the Presidential address and lighted the Kuthuvilakku. * Prof. L. Peter S t a n e l y IIPE-VCET Students Chapter Inaugurated at Erode Students’ Chapter under Indian Institution of Production Engineers was inaugurated at Velalar College of Engineering and Technology, Erode on 6th Feb. 2014. The Chief Guest for the Inaugural Function, Shri R. Chandrasekar, National Vice Chairman, Indian Institution of Production Engineers, Bangalore, delivered the keynote address and presented Institutional Membership Certificate to the Secretary and Correspondent, Thiru. S. D. Chandrasekar. Later, he also distributed the Membership Certificates to our faculty and students. In his special lecture on “Building Manufacturing Competitiveness” he underlined the fact that our national competitiveness in the global manufacturing arena, depends entirely on our future engineers who are going to run our industries. Hence, it is important that the students maintain close relationship with industries and know about innovative problem solving techniques needed by the industry. For this, they should search outside their regular curriculum, develop an entrepreneurial curiosity, and come forward with innovative ideas for application in manufacturing sector. In the Global Competitiveness Index, India has slipped from 48th rank to 52nd rank in the last four years. (China has risen from 28th rank to 24th position during the same period). A lot can be done at the institution and students’ level. We are looking at fantastic opportunities for India in the nextdecade. Thiru. S. D. Chandrasekar, Secretary and Correspondent, Vellalar Educational Bebington, D e a n (Academic), delivered Special address and Dr. M. A. Veluswami, Dean (R&D) delivered felicitations. The function was organised by Dr. R. Kumaravelan, Professor and HOD of Mechanical Engineering Department, the faculty members and students of Department of Mechanical Engineering. Dr LV Muralikrishna Reddy Nominated as Vice President Institution of Engineers (India) Dr LV Muralikrishna Reddy, who is also a National Vice Chairman (Programmes and Professional Networking) of IIPE has been nominated as all-India Vice-President of Institution of Engineers India (IEI). He holds a BE(Chemical); MTech(Energy); PhD(Energy) and Post-Doctoral Fellow- USA. H e h a s l o n g . association with ; ' ' ' IEI, as Secretary and Chairman for Karnataka Centre, currently Director - National Design a n d R e s e a r c h Forum. Served IEI a s C o u n c i l Member, Chairman, CHDB and several Committees such as Finance, Examination-Accreditation, CATE, AITC, AISC, RCC and RDC. He has 23 years of global experience spanning Industry, Consultancy, Academic and R&D establishments, in Design, Research, Development, Training and Management. IIPE-ESEC Students chapter Lectures at Erode Leader's Talk The Leader's Talk programme of Mechanical Engineering Student's Association (MESA) and Indian . (.1 . .V( .11.": Lilr 1} institution of production (IIPE) student's chapter for the academic year 2013-14 was held 17.01.2014. (Friday). Mr. N. X Ravindar, Techanical Graduate Trainee, Roots Industries India Ltd, Coimbatore, was the chief guest and delivered the address on . VLELVARIMENT or MECHAN’CA'LWENGll‘EF‘R| NG- L'E’A“DER«S"[A§! .K £: !3a: rS1113:!1.E: rm: ':’.31i~: -.: .:-L11.. . IIPE S7U. "‘= N”. ’b : I. .4 ‘J! A §". 'l. ‘ " 51* 3 7 / I-“pp? . . . ._ VA [ A; ‘‘c&_ _ F9’? S’ I Product Design and Validation The Department of Mechanical Engineering and Indian Institution of Production Engineers (IIPE) students chapter had organized a guest lecture on “Product Design and Validation” on 06.02.2014. Mr. Karthik Kaliappan, Senior Technical Lead-Product Safety & Compliance, Standards and PD & V, John Deere, Pune, Maharashtra addressed the gathering. _=4,= tiL= w; He conveyed the importance of selecting the domain in Engineering during the course of study. The students were advised to concentrate and update their knowledge in the identified domain to enhance their employability potential. He also presented the recent Erodggiciigunthar bk . «veep? -g C0119Se Thudupmu E ‘ technologies and developments in the Mechanical Engineering based core industries. Mr. S. Sivananthan, Secretary, Erode Sengunthar Educational Trust presided over the function. Er. R. Mohanraj, Correspondent and Dr. A. T. Ravichandran, Principal felicitated the gathering. I I -J Egg-. oi; -;
  6. 6. Metal injection molding (MIM) offers a manufacturing capability for producing complex shapes in large quantities. The process utilizes fine metal powders (typically less than 20 micrometers) which are custom formulated with a binder (various thermoplastics, waxes, and other materials) into a feedstock which is granulated and then fed into a cavity (or multiple cavities) of a conventional injection molding machine. After the “green” component is removed, most of the binder is extracted by thermal or solvent processing and the rest is removed as the component is sintered (solid-state diffused) in a controlled-atmosphere furnace. The MIM process is very similar to plastic injection molding and high-pressure die casting, and it can produce much the same shapes and configuration features. However, it is limited to relatively small, highly complex parts that otherwise would require extensive finish machining or assembly operations if made by any other metal-forming process. The advantages of the metal injection molding process lie in its capability to produce mechanical properties nearly equivalent to wrought materials, while being a net-shape process technology with good dimensional tolerance control. Metal injection molded parts offer a nearly unlimited shape and geometric-feature capability, with high production rates possible through the use of multi-cavity tooling. 1. Powder Mixing and G1-anulating The first step in the MIM manufacturing process is the production of the feedstock that will be used. It begins with extensive characterizati on of very fine elemental or p r e all 0 y e d metal powders (generally less than 20 um). In order to achieve the flow characteristics that will be required in the injection molding process, the powder is mixed together with thermoplastic polymers (known as the binder) in a hot state in order to form a mixture in which every metal particle is uniformly coated with the binder. Typically, binders comprise 40% by volume of the feedstock. Once cooled, this mixture is then granulated into pellets to form the feedstock for the injection molding machine. 2. Molding The next step is the molding of the part in a conventional injection molding machine. The feedstock pellets are gravity fed from a hopper into the machine's barrel where heaters melt the binder, bringing the feedstock to the consistency of toothpaste. A reciprocating screw forces the material into a two-part mold through openings called gates. Once cooled, the part is ejected from the mold with its highly complex geometry fully formed. If necessary, additional design features not feasible during the molding process (undercuts or cross holes, for example) can be easily added at this stage by machining or another secondary operation. 3. Binder Removal The ejected as-molded part, known as a “green part, ” is still composed of the same proportion of metal and polymer binder that made up the feedstock, and is approximately 20% larger in all its dimensions than the finished part will be. The next step is to remove most of the binder, leaving behind only enough to serve as a backbone holding the size Page 06 METAL POWDER FEEDSTOCK PELLETS EXHAUST BATCH FURNACE BROWN PART CATALYST
  7. 7. _t"_‘7l': If'gi= _lFff ui»~'. :l 1 and geometry of the part completely intact. This process, commonly referred to as “debinding, ” may be performed chemically (catalytic debinding) or thermally, which in some cases may involve a solvent bath as the initial step. The choice of debinding method depends on the material being processed, required physical and metallurgical properties, and chemical composition. After debinding, the part is referredto as a “brown part. ” 4. Sintering In this process, which is performed in the highly controlled atmosphere of either a batch furnace or a continuous furnace, the brown part is staged on a ceramic setter and is then subjected to a precisely monitored temperature profile that gradually increases to approximately 85% of the metals melting temperature. The remaining binder is removed in the early part of this cycle, followed by the elimination of pores and the fusing of the metal particles as the part shrinks isotropically to its design dimensions and transforms into a dense solid. The sintered density is approximately 98% of theoretical. The end result is a net- shape or near—net—shape metal component, with properties similar to those of one machined from bar stock. Of course, if necessary, post—sintering operations such as coining, machining, heat treating, coating, and others, may be performed on the part to achieve tighter tolerances or enhanced properties. General Guidelines for Choosing MIM MIM is an established, highly evolved metal- forming technology, producing intricate components that go into a great variety of end products in countless industries. But, as is true with all metal-forming technologies, MIM is not suited for every application, all the time. To understand exactly where MIM emerges as the ideal fit for component fabrication, below are some general guidelines to use in assessing whether your part is a candidate for the metal injection moldingprocess. Complexity MIM offers the same design freedom as plastic injection molding. The more geometrically complex a part is, the more solid the rationale for manufacturing it via the MIM process. Parts may include cross holes, angle holes, internal threads, irregular shapes, splines, undercuts, side holes or grooves, complex contours, or cantilevers. Parts that would usually be made by assembling multiple components can be designed as a single MIM part. Some parts that could not be fabricated via any other process can be made through MIM. Complexity that would be cost prohibitive to do via multiple machining operations or by casting and then finishing can be achieved cost effectively through MIM processing. Size In general, the weight range MIM parts tend to fall within is 0.1 to 250 grams, although above 100 grams the high cost of the extremely fine powders used in the process begins to neutralize MIM's cost advantages, unless the complexity is extreme. Parts should have wall thicknesses not less than .13 mm (.005 in. ) and not more than 12.7 mm (.5 in. ). Due to material flow limitations, the distance from gate to the farthest point on the part should be around four inches. MIM part tolerances are nominally : t0.3%o.5%, although tighter tolerances can be achieved in some cases if deemed essential. ProductionVolume Medium to high volumes of 10,000 to 2,000,000 parts annually are typically needed in order to be able to amortize costs associated with tooling and start-up engineering. The best economic advantages are achieved at the highest quantities, due to the benefits of larger material purchases, multi-cavity tooling, and dedicated production units. Final Properties MIM fabrication is ideal where near—full density, high impact toughness, fracture toughness, and fatigue and corrosion resistance are required. And if non-standard material properties are required, these can be developed with new alloy systems. MIM is appropriate for materials that are difficult to machine, materials with multi- phase microstructures, or high work- hardening materials. And it delivers a high- quality surface finish (32 rms or better) and cleaner feature detail than investment casting. x IIPL _, , tilt tl For more info on Metal Injection Moulding Process and Powder Metallurgy, visit mimclweb. org MIM — Design for Manufacture ZIIZ I THIS ’ 1,4‘; {ti
  8. 8. 455 I i L‘1EE*S‘ . ,: E L V _' El 314 -21 TED / / / F‘ / / ll / '. .i. It Pl . lIl7Tllll. lilICfi _t: ';. i'_oiu_Ikl= .lhv_ : J!"lv£l microparts because the high cost of P/ M is not as much of a factor as it is with . I , 5 5 larger parts. While / l IT‘ ' MIM can be used to Metal injection molding (MIM) has been around for nearly 30 years, but it's only been in the last decade that its use has picked up steam, particularly in the Micro-manufacture of dental devices, medical instrumentation, firearms and other industrial parts. MIM makes use of injection-molding technology by combining fine powder metals (P/ M) with a polymer binder to create parts that offer the advantages of injection molding and the strength and integrity of metal, typically 17-4 stainless steel, iron, copperor titanium. Though MIM is injection molding, it presents some unique challenges. Injecting P/ M combined with a polymeric binder into a mold is quite a different animal than injecting plastic. That's because metals are not typically injection molding—friendly. Growing us age Despite the challenges of the technology, micro-MIM is finding a place in the manufacture of small metal parts such as dental brackets for braces, small gears and other components for increasingly smaller electronic instruments, jewelry clasps and components for handguns. Compared to plastic injection molding, MIM offers advantages that include greater strength, but the biggest bang for your buck comes when converting a part from a machining process to MIM. It can give you higher value at a lower cost. MIM is an excellent process for make parts ranging from 0.1g to 25og, parts weighing more than 100g can start gettingpricey. A c c o r d i n g t o i n f o r m a t i o n provided by the Metal Injection M o l d i n g Association, the process can produce wall thicknesses of not less than o.13mm (o. oo5") and not more than 12.7mm (o.5"). Also, due to material flow limitations, the distance from the gate to the farthest point on the part should be no more than 100 mm (4”). MIM part tolerances are nominally $0.5 percent of the distance from the gate to the farthest point of the part, although tighter tolerances can be achieved, in some cases, for critical dimensions. Tooling chaldenges With those kinds of tolerances, making the tooling for Micro-MIM is extremely challenging, much more so than the tooling for plastic injection molding, with properly engineered clearances that will prevent flash while providing tight shutoffs. But there's a fine line between tight and so tight that the mold will self-destruct after a few thousand shots. Those challenges increase exponentially when dealing with micro-MIM parts. Typically, a micro-MIM part involves a lot of detail. And the smaller the part, the harder it is to get in the detail. Feedstocks for MIM typically flash at 0.005 mm, so simply venting MIM toolingis a challenge as well. Further, MIM tooling must be highly polished to produce high-quality parts. However, it is critical to keep edges sharp in MIM moulds because the material flashes easily. There's also the risk of losing the size tolerances because it is “difficult or impossible” to control A bracket, slide and removable drop—in hook used in the Damon 3M>< se| f—| igation orthodontic tooth—positioning system. The parts were made by FloMet via micro-MIM from 17-4 PH stainless steel powder. Image courtesy Metal Powder Industries Federation. the amount of steel being removed in the polishing process. Debinding and sintering As challenging as making the tooling for micro-MIM parts can be, are the bigger challenges of debinding and sintering. It's one thing to worry about sintering a tiny part with extremely minute detail, but quite another to sinter it in a way to keep the physical properties of the metal and maintain the detail. If you don't, you'll destroy a perfectly good part. While micro-MIM may be a bit of a black art, it can produce some real “green”in terms of cost savings vs. traditional machining. Micro-MIM powders are superfine P/ M for micro-MIM is more complex than for standard MIM because the smaller the part, the smaller the metal particles must be to accommodate the microstructure. With these extremely small parts, you need smaller particles of powder to get crisp edges and fine surface finishes, which are both critical in a small part. The smaller the particle, the more critical it is to balance the mix of powder to binder, but there is a critical load (maximum allowable amount) of powder. If the ratio of powder is too high, the part won't bind. The typical micro-MIM powder grades used are D90-23 and D90-16, in which 90 percent of the particles are smaller than 23um or 16pm, respectively. As particle size gets smaller, the feedstock gets more expensive. _ r / ' Clare Goldsberry is a freelance writer who covers the injection molding and the mouldmaking industry. E—mail= c| arewrite@aol. com. I { . ,v'‘’. .§g'. H-‘i
  9. 9. v"= I’0IlII€. It"V '1il~”l. :l” . .. , . , , Disruptive technologies, sound economics and innovative thinking will allow the sector to prosper in 2014. 3D Printing Technology Will Drive Future Manufacturing Education In 2014 technology and education will merge in the manufacturing sector creating propelling the sector to new heights. In 10 years we face the very real prospect of a young highly—skilled manufacturing workforce all being fundamentally re—tooled with very state of the art additive manufacturing skills. The price of 3D printing technology is rapidly undergoing the effects of Moore’s Law; the speed and functionality of 3D printing is doubling every 18 months (holding cost constant). Today a basic 3D printer can be purchased for $3,000. That same 3D printer will only cost $1,500 in 18 months time for roughly the same functionality. With the reduced costs the education sector is taking notice. MIT students (and others) are already working very cost effecive learning is expected at ‘ the university level there is n o w a ' -' m o v e m e n t t o w a r d - moving this t y p e o f learning at m u c h younger ages. For example the UK has r e c e n t l y announced a pilot program to invest $1 million into 3D printing in order to drive up standards in science and math. Imagine a 6th grader who will have very regular access to 3D printing for the next decade, though high school and through college. Project—based learning suggests ’learning by doing’ offers a myriad of benefits to the students: E requires critical thinking, problem solving, collaboration, and various forms of communication, often known as "21st Century Skills. ” E increases retention E fosters creativity E requires student to create something new E provides feedback I: keeps learning exciting, and E accelerates the overall pace of leaming Wearable Devices Next Evolution in Manufacturing Although it may be too early for the Amazon Prime Air Octocopter to impact manufacturing and distribution in 2014, there are a number of other technologies that will begin to gain notice. Wearable devices are the next evolution/ extension of the mobile x | |?‘£ _, , boom that has been raging for the last few years. Some forecasts project this emerging area to be as much as a $50 billion market over the next 5 years. Want that Amazon order in just 30 minutes? Amazon "Prime Air" would be up and running within four to five years. "These are effectively drones but there's no reason that they can't be used as delivery vehicles. We can do ha| f—hour de| ivery. ..and we can carry objects, we think, up to five pounds, which covers 86% of the items that we deliver, " says Jeff Bezos, Amazon Chief. The body of the device is about the size of a f| at—screen monitor, and it is attached to eight small helicopter rotors and sits on four tall legs. l"’: EJ¢ gl Ll 1-‘r‘ I ' . F: Spurred on by smartphones, mobile * operating systems and easy to use apps, :1 these new wearable devices have gained an initial foothold in the consumer -pl market. Vendors such as Fitbit, Pebble, Nike and others have started with relatively simple implementations to get traction in the health and fitness arena. In 2014 these devices will start migrating into the enterprise. You can expect to hear about initial trials as early adopters and innovators in manufacturing, distribution, maintenance services and related industrial sectors begin to experiment with wearable technologies and platforms. Anticipate initial trials and use cases like the following: % Wrist bands and smart rings monitoring roaming workers vital signs for health status, well—being and alerts A 3D printer developed in the basement of an MIT fraternity house has evolved into a startup, Cambridge—based ll’ ”' New Valence Robotics, spearheaded by 21-year-old MIT grad student AJ Perez. The company leases easy—to—use ‘Nb 3D printers to schools with the goal of sparking creativity among elementary— and high schoo| —aged students who i ' _ would otherwise never be exposed to the technology, Perez said. The printer is managed by software that allows C‘; 3D printing ‘A1’ -I, solutions. While 3,}. W} accelerated lii” 5 ‘IL V, l '-' ' ‘.7: . .- pg; —‘——£ | T»~ students of all backgrounds, who are at various levels of science education, to create 3D models of objects.
  10. 10. 0 lfl_= ,{_= I;‘, I,' r; l 13 fig / / / % Wearable / / / / / / | t"£ ': ":I’oIlI, I1l: ”' :1!“-A‘, I ‘i‘! o / clothing and R ‘VELT } “'1 fl ‘>+ : ~TV £3. / / devices monitoring L . ' l it It Y? ’ 0 '0 ' ‘ ,1] , 7 / / the environment f0I‘ V: /tic/ e,a. l‘. r¢i‘, per. ta-i. & pef ; l7n2«Jhu¢ ue/ M4/1'4-i Cneczy cawugpfion 5¢£uri. '(‘j nulnjan; / carbon monoxide or other “"""”"'ffl 8‘ “""””"J mm‘/ /we hazardous materials and Everydaymingg/ __ forsmaner issuing alerts to ensure safety % Internet enhanced eyewear to bring real—time, hands—free information (manuals, data, order status, repair videos. ..) to maintenance, warehouse and service personnel for greater efficiency % Integrated wearable device network platforms that combine data from multiple wearable devices on workers throughout a facility and feed Big Data applications for more insights into improvingproductivity. Mobile Commerce Enables Manufacturing Success for 2014 2014 will see an increased focus on mobile commerce and mobile decision- making, and this will have major implications for manufacturers. Successful manufacturers in 2014 will /12% & M/ at Jeuar lie/ work Fl Cvegdfl / /Lily: i. All digital touchpoints used by customers will have to be mobile friendly. Mobile—enabled marketing, websites and emails will become an essential part of staying in touch. Becoming fully mobile—friendly will be an urgent priority in 2014, and those that do not comply, will lose sales. 2. There is an increasing trend towards retail shoppers using their mobile devices to drive decision-making at the point of purchase. Manufacturers will need to extend product marketing to accommodate this trend through use of QR codes and other tags, to link interactive content to help drive sales Internet of things 9‘*‘°°"“‘*°‘e“ “ ‘A it 3-uuf / mu: & c£He. I re- ‘ tomorrow El-Isl @. -‘> El 9.» 7;/ aiuulzfcrlu 8: / Le/ I‘/ Lou‘: while the customer is standing in the store. Manufacturers need to start laying a foundation now, for when near field communication (NFC) becomes mainstream. 3. The Internet of Things (IoT) is dawning, and 2014 will be a major leap as more manufacturers build in "smart" components to their products. Do you manufacture "things? " Find ways to add value to your products by making them accessible and integratable. Look at Phillips’ LED light bulbs that can be controlled via an app and consider how that type of thinking could apply to your product. focus on three things: / :7sAit’! ¢:FA£7!¢: R.7/V6 T001 80). ’ Manufacturing in Vectorial Space The performance of Manufacturing is measured by Throughput i . e. number of pieces or quantity of goods produced over a period of time daily, weekly, monthly, quarterly, yearly etc. Improvement in its performance is tracked and rewarded based on increased in Throughput during the time period. Rewards for those working in manufacturing plants and factories are in direct proportion to the Throughput they achieve vis—a—vis agreed targets. Thus largely, performance of manufacturing is a secularly scalar metric, more the quantity better is the performance. Over the past decade, the world in which manufacturing companies operate has changed dramatically. The business, competition and demand are volatile, uncertain, chaotic and changing. In fact, manufacturing field itself has become more complex in product portfolio, operating structure and value chain. As a result, today's manufacturing setup is subjected to frequent uneven demand in quantity as well as product variety. But a vast majority of manufacturing organizations still remain in the old paradigm of scalarity and continue to measure their production by scalar Throughput. They plan their production by forecasting and continue to produce goods in large batches. They produce based on quarterly forecasting, which leads to heavy mismatches in the market demand and what they ultimately land up producing. With input cost skyrocketing they lock their money in overproduction that stay in their books, shop floors and warehouses for long enough to choke their cash flow and response time. Today's manufacturing needs to understand that it is no more operating in Contributer: Shridhar Lolla Ph D Email: |o| |a@time2change. co. in a scalar world, the operating space is in fact Vectorial. A manufacturing organization, in order to succeed in today's environment, must be able to sense the direction of demand and quickly configure itself to the changes taking place in the market. And, in order to have sustainable growth, manufacturing must follow closely to the changes in quantity and scope, and must also improve its Throughput on an ongoing basis. This is the reason why manufacturing is no more operating in ascalar but a vector space. Here is the new metric for Manufacturing: Traditional Metric: Throughput = Quantity New Metric: Throughput = Quantity ' Indicates sellable fraction of The actual produced quantity In the same period Agreeing on the Vectorial Metric is the first step for manufacturing organizations on their effort to be successful in today's environment. Glad to know that IIPE is stepping up its objective to promote manufacturing in India by coining a term, Quick Response Manufacturing (QRM). QRM is not just another word for quick, fast or flexible manufacturing, ‘ it is aparadigmshift. In this column we will unravel the true meaning and more aspects of QRM. Suffice to say at this moment that failure to embrace QRM would threaten not only survival and competitiveness of manufacturing sector, economic growth of the entire nation might be derailed. I . ,."i; g-. :_ut
  11. 11. MONTH’S THOUGHT ADD LIFE TO YOUR YEARS Speech by P. P. Ramachandran (Former senior ofiicer of the Reserve Bank oflndia, at his farewell party, retired at the age of 60, afterserving for forty years) First God created the Cow and said, “You must go with farmer daily to the field all day long and suffer under the Sun, have calves, give milk and help the farmer. I give you a span of sixty years. ” The Cow said, “That’s surely tough. Give me only twenty years. I give back forty do nothing. I will give you twenty years. ” Man said, “Only twenty years! No way. I will take my Twenty and give me the Forty the cow gave ' back, the Ten that the Monkey returned, and the Ten the Dog surrendered. That makes eighty. O. K?” O. K said God. That is why for the First twenty years we sleep, play enjoy and do nothing. For the next forty years we slave in the Sun to support our family. For the next ten years we do Monkey tricks to entertain our grandchildren. And for the last Ten years we sit in front of the house and bark at everybody. We live in three Boxes. First is the Box of Learning, which starts from birth and goes on till 20 plus. Second is the Box of Work which commences at 20 plus and goes on up to 58 or 60—the age of retirement. Third is the Box of Leisure. When we are in the Box of Work what is significant is Status, Prestige, Power—all these we aspire for and it is what we get from Life. The day we retire we move into Box 3—the one of Leisure. If we have to enj oy this we have to change our psychological position and appreciate creativity, autonomy and integrity. When you were a small child of two or three, did status, prestige or money mean anything? What you wanted was autonomy, creativity. A child is years. ”OnDayTwoGodcreated MONTH’S always creative. It enjoys the Dog and told him, “Sit all day by the door of your house and bark at strangers. I give you a span of twenty years. ” The Dog said, “Too long time for barking. I give up ten years. ” On the third day God created the Monkey and said to him, “Entertain people. Make them laugh. I give you Twenty years. ” The Monkey said to God, “How boring, Monkey tricks for twenty years. Give me only Ten years”. Lord agreed. On the fourth day God created Man. He told him, “Eat, sleep, play, enjoy and -IIIIE EIIGIIY -IIIII TIIIIB -Ill! llll IIIIIIICV Zjnulls -Haw: enerull —Il: ve money —But no time TAUNT The 3 SIIIIIIII SHOES OI IIIG tcnilaren nrleenlnars II. fl|tl nennle or the Elderly -Have Time -Have Mnnev -Buino energy creativity. By the time we enter the Box of Work values change. We are not taught to respect our autonomy but fall in line—conformity is the rule. When we enter the Box of Leisure, values change . Your psychological position has to be changed. New values of creativity, integrity and autonomy emerge. Hobbies are an excellent way of getting Leisure Value. Everybody must identify his hobby that he can enjoy. No bother about Power, Prestige and Status. Since we live in three Boxes we must prepare ourselves for crossing from one to the other. Structuring our time is the prime requirement. After retirement you can think of Leisure Value. Develop good hobbies which incorporates your creativity, autonomy and integrity. You will lead a happy life. Retirement is not adding “Years to your Life but adding Life to yourYears” GVR’s conmsn Age has no relevance to Being Human Domestically, Professionally & Spiritually 1. Right from Childhood every human has duty till end to fulfill home work, Office work and relaxing 2. No doubt it is boring, tiring and frustrating 3. During child Stage, get trained by parents at home and in school by a good Teacher 4. Learn to balance work at home and School 5. The above foundation bearing knowledge, behavior and honest thinking can face tough Problems at each in life 6. When you grow from childhood to adulthood, you learn to respect your teachers, your parents and your neighbors 7. You do not think about work when you are at home. Maintain your physical strength by walking, swimming etc. , Your mind by reading good books and meditation so that body and mind will lead to happy living. Make relaxation your goal 8. Early to bed and early to rise makes a person wise. He who wakes up late will never be wise 9. Eat healthy food. Be calm and controlled before going to bed. Night prayer will give good sleep 10. Hear bad things through your left ear and throw away through your right ear. Compiled by Er. G. Venkatarathnam Chairman, IIPE-Karnataka III E I- < III I-
  12. 12. :_i f; i f; I}; -;f The New Digital Age / Reshaping the Future of People, Nations / and Business / By Eric Schmidt, Jared Cohen Starting with a simple, powerful and terrifying observation - that "the internet is among the few things humans have built that they don’t truly understand" - this fascinating book takes you on a wonderfully stimulating and important journey. It will make you rethink your concepts of the digital age, the way the world works, what lies ahead, and what all this means for you, your family and your community. You don’t need to know much about technology to benefit from this incredibly insightful book. Using their repeatedly—tested talents and their highly successful experiences, Eric Schmidt and Jared Cohen brilliantly detail for us how the digital age is rapidly altering the . .. . :. .l. ,:. .: .. ,.: . . ,.. . 'hmidt l‘J 4:1,: lIl‘. ‘.l . nit ]¢rcd Cohen im. .i. .;. 1. —: li' I. |. D‘ ‘t I i<. ~.in, . its {TIL lul1:. i . » The New T"§l’oIl! I‘-_Ir" gar-Al and governments, between the physical and virtual worlds, and between good and bad. Whether we like or not, technology is fundamentally changing the manner in which we all interact and depend on each other — and in an accelerating manner whose scale and scope remain obscure for too many of us. This brilliant book is a must read for all those seeking to understand, and navigate well a fundamental structural shift that will play a critical role in determining the wellbeing of current and future generations. Eric Schmidt and Jared Cohen’s thoughtful, well—researched work elucidates the staggering impact of technology on our daily lives, as well as what surprising and incredible developments the future may hold. Readers might be left with more questions than answers, but that’s the idea - we are at our best when we ask "What’s next? Eric Schmidt is the Executive Chairman of Google. Earlier he was the chairman and CEO of Novell Jared Cohen is Director of Google Ideas and an Adjunct Publisher: John Murray Pub Date: April 2013 Pages: 336 Hardcover ISBN: 978-1848546202 Price: MRP Rs. 650.00 ¢'. I'Il . lll Iiusm. .. balance of power between citizens Fellow at the Council on Foreign Relations. -— L —4iT’j—"""""" Two Birds in a Tree Timeless Indian Wisdom for Business Leaders By Ram Nidumolu “There are two birds, two sweet friends, who dwell in the self- same tree, ” says the ancient Indian scripture the Upanishads. The first bird, dwelling on the lower part of the tree, lives “in sorrow and anxiety. ” Unable to see beyond the branches it hops around compulsively indulging its appetites, eating every fruit, sweet and sour. The ‘ other bird, higher up, can see the : .i. .u . -------. v.-u - whole tree and the wider worldthis perspective puts it in touch with its I innate sense of being, the quality of existence that it shares in common : - I , , with all other living beings and the ' ' ‘ . “. natural world. Content, it “looks on I" ‘ " in compassionate silence” at the otherbird. -" - Ram Nidumolu’s provocative book i. on business leadership uses this ' _. ~ 3- allegory from Indian scripture to highlight why many businesses are _ distrusted by the public and contribute to social ills like environmental destruction, wealth inequality and climate change: they mimic the bird on the lower branch. But can business, compassion, and stewardship really coexist? Ram’s surprising insight is to hearken back to the earliest Indian philosophical texts to reclaim their lessons for acting in accordance with our connection to Being. He outlines a four- part framework for what he calls being—centered leadership and offers examples of this kind of leadership in action, from companies such as Harley Davidson, Timberland, Puma, Pepsi and many others. It is time, he writes, to “look up from our rickety perch on the lower branch of a storm—tossed tree and begin the journey to the higher branch. ” Ram Nidumolu is a celebrated entrepreneur, business scholar, and student of Hindu scripture. He was lead author of the 2009 Harvard Business Review cover story: “Why Sustainability is Now the Key Driver of Innovation” and has also written for Stanford Social Innovation Review. Publisher: Berrett-Koehler Pub Date: Nov. 2013 Pages: 216 Paperback ISBN: 978-1609945770 Price: approx Rs. 1490.00 Edited and Published by R. Chandrasekar on behalf of the Indian Institution of Production Engineers, 16, Park Road, Bangalore 560051, and Printed by P. Rangarajan, Director, Grafiprint (P) Ltd, at W. Q.Judge Press, 97, Residency Road, Bangalore 560025 IIPE MANUFACTURING NEWS If undelivered return to - Indian Institution of Production Engineers 16, Park Road, Tasker Town, Bangalore 560 051 RNI Regn. No. KARENG/2005/14740 Postal Regn. No KA/ BGGPO/2509/2014-16 Licensed to Post without prepayment - License No. WPP-243 Posted at GPO Bangalore, on the 25th of every month To ll,

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