India’s automotive landscape is diverse, with multiple segments showcasing significant sales. Recent reports indicate the sale of 3.5 million three-wheelers, 20 million two-wheelers, 3.6 million four-wheelers, and nearly half a million light and small commercial vehicles. This scenario paints a vibrant picture of the current market dynamics, where various Original Equipment Manufacturers (OEMs) are actively engaged, contributing to the country’s diverse and bustling automotive industry.

India demonstrated its capability for rapid transformation when it shifted from Bharat Stage 4 (BS4) to Bharat Stage 6 (BS6) emissions standards in just two years. This agility, driven by Indian innovation, indicates that India has the potential to surprise the market once again with its transition to electrification.

The electrification drive presents ample opportunities. While the current EV penetration in the market is only around 5%, the government is committed to achieving a 30% market share for EVs by 2030, with a significant milestone set for 2026. Tier-one suppliers from Western countries have adapted to this change in the Indian market for the past five years.

E-mobility reshaping EV manufacturing
Over the past few years, a significant transformation has been underway in the manufacturing sector, where traditional components like the Electronic Throttle Controller Actuator (ETC actuator) are being phased out due to the rise of electric vehicles (EVs). In the past, when you pressed the pedal of a passenger vehicle, the ETC actuator played a pivotal role in controlling the air intake valve into the combustion chamber. However, with electrification, numerous under-the-hood applications, including exhaust gas recirculation systems, are becoming obsolete, making way for advanced, high-tech components.

Recognising this trend, Gopalakrishnan VC , Director Automotive and EV Sector, Industries and Commerce Department, Government of Telangana, noted that the Government of Telangana, like many other regions, proactively introduced an EV policy early on. He adds, “This policy extends beyond EVs to encompass energy storage systems and the development of a robust charging network. Through stakeholder engagement and insights gained from international practices, the state crafted a comprehensive policy framework. Their objective was clear: attract manufacturers to invest in Telangana and promote higher adoption rates of EVs within the state.”

Customer Value
India’s electric vehicle (EV) landscape is evolving rapidly, with a strong emphasis on localisation and government support. However, it’s essential to remember that an EV is fundamentally a vehicle, and it must adhere to the core principles of vehicle manufacturing, such as safety, reliability, durability, affordability, and total cost of operation.

Keshab Chandra Sen, Principal Consultant, Vroomble, noted, “Over the next decade, the industry may witness the consolidation of smaller players as larger, more technologically advanced companies enter the market, benefiting from economies of scale and advanced technology. To sustain the growth of EVs in India, it is crucial to view them as a proposition to financiers. Financiers evaluate the residual value of vehicles when funding them. Therefore, for EVs to succeed, they must be designed to meet customers’ financial requirements, deliver consistent performance, and remain operational for a decade or more.”

Opportunities
Vikas Gupta, Founder, MD and CFO of Sampoorn EV Limited, shares that the electric vehicle (EV) sector presents an exciting opportunity, even for non-technical individuals like himself, who by qualification is a chartered accountant. This highlights the industry’s significance and unique blend of advanced technology and relative simplicity. He adds, “One remarkable aspect of the EV industry is its potential to empower around 200,000 people who may not have considered investing in traditional internal combustion engine (ICE) products. In the ICE industry, dealership investments typically start at a hefty range of ₹2.5 to ₹ three crore, while in the EV sector, the entry threshold can be as low as ₹7.5 to ₹10 lakh.”

EV ride-hailing services
Ride-hailing services, such as HALA Mobility and others, rely significantly on platforms or apps. Mr Gopalakrishnan adds, “Our current policy does not directly address the gig economy, mainly because these platforms are often used for delivering goods, like food delivery apps. One notable challenge we’ve identified through discussions over the past year is related to the speed of these vehicles. Some of them operate at speeds below 25 kilometres per hour, while others exceed this limit. Registering such vehicles can be problematic. When a vehicle falls below the 25-kilometer-per-hour threshold, it can’t be officially registered, which means it lacks a formal identity. This poses difficulties for ride-hailing platforms in terms of vehicle identification and security. In theft cases, proving that a vehicle has been stolen becomes a challenge.”

Spare part market
The transition to electric vehicles (EVs) is reshaping the spare parts industry. Unlike internal combustion engine (ICE) vehicles with hundreds of components, EVs have significantly fewer parts. Additionally, the repair of electronic components is often considered disposable. However, EVs will still rely on certain parts, especially wear and tear components and some electrical parts with unpredictable lifespans.

Mr Sen notes that the service model for EVs is evolving because they are now connected vehicles. Shortly, we might stop referring to them as “EVs” and instead call them “connected vehicles” or “e-mobility.” These vehicles can predict their failures, particularly with four-wheelers and large trucks. They can notify the owner in advance, allowing time to arrange the necessary parts. This shift means higher reliability as fewer parts are involved. Moreover, the traditional wait-and-see approach for repairs will change with digital transformation and technology.

Mr. Sachin Wagh, Director of Vehicle & Consulting, FEV India Pvt Ltd, added, “Regarding spare parts and services, there is anticipation of the emergence of new models. With the increasing incorporation of electronics, especially in electric vehicles (EVs), we’re witnessing the rise of technologies like digital twins.” These technologies are crucial for managing the complexities of EVs, which essentially become “software on wheels.” While traditional spare parts like tires, brakes, and suspensions will remain, electrical and electronic components are becoming more reliable. Failures are often software-related and are logged in the cloud, allowing data analytics teams to identify and address issues remotely. This suggests that the $54 billion industry will undergo a transformation, with different models emerging for servicing EVs. While hardware may decrease in importance, the overall market potential remains significant.

AI and Machine learning
According to Mr Gupta, the monthly production volume for four-wheelers is around 30,000 to 35,000 units. Three-wheelers see a monthly production volume of approximately 1.5 to 2 lakh vehicles; the two-wheeler industry produces roughly 2 to 2.5 lakh vehicles per month. Given these production levels, there is currently little need to implement AI extensively in the assembly or manufacturing processes. However, AI technology will become more relevant and valuable as production volumes increase. It has the potential to automate manual tasks and enhance precision in the assembly and manufacturing processes within the EV industry.

Mr. Sen also notes that while our fascination with technology is evident, it’s essential to consider both return on investment (ROI) and production volumes when implementing artificial intelligence (AI). AI can be particularly valuable in decision-making processes, especially in scenarios like supply chain management, where fluctuations in demand, supply, and sourcing costs occur. AI and analytics are essential for enabling flexible manufacturing. Integrating management information systems (MIS), enterprise resource planning (ERP), and other systems with AI and analytics is crucial to achieve this flexibility. Machine learning and other AI technologies can also significantly enhance quality control processes.

Future of connected mobility
Electric bicycles have become the standout product of this decade, fitting into the trend of people prioritising their health. Mr Gupta shares, “In pursuing a healthier lifestyle, many opt to cycle short distances and then resort to an auto for the return journey. Electric bicycles provide an ideal solution by allowing you to cycle as much as you want. You can switch between pedal-assist mode, where the motor and your pedalling share the workload, or go into full motor mode. This technological advancement offers flexibility and convenience.”

Electric two-wheelers are taking centre stage with budget-friendly models around ₹50,000 that offer luxury car-like features. Innovations like a side stand sensor to prevent movement with the stand down, a reverse gear, and a convenient repair switch were unheard of in traditional ICE technology, making EVs a game-changer for two-wheeler riders.

Environmental concerns
The concept of the future is intriguing, particularly when we consider the term “connected vehicle” instead of solely “electric vehicle.” Mr Sen implies that while electric vehicles (EVs) are currently in the spotlight, they might be replaced by alternative technologies like hydrogen or others. The future remains uncertain in this regard.

Another critical aspect to ponder is that a substantial portion, approximately 58%, of India’s power generation relies on coal. This raises concerns about environmental pollution despite the efforts to promote cleaner mobility within cities. The path to achieving carbon neutrality hinges on transitioning to renewable energy sources to replace coal, a significant contributor to pollution. Otherwise, generating electricity for electric vehicles within cities might still involve environmentally harmful practices.

EV Trucks
The full adoption of electric vehicles (EVs) hinges on addressing hurdles related to heavier vehicles like trucks and ensuring seamless last-mile connectivity. Presently, EVs grapple with limitations due to the substantial weight and cost of batteries, especially in the context of trucks. However, Tesla’s introduction of an electric truck represents progress, potentially driving innovations that can reduce battery weight or enable onboard energy generation. Onboard energy generation is not a new concept, exemplified by diesel locomotives operating for years – essentially functioning as EVs by producing electricity onboard using diesel fuel to power traction motors. This enduring approach underscores the significance of generating energy on board.

For EVs to substantially impact, particularly in the trucking industry, we must conquer challenges such as battery weight, cost, and energy generation. Trucks might require alternative solutions, like drawing power from overhead lines like electric trains. We need to overcome these obstacles before the success of EVs remains uncertain. Merely producing a high volume of two-wheelers will not resolve the broader issues in mobility. To genuinely shape the future, we must address these challenges, primarily focusing on larger vehicles and finding energy generation solutions.

Quotes

Gopalakrishnan VC, Director of Automotive and EV Sector, Industries and Commerce Department, Government of Telangana“With electrification, numerous under-the-hood applications, including exhaust gas recirculation systems, are becoming obsolete, making way for advanced, high-tech components in the automotive industry.”

Keshab Chandra Sen, Principal Consultant, Vroomble
“The concept of the future is intriguing, particularly when we consider the term “connected vehicle” instead of solely “electric vehicle.”

Sachin Wagh, Director – Vehicle & Consulting, FEV India Pvt Ltd
“The EV revolution has the potential to transform not only the Indian automotive landscape but also influence the global automotive industry.”

Vikas Gupta, Founder, MD and CFO, Sampoorn EV Limited
“One remarkable aspect of the EV industry is its potential to empower non-technical individuals to venture into the automotive industry who may not have considered investing in traditional internal combustion engine (ICE) products.”

While discussing the manufacturing sector, Mr Shantanu Sharma, General Manager – Brand Marketing South AP, ExxonMobil Lubricants Pvt. Ltd., emphasised the critical role of lubricants in achieving energy efficiency in machine maintenance.

Please share your insights on India’s manufacturing sector.
India’s manufacturing sector is poised for robust growth, aligning with the nation’s overall economic journey. Presently, the sector contributes ~17% to Gross Domestic Product (GDP), and promisingly, it is anticipated to expand to a size of USD 1 trillion by the year 2025. This outlook is underpinned by favorable indicators, including government initiatives and programs such as Make in India, Aatmanirbhar Bharat, and more recently, the Production Linked Incentive (PLI) schemes. These supportive measures are poised to fuel the growth trajectory of India’s manufacturing sector.

What is your Make in India perspective for manufacturing growth?
At Mobil™ Lubricants, we emphasize localisation, and with increased domestic production through incentivised investments, we are strongly aligned with the government’s Make in India initiative. Mobil has recently announced a significant investment of INR 900 crore, equivalent to USD 110 million, to build a state-of-the-art lubricant-manufacturing plant in Maharashtra Industrial Development Corporation’s (MIDC) Isambe Industrial Area in Raigad. This facility is expected to become operational by year-end 2025. This investment underscores our dedication to localization, as Mobil plans to source a larger part of its raw materials and all packaging locally. This move will also create significant employment opportunities during the construction phase.

What are some key operational challenges the manufacturing sector faces in India?
As a country, we aim to attain global competitiveness for our manufacturing sector. To achieve this goal, we must focus on modernising equipment and machinery to enhance efficiency. This modernisation effort will enable us to produce more with fewer resources, particularly in cases where input materials are not abundant or readily available. While it may present challenges, it also gives us a unique opportunity to enhance our capabilities and global standing. By investing in these advancements, we are laying the foundation for the Indian manufacturing sector to excel globally.

How is ExxonMobil participating in transitioning the automotive industry?
At ExxonMobil, we are committed to creating value by advancing our customers’ productivity, mobility, and sustainability goals through the deployment of technologically advanced solutions and our deep application expertise. Within the manufacturing realm, the automotive sector holds significant importance and is a key focus area for us. This sector comprises a vast network of small and medium-sized enterprises (SMEs) and micro-enterprises, which play a vital role in supporting the larger automotive industry.

From an ExxonMobil perspective, we aspire to be a comprehensive solution provider for the automotive sector. Through our application expertise and technological leadership, we aim to offer more than just lubricants – we aim to provide complete lubrication solutions and support. This approach includes the provision of advanced lubricants, a suite of services, and the integration of digital solutions. By evolving our offerings in this manner, we are poised to support and contribute to the growth and development of the automotive sector in a meaningful way.

How can manufacturers achieve profitability and energy efficiency in their operations?
Two key avenues come into play for manufacturing companies to bolster their competitiveness and boost profitability. First, they can focus on elevating sales and delivering greater customer value. Equally important is the need to reduce their Total Cost of Ownership (TCO). TCO encompasses various aspects, but one critical facet involves optimising maintenance practices. Companies can substantially curtail maintenance costs by enhancing their approach, particularly by investing in preventive maintenance practices. This, in turn, improves their overall competitiveness. Manufacturing firms must shift their perspective from solely considering initial expenses to factoring in the comprehensive TCO regarding machine maintenance. Embracing technologically advanced solutions is critical to achieving this goal, as they can effectively drive down the TCO for these enterprises.

How can the manufacturing sector align with sustainability targets?
From a lubricant perspective, it’s crucial to highlight sustainability, particularly in terms of energy efficiency and resource conservation. Achieving more with less is a key sustainability principle. We offer technologically advanced products like Mobil DTE 10 Excel™, a hydraulic oil that not only enhances energy efficiency by up to 6%*, but also boasts of a high viscosity index while being zinc-free. This oil can extend oil drain intervals up to three times*** that of standard hydraulic oil, delivering improved total cost of ownership while concurrently promoting reducing resource consumption. 

How does ExxonMobil’s integrated approach offer end-to-end solutions?
Manufacturing customers today are increasingly seeking comprehensive solutions and looking for partners who can offer more than just lubricants. Mobil recognises this need, and we are evolving to provide end-to-end solutions. This includes a range of products, services, and digital solutions, offering a one-stop shop for manufacturing needs. For example, our Mobile SHC™ 600 Series, a premium synthetic product, can boost energy efficiency by up to 3.6%** in gearboxes and transmission systems, and provide upto  six-times**** longer service life than conventional lubricants. Additionally, we offer several lubricant analysis programs that allow customers to monitor oil and equipment conditions for proactive maintenance.

We have also introduced the Mobil™ MachineXT program, a doorstep solution with services like oil filtration systems and vacuum dehydration systems. This eliminates the need for customers to seek solutions elsewhere, and is particularly valuable in sectors like manufacturing.

In the automotive sector, Mobil is providing digital solutions through the Mobil™ Solcare Service application by streamlining the management of cutting fluids through digitising tracking and servicing records. This is empowering customers to make more informed decisions. These comprehensive lubrication solutions and management practices are enabling companies to achieve more efficiency and profitability.

How are you developing specific solutions to enhance operational efficiency for its customers?
Research and technology play a pivotal role in the development of lubricants. ExxonMobil, with its 150-year heritage, places a strong emphasis on technological leadership and application expertise. Instead of relying on generic specifications, we have been designing our lubricant products to suit specific applications. This process involves close collaboration between technical teams, research experts, Original Equipment Manufacturers (OEMs), and equipment builders (EBs).

For instance, our Mobil Vactra™ Oil Numbered Series premium-quality slideway lubricants have been specifically designed to meet the requirements for accuracy, aqueous coolant separability, and equipment protection of precision machine tools. It has been tailored to address the lubrication requirements of slideways and tackles issues like stick-slip – a common problem in slide-way applications. This demonstrates how research and collaboration can lead to solutions tailored precisely to the unique challenges of specific applications.

How do you support Make in India by integrating technologically advanced lubrication solutions and strategic OEM collaborations?
We are deeply committed to providing top-notch lubrication solutions for the Indian manufacturing sector. We are highly optimistic about the ongoing developments in India’s journey towards becoming a manufacturing powerhouse. Our commitment to the “Make in India” vision is evident in our various initiatives, such as establishing a local lubricant-manufacturing plant. Additionally, our focus on technologically advanced products and close collaboration with OEM partners within the Indian sector underscores our dedication to enhancing competitiveness in the manufacturing sector.

*The energy efficiency design is a trademark of Exxon Mobil Corporation. Energy efficiency relates solely to the fluid performance when compared with Mobil’s standard hydraulic fluids. The technology used allows up to 6 percent increase in hydraulic pump efficiency when tested in standard hydraulic applications. The energy efficiency claim for this product is based on test results on the use of the fluid conducted in accordance with applicable industry standards and protocols. Efficiency improvements will vary based on operating conditions and applications.

**Energy efficiency relates solely to the performance of Mobil SHC 600 when compared to conventional (mineral) reference oils of the same viscosity grade in circulating and gear applications. The technology used allows up to 3.6% efficiency compared to the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and application.

***Under test condition versus a market general hydraulic oil with viscosity index around 100 and a zinc-based anti-wear system – meeting at least ISO 11158 (L-HM) and/or DIN 51524-2 (HLP type) requirements. Actual performance may vary depending on application and operating conditions.

****Relates solely to the performance of Mobil SHC 600 when compared to conventional (mineral) reference oils under test conditions. Actual performance will vary based on particular application and operating condition.

According to Sanjeev Arora, President, Motion Business, ABB India, the primary focus remains centred on sustainability and reliability, encouraging the widespread adoption of high-energy-efficient motors and variable-speed drives.

Please discuss ways to improve electrical motor solutions’ performance and energy efficiency.
Advanced technology is imperative for the global shift towards sustainability in electric motion. As the global embrace of electric technologies continues, there is a projected twofold increase in the demand for energy-efficient motion solutions by 2040.

There has been a consistent improvement in the effectiveness and capabilities of electric motors. Some of the key factors that have enabled and will continue to enable further advancements include the availability of superior materials, improvements in manufacturing techniques, the utilisation of Multiphysics computational tools, and the growing trend of using Variable Frequency Drives (VFDs) for variable-speed applications, particularly those involving centrifugal loads.

To illustrate, approximately 45 percent of the electricity generated worldwide is  transformed into motion by electrical motors. In India, a substantial installed base of motors with low efficiency exists, referred to as IE1. To foster growth and enhance performance, it is imperative to transition to at least IE3 as the minimum efficiency standard. It is also essential to educate customers about the long-term benefits of cutting-edge technologies that offer efficiency levels of IE5 or more, even if they require a higher upfront investment.

Please talk about ABB Motion’s business activities, specifically focusing on motors, drives, and related areas.
Our pioneering products, including drives, motors, generators, and comprehensive integrated digital powertrain solutions, are leading the way towards a low-carbon future across various industries, cities, infrastructure, and transportation sectors.

Our primary focus is on energy efficiency, sustainability, and reliability. We provide IE5 efficiency synchronous reluctance motors and ultra-low harmonic drives, which limit current harmonics to less than 3 percent. ABB’s Motion Business area delivers many products, including low and high-voltage motors, generators, variable frequency drives, PLCs, traction motors, converters, batteries, and chargers. Additionally, we offer complete package solutions that incorporate these products seamlessly.

Our Service division goes beyond commissioning and post-sales support for our products. We assist customers in their digital transformation journey, particularly in areas such as predictive maintenance, energy assessment, and optimising the operations of industrial power and drive systems through our digital offerings.

What recent advancements have been made in power transmission and integrated digital powertrain solutions?
Through digital powertrain, we monitor the health of variable frequency drives, motors, and the driven equipment. The analytics and dashboard help in predictive maintenance, avoiding unplanned downtimes while increasing the availability and OEE.

There is a growing interest in the efficiency of the complete system rather than looking only at individual components of the drivetrain. Due to dynamism in the operations, the systems work at the best efficiency points. Energy appraisal of the drive system is a good starting point to identify improvement areas. The use of IE2 efficiency VFDs and IE4 / IE5 efficiency motors, along with high efficiency driven equipment, go a long way in improving the system efficiency.

What are the advantages of implementing IE3 as the minimum efficiency standard in India?
As Energy efficiency becomes a centre point in reducing climate change risks, the need to promote the adoption of sustainable technologies gains greater significance.

Electric motors are designed to operate for 20 years or more. In the total cost of ownership (TCO) of the motor, which is the cost incurred during the motor’s lifetime, the purchase cost is less than 5 percent. The majority of this is the energy cost to run these motors. Though buying higher-efficiency motors is logical, most industrial buyers, especially the OEMs, continue to focus on the purchase cost. In India, the present MEPS for motors is IE2 efficiency. IE3 motors have around 15 to 20 percent lower losses than IE2 motors, and similarly, IE4 motors have further 15 to 20 percent lower losses than IE3. Of the total motors manufactured, IE3 and IE4 constitute up to 15 percent. Regulation and mandatory MEPS (minimum energy performance standards) are essential for the mass transition. By replacing IE2 with IE3 as MEPS, savings from one year of production are greater than 1 TWh. This has a cascading effect, hence the urgency to implement. Markets like the EU have moved to IE3 and IE4 efficiencies, and coincidently, these technologies are already available in India.

Educating customers about the advantages and garnering government backing to establish efficiency benchmarks will be crucial in achieving these savings, recognising the significance of collaborative endeavours.

What measures can be implemented to promote energy efficiency and sustainable solutions in industrial applications?
ABB is actively driving the energy efficiency movement, which commenced in 2021. The initial step involves measuring energy consumption at both equipment and system levels. Subsequently, assessing potential opportunities for savings and evaluating these gains after implementation is crucial. Enhancing efficiency by using higher-rated motors and driven equipment, deploying variable frequency drives to regulate operation speed and thereby boost system efficiency, holds significant importance.

Utilising variable frequency drives, particularly in systems predominantly operating at partial loads, can result in substantial energy conservation. Considering that many industrial systems tend to be overdesigned, there is an average potential for savings of around 30 percent in variable torque applications like pumps and fans. These measures, encompassing the elevation of energy efficiency to IE3 standards and advocating the adoption of energy-saving technologies such as motors and drives, are indispensable for a sustainable future.

What initiatives are necessary to facilitate technology transfer for energy efficiency, conservation, and adopting highly efficient appliances?
Our primary focus remains centred on encouraging the widespread adoption of high-energy-efficient motors and variable-speed drives. ABB India aims to empower our customers with these solutions, enabling them to fine-tune their energy consumption and reduce their carbon footprints. This commitment to sustainable development is poised to be a game-changing factor, especially as global companies consider sourcing from India.

It’s essential to elevate awareness regarding the advantages of energy efficiency and the availability of related technologies. As previously mentioned, regulations play a pivotal role in steering this transition. Even though technologies achieving IE5 efficiencies are accessible, localising and optimising costs may remain challenging until adoption rates increase and market demand surges. The availability of incentives and financing options for energy-efficiency products and projects is also crucial.

Furthermore, we acknowledge the critical role of digitalisation in overall business expansion. Digitalisation substantially enhances operational efficiency. ABB will persist in improving its facilities by implementing advanced automation and interconnected products, which enhance reliability and productivity. We have already embarked on this journey and will further strengthen our efforts.

How is ABB actively contributing to the development of a sustainable industrial ecosystem?
ABB is committed to embracing sustainability using a triple-bottom-line framework, focusing on the planet, people, and profits. Through various sustainability initiatives, we have achieved an impressive 81 percent reduction in scope one and scope two greenhouse gas emissions compared to our 2019 baseline. All our manufacturing facilities are powered by 100 percent renewable electricity and have received platinum or gold certification from the Indian Green Building Council (IGBC).

Moreover, we understand the significance of addressing scope three emissions and are actively collaborating with our suppliers, vendors, and customers to ensure their involvement in our sustainability journey. This collective effort contributes to the establishment of a sustainable industrial ecosystem.

In your opinion, what does the future hold for clean energy?
As India is poised to become the world’s third-largest economy by 2030, there is significant room for growth and development. However, this will also lead to a substantial increase in energy demand, surpassing that of any other country in the coming decades.

Therefore, prioritising a shift towards clean energy becomes imperative. India actively seeks intelligent and sustainable technological solutions to meet its expanding energy needs while minimising environmental repercussions. ABB’s ‘Energy Efficiency Movement’ aligns perfectly with the company’s Sustainability 2030 strategy, which is committed to assisting ABB’s customers in collectively reducing their CO2 footprint by 100 megatons annually by 2030. This reduction is equivalent to removing 30 million combustion cars from the roads each year.

Two key challenges emerge with the growing integration of renewable energy into the grid. The first pertains to the intermittent and uncertain nature of wind and solar energy, which is only sometimes available. This challenge can be addressed through energy storage, and ABB has established solutions for safely and reliably powering electrolysers, making green hydrogen a sustainable means of energy storage. The second challenge relates to grid management and stability, where ABB offers synchronous condensers to enhance grid stability.

In the words of Anil Kumar, Director at Inovance Technology, the IIoT is revolutionising manufacturing. It connects machines, boosts efficiency, enhances safety and security, optimises supply chains, enables predictive maintenance, and drives significant cost reductions.

In what ways is the manufacturing sector being transformed by the influence of IIoT? 
The Industrial Internet of Things (IIoT) has emerged as a potent force in the digital realm, particularly within the manufacturing and automation sectors. It is revolutionising global manufacturing by linking machinery and equipment to the internet, resulting in smarter and more efficient operations. At Inovance, IIoT is designed to connect factories and their processes in real-time via the internet, fostering transparent data sharing and enhancing operational performance. IIoT is a pivotal technology in the industrial revolution, propelling progress and innovation in various industries.

For instance, factories can utilise sensors to anticipate machine maintenance needs, thus preventing unexpected breakdowns. IIoT also aids in optimising processes, such as fine-tuning assembly line robots to reduce errors. It improves inventory management, boosts energy efficiency, provides visibility in the supply chain, enhances product quality through continuous monitoring, elevates employee safety, enables mass customisation, and facilitates remote monitoring and control of equipment. In essence, IIoT simplifies manufacturing processes, elevating productivity and nurturing innovation across diverse sectors.

Recognising the profound influence and wide-ranging advantages of IIoT technology, Inovance has recently unveiled the IoT-WL135 device. This state-of-the-art equipment is a central player in industrial manufacturing, enabling real-time data collection and monitoring, predictive maintenance strategies, and comprehensive process optimisation. Its standout feature lies in its seamless integration capabilities, allowing it to interface with existing systems smoothly. This feature proves invaluable to manufacturers seeking to modernise their operations without disruptions.

What challenges are manufacturers facing while implementing IIoT technologies in their production processes?
Manufacturers need help with incorporating IIoT technologies into their production processes. To begin with, there is the potential for high expenses associated with establishing IIoT systems. Secondly, it is essential to prioritise data security due to the involvement of confidential and sensitive information. Overcoming challenges related to integrating these systems with existing ones and ensuring scalability as the business expands is also crucial. Effective data management and analytics, bridging the skills gap, and complying with industry regulations all assume significant importance. Manufacturers must also guarantee the reliability of IIoT systems to minimise downtime, address privacy concerns, and navigate the organisational shift as employees adapt to new technologies.

How does IIoT enhance predictive maintenance within the manufacturing realm, resulting in minimised downtime and significant cost savings?
Predictive maintenance, which involves anticipating equipment failures, has gained fresh impetus with the advent of the Industrial Internet of Things. IIoT enhances predictive maintenance by harnessing real-time data from sensors and connected devices. This technology not only assesses the condition of machinery but also delivers a continuous stream of data for more precise predictions. In contrast to conventional methods, which may have encountered limitations due to the sheer volume of data, IIoT’s capacity to handle and process extensive data sets allows for more advanced and accurate predictive maintenance strategies. The convergence of predictive maintenance and IIoT results in more efficient equipment monitoring, reduced downtime, and substantial cost savings for manufacturing industries compared to traditional maintenance approaches. Here are five key ways in which IIoT enhances predictive maintenance:

·         Real-time Equipment Monitoring: IIoT sensors continuously monitor the condition of machines, providing real-time data.

·         Data analytics: Advanced analytics and machine learning algorithms process the collected data, identifying patterns indicating potential equipment failures or maintenance needs.

·         Predictive alerts and notifications: When the analytics detect any issues, IIoT systems send alerts and notifications to maintenance teams, allowing them to address problems before they lead to major breakdowns.

·         Proactive maintenance scheduling: Instead of relying on fixed maintenance schedules, IIoT enables maintenance to be scheduled based on the actual condition of equipment. This minimises unnecessary servicing and reduces downtime.

·         Resource optimisation: With predictive maintenance, resources such as labour, spare parts, and maintenance equipment are allocated more efficiently. This optimisation reduces operational costs and extends machines’ lifespan, resulting in significant cost savings over time.

What impact does the integration of IIoT devices with AI have on manufacturing operations?
Integrating IIoT (Industrial Internet of Things) and AI (Artificial Intelligence) integration in the manufacturing sector brings numerous benefits. It has a profound impact, spanning from predictive maintenance to data analytics. AI optimises production processes by utilising IIoT data, resulting in heightened operational efficiency. Manufacturers can reduce waste, improve product quality, and streamline product customisation, catering to specific customer needs more effectively. Furthermore, AI-driven quality control ensures the real-time identification of defects, ensuring consistent product quality.

Safety in manufacturing also sees significant enhancements as AI processes IIoT sensor data to detect and respond to safety hazards swiftly, creating a safer workplace. Data analytics is another pivotal outcome, as AI’s ability to analyse extensive volumes of IIoT data reveals valuable insights and patterns that inform data-driven decision-making. Continuous improvement is fundamental to this integration, as AI consistently learns from IIoT data, facilitating ongoing process optimisation, cost reduction, and innovation. Ultimately, these advantages provide a competitive edge, enabling manufacturers to operate efficiently, adapt to market fluctuations, and make real-time decisions in an ever-evolving industrial landscape.

To address concerns related to safety and security, Inovance’s IoT-WL135 device proactively identifies potential safety risks and mitigates them, contributing to a safer work environment. Additionally, its ability to reduce costs by minimising downtime significantly benefits manufacturers. By preemptively detecting issues and enabling swift responses, it not only saves valuable time but also financial resources.

One of the most compelling features of the IoT-WL135 is its capability to offer remote monitoring and instant alerts. This means manufacturers can closely monitor their operations, even from a distance, and receive immediate notifications when issues arise.

How does cloud computing contribute to enabling the broad acceptance of IIoT solutions in manufacturing?
Cloud computing is crucial in promoting the adoption of Industrial Internet of Things (IIoT) solutions in the manufacturing industry. IIoT generates vast data streams from various sensors, devices, and machinery. Cloud platforms offer adaptable and cost-effective storage solutions, allowing manufacturers to manage and supervise data without substantial investments in physical infrastructure. This scalability will enable companies to quickly adapt to changing data requirements while using powerful data processing and analytics capabilities.

With the increasing demand for smart factories, how will integrating IIoT in manufacturing reshape the industry’s landscape?
Implementing IIoT technology offers significant advantages for companies in the manufacturing sector, simplifying various processes such as real-time monitoring, tracking, management, predictive maintenance, process optimisation, and seamless integration across their operations. Furthermore, IIoT systems can enhance safety and security, optimise supply chains, improve quality control, enable predictive maintenance, and lead to substantial cost savings.

Inovance’s IoT-WL135 device is designed to boost machine efficiency, increase reliability, and elevate customer satisfaction. Its proactive problem-solving approach ensures identifying and resolving potential issues before they escalate, benefiting all manufacturers seeking to optimise their processes and deliver top-notch products and services to their customers.

He shares his views; Mr. Karthik B, Business Head, Automation Division, says that Fuji Electric’s primary focus encompasses Oil and gas, Petrochemical, Refinery, Fertilizer & Power sectors. Their century-long legacy reflects reliability, innovation, and precision in instrumentation, ensuring efficient automation solutions.

Please talk about Fuji’s Instrumentation Division and its primary areas of expertise within the instrumentation industry.
Fuji Electrical has a global reputation for its expertise in instrumentation and cutting-edge technologies. Our primary focus is serving various sectors, including oil and gas, fertiliser, power generation, and petrochemical industries. Additionally, we are expanding our presence into the broader utility sector. These represent the primary industries that Fuji is actively exploring.

What key technologies and products distinguish the Fuji Instrumentation Division in the market?
We offer a diverse range of products across three to four distinct segments. These include Pressure Transmitters, Gas analyzers, and Ultrasonic flow Transmitters, PID controllers. Our line of analyzer products is particularly robust, enabling us to effectively measure various critical parameters such as Sox, NOx, CO2, and O2 that are essential in the same industries. Our ultimate goal is to contribute to a healthier environment by precisely measuring these parameters and transmitting the data to pollution control authorities. This, in turn, ensures accurate data collection, thereby supporting our aim of promoting a sustainable environment.

What are the major sectors to which Fuji instrumentation caters?
Our primary focus lies within the oil and gas, petrochemical, refinery, and fertiliser power sectors. We have established a strong presence in these industries by acquiring a comprehensive product line, obtaining necessary certifications, and offering valuable solutions tailored to these segments.

How does Fuji ensure the reliability and precision of its instrumentation products?
Fuji is renowned for the dependability and excellence of its products, with a nearly century-long legacy in the field of instrumentation. Fortunately, 2023 marks Fuji’s centenary in the instrumentation and Fuji Electric product industry. Throughout these years, we have played a significant role in developing cutting-edge products and advanced technologies. We have consistently expanded our product range to cater to the market’s evolving needs. For instance, we have pioneered research and development in hydrogen application security, including developing gold-plated diaphragms for hydrogen-related applications. Our innovations have often set the benchmark in the industry, with competitors and suppliers following our lead. Consequently, with nearly a century of experience, we have a rich history of delivering well-researched and well-organised instrumentation products.

How does efficiency in instrumentation assess the automation of the system?
Efficiency has consistently remained a critical criterion for instrumentation. Instrumentation’s essence lies in achieving 100 percent availability of process parameters, and we specialise in delivering highly precise solutions. These precision solutions ultimately guarantee optimal efficiency, ensuring product parameters are available 100 percent for various industry verticals.

How does efficiency help the automation of the system?
When I mention automation, it involves optimizing all aspects of your processes, from measuring to controlling parameters, and this parameterization is happening only with efficiency. Efficiency is a crucial factor, and over the years, customers have chosen Fuji products and trusted them because of our high level of efficiency and reliability.

In the context of globalisation, how does Fuji’s instrumentation division adapt to meet the unique requirements and standards of various regions and industries?
In today’s era of globalisation, the focus has shifted towards initiatives like achieving zero carbon footprints and Net Zero objectives. Two key areas stand out within these initiatives: Smart Water and Smart Energy. Fuji is well-equipped with a comprehensive range of products and solutions for smart energy, contributing to reducing carbon emissions worldwide. The world emphasises the Smart Water Initiative, which aims to provide sustainable and clean water access. It also ensures the long-term utilisation of water resources, and Fuji plays a pivotal role in assisting water industries. We do so by ensuring accurate and efficient measurements, with our reliable product line comprising Pressure & Flow measurement and solutions supporting the responsible and sustainable management of these vital resources.

What is Fuji Instrumentation’s presence in the automotive sector?
We have a significant presence in the automotive sector, offering a comprehensive product line that includes UPS systems, drives, and field instrumentation. One notable addition to our product portfolio is the S-Flow Ultrasonic Flow meter, which has proven highly valuable in the automotive industry. This meter finds applications in pre-delivery inspections (PDIs), where precise fuel measurement, such as for petrol and diesel, is critical. We’ve received positive feedback and interest from companies like Honda and FIAT, indicating a promising future in the automotive sector.

Looking ahead, India’s automotive industry is flourishing, with a dual focus on traditional vehicles and the emerging electric vehicle market. We’re actively engaged in both segments. In the EV sector, we’ve introduced a range of semiconductor products that facilitate and support the industry’s growth, helping businesses go a long way in this dynamic market.

Regarding the packaging solutions, Dinesh Mungi, Branch Head, B&R Automation, Pune, stated that B&R Automation offers cutting-edge control and automation solutions, including ACOPOStrak and ACOPOS 6D, for adaptable and efficient packaging lines.

Please discuss the specific or advanced packaging solutions from B&R Automation.
B&R is renowned for delivering control and automation solutions to OEMs, focusing on the packaging industry. Our solutions range from basic controls and motion control elements like servo drives and motors progressing to HMIs. As we move into more advanced stages, the integration of vision technology becomes increasingly vital in packaging lines.

In today’s dynamic market, the demand is for highly adaptable and flexible machines. Traditional long production runs are being replaced by the need for quick product changeovers and reduced setup times due to labour constraints. We understand the desire for adaptable, space-efficient production lines, and B&R is well-equipped to provide the ideal solutions.

One of our flagship products is ACOPOStrak, a system featuring long linear motor modules that use magnetic shuttles to move individual products. These shuttles gain intelligence as they are controlled to determine their path and which processing station to visit. For example, imagine a scenario where you’re filling bottles of two different sizes, 100 ml and 200 ml. In a standard setup, you must stop the line and switch between the two sizes. With ACOPOStrak, you can load bottles of any size, and the system detects the size and directs them accordingly. This eliminates the need for changeovers and boosts overall productivity.

Another remarkable product is ACOPOS 6D, which provides six degrees of freedom for handling products. This means you can rotate, shake, move horizontally, and even adjust the elevation of the product. This versatility is invaluable in various applications, such as assembling different perfume caps on a single line, streamlining the process, reducing the need for extensive mechanical setups, and providing operators with a more straightforward and efficient production line. In essence, B&R is at the forefront of shaping the future of packaging solutions.

What is the reason behind using the term six degrees in this context?
This system offers the ability to move the product in multiple directions – horizontally along the X and Y axes, rotationally, and vertically (elevation). This comprehensive movement capability is referred to as having six degrees of freedom. What’s particularly advantageous is that you can also weigh the product while it’s on the shuttle, eliminating the need for an additional weighing system or quality check to ensure it is not perfectly filled.

How has B&R Automation addressed remote access and predictive maintenance to enhance production efficiency?
With recent experiences, highlighting the critical role of remote connectivity in our lives. B&R offers a range of solutions that allow direct access to B&R controls remotely, but we prioritise data security in these connections. This means that engineers can securely access controllers located at a distance.

Predictive maintenance has gained significant importance because people want to minimise downtime. In this regard, we’re actively working on concepts, especially with ACOPOStrak. For instance, we can perform calculations to estimate the shuttles’ overall lifespan and provide operators with indications when maintenance is required. What’s advantageous is that this approach offers flexibility; you don’t need to halt production. Picture this: the shuttle arrives, you remove it, replace it with a new one, and the production line continues running smoothly. So, on the one hand, we offer predictability for maintenance timing, and on the other hand, we ensure that maintenance doesn’t disrupt production.

Please provide insights into the expected market size, both in terms of revenue and product volumes, for this new offering.
This technology is part of a broader ecosystem. When considering a project, comparing it with conventional methods is essential. While adopting this technology may involve additional costs, evaluating the long-term benefits is crucial. Instead of just looking at the initial investment (X), you should also factor in the savings from reduced downtime, increased flexibility, and decreased changeover time. When you calculate the overall productivity of your investment, you’ll likely find that the return on investment is significantly quicker, making it a more advantageous choice.

What is the turnaround time from the initial design phase to product demonstration and market launch?
Typically, the design of such machines can be quite time-consuming, but the process has become significantly faster thanks to simulation tools. People can now visualise the entire process in very little time. They start with a conceptual idea, simulate it, and assess the expected productivity. They can fine-tune the design by adjusting various parameters to achieve their desired results. Any obstacles or issues are identified in advance and addressed through modifications. In essence, while the design phase may take longer, it ensures a high level of certainty that the actual machine, when built, will operate just like the virtual replica. This approach can substantially shorten the time it takes to bring a product to market.

However, the key advantage lies in the overall process. Since you’ve already simulated it comprehensively, you won’t need to undergo repeated redesigns. You build it, initiate the trial phase, and because of the thorough simulation, you’re saving a significant amount of time that would have otherwise been spent on trial and error and subsequent error corrections.

Sarthak Upadhyay, Chief Manager, Mobile Robotics, Addverb, asserts that smart technologies have proven beneficial for manufacturers in maintaining efficiency and increasing productivity to remain competitive in the ever-evolving market.

How has the integration of IoT devices with AI impacted smart manufacturing operations?
With the advancements in the technological landscape, it has become increasingly vital for manufacturers to incorporate cutting-edge technologies such as IoT devices and robotics into their manufacturing operations. These technologies play a crucial role in improving communication and storing and managing data across a network of interconnected machinery.

IIoT devices enhance machine vision, monitor inventory levels, and analyse data to optimise the mass production process. IoT devices and sensors collect data from various sources, including machines, equipment, and assembly lines.

AI-driven insights are instrumental in predictive maintenance, optimising resource utilisation, waste reduction, and enhancing production quality. Algorithms powered by AI can rapidly process and analyse inputs to identify patterns and trends, providing manufacturers with insights into the functioning of their production processes. Additionally, AI facilitates efficient real-time data analysis.

The integration of smart technologies has proven highly advantageous for manufacturers by enabling them to maintain efficiency and boost productivity, thus enabling them to stay competitive in the constantly evolving market.

In what ways do ASRS and robotic systems optimise vertical storage, enhancing space utilisation?
Automated Storage and Retrieval Systems (ASRS) and robotic and shuttle systems employ key strategies to enhance space utilisation in vertical storage. Firstly, they utilise tall storage racks that fully exploit vertical space, reducing the necessity for extensive horizontal storage areas.

Secondly, the cranes or shuttles within ASRS systems are exceptionally precise in storing and retrieving materials from specified locations, ensuring dense and efficient item storage. This precision in placing items reduces wasted vertical space. Moreover, ASRS systems can dynamically adapt the storage of goods based on demand, ensuring that frequently accessed items are stored at easily reachable heights, further optimising vertical space. Additionally, these systems eliminate the need for wide human-operated aisles, traditionally required for navigation, allowing for more storage within the same footprint.

Lastly, ASRS systems provide quick and efficient access to goods, reducing the time required for retrieval and minimising the need for excess storage to accommodate slow retrieval processes.

How does IIoT enhance predictive maintenance in manufacturing and contribute to cost savings through proactive management?
The Industrial Internet of Things (IIoT) is revolutionising maintenance practices in manufacturing by implementing predictive maintenance. Predictive maintenance using IIoT relies on continuous sensor-based data monitoring within machinery. These installed sensors track real-time parameters, including temperature, vibration, pressure, and performance metrics. This collective data enables anticipation of maintenance needs earlier, ultimately reducing unexpected equipment breakdowns.

Furthermore, the decrease in unplanned breakdowns alleviates financial burdens for manufacturers and ensures the sustained efficiency and productivity of operations, ensuring smooth continuity. It also contributes to extending the lifespan of equipment and machinery, which, in turn, diminishes the likelihood of accidents and injuries for the workforce, as equipment can be replaced or repaired on a scheduled basis.

In addition, predictive maintenance streamlines the management of spare parts inventory. It provides clear indicators of which components will likely require replacement soon, empowering manufacturers to maintain an efficient and cost-effective spare parts inventory. This minimises excess inventory and the associated costs while enhancing safety and reliability. Ensuring that equipment is in optimal condition reduces the risk of accidents and bolsters overall operational dependability.

Moreover, predictive maintenance facilitates a more efficient allocation of resources. By incorporating maintenance activities into the production schedule, resources like labour and materials are utilised more effectively.

What benefit does AI-driven defect detection offer regarding precision during the inspection process?
AI-powered defect detection offers numerous benefits, primarily enhancing precision during inspection. These AI algorithms have been trained on extensive datasets, enabling them to identify even subtle or complex defects with high accuracy. Furthermore, AI systems maintain consistent performance, unlike humans, who can be influenced by fatigue or distractions. This ensures that defects are consistently and accurately identified on every occasion.

AI can swiftly process vast amounts of data, facilitating rapid inspections crucial in time-sensitive production cycles. Additionally, AI-powered systems can identify the likelihood of errors, significantly reducing the risk of passing faulty products or rejecting good ones. They are adaptable to various environmental conditions and product appearances, ensuring reliable defect detection.

Moreover, AI improves scalability, enabling the handling of larger workloads without incurring additional costs. AI maintains objectivity in its assessments, eliminating arbitrary judgments to ensure that error identification is consistently based on precise parameters. As quality standards change, AI models can be adjusted based on new information and user feedback, improving error detection accuracy.

How will the integration of IIoT in manufacturing reshape the growth of the manufacturing industry?
The Industrial Internet of Things (IIoT) is a technology designed to transform the manufacturing industry, particularly when the demand for smart factories is rising globally. IIoT facilitates real-time data exchange through improved connectivity and communication, increasing productivity and efficiency.

Furthermore, IIoT enhances production processes by harnessing data insights, producing higher-quality goods and improved throughput. It also simplifies inventory management, ensuring accurate restocking and reducing excess inventory. Additionally, IIoT provides advantages in quality control, error reduction, and energy efficiency.

IIoT further offers end-to-end visibility in the supply chain, facilitating logistics optimisation and timely deliveries. It enables greater customisation and personalisation in manufacturing to meet individual customer demands. Moreover, real-time monitoring of conditions and equipment status enhances safety and compliance.

What challenges are manufacturers facing while implementing IIoT technologies in their production processes?
Advanced technologies often come with challenges. Manufacturers are using IIoT also have challenges in their production processes, such as:

High Initial Costs: Incorporating IIoT includes integrating new hardware, software, and infrastructure changes, which can result in a substantial initial implementation cost. Smaller manufacturers may need more capital and available resources.

Security Concerns: With a vast amount of data, maintaining data privacy becomes critical. Given the high level of connectivity in IIoT, the primary risks revolve around cybersecurity threats. Safeguarding sensitive data and ensuring security becomes a significant challenge.

Skill Gap: The successful implementation of IIoT requires a skilled workforce. Training existing employees for skill enhancement or hiring new talent with the required skills can pose a challenge for manufacturers.

Infrastructural Challenges: Many manufacturing facilities still operate with outdated systems and machinery, making it challenging to integrate IIoT solutions seamlessly. It can be difficult and time-consuming to integrate new technologies with the infrastructure that already exists.

What are the technological, ethical, and practical challenges and opportunities associated with adopting your innovations in healthcare?
Robotic technologies have brought about a revolution in various medical procedures worldwide, and one of the most widely adopted applications is the use of telerobotic ultrasound. This groundbreaking innovation allows for remote ultrasound procedures, utilising wired and wireless ultrasound procedures.

An excellent illustration of this pioneering technology is the partnership between Addverb, AIIMS Hospital, and IIT Delhi, particularly during the challenging COVID-19 pandemic. Given the heightened risks of healthcare professionals being near infected patients, traditional ultrasound procedures presented a significant danger. Over roughly 7-8 months, the team diligently refined and perfected this technology.

Telerobotic ultrasound enables radiologists to control the ultrasound probe from a secure remote location. The patient’s images are transmitted to the doctor’s monitors through a Wi-Fi network. This allows the doctor to interact with the patient and observe all the acquired images.

Vineet Seth, the Managing Director of Mastercam APAC for South Asia & Middle East, asserts that CNC machines are indispensable in die and mould manufacturing, serving as the backbone of discreet production processes. Their affordability, versatility, and unparalleled precision and efficiency make them invaluable. Seth also highlights the significant impact of recent CAD/CAM software advancements on enhancing CNC programming.

What key factors drive the shift towards advanced manufacturing techniques in the die and mould industry?
The die and mould industry has recently witnessed a decisive shift towards advanced manufacturing techniques, particularly in multi-axis and multi-tasking machining. This shift has seen manufacturers adopt advanced manufacturing techniques, particularly in multi-axis and multi-tasking machining. They increasingly embrace cutting-edge software solutions to optimise machining processes, enhance efficiency, and achieve superior precision. As a result of these progressive manufacturing trends, there has been a noticeable reduction in manufacturing lead times and an overall improvement in the quality of moulds and dies. This has made manufacturers more competitive and pushed the boundaries of what can be achieved in terms of complexity and precision in their products.

Furthermore, on the automation front, robots play a pivotal role in elevating mass production and precision. They are deployed for various tasks, including material handling on and off machines and machining large moulds for advanced composite materials. Integrating advanced sensors and software with these robots increases accuracy, producing high-quality end products. Moreover, robots’ ability to operate continuously around the clock ensures reduced downtime and a substantial increase in production capacity.

How are manufacturers adapting their operations and skillsets to fully leverage sophisticated tools for enhanced precision and efficiency?
CAD and CAM technologies are fundamentally reshaping the future of die and mould manufacturing in numerous ways. CAD facilitates the creation of intricate and innovative moulds and die designs with exceptional precision. CAM software, such as Mastercam, complements this by generating efficient tool paths that minimise machining time and material wastage. Through their advanced features and capabilities, CAM software offers sophisticated toolpath strategies that optimise machining processes, reduce cycle times and enhance efficiency. Multi-axis machining capabilities enable intricate contouring and precise surface finishing, addressing the complex geometries often found in dies and moulds. Simulation and verification tools help identify and rectify errors before they occur, minimising scrap and rework. Customisation and automation options streamline workflows, while efficient toolpath editing ensures precise control over machining operations. Further, seamless integration with CAD facilitates a smooth transition from design to manufacturing, and comprehensive tool management features enhance tool selection and usage tracking. As further development occurs in the respective domains, this software empowers manufacturers to remain competitive by consistently producing complex, high-precision, efficient and quality components.

What new advancements have occurred in CAD/CAM software tools for CNC programming needs?
CAD/CAM software tools have seen significant advancements in recent years. These improvements encompass various aspects of CNC programming. User interfaces have become more user-friendly, simplifying the toolpath creation process. Multi-axis machining capabilities have expanded, enabling the production of complex parts in shorter times. Furthermore, software algorithms now offer toolpath optimisation, leading to reduced cycle times and minimised tool wear. These developments signify a continuous effort to enhance efficiency and precision in CNC programming for die and mould manufacturing. Specifically, advancements have been made to offer more precise visualisation of multi-tasking machining processes, facilitating collision detection. Robust support for live tooling allows for milling and drilling operations in a single setup, while synchronised tool paths streamline complex operations.

Additionally, improved post-processing capabilities generate CNC code tailored to multi-tasking machines. Furthermore, integrating hybrid machining enables combining subtractive and additive processes in one setup, helping manufacturers accomplish end-to-end manufacturing in a very small real-estate footprint. Comprehensive material libraries cater to additive manufacturing requirements, and Toolpath optimisation reduces cycle times and enhances machining quality.

What innovations and developments in CNC and CAM can we anticipate to further optimise precision, speed, and efficiency in die and mould manufacturing?
In the realm of die and mould manufacturing, CNC (Computer Numerical Control) machines are the workhorses, carrying the entire discreet and production manufacturing on their backs due to their affordability, range, exceptional precision and efficiency. Think of them as the artisan’s tools for crafting intricate masterpieces. For instance, when creating moulds for precision-engineered aerospace components, CNC machines ensure that every contour and detail align flawlessly, meeting the stringent standards of the aerospace industry. Similarly, CNC machines work tirelessly in the automotive sector to produce intricate dies used in manufacturing complex vehicle components. These machines go beyond mere automation; they orchestrate continuous production, significantly cutting down on lead times and enhancing overall operational efficiency. While many complex Dies and Moulds were made even before CNC machines, the time and cost required to make them today has exponentially reduced, increasing reliability and accuracy by miles – thanks to CAM software and CNC machines!

How is the growth of injection moulding impacting the die and mould industry?
The continued expansion of the injection moulding sector exerts a direct influence on the die and mould industry. Mould manufacturers progressively accommodate the increasing need for moulds essential in producing diverse injection-moulded items. Given plastic’s intrinsic moldability, even in exceptionally delicate and intricate configurations, plastic injection moulds typically require rigorous precision machining and unique surface finishing processes. Consequently, this trend drives the demand for CNC machinery, cutting-edge manufacturing methodologies, contemporary CAD/CAM systems, compact and highly efficient cutting tools, and advanced high-performance cutting fluids, among other technological requisites. We can see how this impacts various markets, businesses and macro-economics.

How are additive manufacturing and 3D printing influencing the production of components and equipment parts in India?
Additive manufacturing and 3D printing technologies are revolutionising component and equipment part manufacturing in India and worldwide. These technologies offer rapid prototyping capabilities, expediting mould development and die development. They excel in producing components with complex geometries – especially conformal cooling in complex cores and cavities for moulds, all while minimising material waste. The flexibility and speed of additive manufacturing enhance manufacturing capabilities and enable innovative solutions in the die and mould industry, ultimately increasing efficiency and encouraging design freedom.

What material and design innovations are shaping the progress of the die and mould industry?
The die and mould industry has witnessed significant innovations in materials and design techniques, fostering greater efficiency, durability, and adaptability in mould and die manufacturing/production. These advancements encompass high-performance tool steels with enhanced hardness and wear resistance, novel coatings like diamond-like carbon and titanium nitride for improved surface properties, and integrating 3D printing and additive manufacturing to create intricate mould components and cooling channels. Composite materials blending metals and ceramics are gaining traction for their exceptional thermal stability and durability, ideal for high-volume manufacturing. Moreover, innovations like conformal cooling design, simulation software, and digital twin technology are streamlining the optimisation of mould designs and real-time production monitoring. Specialised materials for demanding applications and a focus on sustainability through light-weighting techniques further underscore the industry’s commitment to advancing mould and die technology – especially in aerospace and medical applications.

What latest developments have occurred in the die and mould industry to support the EV industry?
The burgeoning electric vehicle (EV) industry catalyses developments within the die and mould sector. Manufacturers produce custom moulds tailored to the specific components required for EVs, such as battery casings and motor components. Material advancements are another crucial facet, focusing on developing materials optimised for EV components, considering factors like heat dissipation and weight reduction. These developments validate and demonstrate the adaptability of the die and mould industry to meet the unique demands of the rapidly expanding EV sector.

Atul Aggarwal, the Whole Time Director at Sterling Tools Limited, is committed to spearheading advancements in automotive technologies, especially within E-Mobility. His dedication aims to surpass expectations and significantly contribute to a greener and more sustainable future.

Please talk about STL product portfolio and other business activities, as well as your primary product offering in the automotive industry? 
At Sterling Tools Limited (STL), we have a rich heritage in the automotive industry that extends over four decades. Our company excels in two primary business areas: Fasteners and EV Components. Our product range is extensive, catering to a wide range of industries, from two-wheelers to Heavy Commercial Vehicles.

Our Fastener Product Range includes Standard, Chassis, Special, and Engine Fasteners, all meticulously manufactured in state-of-the-art facilities located in the National Capital Region (NCR) and Bengaluru. STL has boldly ventured into the EV Components business through our 100% subsidiary – Sterling Gtake E-Mobility Limited (SGEM). As pioneers in this space, we have successfully established a strong market presence in electric two-wheelers as well as the three-wheeler and LCV segments.

Our unwavering commitment to innovation, operational excellence, and strategic partnerships drives our journey towards sustained growth and success in the automotive industry. We envision leading the way in advancing automotive technologies, especially in the field of E-Mobility. We continuously strive to exceed customer expectations and contribute to a greener, more sustainable future.

Which geographical regions does STL supply their cold forged high-tensile fasteners to, and what is their standing as a fastener manufacturer in India?
STL Fasteners, a leading business in the Indian OEM market, specializes in supplying cold-forged high-tensile fasteners. Our strategic advantage lies in our four advanced manufacturing facilities, strategically located in Faridabad and Bengaluru. This extensive network enables STL to serve major original equipment manufacturers (OEMs) across the country and in a diverse range of segments, including passenger vehicles, commercial vehicles, two-wheelers, construction equipment, and farm equipment.

Over the past four decades, we have firmly established our position in India’s automotive industry, earning a reputation for operational excellence and ethical practices. While our primary focus remains on the domestic market, we actively explore opportunities to export our products to other regions.

The cornerstone of our success lies in our unwavering commitment to providing quality and reliable products to our customers through continuous investments in equipment and process upgrades. This dedication has earned us the trust of our customers, reaffirming our standing as a dependable and respected supplier in the automotive industry. With this foundation of continuous improvement and customer satisfaction, STL remains focused and dedicated to shaping a brighter future in the automotive realm, both within India and on the global stage.

What market growth do you see for Motor Control Units supply to high-speed scooter manufacturing plants?
We anticipate significant growth in our Motor Control Units (MCUs) business. SGEM has positioned itself at the forefront of the EV component business, offering a robust portfolio of MCUs for all segments of the industry. The rapidly growing acceptance of electric two-wheelers, particularly high-speed scooters, as well as the electrification of three-wheelers and LCVs, will drive a surge in MCU demand.

SGEM is proactively looking to expand its manufacturing capacity from 3 lakh units to 6 lakh units per annum and aims to double its revenue from the EV segment in FY24. This strategic expansion, combined with the upward trajectory of the EV market, presents exciting growth opportunities for STL’s MCU business.

Can you provide an overview of STL’s financial performance, and the revenue generated from their Fastener Business and EV Component Business?
In FY23, STL achieved a commendable standalone total income of Rs. 604 crore. Our fastener business demonstrated consistent growth, benefiting from robust customer relationships and dedicated product development efforts.

Meanwhile, the EV component business emerged as a powerful growth driver, propelling STL to capture over 40% market share in the high-speed electric two-wheeler segment. In FY23, the revenue contribution from the EV component business surged from 7% in the previous fiscal year to a remarkable 22%, reaching Rs. 171 crore. It is our ambition that, in the medium term, green technologies will make up one-third and eventually half of the group’s revenues.

In what ways Sterling Gtake E-mobility (SGEM) business is associated with STL?
STL maintains a laser-sharp focus on the automotive industry. Our core competence lies in automotive industry processes and relationships, and we are committed to ongoing investments in this area. We aim to leverage our expertise and credibility in the automotive sector to develop additional auto ancillary businesses.

The automotive industry is currently transitioning towards ACES (Autonomous, Connected, Electric & Shared) technologies, and we have adjusted our focus to align with these trends. We are actively working to build competencies that will support and enable this transition in the automotive sector.

While the power electronics core of our MCUs is fundamentally different from the metal forming operations in our fastener business, both verticals share a common focus on automotive quality systems and process excellence. Although their facilities operate independently, they serve the same customers.

We remain vigilant in our search for additional opportunities in the ACES space and anticipate announcing new ventures in this area in the coming months.

What trends are influencing transitioning towards EV manufacturing and charging infrastructure?
The shift towards EV manufacturing and charging infrastructure was initiated by global sustainability goals and government incentives. Technological advancements and cost efficiencies in batteries have significantly boosted consumer confidence in EVs. Interestingly, as OEMs have introduced high-quality vehicles, consumer adoption is also being driven by the performance, features, and ride quality that EVs offer. Furthermore, consumers have experienced the promised Total Cost of Ownership (TCO) savings, making them more willing to bear the initial higher cost.

EV manufacturing differs from Internal Combustion Engine (ICE) manufacturing. ICE powertrain technology is typically developed in-house by OEMs, serving as a significant barrier to entry in the automotive manufacturing industry. However, in the case of EVs, there are external partners capable of supporting the development and supply of EV powertrains. This change is expected to fuel the emergence of new players and start-ups. As a result, we are now witnessing the entry of hundreds of new participants in the EV market, some of whom will survive the inevitable shakeout and industry consolidation.

The rising adoption of EVs will inevitably create a demand for charging infrastructure, and this will evolve in several ways. Commercial users will establish charging infrastructure at their warehouses and central locations. On the other hand, retail users will require convenience charging, such as at their homes, offices, and malls. This will become a “Real Estate” play, necessitating public and private participation and a significant push from the government. Additionally, we can anticipate further adoption of battery swap stations. With so many different approaches and options to address the challenges of charging infrastructure and range anxiety, the future promises exciting developments. So, it’s safe to say, “Watch this space.”

What advancements are shaping India to be the third-largest automotive industry globally by 2030?
The Indian auto industry has experienced substantial growth, driven by India’s increasing economic strength and the rising wealth of our population. Over the years, the Indian auto industry has made significant investments in capacity and capability. Some Indian auto ancillaries have even emerged as truly global-scale players.

Global sustainability goals and government incentives are accelerating the shift towards EV manufacturing, positioning the country for substantial growth in the automotive sector by 2030. With advancements in EVs, autonomous driving, and government support, India is poised for significant expansion in its automotive sector. The integration of technologies like IoT, AI, and ML is further enhancing safety features, facilitating the transition towards electric mobility.

What are the potential challenges when adopting automation in production processes?
The adoption of automation in production processes presents several “challenge-can-be-opportunities” scenarios. Initially, the need for significant investments and infrastructure changes may appear daunting, especially for well-established industries with long-standing infrastructure and processes. However, this challenge also creates an opportunity for transformative advancements in efficiency and productivity once the new technology is seamlessly integrated through strategic planning.

The human factor plays a crucial role as well, as the need for workforce training and digital skills adaptation offers the opportunity to foster a more dynamic and versatile workforce. Additionally, data security and privacy concerns, while critical, also present an opportunity to implement robust measures that not only safeguard sensitive information but also build trust with customers and stakeholders.

By proactively addressing these challenges, businesses can unlock the full potential of automation, leading to increased competitiveness, innovation, and overall growth in the industry.

At STL, we are committed to automation and Industry 4.0, and we believe that our new plants set world-class standards and serve as a benchmark for the industry.

What are your suggestions for the automotive industry in the near future?
The success of the automotive industry hinges on prioritizing innovation and making substantial investments in research and development to advance electric vehicles (EVs), autonomous driving, and connectivity. Embracing sustainability by adopting eco-friendly materials, energy-efficient technologies, and environmentally conscious manufacturing processes is crucial for building a greener future. Collaborating with the government to establish robust charging infrastructure networks and upskilling the workforce to adapt to new technologies are essential steps to overcome the challenges associated with EV adoption. Additionally, fostering partnerships with technology leaders and addressing data security and privacy concerns in connected vehicles can help the industry thrive in the dynamic and competitive landscape that lies ahead.

The constantly and rapidly evolving landscape offers opportunities for strategic partnerships, and some of the old paradigms of competition are now being redefined. Being nimble and adaptable is essential for navigating these scenarios and staying committed to long-term goals.

In the landscape of India’s oil and lubricants market, a transformation is underway. Amid a global shift towards sustainability and the imperative to cut emissions, the lubricants industry finds itself at the forefront of innovation. This story delves into the latest advancements, surging demand, and eco-friendly solutions shaping the future of oils and lubricants within the Indian market.

In India, the growth of industries and cities has greatly increased the need for lubricants. One of the main reasons for this is the booming automotive industry, which includes cars, trucks, and motorcycles. They all require lubricant solutions to run smoothly. But it is not just vehicles. Other sectors like manufacturing, construction, data centres, and agriculture have expanded rapidly. These industries rely on machinery and equipment that need good lubrication to function well. Hence, as India becomes more industrialised and urbanised, the demand for lubricants keeps increasing.

The lubricant industry is significant for making machines work better, especially in metal cutting. The companies that make machines and tools are changing how they do things. They are choosing more precise and special machines that can work on their own, which makes things safer and helps them make more money. In the manufacturing sector, single and multistage air compressors also have a critical role to play. They run for a long time at really high temperatures. It can result in increased deposits in discharge systems. But the big new thing is emerging data centres. These are places where lots of computers and air conditioners run to keep our data safe. Lubricants are most important here because they help save energy. The lubricants play a crucial component in the efficient operation of machines.

Demand and growth
According to a recent study by Mordor Intelligence, there is a forecasted increase in the global demand for industrial lubricants. It is expected to grow from 21.35 billion litres in 2023 to 25.21 billion litres by 2028, at a CAGR of 3.38 percent. Sustainability, particularly in terms of reducing carbon emissions, is a critical focus in this context.

Modern manufacturing relies heavily on machine tools, and an essential element in ensuring their functionality is the application of metalworking fluids. These fluids are vital in minimizing heat from friction during cutting or grinding processes, ensuring seamless and effective manufacturing. Their applications range from producing coins to crafting aircraft engine parts, providing improved accuracy and protection against bacterial contamination. This trend is expected to pick up speed.

Technology improvements in metalworking fluids make it harder to tell the differences between the types and their pros and cons. These fluids are poised to become more efficient, cost-effective, and environmentally sustainable. Dr. Kalpendra Rajurkar, Head of Technology at GP Petroleums, emphasises that they will continue to be an increasingly indispensable part of the manufacturing process as they evolve.

Automotive lubricants
According to a recent report by Bain & Company, India is set to witness a significant transformation in its automotive landscape by 2030. The report projects that electric vehicles (EVs) will account for an impressive 35 to 40 percent of all vehicle sales in the country, marking a substantial rise from the modest 2 percent figure recorded in 2022. This surge in EVs is compelling major lubricant companies to introduce a range of fluids specifically designed for EVs, which may address the need for sustainable solutions. The remarkable growth of EVs can be attributed to changes in consumer behaviour. It also banks on strong policy support and investments from governments and the private sector.

Amid a rapidly evolving automotive industry, the demand for automotive lubricants is significantly transforming. Today’s consumers seek lubricants that boost engine fuel efficiency and deliver the best overall performance. However, the emergence of electric vehicles in the transportation sector is poised to usher in disruptive changes, adding another layer of complexity to this shifting landscape. Consumers seek vehicles with fuel efficiency, lower emissions, and reduced environmental impact as the environmental consciousness grows.

Electric vehicles (EVs) have distinct operational demands. It sets them apart from internal combustion engines, making it essential to develop custom lubricants. These specialized lubricants are carefully crafted to cater to the specific requirements of electric drivetrains, encompassing electric motors, transmissions, and battery systems. The growing demand for eco-friendly and sustainable options is a notable transformation in the automotive market. To comply with eco-friendly regulations, the lubricant industry is bound to intend an approach, thus transitioning from mineral-based oils to biodegradable alternatives.

Sustainability lubricants
In an era of environmental consciousness, the lubricants industry is making strides towards sustainability. With concerns about greenhouse gas emissions and environmental impact, there’s a growing emphasis on prolonging equipment life. One significant development in this regard is the rise of bio-based lubricants. These lubricants have specifics to offer reduced carbon footprints and biodegradability. Companies in India should focus on aligning with global trends in sustainable manufacturing.

The impact of eco-friendly standards on the lubricant industry is of utmost importance. A key aspect of this involves the development of greener formulations. Adopting environmentally friendly standards has brought about a fundamental shift in lubricant formulation, production, and usage. Lubricants derived from hydrocarbons have been found to have detrimental effects on the environment. This has created a growing recognition of the importance of ‘Environmental, Social, and Governance principles for sustainable growth. Jayanta Ray, GM Industrial and OEM of GS Caltex India, emphasises that climate change has resulted in global environmental challenges, prompting countries and businesses to collaborate in addressing these issues. However, Hitendra Bhargava, CEO and Regional Management Board Member Asia-Pacific of Klüber Lubrication, remarks an increasing demand for sustainable and environmentally friendly solutions across various industries as natural resource depletion rises.

In industrial lubricants, synthetic oils are making waves for their outstanding performance. These high-tech lubricants are turning heads with their ability to withstand extreme temperatures, extend the time between oil changes, and reduce wear and tear on machinery. As industries in India strive to boost efficiency while staying eco-conscious, the popularity of synthetic lubricants is set to soar. But there is a shift towards eco-friendliness, too, with a growing preference for biodegradable base oils, renewable resources, and additives that are free of harmful substances.

Digital data-driven lubrication
The digital age has yet to spare the lubricants industry. The implementation of IoT and data analytics has transformed maintenance practices. Predictive maintenance allows for precise lubrication scheduling. This extends the life of equipment and also reduces downtime, increasing productivity. In India, industries are gradually embracing these data-driven lubrication practices. This shift is particularly prominent in sectors such as manufacturing, where unplanned machinery failures can result in substantial financial losses. By optimising lubrication schedules based on machine conditions, companies achieve significant cost savings and increased operational efficiency.

Technologies impacting oil and lubricants
The machine makers are now adopting cutting-edge technology, especially from a performance standpoint. Praveen Nagpal, Chief Technology Manager, Shell Lubricants India, said, “Today, the equipment is becoming more compact and smaller; and at the same time, oil quantity is decreasing.” The same oil must perform under stress conditions because of compactness. In the ever-evolving world of lubricants, products must continuously evolve to tackle emerging challenges while safeguarding equipment safety. Advanced lubrication formulations are crucial in preserving equipment health, minimising downtime, and facilitating efficiency, productivity, and profitability.

With its burgeoning economy and industrial landscape, India has experienced a significant surge in the demand for high-quality lubricants. In response to this growing need, manufacturers and suppliers in the lubricant industry are stepping up substantial investments in cutting-edge technology since lubricants should be equipped to meet the ever-evolving challenges of modern industrial applications.

Investments and collaborations
In response to the increasing need for lubricants and to drive innovation, local and international companies have made substantial investments in manufacturing facilities and research hubs within India. These investments serve a dual purpose: consistently providing high-quality lubricants and stimulating job creation while boosting the local economy. Collaborations between Indian oil firms and global lubricant manufacturers have become increasingly prevalent. These alliances seek to capitalise on the strengths of both parties—Indian companies’ local knowledge and extensive distribution networks, combined with the technical expertise of renowned global lubricant corporations. Such partnerships are crucial in introducing advanced lubrication solutions to the Indian market.

A greener and more efficient future
In conclusion, India’s oil and lubricants market is transforming remarkably, fueled by surging demand and a commitment to sustainability. The expansion of industries and the call for eco-friendly solutions have sparked innovation and substantial investments in the sector. India is advancing along its industrialisation journey. The lubricants industry is important in shaping the nation’s greener and more efficient future.

In the landscape of the automotive sector, the spotlight is firmly on the quest for heightened fuel efficiency, driving a surge in demand for ultra-thin oils. This trend shows no signs of slowing down, with both the automotive and associated industries experiencing a significant uptick in lubricants. Consequently, there is an urgent call to action for streamlining lubricant usage. Through strategic investments, collaborative partnerships, and cutting-edge technological innovations, India’s lubricant market is poised for a remarkable transformation to cater to the ever-evolving demands of various industries. It is also pivotal in advancing the nation’s sustainable development goals.

As India progresses, its lubricants industry will remain at the forefront of progress while committed to environmental responsibility. This trajectory propels us toward a future characterized by enhanced efficiency and a dedication to sustainability.

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Praveen Nagpal, Chief Technology Manager, Shell Lubricants India 
“Nowadays, the equipment is becoming more compact and smaller, and oil quantity is decreasing.”

Jayanta Ray, GM Industrial, and OEM, GS Caltex India
“Climate change has resulted in global environmental challenges, prompting businesses to collaborate in addressing sustainable issues.”

Hitendra Bhargava, CEO and Regional Management Board Member Asia-Pacific of Klüber Lubrication
“An increasing demand for sustainable and environmentally friendly solutions exists across various industries as natural resource depletion rises.”

Dr. Kalpendra Rajurkar, Head of Technology, GP Petroleums.
“As the technology that goes into developing metalworking fluids evolves, they will continue to get more efficient, economical and sustainable.”

In a rapidly evolving landscape, the manufacturing sector faces unprecedented disruptions. Tools, a cornerstone of production, must adapt to varying sector needs. The Indian Die & Mold sector is primed for substantial growth, projected to surge by 10-15 percent in the coming years, as per TAGMA’s survey.

The die and mould industry is under a significant transformation. The manufacturers are embracing advanced manufacturing techniques. They are incorporating cutting-edge software solutions to optimise their machining processes, enhance efficiency, and achieve greater precision. Recently, with the rapid emergence of EVs, the development of autonomous cars is also happening faster, more than enough to propel innovation.

Vineet Seth, Managing Director of Mastercam APAC for South Asia and the Middle East, highlighted how the burgeoning EV industry had catalysed innovations within the die and mould sector. Manufacturers need to customise moulds explicitly tailored to the components required for EVs, such as battery casings and motor parts. Here, it is essential to prioritise the development of materials tailored for EV components. However, the particular emphasis has to be on factors such as efficient heat dissipation and weight reduction. The developments underscore the die and mould industry’s adaptability. It needs time to meet the distinctive demands of the expanding EV sector.

Consequently, the industry has to deliver tools more efficiently, with higher accuracy, and bracing for automation. That calls to incorporate automation. The innovative laser-cutting equipment is an example of automation in action, requiring less human intervention. Maulik Patel, Executive Director of Sahajanand Laser Technology, talked about the modern features of today’s laser cutting machines. These are compact and faster for more precise cutting speeds. He stated that these powerful machines should meet the features to cut various materials, including thin and thick metals such as steel and aluminium.

Technologies shaping the future
The emergence of 3D printing, or additive manufacturing, marks a departure from traditional subtractive methods. While subtractive manufacturing involves starting with a solid block and removing material until the desired part is achieved, 3D printing operates in reverse. In mould manufacturing, where injection, processing, cooling, and ejection are critical stages, efficient cooling is particularly vital. Shatyabrata Das, Senior General Manager at IAC-International Automotive Components, hints at the advantages of 3D printing in this context. With 3D printing, cooling channels can be designed and printed precisely to meet specifications, greatly enhancing cooling efficiency. This leads to faster cooling of moulded parts, ultimately reducing cycle times, a game-changer in manufacturing.

Further, CAD and CAM technologies are at the forefront of shaping the future of die and mould manufacturing. These two form the very foundation of this industry. One of the critical phases is mould design. Precision machines like CNC or VMC are employed in shaping the final product and bringing intricate designs to life. Now, the advanced 5X machines have emerged, representing the cutting edge of this technology. CAM involves translating the CAD model into machine-readable code, which the computer-controlled machinery comprehends and executes. In contemporary manufacturing, this CAD-to-CAM workflow has become indispensable. It now forms an integral part of the entire production process.

Discussing this transformative phase, Vineet emphasises how CAD and CAM technologies fundamentally reshape the die and mould manufacturing landscape in multiple ways. CAD empowers the creation of intricate and innovative mould and die designs with unparalleled precision. Moreover, introducing robotic systems capable of continuous operation round the clock plays a pivotal role in minimising downtime, thus enhancing production capacity.

Trends in the die and mould industry
The recent trends and technological advancements stand to reshape the way businesses operate, particularly in India. The localisation of mould production in India reduces development times, accelerating the overall product development process. One can be the integration of robots into the die and mould industry. Robots are pivotal in manufacturing plastic components, particularly when combined with dies and moulds.

The adoption of robotic systems interfacing with manufacturing machines is revolutionising production. This innovation has mitigated the risk of problems during the moulding process. As a result, robots in the moulding industry are propelling the sector’s growth and competitiveness.

Injection moulding is reshaping the way for the production of various plastic components. The mould manufacturers must adapt to meet the escalating demand for moulds that produce various injection-molded items. Even in delicate configurations, the plastic’s inherent moldability underscores the importance of precision machining and surface finishing processes in plastic injection moulding. Vineet emphasises the critical role of precision in this process. Injection moulding is of special use in the automotive industry for its plastic components.

One innovation that has made waves in injection moulding is ‘conformal cooling’. Leveraging the capabilities of 3D printing technology, conformal cooling has ushered in significant improvements in mould performance. Furthermore, smart software also is emerging as a game-changer in the metal forming industry.

Improvements and advancements
There have been advancements in providing more precise visualisations of multi-tasking machining processes. An aspect of CAM technology is its ability to accelerate production. Also, the software algorithms resulted in reduced cycle times and minimised tool wear. These developments underscore a commitment to refining CNC programming in die and mould manufacturing. It monitors cutting tool performance and ensures precise control and efficient tool movement. This optimisation has led to a reduction in manufacturing processes, resulting in a continuous workflow. Each year brings fresh additions to the core software, continually boosting the efficiency of mould manufacturing. Consequently, the cycle from CAD design to actual production on the factory floor gets reduced, with improvement in overall accuracy.

The Indian die and mould industry is on the brink of significant improvements, as indicated by a TAGMA survey forecasting a growth rate of 10-15 percent in the coming years. A couple of Tools Rooms with foreign direct investment (FDI) have already set up shop in the country. To capitalise on this opportunity, existing toolmakers in India need more gearing up to embrace these new technologies to stay competitive. The technologies call for upgrading skills. In light of the need to train the workforce, Vivek Nanivadekar, Executive Director of FIBRO India Precision Products, underscores the importance of aligning the education system with industry needs. He advocates for a swift examination of the curriculum in technical institutes across India. These educational programs should be upgraded to include the latest innovations and techniques to ensure that graduating toolmakers are well-versed in the advancements of the field. This, in turn, enhances employability in factories where new technologies and machines are in use. The call for the right training and education in the Indian die and mould industry will be a course toward progress and competitiveness.

Way forward
Cutting-edge advancements in materials and design techniques mark the die and mould industry transforming. It results in enhanced efficiency, durability, and adaptability in manufacturing. A hybrid manufacturing approach that fuses Additive Manufacturing (AM) and Subtractive Manufacturing (SM) is taking centre stage, promising varied possibilities.

Talking about the growing importance of high-tech manufacturing in die and mould tool rooms, Vineet says that precision manufacturing – a hallmark of this industry, seamlessly caters to the exacting demands of the aerospace and defence sectors. CNC machines are at the forefront. They ensure alignment of every detail. Such machines meet stringent aerospace standards while tirelessly crafting intricate dies for complex vehicle components in the automotive sector.

Additive manufacturing and 3D printing technologies are revolutionising component production, offering rapid prototyping, reducing material waste, and enhancing design freedom. As industries adapt and innovate, the die and mould sector will play a decisive role in shaping the manufacturing landscape. Automotive remains a prime driver, and as the industry navigates changes, toolmakers will continue to play a vital role. The future holds the promise of IoT-enabled machines, the adoption of Industry 4.0 principles, and the digitisation of applications. The advancements must propel the industry to new technologies, refurbishing the industry’s future.

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Vineet Seth, Managing Director – South Asia & Middle East, Mastercam APAC.
“Manufacturers are now producing custom moulds explicitly tailored to the unique components required for EVs, such as battery casings and motor parts.”

Shatyabrata Das, Sr. General Manager, IAC-International Automotive Components
“With 3D printing, cooling channels can be designed and printed precisely to meet specifications, greatly enhancing cooling efficiency.”

Vivek Nanivadekar, Executive Director, FIBRO India Precision Products Pvt. Ltd.
“To align the education system with industry needs, a swift examination of the curriculum in technical institutes across India is needed.”

Maulik Patel, Executive Director, Sahajanand Laser Technology Ltd.
“Modern features of today’s laser cutting machines are compact and faster for more precise cutting speeds. These robust systems can cut various materials.”

OMRON unveiled the MD-650 autonomous mobile robot (AMR), expanding its range of industrial robots for efficient part and material transport applications in manufacturing sites.

OMRON launched MD-650 autonomous mobile robot (AMR), that provides greater efficiency at production sites. With the addition of this medium-payload (650 kg) mobile robot, OMRON has expanded the lineup of autonomous robots to appeal to a wider variety of part and material transport applications.

OMRON’s existing lineup of mobile robots ranges from 60 to 1500 kg, and the MD-650 provides a mid-weight range option (650 kg). Its unique control technology enables safe and smooth transport that can be easily implemented at production sites where people and machines work in the same area. 

According to Sameer Gandhi, MD, OMRON Automation, India, “Matching the pace and needs of the industry for high-speed pick & place, and human collaborative robotics solutions, OMRON Automation Business in India is expanding its diversified Robotics portfolio. This new addition to our AMR family is to strengthen & enhance the solution for warehousing (pallet transfer to warehouse), line side replenishment as well as aid flexible manufacturing thus generating value for our customers to make hassle free & automated material movement. It provides operators relief from manual tasks for transferring material while ensuring safety of human beings working in the same space. We look forward to collaborating with the right solution partners to co-create & develop advanced industrial solutions based on the human- machine collaborative technology the robot offers.”

In recent years, manufacturing sites have become increasingly important not only in pursuit of productivity and quality, but also in creating workplaces that reduce the burden of repetitive work for workers. There are increasing demands to improve efficiency in part- and material-transport operations that repeatedly carry heavy materials, work-in-process products, and finished products through automation to reduce the heavy physical burden on the workers. In the automotive industry, for example, the development of a high-mix, low-volume production system needs dispersal of materials to multiple locations, and the increased frequency of inter-process transfer of small lots of work-in-process has increased the physical burden on workers.

However, even if the optimal robot for each process is selected, controlling a large fleet of mobile robots requires different management systems and processes for each robot model. This requires investment in each system and management to ensure smooth transportation of a wide variety of heavy objects.

The unique “OMRON Fleet Manager” software enables integrated control of up to 100 mobile robots on a single system, eliminating the need for multiple fleet management systems, and automatically selects the optimal mobile robot for each process based on payload and availability.

Product Features
1. High speed and safety with top-level transfer speed*² in the medium payload range*¹ and unique obstacle avoidance algorithm.
OMORN MD-650 has proven experience, based on the implementation of several thousand units at manufacturing sites around the world. The new system operates smoothly even in narrow aisles thanks to its maximum speed of 2.2 m/sec, advanced navigation functions, and obstacle avoidance algorithms. In addition, the introduction of advanced battery and charging technology enables 8 hours of operation on a 30-minute charge.

2. Integrated control of all mobile robots using proprietary software technology
A single system can provide integrated transfer routes for up to 100 mobile robots with different payloads and control the transfer sequence in real time. The advanced linkage within a single system enables real-time routing, even for inter-process transfers at different production speeds, to achieve efficient transfers with minimal retention.

3. High level of safety in accordance with international standard ISO3691-4*³.
It is designed for compliance with ISO 3691-4 (enacted in 2020), the latest safety standard for industrial Automated Guided Vehicles (AGVs). 

OMRON will continue to expand its existing product lineup to contribute to the creation of safe factory environments and to robots to help reduce the burden of material transport processes across various industries. Further developments to its proprietary software control will promote safe and optimized transport paths at sites across industries. The company’s vision is to develop solutions that maximize the value of people and create a prosperous future for people, industry, and the earth.

Rockwell Automation has released a report titled “Anatomy of 100+ Cybersecurity Incidents in Industrial Operations,” revealing that state-affiliated actors are responsible for nearly 60% of cyberattacks on the industrial sector, with key findings highlighting the critical need for improved OT/ICS security.

Rockwell Automation, the company dedicated to industrial automation and digital transformation, today announced the findings of its report “Anatomy of 100+ Cybersecurity Incidents in Industrial Operations.” The global study conducted by Cyentia Institute analyzed 122 cybersecurity events that included a direct compromise of operational technology (OT) and/or industrial control system (ICS) operations, collecting and reviewing nearly 100 data points for each incident.

The first edition of the report finds nearly 60% of cyberattacks against the industrial sector are led by state-affiliated actors and often unintentionally enabled by internal personnel (about 33% of the time). This corroborates other industry research showing OT/ICS security incidents are increasing in volume and frequency, and are targeting critical infrastructure, such as energy producers.

“Energy, critical manufacturing, water treatment and nuclear facilities are among the types of critical infrastructure industries under attack in the majority of reported incidents,” said Mark Cristiano, commercial director of Global Cybersecurity Services at Rockwell Automation. “Anticipating that stricter regulations and standards for reporting cybersecurity attacks will become commonplace, the market can expect to gain invaluable insights regarding the nature and severity of attacks and the defenses necessary to prevent them in the future.”

Based on incidents analyzed, key findings include:

• OT/ICS cybersecurity incidents in the last three years have already exceeded the total number reported between 1991-2000.
• Threat actors are most intensely focused on the energy sector (39% of attacks) – over three times more than the next most frequently attacked verticals, critical manufacturing (11%) and transportation (10%).
• Phishing remains the most popular attack technique (34%), underscoring the importance of cybersecurity tactics such as segmentation, air gapping, Zero Trust and security awareness training to mitigate risks.
• In more than half of OT/ICS incidents, Supervisory Control and Data Acquisition (SCADA) systems are targeted (53%), with Programmable Logic Controllers (PLCs) as the next-most-common target (22%).
• More than 80% of threat actors come from outside organizations, yet insiders play an unintentional role in opening the door for threat actors in approximately one-third of incidents. 

In the OT/ICS incidents studied, 60% resulted in operational disruption and 40% resulted in unauthorized access or data exposure. However, the damage of cyberattacks extends beyond the impacted enterprise, as broader supply chains were also impacted 65% of the time.

The research indicates strengthening the security of IT systems is crucial to combatting cyberattacks on critical infrastructure and manufacturing facilities. More than 80% of the OT/ICS incidents analyzed started with an IT system compromise, attributed to increasing interconnectivity across IT and OT systems and applications. The IT network enables communication between OT networks and the outside world and acts as an entryway for OT threat actors. Deploying proper network architecture is critical to strengthening an organization’s cybersecurity defenses. It is no longer enough to simply implement a firewall between IT and OT environments. Because networks and devices are connected daily into OT/ICS environments, this exposes equipment in most industrial environments to sophisticated adversaries. Having a strong, modern OT/ICS security program must be a part of every industrial organization’s responsibility to maintain safe, secure operations and availability.

“The dramatic spike in OT and ICS cybersecurity incidents calls for organizations to take immediate action to improve their cybersecurity posture or they risk becoming the next victim of a breach,” said Sid Snitkin, vice president, Cybersecurity Advisory Services, ARC Advisory Group. “The threat landscape for industrial organizations is constantly evolving, and the cost of a breach can be devastating to organizations and critical infrastructure. The report’s findings underscore the urgent need for organizations to implement more sophisticated cybersecurity strategies.”

The full findings of the report can be found here.

ABB India leads the way in sustainable and responsible resource consumption in manufacturing after achieving water positivity ratings and Mission to Zero™ status for one of its factories in Nashik.

Water positivity is the concept of returning more water to freshwater sources than is withdrawn and maintaining sustainable water stewardship by establishing a framework for water management. The Nashik site, which covers 49,000 m², has been certified as water positive with a water positivity index of 1.14 by the GRIHA Council (Green Rating for Integrated Habitat Assessment), India. Mission to Zero is ABB’s global initiative to enhance energy efficiency and enable building decarbonization, creating best practice solutions for manufacturing and production sites.

The Nashik facility produces medium voltage (MV) switchgear as well as primary and secondary gas insulated switchgear (GIS) equipment to provide efficient power solutions across India. This equipment is critical to the continued urbanization and electrification of the country and the provision of energy systems for sustainable transportation.

As water is a critical issue for the country and globally, ABB India made achieving water positivity a key goal. ABB hopes its operations will become a blueprint for its partners and customers in India – and globally – where water neutrality is quickly becoming as important as carbon neutrality in the fight to save the planet.

To achieve water positivity, the Nashik site introduced a range of measures including a rainwater harvesting system to reduce run off and recharge the groundwater table and reuse the stored rainwater to meet other domestic requirements. The installation of water-efficient fixtures reduced water consumption by 30 percent and a drip-based irrigation system, and sewerage treatment plant allow wastewater to be reused for irrigation and other domestic purposes. This ensures there is zero liquid discharge (ZLD) from the factories. The annual rainwater harvesting potential of the system is 34.486 million liters, which translates to 14 Olympic swimming pools worth of rainwater annually.

ABB also established water meter monitoring and analysis to allow suitable action to be taken on water conservation. The company also invested in water management structures for the local water scarce area to capture rainwater in streams to be used by nearby rural villages for drinking and agriculture.

The scope of the GRIHA water positivity certification is for the site only and does not include upstream supply chain for the water positivity analysis.

ABB’s approach to responsible resource management includes reducing energy use and carbon emissions. Understanding that you can only improve what you can measure, Nashik achieved full visibility of energy use for the Mission to Zero factory using ABB Ability Energy Manager, a cloud-based solution that collects data from 76 sensors to monitor energy consumption and identify inefficiencies.

To further reduce emissions, ABB’s factory in Nashik also invested in measures to improve energy efficiency using LED lighting, insulated wall and roof panels, more efficient air conditioning, demand-based lighting, and cooling in meeting rooms all managed via a KNX and Cylon building management system. Finally, 1 MWp of rooftop solar panels were installed which provide 35 percent of the electricity needed annually to run the factory at a much lower cost than electricity from the grid. The factory operations use 100 percent green electricity, 35 percent from solar and the remaining 65 percent from International Renewable Energy Certificate (IREC). All these measures combined earned the Nashik facility a Green Factory Building, Platinum Rating Certification from the Indian Green Building Council.

Ganesh Kothawade, President, Distribution Solutions, Electrification Business, ABB India said: “The importance of reducing energy use and carbon emissions form a key part of our Mission to Zero journey. However, water positivity is the next frontier in creating sustainable buildings which work in balance with their environment. ABB has shown how green manufacturing can be done to great effect to support the country’s energy transition, and we will be sharing our blueprint for success with our local and global partners to encourage more manufacturers to rethink their energy and water use.”

Pharmaceutical Manufacturing Equipment Market size was valued at USD 13.15 Billion in the year 2022 and it is expected to reach USD 21.19 Billion in 2030, at a CAGR of 6.1% from 2023 to 2030.

The production and supply of machinery and equipment used in the manufacturing processes of pharmaceutical products are a part of the global pharmaceutical manufacturing equipment market. Increasing global demand for medicines, technological improvements, and the focus on quality control and regulatory compliance are some of the factors driving the industry. The Global Pharmaceutical Manufacturing Equipment Market report provides a holistic evaluation of the market. The report offers a comprehensive analysis of key segments, trends, drivers, restraints, competitive landscape, and factors that are playing a substantial role in the market.

Global Pharmaceutical Manufacturing Equipment Market Definition

The industry that creates and provides tools, equipment, and machinery utilized in the production of pharmaceutical products is termed the global pharmaceutical manufacturing equipment market. This market includes a wide range of machinery, such as tools for drug formulation, packing, labeling, quality control, and other crucial steps in the manufacture of pharmaceuticals. For pharmaceutical goods to be safe, effective, and of high quality, pharmaceutical production equipment is essential. The Food and Drug Administration (FDA) and the European Medicines Agency (EMA), among other regulatory authorities, have set strict rules and regulations for these types of equipment. A wide variety of pharmaceutical products, including tablets, capsules, injectables, liquids, creams, and ointments, are manufactured using them.

Several factors influence the pharmaceutical manufacturing equipment industry. Firstly, there is an increasing need for pharmaceutical products on a global scale, which is fueled by factors including population growth, rising healthcare costs, and the development of chronic diseases. Additionally, technological developments like automation, robotics, and digitalization have produced more advanced and precise machinery, which has further fueled market expansion. Furthermore, the increased focus on regulatory compliance and quality control has increased the demand for cutting-edge production machinery that can guarantee compliance and reduce the danger of contamination or errors.

Additionally, the market has grown as a result of the pharmaceutical industry’s expansion in emerging regions and the outsourcing of manufacturing tasks to contract manufacturing organizations (CMOs). Multinational firms and specialty manufacturers are significant market participants in equipment for pharmaceutical manufacturing. These businesses provide a wide range of products and services, including production tools, packaging tools, sterilization systems, and lab equipment. The market for pharmaceutical manufacturing equipment is expanding as more regulatory frameworks are being established globally to support drug innovation and safety, as well as due to rising generic drug demand, rising healthcare spending, and expanding demands for pharmaceutical manufacturing flexibility.

Global Pharmaceutical Manufacturing Equipment Market Overview

The Global Pharmaceutical Manufacturing Equipment Market is a booming market that is supported by a number of important aspects. The pharmaceutical industry’s key sector for the production of numerous pharmaceuticals, medicines, and healthcare items is the global market for pharmaceutical manufacturing equipment. The market’s growth and development are shaped by a number of drivers and restraints. The demand for pharmaceutical products is driven by the expanding world population, rising healthcare costs, and the development of chronic diseases. This demand has a direct bearing on the necessity for cutting-edge manufacturing machinery to meet the rising production demands. The production of pharmaceuticals has gone through a revolution because of ongoing technical improvements.

The efficiency, accuracy, and speed of manufacturing have all been improved through automation, robotics, and artificial intelligence (AI). Pharmaceutical businesses can optimize their manufacturing capacities and raise product quality by implementing cutting-edge equipment. The use of modern manufacturing technology is driven by the strict rules and quality requirements established by regulatory agencies like the FDA (Food and Drug Administration) and EMA (European Medicines Agency). Companies must abide by these rules in order to guarantee the security, effectiveness, and caliber of their goods, which increases investments in machinery that meets regulatory requirements. The need for effective manufacturing procedures is driven by the increased demand for pharmaceutical products that are affordable, particularly generic medications.

To address the rising demand for generic pharmaceuticals, pharmaceutical companies are investing in equipment that enables them to increase output, reduce manufacturing costs, and maintain high standards of quality. Contract manufacturing organizations (CMOs) and contract research organizations (CROs) are used by many pharmaceutical businesses to outsource their manufacturing operations. Due to CMOs and CROs’ growing investment in cutting-edge technology and machinery to meet the demands of numerous clients, this trend has raised the demand for manufacturing equipment.

The global market for pharmaceutical manufacturing equipment has some limitations and difficulties despite the growth prospects. Significant capital investments are required for manufacturing pharmaceutical equipment, especially innovative and automated systems. The high cost of equipment, coupled with the need for skilled personnel and infrastructure, poses a challenge for small and medium-sized pharmaceutical companies. This can limit their ability to adopt advanced manufacturing technologies. Although regulatory compliance serves as a driver, it can provide problems for pharmaceutical companies. The validation and qualification of equipment may be delayed by the need to comply with complex regulatory standards. Additionally, organizations might need to upgrade or replace their current equipment due to changing regulatory standards and norms, which would incur additional expenditures.

Global Pharmaceutical Manufacturing Equipment Market Segmentation Analysis

The Global Pharmaceutical Manufacturing Equipment Market is Segmented on the basis of Equipment Type, End-Product Type, And Geography.

Pharmaceutical Manufacturing Equipment Market, By Equipment Type

• Packaging Machines
• Mixing and Blending Machines
• Spray Drying Equipment
• Milling Equipment
• Filling Machines
• Extrusion Equipment
• Inspection Equipment
• Tablet Compression Presses

Based on the equipment type, the market is bifurcated into packaging machines, mixing and blending machines, spray drying equipment, milling equipment, filling machines, extrusion equipment, inspection equipment, and tablet compression process. The packaging machine segment holds the largest market share and is estimated to witness the highest CAGR during the forecast period. Pharmaceutical packaging equipment is used to preserve the finished product from contamination, damage, and deterioration and to guarantee that it complies with labelling, dosage, and storage requirements. Drug items must be packaged effectively and precisely in order to be both safe and effective for patient usage and to meet regulatory criteria.

N-Tron^® Series NT5000 Gigabit industrial switches of Red Lion offers security features and set a new standard for performance, reliability and ease of use.

The NT5000 switches and their gigabit speed are designed to improve network security and reliability. They maximize operating performance and system uptime through seamless integration, offer advanced management and diagnostic capabilities as well as network redundancy and layered security.

The N-Tron® Series NT5000 switches are available in 6, 8, 10, 16 and 18 port configurations in all copper or a mix of copper and fiber options that can meet specific installation requirements. With a durable, metal enclosure and wide temperature range, the NT5000 is a compact solution for reliable operation in harsh, industrial environments.

Configuring switches can be a confusing and time-consuming process. The NT5000 is engineered for fast and easy deployment right out of the box. Its modern, graphical user interface includes a configuration wizard that walks users through initial setup.

Today’s cybersecurity threats can result in severe consequences. The NT5000 features password encryption, multilevel user access and MAC security, IEEE 802.1X with RADIUS remote authentication and more. Administrators can view the event and syslog to clearly see the state of the network in real time and receive notifications about access attempts or configuration changes. The switch can be set to automatically disable user or port credentials after failed access attempts.

The NT5000 also features:

• Graphical dashboards
• N-Ring^TM auto-member
• Port mirroring
• Cable diagnostics
• STP/RSTP/MSTP
• IGMP v1/v2/v3
• SNMP v1/v2/v3
• NTP, LLDP and LACP
• Fast boot allowing traffic to pass in less than 20 seconds
• Wide shock and vibration tolerance
• Extensive compliance certifications, including Product Safety: (UL/CUL) Ordinary and Hazardous locations, Emissions/Immunity: FCC/ICES/CE, ATEX/IECEx, Marine: ABS, Rail: EN 50155, EN 50121, EN 61373, UKCA

To learn more about the NT5000 and view model specifications, visit redlion.net/nt5000

Supply chain software leader EPG cemented its already strong partnership with Dubai-based Falcon Pack, as the disposable food packaging specialist is to implement EPG’s Transportation Management System (TMS). The two companies have forged strong bonds since Falcon Pack’s introduction of EPG’s LFS Warehouse Management System (WMS) in 2018.

With its adoption of the TMS, Falcon Pack is taking advantage of EPG’s much-admired suite approach to supply chain software solutions. The EPG ONE Supply Chain Execution Suite comprises bespoke applications for each branch of the supply chain journey, from Gartner Magic Quadrant-recognized storage and fulfillment (WMS) to transport and distribution (TMS). Key business drivers within the TMS are routing optimization and scheduling, provided by EPG’s Greenplan application, winner of the prestigious Best Product award at LogiMAT 2023. Dozens of Falcon Pack transport vehicles, from small vans to truck-trailer combinations, are to be implemented with the software.

Speed and efficiency via digital solutions

The digitization of transport execution processes will help Falcon Pack to improve speed, accuracy and efficiencies in its fast-growing ecommerce operations in Dubai. The state-of-the-art technology also enables the packaging experts to introduce same-day delivery to customers, alongside enhanced documentation control and shipment monitoring via an easy-to-use intuitive interface.

“Investing in EPG’s TMS was an easy decision for us to make,” comments Syed Ehtisham, Executive Director IT, Falcon Pack. “We have enjoyed a productive relationship with EPG’s expert engineers and on-the-spot field teams since we installed LFS five years ago. We have great trust in their portfolio, and we expect the TMS to provide us with valuable savings in terms of both time and money as well as clear transparency of our day-to-day operations and, consequently, even better relationships with customers. It is also a bonus for our hard-working staff that the system they have supplied us is so easy to get used to.”

Niels Meinken, EPG Logistics Consultant, is delighted with Falcon Pack’s decision to invest once more in EPG’s product expertise. “Our suite approach means that our customers can source all of their supply chain software needs from a single source, which results in smoother transitions and fewer pinch points, as well as a single contact. At the moment we are fully focused on implementing our TMS with them, and we look forward to expanding our relationship with Falcon Pack still further in the future.”

Pairing Solmetric’s innovative technology with Fluke’s vast distribution channels expands their ability to serve a global audience with high-quality, safe, and reliable tools. 

Fluke Corp, a wholly owned subsidiary of Fortive Corporation and a leader in test and measurement instruments, acquired California-based Solmetric, manufacturers of high precision, solar test, and measurement products.  

This reinforces Fluke’s strategic commitment to investing in the electrification of the world on a global scale, while continuing to bring innovative products to technicians who demand reliability, high quality, and safety.  

Solmetric is best known for the PV Analyzer, a US market-leading I-V curve tracer, the de facto industry standard for commissioning solar installations. It’s used for field testing applications such as commissioning, auditing, and troubleshooting PV arrays. The PVA-1500HE is a 1,500-volt I-V curve tracer, capable of testing high-efficiency modules, and is particularly suited to the utility-scale solar industry. 

The acquisition also includes its shade measurement tool, the SunEye used for shade analysis, enabling expert solar designs with the highest ROI for solar professionals and their customers.  

Fluke Corporation’s President Jason Waxman commented: “Today marks a significant milestone in our journey. Fluke’s acquisition of Solmetric reflects our commitment to delivering the best possible products to technicians in the field. Their innovative solar tools and team’s deep knowledge in the space, combined with Fluke’s passion to advance the electrification of the world more efficiently will enable us to transform this landscape to serve customers better.”   

Willard MacDonald of Solmetric added: “We are excited to see Solmetric grow under Fluke’s leadership. With access to their vast distribution channels, an expanded, global audience will be able to experience the benefits of our products. Fluke is as passionate about delivering the next generation of solutions for solar customers as we are – it’s a great fit.” 

This acquisition extends Fluke’s product line, combining two powerful brands in the solar test and measurement space. 

Solmetric was founded in 2005, their experts have extensive experience in the solar installation industry and in the development of high-precision test and measurement tools. The acquisition will see all employees retained under Fluke’s leadership. 

The slogan of the UNITED GRINDING Group was also its motto at this year’s EMO Hannover: UNITED FOR YOUR SUCCESS. The group celebrated its 30th anniversary and announced its partnership with Transaction-Network. It also presented three product innovations in grinding and measuring technology on 1,000 sq. m.

This year’s EMO Hannover 2023 was once again a showcase for the latest technologies from the manufacturing industry. With its 1,000 sq m (10,765 sq ft) booth, the UNITED GRINDING Group was again prominently represented this year too, and presented several innovations.

Premiere of three new products

At the 16 machines on display, the trade professionals were also able to experience the following innovations live:

BLOHM, the specialist for surface and profile grinding machines, presented the UNIMATE workpiece automation system for the PLANOMAT XT, a more precise and productive solution for the internal machining of hydraulic motor stators. The new vertical grinding arrangement offers numerous advantages for this application. And the automatization solution developed specifically for this purpose also contributes to higher productivity.

STUDER presented a universal automation solution for the S33 and S31 cylindrical grinding machines: the new insertLoad loading system. This new standardized loading system can handle horizontal- and vertical-oriented workpieces and load the parts between centers and into a chuck.

And WALTER, one of the leading manufacturers of machine tools, presented the innovative “Laser Contour Check” measuring system for the first time at EMO. This combines a new type of blue laser with an intelligent measuring system and is used for highly accurate, contact-free measurement of various tool parameters on cylindrical tools directly in the working area of the grinding or eroding machines.

In Trichy, India, a manufacturing firm grappled with operational setbacks due to coolant challenges. With Mobil’s expertise, a transformative solution involving MobilcutTM 220 brought efficiency, savings, and improved performance.

As India inches closer to its goal of becoming a USD 5 trillion economy, the manufacturing sector will play a more active role in driving economic growth for the country. Within the sector, the machine tools segment, in particular, will play a pivotal role in impacting overall industrial activity. Machine tools find application in a wide spectrum of tasks that enhance product consistency and ensure higher labour productivity. Consequently, maintaining optimal health and functionality of the machine tools segment is essential for seamless manufacturing operations.

As the segment focuses on equipment performance, there is a need to enhance the precision of production processes at a microscopic level. This involves the utilization of advanced lubrication solutions and services to optimize the well-being of machines. This is particularly significant due to the projected expansion of the machine tools market that is expected to reach USD 2.5 billion by 2028, exhibiting a growth rate (CAGR) of 9.4% during 2023-2028.

Recognizing the sector’s prospects, MobilTM is actively collaborating with enterprises that manage intricate machinery to help them monitor equipment performance and achieve higher levels of performance, productivity and profitability.

Partnerships for productivity
In the vibrant industrial hub of Trichy, India, a dedicated engineering equipment manufacturing firm had long been dependent on a market general water-soluble metalworking fluid to support its machining activities. Nevertheless, the company found itself entangled in a series of hurdles that were impeding both its operational efficiency and financial well-being. Among these challenges were the notorious ‘Monday odour’, excessive oil usage, elevated top-up rates, and a disappointingly abbreviated tool lifespan. Despite concerted efforts to seek remedies, these persistent issues cast a shadow over the company’s operations.

Like clockwork, each week saw workers returning to the shop floor only to be greeted by a strong and unpleasant Monday odour. This not only created an uncomfortable atmosphere but also raised doubts about the coolant’s efficacy. Additionally, the company struggled with high oil consumption and the need for frequent top-ups, resulting in significant operational expenditures. Moreover, the tools employed in the machining process had reduced lifespans, leading to escalated costs.

In a bid to overcome these challenges, the company sought assistance from Mobil’s Field Engineering Services (FES) team. After comprehensive investigations, the FES team recommended the adoption of MobilcutTM 220 as the lubricant, complemented by the utilization of the MobilTM Solcare kit for comprehensive servicing. This strategic switch brought about remarkable improvements in coolant longevity and helped the company achieve an optimal top-up ratio of 1:40, consequently, reducing oil consumption. The switch to Mobilcut 220 also led to diminished instances of eye and skin irritation, prolonged machine tool longevity, and ultimately resulted in a total cost savings of USD 8438.

Profitable Innovation
MobilcutTM represents Mobil’s range of high-performance metalworking fluids. Blended with cutting-edge base oils, additives, and emulsifiers, the Mobilcut Series of cutting oils deliver reliable results across a diverse spectrum of metal removal processes. These products are engineered to function effectively in various water qualities. One noteworthy product of this collection is the Mobilcut 220, a versatile and enduring semi-synthetic metalworking fluid concentrate. It is well-suited for moderate machining and grinding operations on metals. Mobilcut 220 incorporates a unique formulation comprising high-performance extreme pressure additives, corrosion inhibitors, and biocides, ensuring prolonged stability and performance during application.

To complement product use, the company also adopted the Mobil Solcare Service app that empowers customers to reach their ambitions with data-driven insights and tailor-made recommendations. The app helps operators access critical data easily, aiding the shift from reactive to proactive maintenance, and achieving ease of operations with constant task updates. The app ensures more effective service management, more efficient data analysis, greater focus on productivity and increased customer satisfaction.

As Mobil remains dedicated to enhancing customer experience through cutting-edge lubrication solutions, fostering industry partnerships remains an area of key interest. By offering timely guidance, recommendations, and services, Mobil is advancing customer productivity, aiding them in achieving greater efficiency and realizing their business objectives with a leaner approach.

For more information, visit www.mobil.in/business
(Exxon Mobil Corporation has numerous affiliates, many with names that include ExxonMobil, Exxon, Esso, and Mobil. For convenience and simplicity, those terms, and references to “corporation,” “company,” “ExxonMobil,” “EM,” and other similar terms are used for convenience and may refer to one or more specific affiliates or affiliate groups.)

The advancements in technology and society are not limited to component cleaning alone. In addition to new products, materials, and production technologies that necessitate customised cleaning solutions, there is a shift in the requirements for industrial parts and surface cleaning due to trends like energy and resource efficiency and the rapid progression of digitalisation.

Component cleaning has become vital in production across various industries, ensuring that downstream processes meet necessary standards and uphold product quality. However, the nature of these tasks has undergone significant transformations in recent years due to industry-wide structural changes. Moreover, there is a growing demand for cleaning processes to be more sustainable, energy-efficient, and resource-efficient. Additionally, the integration of cleaning into digitally connected production environments and the utilisation of AI is becoming increasingly important.

New applications due to the mobility and energy transitions
From electric vehicles and heat pumps to wind turbines and photovoltaic modules, products and solutions for mobility and energy transitions are leading to new applications in industrial cleaning technology.

In electric mobility, in addition to the classic components such as those for steering and braking systems, there are also mechanical drive components, including stators, rotors, housings and gear units. In some cases, relatively high particulate and/or filmic cleanliness requirements must be met for these tasks – which can usually be solved with wet chemical processes. Pre-assembled electromechanical components, on the other hand, require dry cleaning solutions. The requirement is that they can be easily integrated into production lines – if necessary, subsequently – and enable efficient cleaning in the production cycle. The cleanliness of production equipment, such as handling systems and grippers, also plays a role in avoiding re- and cross-contamination. 

Cleaning in high-voltage technology like inverters is also receiving more attention. The focus here is no longer only on avoiding short circuits but also flashovers. Various tasks for wet-chemical and dry cleaning also arise in producing battery cells and systems, as well as fuel cells, in which the requirements for particulate cleanliness extend into the range of ten micrometres. Dry cleaning technologies like laser cleaning also benefit from the trend towards the cold body-in-white in the automotive industry. In this context, bonding is increasingly used in car body construction, and the joining surfaces are selectively cleaned. 

Sensor and microsystems technology on the rise
Whether it involves autonomous driving or the digitalisation of manufacturing processes, the presence of reliable sensors, microsystems, and monitoring technology is a fundamental requirement. Camera systems, for instance, play a crucial role in meeting the increasing demands for performance and reliability in these technologies, especially as they become smaller. The smaller the size, the more susceptible they are to impurities, making cleaning mechanical, electronic, optical, sensory, or actuator components incredibly vital. Achieving high levels of technical cleanliness is often necessary, leading to the need for precision or high-purity cleaning solutions. Sometimes, this may require specialised production environments, such as clean rooms, designed accordingly.

Automation and digitalisation of cleaning processes
Automation and digitalisation in cleaning applications have gained significant importance in recent times. The requirements go beyond the permanent recording, control and documentation of various system parameters, for example, monitoring and readjustment of pressures and temperature as well as condition monitoring of aqueous cleaning and rinsing baths – which have already been implemented. 

In the meantime, there are demands for progress-dependent process control, meaningful monitoring of the process engineering sequences, and adequate storage and provision of relevant process data and information on technical cleanliness. Solutions for implementing these factors are already being offered in some cases and are being developed by practically all system manufacturers. One challenge is the availability and cost of metrological solutions. Likewise, manufacturers – often in cooperation with research institutes and/or partner companies – are dealing with the hot topic of artificial intelligence (AI).

Sustainability, energy and resource efficiency
Rising energy costs and stricter environmental targets have made energy and resource consumption crucial in determining investments in new cleaning systems. The impact of cleaning on the product’s carbon footprint is also becoming a significant consideration. Similarly, there is a growing interest in sustainable and energy-efficient cleaning solutions for existing systems. Manufacturers offer improved mechanical processes and more efficient drying technologies, such as condensation drying with heat pumps, to reduce consumption. Additionally, there is a focus on heat exchangers, heat pumps, and other systems that lower energy requirements, as well as software solutions for optimised energy management. Solvent cleaning may experience a resurgence due to its lower energy and resource consumption as long as it is equally suitable for the cleaning task compared to water-based processes. 

From this perspective, alternative cleaning methods that achieve technical cleanliness without relying on energy-intensive heating of cleaning and rinsing baths and part drying are gaining importance.

Expertise shared by: Doris Schulz, parts2clean

Automated welding has emerged as a game-changer across industries, promising increased efficiency, precision, and reliability. At the forefront of this transformation, Sumon Mitra, Sales Director, Cloos India Welding Technology Pvt Ltd, a subsidiary of the globally renowned welding automation giant Cloos, takes OEM Update through their latest success stories in various section of welding by their innovative technology.

From its inception in 1989, Cloos India has paved the way for cutting-edge welding solutions, making strides towards a future of seamless automation. Cloos India Welding Technology Pvt. Ltd. embarked on its journey as a 100 per cent subsidiary, set to revolutionise welding automation in the Indian market. Initially headquartered in Gurgaon, the company quickly positioned itself as a solution provider rather than a mere product seller. In 2013, the headquarters was shifted from Gurgaon to Pune, setting the stage for even greater accomplishments.

The core strength of Cloos lies in its unwavering commitment to providing comprehensive solutions. With an integrated manufacturing process at Haiger, Germany, everything from manual to automated welding is meticulously crafted under one roof. It starts with the contact TIP of the welding torch. This ensures every technical component – from welding torch tips to cutting-edge robotics, control panels, sensors, welding systems, and crucial software. This unique approach ensures rigorous testing and seamless integration before delivery, ultimately translating to unparalleled success at customer sites.

Welding automation solutions
Cloos India’s success is not just attributed to its exceptional products but also to its strategic foresight. As the Indian industrial landscape embraces automation, the demand for welding automation solutions has skyrocketed. Manual welding could be faster and more reliable due to the unavailability of skilled welders. Previously, robotic welding was considered for high-volume production due to higher capital investment. Cloos has shattered this limitation by introducing entry-level robotic welding systems, democratising automation for businesses of all scales.

The ArcBot -Cobot welding package is a recent game changer, a testament to Cloos’ innovation. This package minimises programming complexities, making it user-friendly and adaptable to various products. The market’s enthusiastic response underlines the package’s potential to revolutionise the automation arena.

Cloos India’s clientele spans diverse sectors, including earth-moving, boiler, and electrical engineering, shipping, and fabrication industries. The company’s exceptional German engineering heritage, spanning over a century, assures quality and reliability that few can match. Numerous instances of Cloos robotic welding systems functioning perfectly in India for over 30 years stand as a testament to their commitment.

Quality extends beyond products to service and support. Cloos India boasts a robust stock of spares and consumables in Pune, ensuring swift nationwide deliveries within 48 hours. The service team is strategically placed across customer locations, working diligently to provide seamless assistance. The company’s commitment to growth is evident in the doubled service engineer workforce and comprehensive training programs.

Under the visionary leadership of Mr Sumon Mitra, Cloos India has achieved remarkable milestones. The company’s expansion into new sectors led to a staggering 2022 turnover that more than doubled, reflecting the widespread adoption of their automation solutions.

Case Study
In early 2021, Cloos India received an inquiry from a renowned global manufacturer of construction and mining equipment based in Chennai. The inquiry pertained to welding a substantial complete mainframe weighing approximately 17 tons. Notably, the customer had previously employed a robotic system for the same product, but expressed dissatisfaction with its performance.

Cloos’ technical sales team meticulously analyzed the issue and made a commitment to rectify it through a fully customised system design and adaptive welding technology. Presently, Cloos India takes pride in sharing that within just two years, they successfully delivered three similar systems to the customer, underscoring the trust they have garnered in the Indian industry.

Driven by current market demand, several customers opted for integrated systems from local suppliers. However, it became evident that these systems fell short of delivering the promised outcomes, lacking a sense of final accountability. In response, Cloos India took on special projects to transform such systems into productive ones. Adding to their accomplishments, Cloos India recently secured the contract for the first welding robotic system designed for shipyards. They were the sole entity to meet the stringent technical requirements, a testament to their expertise.

With over a century of experience, Cloos India takes pride in being a comprehensive solution provider that supports the industry effectively.

A message for the industry
To industry leaders contemplating entry into automated welding production, Cloos India offers a resounding invitation. Reach out to their technical sales team with product details and welding requirements, and rest assured of a partnership dedicated to welding quality, training, and unwavering support. Cloos’ reputation as a reliable single-source supplier remains steadfast. It is poised to drive the industry into a future of automated excellence.

CLOOS India Welding Technology Pvt. Ltd.,
Ground & 1st Floor, Plot No. 114/1/3, General Block, MIDC Bhosari, Pune, Maharashtra 411026, India. Website: www.cloos.de
Email: contact@cloos.in
Contact Details: 7003545907/ 916838393

In addition to an extensive range of automation solutions, including smart sensors, robots, vision systems, drives, etc., the inclusion of i-BELT further enhances Omron’s comprehensive lineup of end-to-end solutions, providing valuable data-based services and consultation from a holistic perspective.

Enabling a streamlined digital evolution, OMRON facilitates gathering data at all operational and process levels. Through i-BELT Data Services, it empowers customers to harness the potential of data for their benefit. This service connects manufacturing data with production and management issues, transforming raw data into valuable insights using OMRON’s proficiency. The aim is to attain enhanced predictive and preventive maintenance standards, addressing various production challenges such as unforeseen downtime, subpar quality, reliability concerns, rising maintenance expenses, and more. The ultimate goal is to elevate overall equipment effectiveness and facilitate well-informed decision-making.

Sameer Gandhi, MD, OMRON Automation, India, said, “One of the most effective traits of i-BELT is the co-creation synergy of OMRON technology and customer processes. The idea is to empower our customers for the best and most effective data harnessing and utilization. The data collected and visualized is fed back to the customer’s production line to help them attain flexible, people and environment-friendly production that is quickly adaptable to changes through Co-creation, formulation of challenges based on data and advancement of innovation in phases. The cycle continues, thus resulting in a truly sustainable value creation over a period.”

OMRON’s plant examination service focuses on four domains -manufacturing, quality, equipment, and energy. The i-BELT team extracts issues through visualization and analysis and provides services, such as improvement assistance and automation, suited to different phases and needs. The technology also focuses on energy efficiency by monitoring power consumption and providing insights into optimizing overall plant system configuration. Fine-tuning these parameters helps minimize energy waste and improves overall system efficiency. This reduces energy consumption, lower operational costs, and a smaller environmental footprint. It significantly impacts the attainment of carbon neutrality goals- one of the prime imperatives for sustainability for manufacturing businesses.

While i-BELT holds promise for various manufacturing sectors. i-BELT includes an application that exhibits the effective integration of historical and real-time data from palletizers into a dashboard. This integration offers improved control and operational visibility. Alongside its emphasis on data-driven services, OMRON continues to bolster its traditional product lineup.

Recent additions to the company’s offerings encompass the advanced NX502 Controller, which incorporates enhanced capabilities in information, motion, and safety control. This enables the achievement of elevated levels of production, quality, and energy efficiency. Additionally, the introduction of the TM-20 collaborative robot for handling heavy payloads marks a noteworthy step in OMRON’s efforts to cater to the Indian market.

The technological evolution of heating in industrial processes involves replacing obsolete dissipative systems (resistors) with advanced energy-saving solutions. The inductive extruders and plasticising barrels transform plastic machinery, elevating productivity and efficiency while reducing operational and maintenance expenses.

The rising energy cost and increasing global awareness about energy conservation drive the adoption of more efficient processes.

The principle of electromagnetic induction

Inductive technology is gaining popularity in various applications, exemplified by the shift from traditional gas cooktops to induction hobs in households. This technology utilises magnetic induction to safely and effectively transfer energy from a coil to a ferromagnetic material. The energy transferred to the load is transformed into heat generated inside the metal. This direct energy transfer maximises heating efficiency, reduces heating time, and minimises energy wastage.

Induction technology for plastic machinery

In the realm of plastic machinery, Atos Induction has harnessed the benefits of magnetic induction to create an innovative heating solution for a common industrial process: plasticising systems. This Inductive technology applied to plasticising barrels offers several advantages over traditional resistive heating systems:

· Energy saving up to 30% on heating energy consumption

· Uniform heat distribution

· 30 percent less of installed electrical power respect equivalent machine with resistors

· Significantly faster heating, less than half time if compared to resistors

· High precision of temperature control, thanks to the absence of thermal inertia and instantaneous heat transfer of inductive technology

· Extended operational lifespan due to the reduced thermal stresses of the inductive coil.

The solution engineered by Atos Induction allows replacing heating elements in both new and existing machines, using the same timed or thermo-regulated control logic of traditional resistive systems.

This solution typically involves one or more coils, depending on the number of barrel zones needing heating. An electronic power generator powers each coil. The machine’s central unit manages temperature regulation for each zone, adjusting the power generator based on temperature feedback.

The electronic power generator self-adapts the current modulation according to the characteristics of the ferromagnetic material to be heated to achieve maximum efficiency in any working condition.

 The inductive coil is wound on highly insulating materials to minimise heat loss from the barrel to the environment. When a large area of the plasticising cylinder operates at a single temperature, inductive coils simplify the machine control scheme and reduce the installed electrical components since a single coil can cover lengths up to 700 mm.

The modular construction technology of the inductive coils allows an easy installation on both cooled and uncooled plasticising barrels:

·         CHC-N coils are designed for temperature sensor installation and are suitable for those zones of the plasticising barrel that do not require cooling.

·         CHC-C coils are provided with openings for airflow and temperature sensor installation. The special internal structure allows air to be conveyed directly over the plasticising barrel, guaranteeing faster cooling than resistive systems.

Inductive energy-saving solutions

The focus on environmental pollution and the current escalation of energy prices is driving markets towards more efficient technologies and solutions. Comparative analyses performed on a 300-ton plastic injection machine revealed that the energy consumption of inductive coils had been lower than 30 percent concerning ceramic resistors, leading to annual savings of 28 MWh.

Energy consumption of 300 tons plastic injection moulding machine with traditional heating system and inductive heating system

Atos Induction offers energy-saving solutions to equip the next generation of induction-based plastic injection and inductive extruder machines.

For more information, visit: www.atosinduction.com

With over 65 trained and Authorised Service Centers comprising more than 220 touchpoints in India alone, MeccAlte is well-equipped to meet customer service expectations promptly.

The success of MeccAlte can be attributed to its innovative and high-quality technical and aesthetic design. MeccAlte alternators are known for their exceptional efficiency and reliability, making them stand out in their respective classes. They are built to have a long lifespan and are backed by various quality certifications that validate their credibility.

With over 65 trained and Authorised Service Centers comprising more than 220 touchpoints in India alone, MeccAlte is well-equipped to meet customer service expectations promptly. The company’s alternators boast several key features that set them apart:

1. They offer the best efficiency within their range, reducing fuel consumption.

2. MeccAlte is the pioneer in India to introduce a Fully Programmable Digital Regulator, which caters to special applications, enhances user and manufacturer performance, and serves as a diagnostic tool across a wide range of power outputs.

3. The insulation systems are designed to suit varying operating conditions, ensuring reliability and extending product life.

4. Including MAUX (MeccAlte Auxiliary Winding) Power Boost enables exceptional excitation.

5. They exhibit excellent motor starting capabilities, providing 300 percent short circuit current for 20 seconds as a standard.

6. The 12-wire re-connectable configuration for 3-Phase is a standard feature, allowing adaptability to different voltage, frequency, and phase requirements.

7. MeccAlte alternators are known for their superior aesthetics and low noise levels.

8. Maintenance is hassle-free, particularly in higher ratings.

9. The company’s commitment to quality is evident in its focus on producing technologically advanced products and services of the highest quality to ensure long-term customer satisfaction.

Its central mission involves seamlessly integrating with our clients’ operations, providing independent and responsive world-class advice to enhance their efficiency and competitiveness. MeccAlte achieves this by designing and manufacturing industrial alternators and associated power solutions, tailoring our approach to best meet clients’ needs. An illustrative example of this commitment is the MeccAlte App, which grants clients round-the-clock access to alternator specifications and data.

MeccAlte has stood out as a highly dedicated player in the industrial alternators field, contributing significantly to our global success. Unlike competitors, we don’t engage in manufacturing or selling complete gensets. It ranks among the world’s leading industrial alternator manufacturers and is the largest independent supplier globally. The product range encompasses a single line of Synchronous Alternators spanning 1 to 5000kVA, covering portable and industrial units and medium and high voltage alternators for power generation.

Additionally, MeccAlte offers 2-pole and 4-pole alternators known for their exceptional efficiencies and performance benchmarks. Being a prominent figure in industrial alternator manufacturing, MeccAlte has consistently met customer demands through continuous product enhancements and innovations.

In the Indian market, abundant opportunities span across all segments. From a manufacturing standpoint, the company is committed to advancing towards higher horsepower (HHP) alternators, catering to requirements ranging from 1 to 2500 kVA LT range, applicable in diverse fields such as Agriculture, Industry, Retail, Data centres, Marine, Aviation, and more. The company’s upcoming range of accessories will further enhance customer value and provide streamlined service across all its products, including alternators.

The unveiling of MeccAlte’s latest advancement, the C-Type alternator range, ushers in a new epoch in power generation. Leveraging over seven decades of expertise, their groundbreaking methodology has sparked innovations that deliver concrete performance advantages for their clientele. Every facet and element has been meticulously reexamined, culminating in an avant-garde series of alternators.

MeccAlte maintains an unwavering dedication to the excellence of its products. Rigorous design standards are upheld across all manufacturing facilities, ensuring unwavering world-class quality across the spectrum.

Acknowledging the trend towards comprehensive power solutions, the company has recognised the escalating desire for a singular supply source. As a result, MeccAlte has expanded its range to encompass Gensets, Engine Controllers, and Battery Chargers. These extensions uphold the same excellence and quality synonymous with MeccAlte Alternators.

MeccAlte remains committed to fulfilling customer orders even after the Covid-19 era by embracing adaptable component bundles and a fresh product lineup. Collaborative endeavours are aimed at shared success as we navigate these times collectively.

Ahire Machine Tools is a prominent leader in work-holding solutions, prioritising innovation and precision. Their range includes versatile vices and cutting-edge machines for various industries.

Ahire Machine Tools Pvt. Ltd. stands as a prominent and distinguished player in the realm of work-holding and tool-holding solutions, showcasing a remarkable legacy of contributing to productivity enhancement over a significant span of time. The company has become highly skilled in creating new and smart solutions for holding workpieces in place. They pay special attention to machines that can move in three or five directions, which are really important for making operations work as efficiently as possible.

At the heart of machining processes, work-holding products assume a pivotal role by facilitating the secure clamping of workpieces, thereby paving the way for meticulous and precise machining operations. Presently, the company’s primary thrust lies in the development and provision of all-encompassing work-holding solutions meticulously tailored for the dynamic Indian market.

Ahire Machine Tools remains steadfast in its commitment to delivering products that epitomize precision, performance, and unswerving reliability. This commitment reverberates across the spectrum of their offerings, including an array of state-of-the-art drill machines and tapping machines. These cutting-edge tools have been purposefully engineered to cater to the diverse and evolving needs of industries spanning from manufacturing to the automotive sector.

 The AMT Allmatic Allite Vice 68 K/M. This product stands out with its CentroLite design, offering mechanical operation coupled with a substantial clamping force of 28 kN and 100 Nm torque. The clamping range spans from 0 to 164 mm, while the integration of gripper-jaws with a width of 124 mm showcases a sophisticated approach to work-holding. A commendable clamping margin of 4 mm enhances its usability, and the spindle’s construction with a high tensile strength of 700 N/mm², impeccable sliding properties, and remarkable wear resistance attests to its durability and performance prowess.

Among the standout products in the company’s arsenal is the Alloy Steel Body & Case Hardened AMT Allmatic Allite Vice 125 K/M. This versatile work-holding solution boasts an ingenious design that ensures even expansion and balanced pressure distribution, thereby fostering secure workpiece clamping. Notably, the clamping force of 28kN combined with clamping range of 0-164 mm.Spindle is with a high tensile strength of 700N/mm2, good sliding properties and a very high wear resistance.

Among the company’s impressive offerings, the small and precise self-centric vice with excellent repeatability captures attention. Its compact design, coupled with enhanced accessibility, creates a tool that balances efficiency and convenience. The vice’s versatile span of 6-125mm or 6-225mm caters to a spectrum of needs. The precision in rack teeth pitch, accurate to within +/-0.02 mm, underscores its meticulous engineering. The incorporation of gripper teeth for enhanced grip, provision for a 45° dovetail, and the inclusion of M5 holes for supplementary jaw mounting attests to its thoughtful design. Moreover, the spindle screw’s TiN coating bolsters its hardness, wear resistance, corrosion resistance, and lubricity, all in one stroke.

In conclusion, Ahire Machine Tools Pvt. Ltd.’s legacy of excellence in work-holding and tool-holding solutions resonates powerfully through its innovative products designed for maximum efficiency. With an unyielding dedication to precision, performance, and reliability, the company has solidified its place as a trusted partner for diverse industries seeking to elevate their machining processes.

D1/18 MIDC Ambad, Nashik, 422010,
Web: www amtplindia.com
Email id: sales@amtplindia.com
Contact number: +91 99224 48079

Manufacturing units in India are moving towards building safer workplaces to ensure a better working environment for humans working on shop floors.

There’s a notable shift in India towards creating safer workplaces in plants, factories, and manufacturing units. This shift aims to provide better working conditions for employees on the shop floors. Manufacturers are now integrating safety measures when constructing machines intended for export to Western nations. This move is driven by the need to adhere to stringent safety standards and legal requirements that come with global machine exports.

The landscape has evolved significantly in recent years. Even Indian manufacturing units actively pursue sustainability and improve human and machine safety. Additionally, the growing concern over cyber threats has led to an increased focus on security measures.

Pilz India emerges as a fitting safety partner for machine builders. They offer a comprehensive range of safety services customised to each company’s specific needs throughout their machines’ entire lifespan. Pilz India can also assist machine builders throughout the conformity assessment, ensuring that their machinery conforms to the regulatory requirements, such as CE marking in Europe, OSHA in the US, NR-12 in Brazil, KOSHA in Korea, GOST in Russia, or CCC in China.

Assistance in the entire machine safety lifecycle
Whether in the design phase, during operations, or during a machine retrofit, manufacturers and operators have a natural and often legal obligation. It aims to identify and resolve potential safety hazards for humans and machines as early as possible. Pilz India offers comprehensive safety services that are personalised to suit the specific requirements of machine builders throughout the entire lifespan of their machines.

A well-known saying holds here: “One cannot fix anything undetected.” Machine builders cannot address a safety gap until they become aware of the limitations of their machine. As a first step towards ensuring the safety of their machines or production lines, machine builders need to undergo a risk assessment. This risk assessment is a customised gap analysis conducted by the Machinery Directive 2006/42/EC. Through this assessment, the machine builder’s machine or production line systematically evaluates potential hazards. Pilz offers a pragmatic, organised, and focused evaluation of plants and machinery that aligns with the machine builder’s company policies, internal procedures, and operational requirements, such as ISO 12100. Pilz India assists machine builders in recognising potential hazards and proposing methods to mitigate these risks.

Following the identification of risks, the next logical step for a machine builder is to develop a safety concept. This concept aids the machine builder in establishing a secure interaction between machines and operators without compromising productivity. These safety concepts are not standardised; they must be uniquely tailored to match the requirements of each machine builder. After completing the risk assessment, experts and consultants at Pilz India create a safety concept that includes a detailed solution proposal for the technical implementation.

Customised concepts and a strong emphasis on safety design empower machine builders to adhere to international standards and directives. Pilz India provides a well-organised design process tailored to the needs of machine builders, drawing on their extensive expertise and experience in design methodologies. Machine builders gain valuable insights from exemplary engineering management that aligns with IEC 61508 compliance.

Following the safety design phase, Pilz India ensures minimal disruption to the production process for machine builders and line builders. While implementing safety measures, it’s essential to strike a balance that doesn’t significantly inflate costs in automation and safety projects. Pilz India takes charge of the entire project planning and management, encompassing the selection, procurement, design, and assembly of required automation components.

After integrating safety systems into the machine, machine builders and manufacturing units must guarantee the accurate implementation of all protective measures by relevant standards and regulations. Equally crucial is the functionality of the safety system. Hence, safety validation is pivotal in ensuring safety for machine builders and manufacturing units. ISO 13849, IEC 62061, and IEC 61508 underscore the importance of validating safety systems, requiring machine builders and manufacturing units to confirm their efficacy. Validation is the sole method to ascertain the precise execution of necessary risk reduction measures and the unequivocal alignment of machinery with applicable standards and regulations.

Pilz India offers a suite of services matched explicitly to its customers. It facilitates efficient machinery validation through a structured approach encompassing machinery safety, risk mitigation, functional safety, and other legal prerequisites.

International compliance at your fingertips
In today’s context, machine builders and manufacturers of production lines are increasingly engaged in global machine and line exports. As this trend expands and India establishes itself as a manufacturing hub, these builders face the crucial task of ensuring that their machines adhere to international standards. Beyond merely seeking services from a reliable source, these builders are searching for partners who can navigate and assist them throughout the compliance journey. They are actively seeking service providers equipped with extensive expertise and experience in comprehending relevant directives and standards and effectively putting them into practice.

Furthermore, when standalone machines, each possessing their certifications, are integrated to create a machinery assembly (such as production lines), the machine builder must perform a comprehensive conformity assessment procedure, including certification, for the entire plant. Given the exact nature of these requirements, machine builders necessitate a service partner with a global presence to ensure a seamless and hassle-free certification process.

Pilz India stands out as the preferred choice for numerous machine builders across India entrusted with aligning their machinery with regulatory prerequisites. Whether it’s achieving CE marking for Europe, compliance with OSHA standards in the US, adhering to NR-12 regulations in Brazil, meeting KOSHA standards in Korea, conforming to GOST requirements in Russia, or obtaining CCC certification in China, Pilz India undertakes the complete conformity assessment procedure on behalf of the machine builder, all by the Machinery Directive 2006/42/EC. They meticulously identify and apply the relevant standards and directives and guide the machine through the entire safety lifecycle, encompassing risk assessment, safety concept and design, safety implementation, and safety validation. Additionally, Pilz India ensures the compilation of documents mandated by law for inclusion in the technical documentation and extends support to the machine builder regarding document archiving and management.

Your certified safety training partner
Pilz India’s qualification program provides a gradual and adaptable approach for machine builders to enhance their knowledge progressively, enabling them to pursue training up to the required level of qualification. These training courses are categorised into four levels, from introduction to expert certification, covering a wide array of machinery safety and automation topics. This initiative empowers machine builders, factories, and manufacturing units to leverage the expertise and insights of Pilz India, tailoring a training program to suit their specific needs.

Pilz India collaborates with TÜV NORD to offer certifications such as Certified Machinery Safety Expert (CMSE), Certified Expert in CE Marking (CECE), and Certified Expert in Functional Safety (CMFS). Upon successfully passing the final examination following the training, participants are awarded an internationally recognised certificate issued by TÜV NORD.

Pilz India’s qualification program allows individuals to gradually expand their expertise, choosing from a range of training levels, and receive internationally recognised certifications through collaboration with TÜV NORD.

Partnering for safety services 

Pilz India stands at the forefront of technology. It has been delivering various safety services encompassing the entire machine safety lifecycle. Their offerings extend to diverse segments across India, including machine builders, factories, plant operators, and manufacturing units. The company is the go-to choice for machine builders seeking to export their machines abroad while adhering to various international standards. Pilz India offers comprehensive safety and security solutions regarding complying with standards such as CE marking for Europe, OSHA for the US, NR-12 for Brazil, KOSHA for Korea, and GOST for Russia or CCC for China. This is made possible by their profound industry knowledge, experience in handling intricate applications, and their roster of certified experts.

Equipped with substantial domain expertise and certified professionals, Pilz India is a dependable partner for machine builders, alleviating concerns related to intricate compliance and legal matters. Throughout the conformity assessment process, the company supports machine builders across India.

Content courtesy: Pilz India.

Choosing the right tools helps overcome challenges associated with the complex machining of titanium, a preferred material in aircraft manufacturing.

The technologies deployed in the aerospace industry have undergone a radical transformation through the decades, resulting in aircrafts becoming compact, lighter, and more efficient. One of the major factors that has influenced the performance of airborne vehicles is the evolving dynamics of material science; yielding changing composition of metals used. Titanium, also known as a strategic material, is being used in increasing proportions today, accounting to almost 15% of the structure of these vehicles. Owing to its lighter weight and higher strength characteristics compared to other metals, impressive properties of corrosion and oxidation resistance, and easier availability overall, it is a preferred material for manufacturing critical parts. Yet, its poor machinability is recognised as an industry-wide challenge. Over the past few years, Kennametal has invested heavily in Research & Development to understand how to better machine titanium, and some of these findings, based on understanding its metallurgical properties are presented below.

Titanium undergoes various phases, from α to ß and depending on these phases, titanium alloys are classified into four main groups: 

• Unalloyed/untreated titanium – excellent corrosion resistance, but lower strength properties

• Alpha structure (α alloys) – great creep resistance, and low to medium strength 

• Beta structure (β alloys) – high strength and high density, but the most difficult to machine 

• Alpha beta structure (α-β alloys) – medium to high strength, and include alpha and beta stabilizer elements

The commercially viable alloys are ß and (α-ß). Beta (ß) Alloys Beta (ß) alloys contain transition metals, such as V, Nb, Ta, and Mo, that stabilize the ß-phase. Examples of commercial ß alloys include Ti11.5Mo6Zr4.5Sn, Ti15V3Cr3Al3Sn, and Ti5553. Beta alloys are readily heat-treatable, generally weldable, and have high strength. Excellent formability can be expected in the solution treated condition. However, ß alloys are prone to ductile-brittle transition and thus are unsuitable for cryogenic applications. Beta alloys have a good combination or properties for sheet, heavy sections, fasteners, and spring applications

In comparison, α-ß alloys contain both α and ß stabilizers. The simplest and most popular alloy in this group is Ti6Al4V, which is primarily used in the aerospace industry. Alloys in this category are easily formable and exhibit high room-temperature strength and moderate high-temperature strength. The properties of these alloys can be altered through heat treatment. 

Titanium is typically produced in the shape of plates and bars, as well as forgings and castings. The Buy-to-Fly (BTF) ratio is typically between 10 and 16, meaning a raw material of 10kg titanium ends up being a finished part with the weight of 1kg. The BTF ratio requires efficient removal of the excess material achieved through titanium roughing applications, which causes the cutting edge to be exposed to extremely high temperatures for a long time. 

Some challenges associated with machining comprise high-chemical reactivity of titanium alloys, which causes the chip to weld to the tool, leading to cratering and premature tool failure. In addition, the chip-tool contact area is relatively small, resulting in large stress concentration due to these higher cutting forces and temperatures, resulting in premature failure of the cutting tool.  

The machining of flight critical components (engine rotatives) at optimal production rates requires reliable, high precision tooling for semi-finishing and finishing turning operations. The entire process needs to be secured to avoid any damage to the part that requires advanced chip breaker technologies.

Requirements:

· Tool stiffness/stability

· Heat management

· Coolant flow

· Grade toughness (chipping resistance)

· Heat-resistant coating

· Chemical wear resistance

· Micro geometry that promotes low cutting forces

· Stable machines and conditions that promote higher Metal Removal Rates (MRR)

Flat bottom drilling is ideal for pre-machining of high-temperature alloy airframe structural parts. Quickly removing large amounts of material remains a challenge for these types of components. Traditionally, the first step of the process is to enter the material by using ramping techniques, which is time-consuming and leads to low metal removal rates. 

Speeding up the machining process requires combining the advantages of a flat bottom drill and a Z-axis plunge mill. The flat bottom design eliminates radial forces, while four effective cutting edges provide increased feed and speed rates, leading up to 200 percent higher metal removal rates than traditional ramping techniques and freeing up capacity for aerospace manufacturers. 

Once the drill has shaped the basic structure of the component, it progresses for the roughing and finishing steps.

A recommended roughing solution for a large structural part is helical shoulder milling that addresses the high metal removal needs in aerospace machining. To achieve lowest possible cost per edge, tool makers have come with up to 8 cutting edges per insert in Helical Milling Cutters. Such designs are proven to reduce power consumption up to 50% and can deliver the highest MRR, especially in high-temperature alloys. 

If the work holding is weak and tool overhang is high, another technique that can be used is High Feed Milling (HFM). With low entering angles, these cutters provide optimum cutting forces with maximum stability. Also, in materials like titanium which has extremely low thermal conductivity (thermal conductivity of Ti6Al4V is ~ 7.2 W/m K), it is prudent to work with higher feeds than speeds. 

An array of new-generation PVD coatings with alloyed substrates are available, which provide resistance to thermal cracks, least co-efficient of friction and prevent chip welding in roughing applications. The cutter body should be constructed of higher-quality steel for improved stiffness and rigidity to withstand the high cutting forces. The variable helix design helps to break the harmonics that lead to chatter, further improving tool life, part quality, and throughput. Positive cutting action reduces vibration, minimizing the cutting zone temperature and prevents work hardening tendencies. 

Finishing operations are mostly performed with solid endmills. Some unique design features include unequal flute spacing, variable helix configuration to minimize chatter and vibration, eccentric reliefs, twisted end face for increased stability and ramping along with the most optimized geometry, and flute design for titanium machining. In some advanced designs, endmills come with positive clamping technologies (safe lock) which prevent tool pull-out and ensure high process security. High-performance endmills will also have features like chip gashers for smooth chip evacuation and lower cutting forces. 

Comprising high strength-to-weight ratio, corrosion resistance, fatigue resistance, and capability to work in high-temperature zones – titanium is usually the primary material for aerospace structures, frames, and engines. Titanium’s low modulus of elasticity, poor thermal conductivity, high chemical reactivity, and hardening properties, together, make it one of the toughest materials to machine. Therefore, an appropriate selection of cutting tool design and machining strategies is extremely important for machining titanium and its alloys along with proper machine, coolant and work holding capabilities, in order to maximize productivity and optimize costs. 

(Content courtesy: Kennametal)

The joint manufacturing of fighter jet engines by GE Aerospace in collaboration with HAL in India will be used to power Tejas fighter jets.

The Indian defence sector has embarked on a transformative journey to enhance its self-reliance and strengthen its strategic capabilities. The development of indigenous fighter jet engines holds immense strategic value for India. Currently, the country relies heavily on foreign suppliers for its fighter aircraft engines, which poses logistical challenges and raises concerns regarding national security and technology transfer. 

Investing in the manufacturing of fighter jet engines will have far-reaching positive effects on the Indian economy. Establishing a robust defence manufacturing ecosystem will generate employment opportunities, attract foreign direct investment, and stimulate innovation, research, and development activities. The multiplier effect of such investments can lead to the growth of ancillary industries and the development of a skilled workforce, thus contributing to the country’s economic prosperity.

Revolutionising the manufacturing of fighter jet engines is challenging. Developing the required technical expertise, infrastructure, and supply chain capabilities will necessitate significant investments and long-term commitment from the government and private sector. Collaboration with international partners, leveraging their expertise, and establishing joint ventures can expedite the process and bridge technological gaps. In a boost to the economy, GE Aerospace and Hindustan Aeronautics Limited (HAL) will produce fighter jet engines for the Indian Air Force. This partnership marks a crucial milestone in defence cooperation between the United States and India, highlighting the growing significance of the Indian aerospace industry. The agreement includes the potential joint production of GE Aerospace’s F414 engines in India, subject to necessary export authorisation.

GE Aerospace’s presence in India
GE Aerospace has been actively engaged in the Indian aerospace industry for over four decades, participating in various areas such as engines, avionics, engineering, manufacturing, and local sourcing. In addition to the potential new work in India, several GE facilities in the United States will experience increased volume due to this collaboration.

The partnership between GE Aerospace, India’s Aeronautical Development Agency, and HAL dates back to 1986, when they began supporting the development of India’s Light Combat Aircraft (LCA) with F404 engines. Since then, GE Aerospace’s F404 and F414 engines have played a critical role in developing and producing the LCA Mk1 and Mk2 programs. With 75 F404 engines already delivered and 99 more on order for LCA Mk1A, the agreement paves the way for the delivery of 99 engines for the Indian Air Force under the LCA Mk2 program.

Global reach and expanding capabilities in India
GE Aerospace’s Chairman and CEO, H. Lawrence Culp, Jr., described the agreement as historic, made possible by the longstanding partnership between GE and HAL. He emphasised the role this collaboration plays in advancing the vision of closer coordination between the United States and India, as President Biden and Prime Minister Modi envisioned. The F414 engines, renowned for their exceptional performance, will deliver crucial economic benefits and enhance national security for both countries.

The agreement positions GE Aerospace to expand its manufacturing capabilities in India by building a family of products, including the F404 engine, which currently powers the LCA Mk1 and Mk1A aircraft. Furthermore, GE Aerospace has been selected for the prototype development, testing, and certification of the Advanced Medium Combat Aircraft (AMCA) program using its F414-INS6 engine. The company will continue collaborating with the Indian government on the AMCA Mk2 engine program.

With over five million flight hours and eight nations operating or placing orders for F414-powered aircraft, these engines have consistently exceeded reliability and time on-wing expectations. Globally, more than 1,600 F414 engines have been delivered, solidifying GE Aerospace’s position as a trusted provider of jet engines.

GE’s Commitment to India
GE’s presence in India extends beyond this manufacturing agreement. The company operates the John F. Welch Technology Centre in Bengaluru, a research and technology hub, and the Multi-modal Factory in Pune, established in 2015. These facilities demonstrate GE’s dedication to advancing technology and manufacturing in India, supporting the country’s aerospace ambitions.

By reducing dependency on foreign suppliers and fostering indigenous technological advancements, India can strengthen its defence sector, boost its economy, and secure its national interests more effectively. The challenges on this path are formidable, but with concerted efforts, collaborative partnerships, and long-term investments, India has the potential to become a global hub for advanced fighter jet engine manufacturing, making significant strides in defence technology.

Conclusively, the revolution in manufacturing fighter jet engines marks a pivotal moment in India’s journey towards self-reliance and enhancing its strategic capabilities. In this way, the collaboration between GE Aerospace and HAL to produce fighter jet engines in India represents a significant advancement for the country’s aerospace industry. By leveraging GE’s expertise and HAL’s manufacturing capabilities, the agreement will contribute to India’s defence capabilities and boost the country’s economy. This partnership is a testament to the strong bilateral relations between the United States and India, fostering closer cooperation in defence and technological advancements. As GE Aerospace continues to expand its footprint in India, the collaboration holds immense potential for future advancements in the Indian Air Force’s capabilities and the overall growth of the aerospace sector. With collaborative partnerships and long-term investments, India has the potential to become a global hub for advanced fighter jet engine manufacturing, making significant strides in defence technology. 

The Education center aims to train 1200 students for three years and offer jobs – directly impacting over 5000 family members.

Phillips Education – a global leader in advanced manufacturing education – inaugurated its Center of Excellence (CoE) at the Vishisht Government Industrial Training Institute, Haridwar, in the State of Uttarakhand. This CoE is established in partnership with Uttarakhand Workforce Development Program (“UKWDP”) and is backed by the World Bank. The state-of-the-art CoE symbolizes the nation’s transition from less efficient manufacturing methods to a new era of advanced technologies, in sync with the world, ready to deliver global excellence.

Saurabh Bahuguna ji (Minister of Skill Development and Employment of Uttarakhand) said – “As we gather here today to inaugurate this Center of Excellence, let us take a minute to realize that Aao Behtar Bharat Banaye is more than just a phrase – it represents how together, we are forging a better Uttarakhand and Bharat. This CoE will create job opportunities, ensure our people are trained using the very latest technologies, and industries will be motivated to set up their factories in our beautiful State and compete in the global arena.” 

Phillips Education is focused on unleashing the potential of the manufacturing industry by tackling its most crippling challenge: the skills gap. Haridwar’s CoE, was awarded to Phillips Education earlier this year to foster the region’s manufacturing prowess and scale its capabilities to newer heights.  Prominent attendees from Phillips included Rakshiit Kejriwal (President, Phillips Education), Nikhil Modi (Global Marketing Leader, Phillips Corporation) and Col. Ankur Sabharwal (Vice President – Operations). The event was also graced by thought leaders such as Col. Mohit Chauhan, with speeches from Dr. Harindra Garg, Chairman Sidcul Manufacturing Association, Uttarakhand.

Understanding the importance of this initiative to the industry, governments, and the employability of the citizens, Phillips Education has been setting up CoE across India and Overseas..  Overseas, the organization has partnered with the Malaysian government agency to develop a CoE to drive Industry 4.0 in their country, and is also instrumental in developing Qatar’s first advanced manufacturing CoE – a project led by McKinsey and involving collaboration with Factory One, a model factory by Qatar Development Bank. Each CoE is the result of Phillips Education working with partner organizations to directly address the skills gap.

 “With an extraordinary customer base and unparalleled proficiency in creating and encouraging new machinists, Phillips is a brand to be reckoned with,” according to Kejriwal. “Our foray into Manufacturing Education reflects not merely another business venture, but us taking the onus and responsibility to contribute to the betterment of our nation and truly making it Atmanirbhar.” 

Haridwar is a state of enormous potential to contribute to India’s manufacturing sector, according to Kejriwal. “We believe this CoE will empower the region’s students to create a paradigm shift from dependency on tourism and farming towards sustainable careers in manufacturing.” 

With the Center of Excellence now officially operational in Haridwar, it stands poised to become a beacon of knowledge, innovation, and excellence, not just for the region but for the entire nation. As more countries and states within India establish CoEs by Phillips Education, the manufacturing education provider plans to develop a vast network where student exchange programs across cities of India and internationally, can help accelerate the incubation of ideas, transfer of technologies, and sharing of best practices.

The inauguration culminated with enthusiasm and hope for the future. The CoE’s cutting-edge facilities, state-of-the-art machinery, and industry-leading curriculum left attendees impressed and optimistic about the impact it would have on the local workforce and region’s overall economic growth. It is also a shining example of how the collective efforts of State Government, Corporate, and World Bank will be needed to foster the missions such as Make in India, Skill India, and Atmanirbhar Bharat.