Stefanie Flaeper, Managing Director at transfluid

Q1: As the transition to Industry 4.0 picks up speed, how do you see the future of the metalworking industry? What are your views on challenges and trends facing the metalworking industry?

Anyone who considers the changes with some foresight is on a good path to a positive future. High-tech for effective pipe processing is the key to progress for many technologies and an important solution driver in all area of daily work and life, for example, when you consider machine and medical technology. Over the course of digital development, we also discovered completely new solutions, which ensure even more efficiency in heavily connected processes. Like I said, anyone who’s forward-thinking and is ready to approach digitalisation challenges and the accompanying shift in thinking openly will be successful. The demand will continue to grow together with increasing productivity. We’re already witnessing this development, for example, with our individual automation systems t motion and our tube bending software t control.

The relevance of highly rigid materials in lightweight construction continues to increase. In the automobile area, the trend is developing towards low quantities together with flexible automatic production, i.e. small quantities and individual pieces in automatic processes. This results in advantages like employee-independent production, process reliability, and influence on traceable processes, for example module assembly. Overall, there’s more planning reliability. Of course, the potential for mechanical engineering is being defined worldwide by automation and digitalisation. I see the clearest opportunities and chance to grow in this area. We’re expanding these trends ourselves with our own innovative power.

-- Stefanie Flaeper, Managing Director at transfluid

International Metalworking News for Asia- December 2017 issue

It is clear; the market for connected equipment and devices will continue to grow. But, as product designers and engineers face the challenges of building smart products, they are realising they need faster, better, smarter tools with which to create them. Part of that solution is to use tools capable of bringing all the disparate processes onto a single, unified platform.

Global high-tech companies are melding Industry 4.0, automation and big data to create metalworking equipment, tools and solutions that will build empires in the industrial manufacturing. They are developing healthy ecosystems that can carry their strategies and values far.

Whatever the situation, Industry 4.0 is here, and manufacturers all over the world are doing their best to prepare. At this issue’s 2018 Outlook Report, industry leaders and senior executives share their views and initiatives on Industry 4.0, and the current and future of metalworking industry, as part of their overall efforts toward automation and big data in manufacturing.

The adoption of Industry 4.0 is indeed a major deportation from traditional manufacturing culture. It not only needs new systems and new set of skills but also a new mind-set, to create a new culture to drive Industry 4.0.

A true digital enterprise will deliver value through physical products or services at the core, through a network of customers and suppliers augmented by digital interfaces and data driven industrial digital ecosystems. These developments will profoundly change individual enterprise, as well as transform market dynamics across the globe.

Although this vision of the future of manufacturing may still be years away for some factories in South East Asia, things are clearly headed in the right direction. InternationalMetalworking News for Asia helps bring Industry 4.0 to life for companies in the region through our motivating technical articles.

Of course, there’s plenty more stories and topics aside from Industry 4.0. Take a moment to read the magazine’s latest print issue or download your copy on iTunes and Play Store. Don’t forget to follow us on Twitter and like our page on Facebook.

A different method of turning

In a market as notoriously competitive as automotive, parts such as hub units, CV joint components and drive pinions share a common requirement: to maximise productivity without compromising quality. The question is, how can you produce these steel parts in high volumes? This is all about to change with a new turning methodology that challenges conventions to deliver productivity increases typically no less than double what can be achieved presently.

Read More: http://www.industrysourcing.com/article/fast-automotive-turning-gets-stamp-approval

International Metalworking News for Asia October issue

The October issue of InternationalMetalworking News for Asia is loaded with insight on some of the most important announcements and initiatives to come out of this year's top industry trends. One of the most intriguing highlights at the recent EMO Hannover is Hoffmann Group's analogy with nature's powers of innovation in its technology – emphasising the company's ongoing commitment to bringing new, high-quality tools to the market as part of its GARANT premium brand. Using the slogan "Innovative by nature", its innovations include a new conical barrel milling cutter, which makes it possible to achieve an improved surface quality and make considerable time savings through the use of state-of-the-art milling strategies.

Håkan Ericksson, Global Product Specialist at Sandvik Coromant, authored this month’s Tooling & Workholding section titled “Fast automotive turning gets stamp of approval.” He explains a different method of turning that challenges conventions to deliver productivity increases typically no less than double what can be achieved presently. In contrast to conventional longitudinal turning, the strategy allows the tool to enter the component at the chuck and removes material in the opposite direction, Turning ‘backwards’ in this manner allows a small entering angle to be applied, which in turn provides considerable productivity gains.

Also don't miss Cornelia Gewiehs article on machine learning, which answers the fundamental question whether machine learning is only something for global players and their ideas for a comprehensive concept of a digital factory. Or whether, besides a top-down development thrust by financially potent large companies with their highly competent research and development departments, a bottom-up breakthrough spearheaded by flexible, innovative small and mid-tier enterprises would also be conceivable.

We are happy to report Siemens Industry Analyst Conference in Boston. The program was designed for attendees to gain deeper understanding of digitalization and its impact on our industry. Siemens executive team presented strategic positioning and the direction of their technologies and industry solutions that are helping customers face the challenges of digitalization. Siemens customers shared best practices and lessons learned on their digital transformation journeys and how Siemens is helping them to succeed.

Lastly, email us with your thoughts, noting any article to which they apply. I read comments and questions on Facebook, Twitter, and Blog. Please contact me directly with any issues that need a response.

Siemens holistic approach to digitalisation

Manufacturing is undergoing a digital transformation driven by smart technology and connected devices. With opportunities to increase efficiency, productivity and accuracy in the industry, it is an excellent match for manufacturing.

In South East Asia, every manufacturing business is interested in what digital transformation could mean for his or her business. They believe digital transformation is key to future competitiveness, growth and agree that it will deliver better business results. 

While there is an awareness of the importance of digital transformation in South East Asia, this has not yet fully translated into reality. Majority of the companies in the region are still not fully on board, suggesting that the digital transformation race has really only just started in South East Asia.

INTERNATIONAL METALWORKING NEWS FOR ASIA (IMNA) spoke to Bisheng Liu, Vice President, Digital Factory Customer Services, ASEAN, Siemens Pte Ltd, and Tindaro Danze, Vice President and Division Lead for Digital Factory and Process Drives, Siemens Vietnam about a range of products and solutions that support companies in their journey towards digitalisation.

IMNA: Reports say that by the year 2025, automation software will replace 140 million full-time employees across the globe, are we in the brink of a jobless future?

Bisheng: We are experiencing the next wave of industrialisation. The most important fact is that digitalisation does not necessarily mean that human workers will be replaced by machines; it actually helps plant operators’ work more effectively. The second most important fact is that digitalisation helps to shorten time to market of products, and also helps plant operators to be more flexible, which means we can now do more high-value work. The manpower that used to be positioned on the shop floor work, contributing to a value-creation environment. By enabling digitalisation, you can enhance productivity, and at the same time develop a more flexible and efficient production environment. 

IMNA: In emerging countries in Asia, job shop owners and manufacturers conjure visions of massive machinery projects, huge capital expenses, and radical business process overhauls when they hear the word automation. Can automation start on a much smaller scale?

Tindaro: Digitalisation is a concept, and every company will have their own vision of how they want to improve on their processes. Companies do not have to invest heavily at once to revolutionise their factory. Some steps can be pertinent only to small shops and not for huge factories, and vice versa. The journey towards digitalisation varies based on factors such as type of company and industry, as well as country where it is based in.

Manufacturers in South East Asia are faced with tougher competition and more challenges, whether they are local small and medium enterprises with small facilities, or multi-national corporations with bigger facilities. Regardless of size, companies are looking to increase competitiveness in the market and become stronger players in the regional and global markets.

Bisheng: Consumers are experiencing a higher demand for customised products to meet their specific needs. We have digitalisation concepts for companies across various industries. We propose effective technology improvements to help customers optimise their manufacturing processes, and digitalise their assets and machineries to enable analytics to better manage operations on a facility-wide level. We deal with plants of different sizes and requirements. Here at Siemens, we educate our customers on what to expect in the current market, and what could happen in the future so that they can set a correct pace for their business.

IMNA: Is South East Asia ready to adopt advanced manufacturing?

Bisheng: Because of the ever-changing consumer demands, manufacturers are increasing flexibility in terms of creating products that meet individualised needs, and at a speed that is faster than competitors. In South East Asia, manufacturers are taking steps to enhance product quality, increasing plant efficiency and integrating protection technology in order to sustain energy, production cost and security.

Tindaro: Digital Enterprise is Siemens’ answer to Industrie 4.0. The Digital Enterprise Suite enables manufacturing companies to streamline and digitalise their entire business process, seamlessly integrating suppliers into the mix. They can begin at any point of their value chain, from product design to service, and can extend digitalisation gradually, depending on their current needs.

With the Digital Enterprise Suite, Siemens offers a comprehensive portfolio of software-based systems specifically for the discrete industries. It integrates and digitalises the complete value chain from product design, production planning, production engineering, and production execution to services. The result of the integration and digitalisation of the complete value chain is a perfect digital copy of the value chain – the Digital Twin. This enables companies to perform simulation, testing, and optimisation in a completely virtual world – before ever committing any resources in the real world. The connection of the virtual and real worlds leads to shorter time-to-market as well as greater flexibility, quality, and efficiency.

Bisheng: Also included in Siemens’ Digital Enterprise offerings is MindSphere, the cloud-based, open Internet-of-Things operating system that forms the foundation and fulfils an essential condition for databased industrial services. As an open cloud platform for industrial applications, MindSphere opens up scope for the link-up of devices and plug-and-play connectivity using open standards. In addition to offering data analysis and versatile connectivity, it also supplies tools for developers, applications and services. MindSphere helps customers to evaluate and utilise their data in ways they had never previously envisaged – such as by optimising the performance of their operating equipment to achieve maximum availability. MindSphere also paves the way for completely new business models such as the sale of machine hours, while users profit from benefits such as a transparent pay-per-use pricing model.

To cater to customers in South East Asia, the company launched ZerOne.DesIgn, Digital Factory Manufacturing Design Consultancy. Officiated by Singapore’s Minister for Trade and Industry (Industry) Mr S Iswaran, it is the first-of-its-kind for the controls and automation industry globally to offer such technical consultancy services to help companies achieve their Industrie 4.0 vision. The consultancy possesses the technical expertise to propose effective technology improvements to help customers optimise their manufacturing processes, and digitalise their assets and machineries to enable analytics to better manage operations on a facility-wide level.

Call it as the fourth industrial revolution or industry 4.0, there is no denying that a fundamental shift in the supply chain is changing the way manufacturing industries operate. The August issue of International Metalworking News for Asia explores a range of articles associated with Industry 4.0. These articles implement digital improvements to business processes that are key to growth.

While modern portal machines have now achieved high level optimisation in terms of performance, and dynamics are little more than details, the question of service is becoming more important. After all, what characterises a good relationship between supplier and user? Zimmermann is currently working on an app that will display the machine state to the customer at all times. If an error occurs, the user immediately sees a message that is sent directly to the company. Find out more in this month’s Metal Cutting section.     

Despite the fact that there is an awareness of the importance of digital transformation in South East Asia, this has not yet fully translated into reality. Majority of the companies in the region are still not fully on board, suggesting that the digital transformation race has really only just started in South East Asia. Enterprise Close- up features two executives from Siemens who are experts in digital factory. Here, they talk about digital concepts for companies of different types. They propose effective technology improvements to help customers optimise their manufacturing processes, and digitalise their assets and machineries to better manage operations on a facility-wide level.  

Meanwhile, users of CNC manufacturing processes are now expecting improved capability in precision part machining, reduced setting and process adjustment time, and integration with automation systems. Learn about Renishaw Equator flexible gauge now offered with IPC (intelligent process control) software, providing the functionality to fully automate tool offset updates in CNC manufacturing processes, in this issue’s Metrology section. This capability has said to be already used by Renishaw customers worldwide to achieve considerable performance gains across a wide variety of industries, applications and CNC machine types, including lathes, machining centres and highly automated machining cells.

We sincerely trust that you will have as much pleasure reading this edition of International Metalworking News for Asia magazine as we enjoyed compiling topics about digitalisation for you. Happy Reading!

International Metalworking News for Asia’s June 2017

Be sure to read International Metalworking News for Asia’s June issue, which spotlights interesting interviews of some of the industry’s movers and shakers.

Philip Parker, Product Marketing Manager of Hypetherm Mechanised Plasma Systems Team talked about most significant advance in mechanised plasma cutting with the introduction of an entirely new class of plasma called X-Definition™. This new plasma is available for the first time in a 300 amp plasma system called the XPR300. He said that the arrival of X-Definition Plasma and our new XPR300 is a huge step forward in the capabilities of plasma technology.

Dr Robert Blackburn, CEO of Hoffmann Group said that market is moving quickly and developing up the value chain. The trend over the coming three years is all about embedding software or embedding intelligence in the tool. He discussed the company’s ambition to further build up intelligence and offer smart solutions that enable efficient communication between the tool and the machine. This is a challenge, but above all it’s a great opportunity for Hoffmann, who is at the forefront of that development.

Industry 4.0 and the constant demand for new innovations can be stressful for companies, but Sandvik Coromant has created an environment for bright ideas to flourish. It’s no coincidence that competitors are still struggling to produce vibration-free boring bar lengths above 10 times the hole diameter while the team is testing bars that can handle double that, now with connectivity and software that save valuable time and money for the customers. Find out the secret behind Sandvik Coromant’s silent tools.

Sure enough, the issue includes columns from such as show previews, industry news and product highlight.

Finally, we take your comments seriously. If you have something other topics in mind, we want you to let us know. Drop us a line and tell us what you want. 

Interview with Hoffmann Group’s new CEO

Dr Robert Blackburn, CEO, Hoffmann Group

Much coverage is being given about the Fourth Industrial Revolution. This era takes us far beyond the steam and water that kicked off industry in the 1800s and builds upon the electronics and computers that seemed so high-tech in the 1980s. You can either be scared or be excited that Industry 4.0 is creating exciting changes in everything from how and where things are created to how they’re distributed.

Most manufacturing executives who have heard about Industry 4.0 are sceptical. Others think that this is just another piece of marketing hype or that only big manufacturing facilities need these technologies that promises to reshape the way things are made.

INTERNATIONAL METALWORKING NEWS FOR ASIA is fortunate to interview Dr Robert Blackburn, the new CEO of Hoffmann Group, during the recent MTA Singapore. Dr Blackburn is considered internationally to be a leading mind with strategic vision and to be a pioneer in the field of digitalisation.

Managing a manufacturing transition
Emerging countries in South East Asia is moving itself down a more advanced manufacturing path. And they need help transitioning to competitive manufacturing environments. But are they ready to enter the next phase in the digitisation of the manufacturing sector?

So what happens to a country when a new manufacturing mind-set becomes reality? How do small companies begin to transition internally, expand locally, or decide to seek opportunities through digitalisation. These are only a few a questions and concerns from small shop owners in Asia that were discussed across conference tables.

The transition to high-complexity manufacturing is not going to happen overnight. What better way to start and be ahead of the game is by using an intelligent dispatch machine that optimises tool administration, and can provide interfaces to the company network including materials management system.

Dr Blackburn, said, "When you’re a small shop owner premium tools are hard enough to get. They’re even harder to keep track. So in a very pragmatic way, we can take the smallest shop and we can provide them a solution, which is of a highest premium standard to protect quality tools from going missing. We always like to talk about the advantages our premium tools provide. But we also have tools in our portfolio that have very pragmatic purposes while at the same time offering a good quality.”
Tool24 Smartline is Hoffmann’s latest innovation for managing tools. GARANT Tool24 Smartline concept is impressively simple: sturdy tool cabinets with up to 90 drawers offer you round the clock access to the desired material. The intuitive software allows you to make your selection quickly, be it by scanner, key word search or article number.

“In a big company what does Smartline do? It allows you to immediately manage your spend on tool and know which worker is using what. But if you’re in a small shop sometimes it can be as simple as protection. You don’t want to be locking everything up. Just like what it does in a big company, the system opens for you and it knows which tool you need when,” he added.

Dr Blackburn explained, “What Smartline is offering sets a real impact in society for the smallest of the small workshops to the biggest most state-of-the-art factory. Let’s say you’re at the port in Singapore and you’re running a rather small business, who got a contract with an oil & gas firm. So instead of locking your tools up or throwing them in the back of your truck, you can put them in your van and inside a Smartline machine.”

Innovation: Market differentiator
He described innovation in Hoffmann’s segment in the tool industry, particularly in Asia, a market differentiator. “The market is moving quickly and developing up the value chain. The trend over the coming three years is all about embedding software or embedding intelligence in the tool. So, our ambition is to further build up intelligence and offer smart solutions that enable efficient communication between the tool and the machine. This is a challenge, but above all it’s a great opportunity for us. Obviously, Hoffmann is at the forefront of that development.”

Dr Blackburn added, “In our Garant tools we have the intelligence already inside. Within our portfolio we offer tools that communicate to the machine and send a signal when replacement is needed, for example. There’s a reason why we are a premium brand, and that’s what our customers can justly expect from a technology leader.”

Dr Blackburn defined the fourth industrial revolution all about connectivity. “But, while focusing on digitalisation and connectivity you have to provide quality, above all. That’s what Hoffmann Group stands for: the highest quality tools in the market.” What is also unique about Hoffmann is the omni-channel approach the company intends to bring to Asia. “In terms of digitalisation, we are continuously improving. We thrive for an integrated approach. That means for example, that we will integrate some of the expertise that our sales team in the field offers our customers in human form into our digital channels. Our consultants will be able to use the new channels to show their “face” to the customer on the website. This approach is unique in our industry.”

By: KATHRYN GERARDINO-ELAGIO 

International Metalworking News for Asia June 2017

Revolution in industrial cutting

“It’s More Than Just a Revolution in Plasma. It’s a Revolution in Industrial Cutting.” This is the message Hypetherm Asia Pacific aims to convey to the press and their channel partners present during the recent "Meet the New Plasma Media Event" in Singapore.


Plasma cutting systems have been used to cut metal for over 50 years and provide numerous advantages over other cutting methods. But despite the fact that plasma cutting systems have been used in industrial applications for many years, some people are still unaware of its benefits and how it can be an essential productivity enhancing tool.

Among the tell-tale signs that Hypetherm is betting its future on helping shape the world is the launch of XPR300^TM and EDGE^® Connect. Philip Parker, Product Marketing Manager of Hypetherm Mechanised Plasma Systems Team, and Nathan Pascarella, Product Marketing Manager of Hypetherm Automation flew all the way from New Hampshire, USA to help introduce XPR300 and EDGE Connect CNC, and to leverage these next-generation technologies through discussions and presentations.

XPR300

Philip Parker, Product Marketing Manager

Philip talked about most significant advance in mechanised plasma cutting with the introduction of an entirely new class of plasma called X-Definition™. This new plasma is available for the first time in a 300 amp plasma system called the XPR300. He emphasised, “The XPR300 has unmatched performance and unbeatable operating cost.” Philip said the X-Definition class plasma combines engineering advances and refined high definition plasma processes to deliver unmatched plasma cut quality on mild steel, stainless steel, and aluminium. Laboratory testing shows ISO-9013 Range 2 cut quality on thin mild steel and extended ISO Range 3 cuts on thicker metals. To reach this point Hypertherm engineers had to develop a number of new patent-pending processes like Vented Water Injection™ (VWI) and plasma dampening, and new vent-to-shield technologies. The end result is squarer cut edges, markedly less angularity, and excellent surface finish on non-ferrous metals like aluminium and stainless steel.

“The arrival of X-Definition Plasma and our new XPR300 is a huge step forward in the capabilities of plasma technology,” said Philip. “The combination of faster cut speeds, unparalleled cut quality, intuitive features, and automatic system monitoring make it our most advanced and productive plasma yet. It really opens up a wide range of opportunities for companies by providing cut quality and consistency that may make it suitable for applications which have previously been associated with laser, but with the much lower initial investment costs associated with plasma,” he added.
Despite being Hypertherm’s most advanced system yet, the XPR300 is easy to use. Sensors in the power supply deliver refined diagnostic codes and significantly enhanced system monitoring information. This reduces troubleshooting time and provides proactive data to improve overall system optimisation and uptime. Additionally, the system is designed with fewer consoles and connections so operators can spend less time setting-up and more time cutting.

For example, an EasyConnect™ feature allows operators to quickly plug the torch lead into the torch connect console without the use of tools, while a patent pending QuickLock™ electrode delivers easy quarter turn tightening to further reduce setup time. Another new design feature is a quick change torch that enables an operator to rapidly change torches with just one hand. All consoles feature advanced autogas capability allowing operators to select and implement cutting jobs directly from the CNC, along with Wi-Fi in the power supply to enable system, or even multiple system, monitoring from afar.

EDGE Connect CNC

Nathan Pascarella, Product Marketing Manager

According to Nathan, the EDGE Connect is the latest CNC designed and built by Hypetherm. This exciting new product combines ease of use and reliability features into the three new hardware configurations powered by Phoenix^® software, the EDGE Connect provides end users with the performance features they need and channel partners with flexibility for installation and integration.
“Our customers wanted greater functionality integrated into their cutting machines coupled with our embedded expertise. EDGE Connect delivers that through our new software applications running on this new hardware platform,” he said.

Nathan added, “The EDGE Connect offers greater flexibility for machine operators with ProNest CNC, a feature that allows SureCut outcomes to be programmed quickly and efficiently from the touchscreen interface. It is a great complement to our offline CAM software, providing a solution when offline CAM programming might not be available.”

Cutting machine customisation is further enhanced by quick and easy set up through an EtherCAT communication platform and custom software configuration that allows for up to 12 axes through an online configurator. The hardware platform is the foundation and software selections enable any EDGE Connect to be set for various cutting applications. Furthermore, cutting machine manufacturers can develop their own operator consoles and auxiliary programs using the Soft Op Con API and PLC Connect.

Creativity and innovation

Israel Gonzales, Regional Director

One of the more interesting takeaways during the media event is Israel Gonzales, Regional Director, Hypetherm Asia Pacific sharing about the company’s vision. He said, “Hypetherm’s vision is to be the agent of innovation in industrial cutting operations globally, working together as a company of owners to make positive change, create shared value and bring out the full potential of every associate.”

The company aims to be recognised beyond plasma, metal, 2D, and cutting systems & consumables. They want to be known as a company that provide the full value stream, including upstream and downstream; not just products and not just at time of sale, rather a trusted adviser and service partner over the full product/customer life cycle.

Israel believes that “The Human Touch Matters!” The company’s overall objectives are: high performance, access and fast delivery, reduce operating costs, high uptime, optimise total cutting value stream, provide training, make purchasing easy, keep me informed, and objective advice on technology.

“Quantify the relative importance of each of the nine services crucial to the customer experience, and understand the relative size of the gap between what the end user desires and what is actually being delivered by Hypetherm and our partners, today on a global scale,” he said.

Finally, Lester Lee, Regional Marketing Manager, Hypetherm Asia Pacific, shared two strategies for creating competitive advantage: 1) Cost Leadership- a cost leader is where the company has decided to create the cheapest product on the market. This strategy requires the product to be commoditised and take advantage of the economies of large scale. 2) Differentiation- The differentiation strategy is where we decide to choose a certain attribute of our business offering to focus on. In order to make this strategy work you have to select an attribute that a big enough section of the market care about enough in order to pay a premium price for your product.

By: KATHRYN GERARDINO-ELAGIO 

International Metalworking News for Asia June 2017

IMPORTANT ANNOUNCEMENT

IMPORTANT ANNOUNCEMENT: We have changed the location of our conference from Chonburi to Bangkok and extended the scope from high performance machining to include other manufacturing process focused on the automotive sector. Please see the details below.

If you have any questions, kindly E-mail: 

S.E. Asia: Kathryn Gerardino-Elagio (kathryn@ringiertrade.com)

China: William Yan: (william@ringiertrade.com)

Taiwan: Sydney Lai (sydneylai@ringier.com.hk)

HK, Europe & North America: Mike Hay (mchhay@ringier.com.hk)

Embracing digitalisation the smart way

The recent TIMTOS 2017 Summit brought together industry experts with an eye toward making the vision of smart manufacturing a reality and promoting Industry 4.0. The summit consisted of 30 minute lectures, broken down into five tracks that run simultaneously. Some highlights of the keynotes are:

Dr Ken Chen, Vice President of Siemens Ltd, Taiwan’s topic is “Paving the way to future smart machine.” His speech talked about how we can build manufacturing process that automatically improve themselves as a result of their experiences, including the basic rules that govern learning processes. According to Dr Chen, machine with intelligent capability brings the future of machine and behave like human being with this Siemens can give the answer for the future of smart machine.
Bryce Barnes, Senior Manager Connected Machines and Robots, Cisco, spoke about “How the Internet of Things will Transform the Global Machine.” According to Bryce Manufacturing and the Internet of Things are two worlds coming together.

He explained, the first industrial revolution used water and steam power to mechanise production. The second used electric power to create mass production. The third used electronics and information technology to automate production. Now a fourth industrial revolution is building on the third, the digital revolution that has been occurring since the middle of the last century. It is characterised by a fusion of technologies that is blurring the lines between the physical, digital, and biological spheres.
Bryce said that the fourth industrial revolution leads to digital transformation that allows us to re-imagine how we enable, differentiate and define how we work, live, learn and play. It is predicated on a hyper-connected world; one where people, processes, data and things (digital and physical things) communicate freely with one another and add and extract unprecedented value of their endless interactions.

He mentioned that connected machines represent huge opportunities, and that 92% of machines are not network connected all over the world. Bryce finds that most CNC machining is still operator driven or craft driven. The movement from build at any cost of efficiency is accelerating. As a service strategies are evolving but not fast enough. Finally, mechanical & process innovation are essential but not enough. The call to action for these outcomes is IOT for machine tools. But what is driving IOT for machine tools? It’s the asset utilisation, optimised consumables, accurate job costing and loss reduction.

Meng-Shiun, Tsai Ph.D. on the topic of “Design and manufacture of machine tools and wisdom control technology,” mentioned two main points: one is how to build a multi-physical digital design system, and the second is how to develop intelligent technology alone. The goal of developing a multi-physical design system is to predict the accuracy of the workpiece contour, surface roughness, and machining time before processing by means of a virtual simulation after a given machining program, and through CAD/CAM software to 3D images to produce processing surface line. The goal of developing stand-alone intelligent technology is to develop the value-added and detection system of the controller and hope to diagnose the tool wear through line measurement. Life estimation provide a set of on-line measurement mechanism to predict the surface quality of the process. The report shows the results of its team in integrating servo and cutting simulation systems, 3D CAD/CAM virtual simulation and intelligent human-machine development.

Manfred Koch, Head of Industry Cluster Machine Building of SICK AG, talked about “Smart Machines Need Smart Sensors.”

He said that machinery, in particular in the area of machine tools, is facing a continuous change in innovation. In the beginning of industrialisation, mechanisation was the first step from handmade products to machine supported production. This step has ensured to cope with the increasing demand of society for higher volume of goods at lower costs, to produce faster along with the changes as well as to favour new production methods with better efficiency.

“Next innovation steps were influenced by automation technology which led to the use of electronic sensors and machine controllers with the benefit of precise, reliable and flexible machine processes, for instance in movement, positioning and safety. For decades, the improvements followed incremental steps and excelled machine improvements towards higher production speed, quality and resource efficiency,” Koch added.

He explained that today’s society has access to new IT capabilities with the result of paperless, flexible order configuration which even allows tracking of the shipment on a smart phone. Thus, the trend is changing from mass products with little variants, e.g., cars, to increasingly individualised products with “lot-size one” especially in consumer products such as sport shoes.

Koch said that these mainstreams, enhanced machine automation and IT use of customer foster a new era and force machine builders to fulfil challenges such as Flexible Automation – Quality – Track & Trace and Safety. The new requirements need answers as well in sensor technology. Modern, innovative sensors use  ASIC technology, which provides the ability to process signals faster, less sensitive to environment influence and more precisely. Moreover, they have the capability of pre-processing information already inside the sensor. Examples are data analysis for predictive information or even the ability to differentiate objects simply based on their characteristics.

Batch changes must already be supported by the sensor, saving set-up time and ensuring appropriate set-up. In combination with intelligent communication, smart sensors provide the ability of increased application functionality. Big data can be made available, but does not necessarily have to be sent via a programmable logic controller or other machine controllers. Avoiding such bottlenecks, data can be transferred parallel to the higher level machine or plant control directly.

Finally Koch said smart sensors serve both worlds: on the one hand proper machine functionality, process flexibility and a higher transparency related for instance to optimised set-up or trouble shooting. On the other hand, smart sensors give added value for the overall production information flow.
Jeng-Shyong Chen, a Professor of the Department of Mechanical Engineering National Chung-Husing University discussed “Digital and Intelligent Machine Tool Technology.” In his speech he mentioned the megatrends of machine tool technology. Indus 4.0 smart factory is about intelligent functions and software, while advance materials is on ultrasonic machining and 3D printing. The roadmap to Machine 4.0 Project begins with 5-axis ultrasonic machining (2017), intelligent ultrasonic machining system (2018) and intelligent hybrid manufacturing system (2019).
Chen explained that from the conventional metal machining to the advanced material machining and 3D printing, aerospace will switch from aluminium to composite materials, while mobile phones from metal case will shift to ceramic case and 2D/3D glass, electric vehicle on the other hand will change from metal frame to composite frame, and we will see fewer and fewer of die/moulds in the 3D printing technology.

According to a survey from Manufacturing Engineering Magazine, 39% of respondents said post-processing requirements are a top challenge in using AM now and in the future.
The 3D metal printing has been proven to fabricate complicated geometric parts in an efficient way, but this technology must evolve to be able to engineer the mechanical properties of a part (both in internal and surface portions), too, he added.

Andreas Schuhbauer, Market Segment, Manager Machine Tool Automation, KUKA AG, talked about “Smart Factory: How Smart?” Here he stated the challenges of the future. Schuhbauer said that the world of work is going to undergo fundamental change. But take note that this is a development, rather than an abrupt change. One that will be accelerated by the following megatrends.

He explained that in a smart factory, machinery and equipment will have the ability to improve process through self-optimisation and autonomous decision making. And the processes impacted will include: factory and production planning, product development, logistics, enterprise resource planning (ERP), manufacturing execution systems (MES), control technologies, and individual sensors and actuators in the field. Therefore, smart production will use a flexible tool and positioning technology and robots that cooperate during a production step.

“Since human labour is a very important cost driver, robotic co-workers are mainly used to improve worker productivity. In human-robot collaboration, the robot assists the human operator. This means: The machine does not replace the human, but complements his capabilities and relieves him of arduous tasks”, Schuhbauer added.

Having heard all these, embracing smart manufacturing ultimately determine a business' success. We are at a point where paradigm shifts and technological changes are a necessity, but we are seeing businesses fail at taking complete advantage of the benefits they offer. Successful supply chain management systems allow for visibility into integrated metrics that can help drive profitability and move the supply chain from a push-based to a pull-based model. When done right, businesses maximise cash flow, minimise lost sales and reduce overstocks.

By: KATHRYN GERARDINO-ELAGIO 

International Metalworking News for Asia April 2017

Learn from the experts! Be part of the action! Come Join!

The 2017 Asia High Performance Machining Technology Conference (June 27-28) brings industry leaders together to discuss Precision Machining, Intelligent Automation, Testing & Measuring, and Equipment ROI, plus Practical Solutions and Ideas. It includes a Mini Expo, Factory Tour, Technical Seminars, and Networking opportunities, all included with 2 days of valuable information exchange on the latest topics, with lunch and drinks and other activities.

International Metalworking News for Asia April 2017 issue is already out!

http://edms.industrysourcing.com/ezine/17/04/imna.htm

Industry 4.0 is emerging as a critical component to manufacturing competence. A trend that will further intensify in the coming years. Leading companies are appearing on the horizon with ideas that will change the face of the industry.

Job shops in South East Asia’s developing economies are now starting to identify technologies that would complement their manufacturing businesses. Here at International Metalworking News for Asia, we strive to present technical articles, stories and products that can help expand outside traditional manufacturing.

DMG Mori supports its customers on their path to consistent digitalisation based on the app-based control and operator system CELOS® with intelligent software solutions and a lot of digital products and services. By now every fourth machine is thanks to CELOS® compatible with the future. Find out what other products the company presented during its recent open house in this month’s Metal Cutting section.

To remain competitive and profitable, shops continually seek the most economical and productive ways to accomplish their work. Industry 4.0 is presently the top level of manufacturing evolution, requiring strong management commitment, specialised personnel and significant investment. The Tooling & Workholding section features simple, cost-effective analyses and actions that can have a large positive effect on the productivity of small to medium-size operations.

Users nowadays are looking for tangible benefits to reach the next level of process simulation in their sheet metal forming software. This month’s Sheet Metal Forming section unveils Auto-Form Engineering’s latest software version. The software enables users to reach the next level of process simulation through a new set of powerful enhancements and functionalities.

Although Industry 4.0 is dominating the discussion of the future like no other topic, efforts to lay out Industry 4.0 in South East Asia is still embryonic. At present, enterprises in the region whose status can be described as Industrial 3.0 or even lower than that know they need a lot of improvements, especially in cost control, production efficiency and process management. 


Nevertheless, these economies are pushing towards development. And in the future, I’m positive that we will see more demand for services, potentially turning them into a major power behind the digital market.

Key Trends significant to IIoT

Manufacturing is on the crossover of a revolution all over the world. Advancements in technologies are not only making manufacturing effective, but also enabling the work to be “Smarter”. Technologies, based on the IoT, are growing exponentially and are becoming more efficient and significant in industries such as Manufacturing, Healthcare, Energy, and Retail. The IoT has created a new wave of transformation for manufacturers over the past decade.

By 2020, Frost & Sullivan estimates nearly 12 billion devices in the manufacturing world are expected to be connected via advanced machine-to-machine (M2M) based technology.

The market research has identified some of the key trends significant to IIoT:
1. Industrial Mobility
2. IoT gateways
3. Smart Sensors
4. Big Data Analytics
5. Virtual and Augmented Reality
6. Manufacturing Cloud
7. Additive Manufacturing

A number of leading manufacturers such as Bosch, Siemens, and General Electric (GE) are early adopters of smart manufacturing. However, today, a number of niche companies namely Waygum, GainSpan, Splunk, and so on are leveraging the technology and making advancements in the industry vertical. A key to successfully migrate into IIoT is to ensure high productivity and efficiency at reduced costs. Innovative evolution and digitization have driven new and different applications of IIoT, especially in the manufacturing vertical.

Göran Näslund: Industry 4.0 trend of automation in South East Asia

Today, equipment manufacturers are facing another form of advancement—the rise of new digital industrial technology, referred to as Industry 4.0. But how do industry experts view the development of Industry 4.0, how do they see the adoption in South East Asia altering the competitive landscape and what range of solutions can they provide the industrial market in the region.

Göran Näslund, Head of Digital Machining, Sandvik Coromant shared with International Metalworking News for Asia its view of Industry 4.0 in South East Asia.

Göran Näslund, Head of Digital Machining, Sandvik Coromant
We see the adoption of Industry 4.0 in South East Asia altering the competitive landscape as the trend of automation and data exchange in manufacturing technologies via cyber-physical systems, the Industrial Internet of Things (IIoT) and cloud computing sets the fundamental for ‘smart factory’ implementation.

For manufacturers, the ability to allow the key elements of the production process to communicate with each other will provide significant competitive advantage and growth potential. This is because digital connectivity solutions will help companies to improve every aspect of the end-to-end production process – from design and production planning through machining to post-process analysis and intelligence. Enhanced connectivity and interoperability will open up new opportunities to improve productivity, profitability and security through better planning and decision-making, more optimised processes, lower levels of waste, increases in efficiency and the rapid identification and resolution of production issues.

With machines, software solutions and cutting tools interconnecting in such a way that they can collect and communicate data from and between every different step of the value chain,  the so-called ‘dark data’ – data that would previously have been either unavailable or, at best, difficult to obtain - can now be analysed. And in line with the old saying that ‘if you can’t measure it, you can’t improve it,’ this will allow companies to identify how their production processes can be made less wasteful and more efficient.
By making it much easier to configure and modify key parameters from the machine control or even by using browser interfaces, smartphones and tablets; the time it takes to set up a process for a new machining job would be significantly reduced. And once up and running, the same remote configuration capability could be used to further improve the process until the optimum set-up is achieved. Ultimately, combining digital solutions with data collected from other areas of the machine opens up the potential to build systems that can ‘self-optimise’ with little or no programming or operator intervention.

Manufacturing “skills gap” (the lack of availability of technically competent individuals) will also be addressed. Digital solutions that are emerging in support of Industry 4.0 allow a greater ability to monitor and record every aspect of the production process. The remote monitoring and control capabilities that IIoT facilitates will also augment the skills within a manufacturing organisation. For example, a scenario where connected solutions might allow key tool parameters to be set via a modern touch screen. This would probably make manufacturing more attractive to the young generation entering the workforce in the next coming years.

Sandvik Coromant’s position in the industry 4.0 process
Strengthening our offer in Industry 4.0 areas like digital transformation, intelligent machining, digital product and application recommendations and tool data in ISO format, just to mention a few, Sandvik Coromant is actively influencing the ongoing industrial revolution. We continue to develop our Industry 4.0 position with modern advancements such as data exchange and manufacturing automation.

Recently acquiring Prometec GmbH, a sophisticated process monitoring company, and opening the Additive Manufacturing Center positions Sandvik Coromant as an industry front-runner in new manufacturing technologies.

Range of solutions
We have recently unveiled CoroPlus™ - a suite of Industry Internet of Things (IIOT) solutions aimed at helping manufacturers prepare for Industry 4.0. The concept is designed specifically to improve the control of productivity and costs through a combination of connected machining and access to manufacturing data and expert knowledge.

The concept of CoroPlus (a new platform of connected tools and software; essentially comprising technologies that can send and/or receive data) makes it possible to reduce data waste and improve manufacturing processes, from pre- to post-machining, through the use of connected technology and machining knowledge from Sandvik Coromant.

With CoroPlus, we are partnering with machining tool builders, cloud suppliers and network companies. In this way we can help users to capitalise on new technology developments. Our role is to increase productivity and flexibility through value-creating technological advancements in digital machining. Our customers can expect more offers from CoroPlus, which spans from connected cutting tools to software solutions and IoT devices next year and beyond.