IMTEX 2011 & Tooltech 2011 - Indian Machine Tool Manufacturers ...

IMTEX 2011 & Tooltech 2011
Being the largest trade show of its kind in South and South
East Asia, IMTEX 2011 along with the concurrent Tooltech
2011, was held from 20 to 26 January 2011 at BIEC,
Bangalore.
The 15th IMTEX reflected a resurgent and competitive
India and an optimistic global machine tool industry.
An exhaustive range of innovations and technological
refinements in the complete product segment of metal
cutting machine tools was on display during the event.
Occupying a net space of 25,500 square metres, around
562 exhibitors from around the world showcased 750
machines valued at Rs. 14,000 million.
Tooltech 2011 featured the newest trends in cutting tools
and tooling systems from all across the globe. It had 252
companies exhibiting their latest innovations.
Key Attraction
The key attraction of displays included dramatic
improvement in aesthetics and ergonomics of machines.
Some of the recent technologies / solutions on show
included contemporary developments of five-axis
machines; use of latest coolant techniques; increased use
of high-level automation; and greater focus on robotics
in manufacturing requirements. A prominent aspect was
the dominance of CNC machines in almost all exhibition
stands.
The participation in the two exhibitions was truly international
with overseas exhibitors numbering 446 of the total 814
exhibitors. The foreign participation came from a total of 23
countries along with eight country-group participants from
China, Czech Republic, Germany, Italy, Singapore, Spain,
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Taiwan and United States – clearly reflecting the process
of globalisation of the machine tool industry in India. The
other participants came from Australia, Austria, Denmark,
Finland, France, Hong Kong, India, Israel, Japan, Korea
Portugal, Switzerland, Thailand and the UK.
The event had a grand opening with inauguration by
Mr. Arun Maira, Member, Planning Commission of India,
along with Dr. K. Radhakrishnan, Chairman, Indian Space
Research Organisation as well as Mr. Arvind Kapur,
Vice President, Automotive Component Manufacturers
Association of India.
Response
The seven-day event recorded a massive footfall of 92,500
business visitors. The visitors comprised a blend of decisionmakers,
managerial level executives, technocrats as well
as technical workforce representing the entire spectra of
the manufacturing industry, from world over. They came
with the objective of not only witnessing the new facets of
manufacturing technologies, but also to firm up business
decisions, forge strategic alliances, and even develop
vendor bases. The event recorded a total value of orders
booked to the tune of Rs. 10,220 million and serious
enquiries worth another Rs. 70,000 million.
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Shailesh R. Sheth
Triggering a paradigm shift
DNA of this company. From being a trading company, he
transformed PMT to become an important manufacturer of
machine tools and triggered an era of global cooperation
through partnerships with reputed foreign companies.
For his outstanding and far-reaching achievements in
propelling the Indian machine tool industry towards global
excellence, Mr. Sheth was honoured with the “IMTMA - H.
R. Gupta Lifetime Contribution Award” at the IMTEX 2011
Inauguration Ceremony.
“Do not go where the path may lead; go instead where
there is no path and leave a trail”. These words of Ralph
Waldo Emerson truly portray the philosophy of one of
IMTMA’s most outstanding and outspoken office-bearers
– Mr. Shailesh Rajnikant Sheth.
Mr. Sheth’s enormous contribution to the Indian machine
tool industry’s journey towards quality, productivity and
beyond all competitiveness is very well known. What is less
documented is his unparalleled foresight in visualising a
leading global position for the industry.
Under his astute guidance, the ‘VISION’ Conferences,
‘Technology Missions’, Summits and Technology Seminars,
raised IMTMA’s capabilities to new heights. The person
who coined the word “stretch goals” must have met or
seen Mr. Sheth in action. For him a setback is only a new
challenge – and Mr. Sheth loves challenges.
IMTMA was the first industry Association under Mr. Sheth
that brought together competing members to together
evolve a challenging vision and matching action plans.
His optimism in the face of new challenges and clarity of
thoughts, which he also articulates extremely well, have
been a hallmark of his long-standing relationship with the
industry as also with the Association.
With an excellent blend of strong fundamentals acquired
during his graduation from IIM Ahmedabad and experience
spanning over four decades, Mr. Sheth played a defining
role in charting the course at several leading companies
and the Indian machine tool industry as a whole.
Earlier in his career, during a 22 year long association with
Perfect Machine Tools Group (PMT), Sheth changed the very
With typical humbleness, Mr. Sheth says, “A lot of my success
is not so much so because of what I did but because of
what many machine tool manufacturers did on my advice,
recommendations and assessments. Companies took the
risk that time and they succeeded. It is their effort that is
being lauded rather than my few words of advice. This
award is a vote of confidence in the fact that the Indian
machine tool industry is well on its way to transformation
and becoming globally competitive.”
Bubbling with optimism, Sheth foresees great potential in
the Indian machine tool industry and says, "The momentum
of the industry is back. New markets such as aerospace,
healthcare, energy have helped the industry focus on highend
technology and innovation.”
Advising machine tool makers to be level-headed despite
the sudden upsurge in business he remarks, “Manufacturers
must not take undue advantage of the current explosive
demand growth situation. This is the time for mature
behaviour and one should not be carried away by the
amount of profits made. Also, manufacturers should not get
complacent and should not stop the effort to continuously
improve and change.”
Mr. Sheth has represented the Indian machine tool industry
in many international fora and authored two seminal
research studies on the industry. As a corporate advisor
in management and manufacturing technologies and an
independent director in several leading companies, Mr.
Shailesh Sheth continues to guide, mentor and inspire
machine tool makers towards meeting new challenges
and reaching greater heights – more importantly in a new
‘avatar’ as the “chief mentor” of the second-generation
entrepreneurs, emerging leaders and young professionals
of the machine tool industry.
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Reaching for the Sky
“You have got to jump off cliffs and build your wings on the
way down” – Ray Bradbury
Truly building his own wings and reaching new heights, Mr.
A. V. Sathe’s entrepreneurial achievements and immense
contribution towards enhancing competitiveness of the
metalworking machine tool industry in India, rightly deserves
to be acknowledged and celebrated. Identifying and
appreciating his contributions, he was bestowed with the
second “IMTMA - Vinod Doshi Outstanding Entrepreneur
Award in Machine Tools” at IMTEX 2011.
It takes a lot of courage for one to abandon a comfortable
job and enter into a completely alien world, with an urge
to make a difference, not for oneself but for the world. Mr.
Sathe is among those few courageous ones. After graduating
from IIT Bombay in 1963, he worked with the Central
Manufacturing Technology Institute (CMTI) and went on to
become the Head of the Design Department. After 13 years
in CMTI, he set-up his a company of his own.
Explaining why, he says: “frankly speaking, I was quite
happy, working at CMTI. The work atmosphere was great.
However, I felt that the Indian machine tool industry needed
to take the optimum advantage of expertise available at
CMTI.”
Despite the satisfaction of ensuring that Pragati is a
world class brand which is giving a tough competition to
recognised European brands, Mr. Sathe has apprehensions
about the growth of the Indian machine tool industry.
He says, “Our country possesses twin advantages of
‘engineering strength’, and ‘low labour cost’. With this
combination, we should be dominating the machine tool
world but the reality is exactly the opposite. India’s share in
world’s machine tool production is less than 1% and with
such a low share, it is no surprise that the world market
gives scant respect to Indian machine. It is necessary to
introspect and work to change the situation.”
Stating that he encountered no problems as an entrepreneur,
he encourages many more to take up such challenges
and courageously strive towards building up the Indian
machine tool industry.
“There is enough potential and enough opportunities
to explore in India. Participation in IMTEX fairs, for one,
has given us a good exposure in the world market. Also
government organizations like CMTI have a lot to offer.
When these are explored and utilized to the fullest, nobody
can stop India from becoming a major force in the global
machine tool market,” says an optimistic Sathe.
His ambition to create world-class machines made in
India led to the inception of Pragati in 1976. Today, it is
a well established company which employs 300 people.
Its products are exported all over the world, including
Germany and China.
“The combination of 'modern technology' and 'reasonable
pricing' is the key to our success in the market. Today, we
can compete with any country, including China and Taiwan.
In fact, we see big potential in the Chinese market and are
building a plant near Shanghai which is expected to be
inaugurated in January 2012,” says a proud Mr. Sathe.
Pragati at a glance
Pragati is part of the Ace - Micromatic Group, which was established in 1976. It has two plants in Bangalore
and one in Yadrav (near Kolhapur). A new plant in Shanghai is coming up on a two acre plot, with 4880
square metres built-up area. Pragati manufactures machine tool accessories like tool turrets, automatic tool
changers (ATCs) and chucking cylinders. It achieved a turnover of Rs. 910 million last year. 40 % of Pragati’s
turnover comes from exports and it is aiming to increase its turnover by at least 50 % this year. Pragati is also
connected to the FIE group of Ichalkaranji. In FIE, control on the cost of production is an ongoing process
and Pragati also follows the same path and regularly reviews production process to reduce costs.
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Discovering Hidden Profits in
CNC Machining
applications all aimed at enabling CNC users to discover
hidden profits.
“For cycle time reduction we have CAPSturn and CAPSmill
- CNC cycle time reduction and programming software;
for downtime reduction we have NCnet - DNC system and
Lean Works-framework for MES (Manufacturing Execution
Systems); for reducing ignorance in CNC technology we
have CAMLab, NCycloturn and NCyclomill for training
on CNC technology and CNC programming. We have
succeeded in bringing the activity of CNC programming
down to the shop floor and enabled operators to be
programmers,” clarifies Das.
A chance meeting, after a long time, of three boyhood
friends who had become engineers and were bored of
their jobs, resulted in the founding of a company whose
name has become a byword in the field of software which
enables reduction of cycle time and down time in CNC
machine tools. The company is the Bangalore-based
CADEM Technologies and the founders are Mr. G. V.
Dasarathi Das, Mr. S. K. Bhagavan and Mr. D. Srihari.
CADEM’s first product was NCpack, which read a manually
written CNC program and simulated the tool path
graphically on a PC. It was designed to replace program
entry and transfer through punched tapes.
“The product took two years to develop, during which the
company had zero revenue and our savings were wiped
out. The first copy was sold to Wg. Cdr. Anantharam of
Dhatu Nirman in Bangalore. He saw the half-finished
product and placed an order, which was a huge morale
booster for us. CADEM is still indebted to him for this. Our
product offered much more than the imported PPRs (Printer
Puncher Readers) for a fraction of their cost” recalls Das.
The company is now 22 years old and has about 4000
installations of all their products put together in India and
abroad. When the going was good in Europe and US 30%
of its revenue used to come from exports to these areas.
It had 16 resellers and supported 5 languages: German,
Italian, Spanish, Dutch and Korean.
“Our dream is that five years from now, there will be a
CADEM product in every production machining shop floor
in India,” says Das. “We also want to be big in education.
Currently, there is a wide gap between the skills that
industry needs and what is imparted in our ITI, Diploma and
Engineering institutes. We want to narrow this gap in the
years to come, both through our products and through our
3i initiative (which stands for Industry Institute Interaction)
which we provide as a free service to educational institutes.
NCnet Lite DNC software is available as freeware on our
web site, with DNC parameters for 100+ CNCs.”
Shortly after this, the company developed a PC-based CNC
controller for which it won a CMTI-PMT trust award. The
controller was used by a couple of small firms making CNC
training machines and small industrial machines. CADEM
tried to get some big machine tool builders interested in
the controller, but sadly did not succeed. Otherwise there
would have been an Indian CNC controller long ago.
CADEM’s current range of products are for three distinct
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International Seminar on
‘Machining Technologies’
The Association organised the fourth International Seminar
on ‘Machining Technologies’ on 18 and 19 January, 2011
in Bangalore. The seminar gave a thrust to the evolving
trends in metal-cutting solutions.
Industry experts and domain leaders from Germany, Italy,
Israel, Japan, Switzerland, United Kingdom, United States
of America, Singapore and India shared their experiences
on the latest developments in machining.
Mr. S. Tomonaga, Deputy Managing Director, Toyota
Kirloskar Motor Private Limited inaugurated the seminar
which was followed by the keynote address presented by
Dr. K. Subramanian, Director - Core Technology, Saint
Gobain Co., United States.
The seminar was spread over two keynotes and three
concurrent sessions and covered the key technology areas
related to – auto components machining; aerospace, die
and mould machining; new generation machine tools;
electrical and micro machining; tooling, work holding
and coolants; control systems; as well as measurements
and automation. The seminar was attended by over 300
delegates from 100 companies from across the globe.
Day 1
A Technology Exchange organized in the B2B Session was
an ideal opportunity for participants to interact on a oneto-one
with global leaders in metal cutting technology.
Participants discussed about specific applications,
technology aspects, joint ventures, collaborations,
commercial issues and other events.
The first day had various sessions conducted by different
industry representatives. The Auto Component Machining
session started with presentations from VIGEL, Prawema,
Leistritz and Fraunhofer.
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In the Electrical and Micro Machining session, the
presentation was made by Robert Bosch, DMG,
Agiecharmillies, Kennametal Extrude Hone and Nagel.
The stream of New Generation Machine Tools, had
presentations made by Yamazaki Mazak, Fritz Studer,
Gleason and Pfiffner.
Day 2
The second day began with two interesting keynote sessions
by Marc Weller from BOSCH and Michael Watts from
BOEING who spoke about the Macro Economic indicators
of global economy and challenges in corresponding
sectors.
The session under the stream of Aerospace, Die & Mould
Machining started with a presentation by Fraunhofer
followed by Starragheckert. The session also had
presentations made by Makino, Delcam and Komet on
various other segments of the subject.
Under the Tooling, Work Holding & Coolant stream ISCAR
made a presentation followed by Schunk, Hainbuch, Heinz
Kaiser and Blaser Swiss Lubes.
The final session on Control Systems, Measurement and
Automation was dealt by Siemens, Heidenhain, Fanuc,
Carl Zeiss and Mitutoyo.
“Jagruti - IMTMA Youth
Programme”
Upholding the responsibility of providing better trained professionals to the machine tool manufacturing
industry, the Association with support from “UDAAN” members, organized the third “JAGRUTI – IMTMA
Youth Programme”. The initiation was scheduled on 22 and 23 January 2011 during IMTEX 2011. A total
of 16 students of mechanical engineering course chosen from eight engineering institutions participated
in the event.
The engineering students were oriented with technological facets of the machine tool industry and were
made familiar with the machines and machining concepts. The participating students were taken through
a guided tour of the entire exhibition and were hand-held by ‘UDAAN’ members, who explained to them
in detail about the machines on display and its technological and other features. The young budding
engineers were also witness to actual shop-floor operations in a manufacturing set-up, through ‘live’
demonstrations at Ace Designers Limited.
9

Right Tooling for CNC Machining
Centres
Activities in IMTMA
Southern Region…
Today, a customer determines the price of a product and
entrepreneurs are expected to keep pace with the changing
trends in order to remain in the competition and meet the
ever exceeding expectations of the market. Although the
material cost cannot be reduced, the machining cost can
be drastically reduced by 20% with appropriate selection
and application of tooling.
on 08 January 2011 at BIEC. The seminar, headed by
industry and technical experts, explored ways to make the
automation solution flexible by providing modular design,
using standard parts, giving total solution with mechanical
assembly, software and control systems. It also provided
an insight on the application of advanced automation
technologies in solving engineering problems.
Surface Finish Measurement
A workshop on Right Selection and Application of Tooling
for CNC machining centres was organized from 05 to 07
January 2011 in Bangalore at the BIEC campus. The event
witnessed participants sharing their experience and expertise
along with problem solving using formulae and practical
solutions through real time machining demonstrations on
CNC machining centres.
The constant demand for increased performance,
interchangeability and functional reliability has resulted in
shrinking of tolerances for a precision component. As the
tolerances shrink, the surface aspects of the component
become more and more dominant and the dimensional
aspects of surface finish become exceedingly important.
Low Cost Automation in
Metalworking
Intelligent application of technology and engineering
expertise can help in achieving low cost automation.
Automation is also perceived as a cutting edge of
competitive manufacturing and assumes paramount
importance in facilitating increased productivity at lower
production costs.
Keeping this in view, a seminar on Low cost Automation for
Productivity Enhancement in Metalworking was organized
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Keeping in view the importance of serious quantitative study
of the quality of a surface which becomes an inseparable
part of component design, manufacture and inspection
and to ensure proper functional behavior of the design,
a workshop on Surface Finish and Measurements was
organized on 11 February 2011 at BIEC. The workshop
was well received by a wide cross section of manufacturing
industries.
Geometric Dimensioning and
Tolerancing
Geometric Dimensioning and Tolerancing (GD&T) is
a universal design engineering language that is being
used to closely capture and transmit the designer’s intent
through all activities in the product cycle. GD&T ensures
seamless communication between design, engineering,
manufacturing and quality teams across the entire
organization, enabling them to work in a concurrent
engineering environment. Understanding the need of
GD&T in Design through Manufacturing, a seminar was
organized exclusively for Yuken India Limited on 16 and 17
February 2011 at BIEC.
Stack - Up Analysis was conducted on 24 and 25 February
2011 at BIEC. The programme enabled the design
engineers to determine how robust a design is at the
drawing phase.
Laser, Plasma and Waterjet
Machining
The applications of Laser, Plasma and Waterjet processes
in machining are fast gaining popularity as ‘Net Shape
solutions’, moving ahead of the conventional gas
cutting process. These can compete both technically
and economically to meet the challenges of achieving
high quality, reliability and price. With their right use, it is
possible to reduce the cost and lead times in machining
centres.
To help the participants choose the best suitable technology
for their applications and to discuss the technology
related issues and specific problems, a seminar on Laser,
In the competitive industrial scenario prevailing today, the
seminar provided a proper guidance on the application of
GD&T system to reduce the manufacturing and inspection
costs.
Tolerance Stack-Up Analysis
Engineers analyze tolerances for the purpose of evaluating
GD&T and the methods include 2D tolerance stacks, 3D
Monte Carlo simulations and datum conversions. However,
the right manufacturing process, productivity and cost
efficiency can often be determined through component
tolerances.
Keeping this in view, a training programme on Tolerance
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Plasma and Waterjet Machining was organized at BIEC
on 11 March 2011. The seminar helped the participants
in familiarizing themselves with these modern machining
technologies.
Process Capability - The Quality
Route to Sustained Growth in
Manufacturing
Machine Tools are not just expected to be reliable and
productive, but are also expected to achieve a high
degree of process capability with consistent precision and
accuracy. During the regular working of machines, change
in variables result in rejections. Hence industries are taking
several proactive measures in order to control this.
This major challenge faced by the production engineers,
tools suppliers and machine tool builders was addressed
at a workshop on Process Capability – The quality route
on 17 and 18 March 2011 at BIEC. The industry experts who
conducted the workshop examined the multiple solutions
for workholding and fixturing problems, how dedicated
fixtures can be designed with modular components that
provide interchangeability for future products and various
other associated aspects.
Digital Factory
Along with increasing the internal efficiency, speed of
communication and management control, the Digital
Factory also provides a paperless environment for efficient
real time management of manufacturing units. To provide
the true experience of working in a Digital Factory, a replica
was created during the two day training programme on
Digital Factory on 15 and 16 April 2011 at BIEC.
The programme spread awareness on the usefulness and
benefits of the Digital Factory concept which, through
to sustained growth in Manufacturing organized on 15
March 2011 at BIEC. The workshop addressed various
concepts of process capability and provided an in- depth
understanding of techniques associated with the same. The
workshop was extensively interactive in nature.
Workholding and Fixturing
Techniques for CNC Machines
In order to make CNC milling more productive and
profitable, right applications of workholding and fixturing
techniques have become more essential than selecting
cutting tools, software, tool holders and coolants. With
chip-to-chip times less than one second, many users still
fail to consider how to get the maximum usage out of the
available table area.
Addressing the common problems associated with this, a
workshop on Workholding and Fixturing Techniques for
Productivity Improvement on CNC Machines was organized
simulation, offers an integrated approach to enhance the
product and production engineering process.
Effective Maintenance of CNC
Machines
A national survey conducted by IMTMA on reliability of
CNC machines highlighted the difficulties confronted by
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users in controlling the downtime of CNC machines. As
the survey indicated that there was a need to familiarize
and upgrade the knowledge base of the man behind the
machine to achieve maximum productivity, a workshop on
Effective Maintenance of CNC Machines for Productivity
Improvement was organized from 19 to 21 April 2011 at
BIEC.
The faculty focused at training the man who handles
the CNC Machines and shed light on the aspects to be
considered for effective maintenance for productivity
improvement.
methodology that tries to pre-empt the occurrence of
errors. Whenever there is a change in product, vendor,
process etc., FMEA is redone to evaluate the effects of the
change. Highlighting the importance of FMEA through
group interaction, a workshop on Failure Mode and
Effects Analysis was organized on 25 and 26 April 2011
at BIEC.
The workshop witnessed participation by representatives
from a wide cross section of manufacturing industries. The
workshop was also addressed by renowned industry experts
who detailed the various aspects of FMEA.
Reducing Cycle Time and Machining
Cost
Productivity and machining cost can be enhanced radically
by reducing the cycle time, especially in large volume
production. Most of the CNC machines are underutilized
with only 20% time effectively spent in cutting and the rest
in non-value adding operations. Even though the material
cost cannot be reduced, the cycle time and machining cost
can be reduced drastically.
Failure Mode and Effects Analysis
Failure Mode and Effects Analysis (FMEA) is a preventive
process, which ensures there is an oriented and proactive
For understanding the importance of reducing the cycle
time, and making the best use of it, a training programme
on Reducing cycle time and machining cost on CNC
machining centres was organized on 27 and 28 April 2011
at BIEC. The programme focused on knowledge inventory,
machining center operations and techniques, demo on
vertical machining centre etc.
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Activities in IMTMA
Northern Region…
Value Engineering
Due to increased competition, constant increase in material
prices and need for consistent cost reduction, the discipline
of value engineering has become extremely crucial in
manufacturing.
Recognizing this, a seminar on Value Engineering and Value
Analysis was held on 17 February 2011 at New Delhi. The
programme was organized jointly by Government of India,
Indian Machine Tool Manufacturers’ Association and
UNIDO-ICAMT under the aegis of Technology Upgrading
for Productivity Enhancement of Machine Tool Industry in
India.
Reducing Costs
Increasing productivity is a key factor for every manufacturing
company and attaining the same needs a lot of research
to be done. Meeting customer expectations and demands,
along with reducing the manufacturing cost, is a challenge
for every company.
Recognizing this need, a day long workshop on How to
Reduce Manufacturing Cost and Enhance Productivity
was organized on 18 February 2011 in Ludhiana. The
workshop addressed the concepts of handling cost
reduction measures of the products and systematic
approach to investigation of the Function/Cost aspect. The
workshop was jointly conducted by Government of India,
UNIDO-ICAMT and IMTMA under the aegis of Technology
Upgrading for Productivity Enhancement of Machine Tool
Industry in India
Sheet Metal Forming
Sheet Metal Forming plays a crucial role in a variety of
product segments like automobiles, auto-components,
consumer durables etc. It is targeted at delivering high
quality products in the market and developing brand
equity.
Keeping this in view, IMTMA in association with Sheet
Metal Forming Research Association (SMFRA) and Centre
for Advance Metal Forming Services (CAMS) organized a
Primer Course on Sheet Metal Forming Technology in New
Delhi on 22 and 23 February 2011.
The course was focused on fundamentals of various
aspects of sheet metal forming with a few sessions on latest
advances in materials and technologies for sheet metal
forming. A panel discussion on key issues relating to the
Metal Forming Industry rounded up the course.
Measuring Surface Finish
In precision engineering, the functional properties of a
component are affected by the boundary areas (or the
surface) of the component. A serious quantitative study of
the quality of a surface becomes an inseparable part of
component design, manufacture and inspection to ensure
proper functional behavior of the design.
A workshop on Surface Finish and its Measurement was
organized on 10 March 2011 in Gurgaon.
Calibration of Dimensional
Measuring Equipment
The process of calibration is significant in achieving required
levels of product quality. The instruments or equipment
used for measurements are initially and also periodically
calibrated to ensure fidelity of measurements.
A workshop on Calibration of Dimensional Measuring
Equipment and Evaluation of Uncertainty in Measurement
was organized on 11 and 12 March 2011 in Gurgaon.
The event had industry experts explaining the importance,
needs and methodologies of calibration in a diverse range
of manufacturing activities.
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Geometric Dimensioning and
Tolerancing
Geometric Dimensioning and Tolerancing (GD&T) converts
a designer’s intentions from paper to part and eliminates
the uncertainty in engineering drawings. In order to ensure
a seamless communication among all the departments,
a proper knowledge of GD&T takes the company a long
way.
Application of GD&T system helps to reduce the
manufacturing and inspection costs drastically. This topic
was addressed at a training programme on Geometric
Dimensioning and Tolerancing in Design through
Manufacturing held on 17 and 18 March 2011 in New
Delhi. The seminar was conducted by experts from IMTMA
Technology and the demonstration on GD&T principles and
CMM were shown at Hexagon Metrology (India) Pvt. Ltd.
Tooling for CNC Machining Centres
The right selection and application of tooling at CNC
machining centres plays a vital role in increasing productivity
and controlling the cost. This was the focus of a training
programme on Right Selection and Application of Tooling
for CNC Machining Centres organized in Gurgaon from
07 to 09 April 2011.
The training focused on topics like selection of tools,
tool holders and coolants for machining centres and
their optimum usage along with the latest developments
in tooling. The programme was extensively interactive in
nature and attended by a large number of participants.
Effective Utilization of CNC Grinding
Machines
Grinding is a finishing process, and its optimization
and effective utilization plays a major role in reducing
and controlling cost. It is one of the complex machining
processes which are often the last in any component
machining.
For shedding light on utilizing the machines to their best
ability, a seminar on Effective Utilization of CNC Grinding
Machines for Productivity Improvement was held on 29
April 2011 in Gurgaon. The objective of the seminar
was to ensure that the participants are exposed through
discussions with experts to various tools and skill sets for
optimizing the grinding process.
Special Programme for TVS
A customisd training
programme on Metal
Cutting was organized
exclusively for TVS Motors
Limited, Bangalore. The
first phase was held
from 31 January to 05
February 2011 and the
second phase from 07
to 15 March 2011. The
programme was focused
at enhancing the skills of
the working engineers of
the company.
15

Failure Mode and Effects Analysis
Activities In IMTMA
Western Region…
Being cautious about the possible errors and nipping
them in bud, pays in the long run. Especially in today’s
competitive environment, industry has realized the
importance of building reliability into the product during
the design and development phase. Keeping this in view,
a workshop on Failure Mode and Effects Analysis (FMEA)
was organized on 04 and 05 January 2011 in Pune.
Application of right tooling can boost throughput and
improve the quality of finished parts drastically and also
reduce machining cost by as much as 20%. Various aspects
of this topic, along with practical solutions through proven
practices were discussed among the participants.
Designing Complex Injection Moulds
FMEA is an “error prevention” oriented and proactive
methodology that tries to pre-empt the occurrence of
errors; reduce their significance (even if they were bound to
occur) and in unavoidable circumstances, to increase the
chance of error detection, so that the process could then
be suitably controlled. As application of FMEA is diverse
in the industry, the workshop was well attended by a huge
cross - section of practicing engineers.
The common complaints coming from commercial tool
rooms today are that they are neither profitable nor meeting
their delivery commitments. A trial and error method is not
acceptable in the shop floors in the long run. It is important
for in-house designers to make the plastic injection moulds
and dies to work right the first time itself.
As theoretical solutions might not be effective when
Tooling for CNC Machining Centres
Installing the best CNC machine and investing on a
variety of tooling will not result in increasing productivity.
With increasing manufacturing costs and decreasing
profit margins, it is extremely important for machine tool
users to choose the right type of tooling that will produce
accurate parts at lower costs. This is an important aspect
and addressing this topic, a training programme was
organized on Right Selection and Application of Tooling
for CNC Machining Centres from 21 to 23 February 2011
in Pune.
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practically imposed in the shop floor, a training programme
was organized in Pune on the topic Practical Solutions
for Designing Complex Injection Moulds on 25 and 26
February 2011.
The programme provided solutions to the common
challenges faced by the tool rooms like shorter lead times
for tool development and stringent quality requirements.
The event was well attended by designers and practical
solutions for common problems were discussed.
Idle Time Reduction in Metalcutting
In today’s competitive world, every minute is capitalized
in order to increase productivity. With CNC machines
expected to perform multiple activities, quick changeover
techniques need to be implemented, failing which there
could be an increase in the idle time.
the components of variation in the measurement. As it
is an important element of Six Sigma methodology and
other quality management systems today, a workshop on
Measurement System Analysis was organized on 15 and
16 March 2011 in Pune.
The process of obtaining measurements and data may
have variation and produce defects. Understanding and
analyzing this process takes the company a long way. The
workshop also included training on common tools and
techniques of MSA which includes calibration studies,
fixed effect etc. The workshop was well attended by
representatives from tool manufacturing companies.
Cost Reduction Through Appropriate
Automation
The need for idle time reduction through quick changeover
/ set-up time reduction is becoming significantly important
due to increased demand for product variability, reduced
product life cycles and the need to reduce inventories, in
metal working.
Keeping this in view, a seminar on the topic Idle Time
Reduction in Metal Cutting through Quick Changeover
Techniques was organized on 11 March 2011 in Pune.
The seminar was coupled with demonstration of Halder
Modular Clamping system and demonstration of set up
change using Jergens System.
Measurement System Analysis
Measurement Systems Analysis (MSA) has today become
a de facto standard of the manufacturing industry. It
is a specially designed experiment that seeks to identify
In order to increase productivity and also get an edge
over one’s competitors, companies need to become
more cost effective. However, a great deal of difference
can be witnessed when appropriate automation is used.
For automation to be successful, several aspects such
as selection of automation system, system integration
and organizational environment need to be carefully
considered.
Keeping this in view, a seminar on Cost reduction through
appropriate automation was organized on 23 March
2011 in Pune. Automation can be deployed in a wide
range of activities such as loading, feeding, clamping,
machining, welding, forming, gauging, assembly and
packing. Automation can also be successfully applied in
process industries such as chemicals, oils, pharmaceuticals
etc. Hence, the participation in the seminar was from an
array of industries.
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Co-ordinate Measuring Machines
(CMM)
Machined parts are becoming increasingly complex, with
more measurement features and tighter tolerances. Keeping
pace with the growing trends, Co-ordinate Measuring
Machines (CMMs) today have replaced traditional methods
of inspection with gauges and fixtures, which in-turn has
reduced inspection time and manpower required.
demonstrations which kept the participants engaged and
involved throughout the session.
Streamlining Tool Rooms
However, understanding and implementing the same in an
ideal manner would bring major impact on the productivity
of the company. Addressing this matter, a seminar on
Getting the best out of Co-ordinate Measuring Machines
was organized on 18 and 19 April 2011 in Pune. The
seminar was focused at guiding the participants towards
the less understood aspects like process control and quality
assurance which increasingly depend on the performance
of CMMs.
A strong foundation of any process guarantees a long
term return, and same holds true even in the function of
tool rooms. The process planning, scheduling and working
systems of tool rooms is a subject which is overlooked and
fine tuning the same will reflect in its productivity.
Keeping this in view, a training programme on Improving
effectiveness of process planning, scheduling and working
systems in tool rooms was organized on 25 April 2011
in Pune. As there exists a mismatch between orders and
capacity, tool rooms are also looking for cost effective
solutions to reduce the lead times. The optimum utilization
Geometric Dimensioning and
Tolerancing
Geometrical Dimensioning and Tolerancing (GD&T)
system eliminates ambiguities in engineering drawings
and brings out the designer’s intent very clearly. It ensures
seamless communication between design, engineering,
manufacturing and quality teams across the entire
organization enabling them to work in a concurrent
engineering environment. Application of GD&T system
helps the companies to reduce the manufacturing and
inspection costs.
A training programme on Geometrical Dimensioning
and Tolerancing in Design through Manufacturing was
organized from 18 to 20 April 2011 in Pune. The training
session was supported with examples, exercises and
of all the resources depends largely on the knowledge and
skill level of the planning engineers. The training session
piloted by industry experts ensured that the engineers were
trained rightly.
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Workholding and Fixturing
Techniques
Workholding & Fixturing plays a crucial role in enhancing
productivity in manufacturing. Optimum fixturing and
tooling can substantially enhance the capability of CNC
machines. Reduction in set-up change is a challenge most
manufacturers face and this is directly related to quality of
fixturing.
Keeping this in view, a workshop on Workholding and
Fixturing Techniques for Productivity Improvement on CNC
Machines was organized on 29 and 30 April 2011 at Pune.
The workshop was very well received by all the participants
and was highly interactive in nature.
Technology Mission to China
& CIMT 2011
As part of the project on
‘Technology Upgrading and
Productivity Enhancement of the
Machine Tool Industry in India’,
UNIDO-ICAMT and IMTMA
organised a “Technology Mission
to China and CIMT 2011” from
14 to 19 April 2011 in Beijing,
PR of China.
The Mission consisted of a threeday
visit to CIMT 2011 which
showcased 2,400 exhibitors
from all over the world. The
exhibition was spread across an
area of 1,20,000 square meters
and attracted 2,32,000 visitors
from China and the world over.
The schedule of the Mission included interactive meeting and plant visits to three Chinese machine tool
companies – two in Tianjin and one in Beijing. Key aspect of the “Technology Mission” was the two interactive
meetings with senior government officials of the China Council for the Promotion of International Trade
(CCPIT) and office-bearers of the China Machine Tool and Tool Builders’ Association (CMTBA).
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