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)