Machining in­dus­try scales up to match pro­duc­tion needs

In­dia’s am­bi­tious drive for `Make in In­dia’, de­pends heav­ily on the avail­abil­ity of world-class ma­chine tools at com­pet­i­tive prices. This can be made pos­si­ble only by man­u­fac­tur­ing them in In­dia. Hence it is nec­es­sary to `ma­chine in In­dia’ be­fore ‘make in

Auto components India - - CONTENTS - Story by: J Prana­vanad

Recog­nis­ing that heavy en­gi­neer­ing equip­ment and ma­chine tools in­dus­try are the back­bone of the en­tire man­u­fac­tur­ing sec­tor, the Union Depart­ment of Heavy In­dus­tries, has con­sti­tuted Coun­cils for the de­vel­op­ment of ma­chine tools, tex­tile ma­chin­ery and con­struc­tion and earth­mov­ing ma­chin­ery.

Mean­while, the Kar­nataka Govern­ment has an­nounced plans to set up the coun­try’s first In­te­grated Ma­chine Tool In­dus­try Park in Tumkur district at a cost of Rs 447 crore. The pro­ject at Hosa Narsa­pur, a joint ven­ture be­tween the Cen­tral and State gov­ern­ments, will come up on 500 acres with a Cen­tral grant of Rs 125 crore. The park will be a clus­ter of ma­chine tool builders, mak­ers of ac­ces­sories, com­po­nents and foundry, among oth­ers, and will help small and medium-scale en­ter­prises to ex­pand their man­u­fac­tur­ing ca­pac­i­ties. Ac­cord­ing to the In­dian Ma­chine Tool Man­u­fac­tur­ers As­so­ci­a­tion, with em­pha­sis on Make in In­dia and man­u­fac­tur­ing growth, for which the ma­chine tools sec­tor serves as the mother in­dus­try, the coun­try is set to be­come a key player in the global ma­chine tools in­dus­try and is likely to see sub­stan­tial high-end ma­chine tool man­u­fac­tur­ing.

The In­dian ma­chine tool in­dus­try has around 1000 units in the pro­duc­tion of ma­chine tools, ac­ces­sories/at­tach­ments, sub­sys­tems and parts. Of th­ese, around 25 in the large scale sec­tor ac­count for about 70% of the turnover and the rest are in the MSME sec­tor of the in­dus­try. Ap­prox­i­mately, 75% of the In­dian ma­chine tool pro­duc­ers are ISO cer­ti­fied. While the large or­gan­ised play­ers cater to In­dia’s heavy and medium in­dus­tries, the small-scale sec­tor meets the de­mand of an­cil­lary and other units. Many ma­chine tool man­u­fac­tur­ers have also ob­tained CE Mark­ing cer­ti­fi­ca­tion, in keep­ing with the re­quire­ments of the European mar­kets.

Global pro­duc­tion of ma­chine tools dur­ing 2015 is es­ti­mated to be worth US $80.1 bil­lion. Top five ma­chine tool pro­duc­ing coun­tries are China (27.6%), Ja­pan (16.8%), Ger­many (15.5%), Italy (6.6%), and Korea (5.9%).

The lead­ing 3 coun­tries ac­count for 61% of the global out­put. China, which in­stalled about $ 27.5 bil­lion worth of ma­chine tools in 2015, is also the largest ma­chine tool con­sum­ing coun­try in the world. On per capita con­sump­tion ba­sis Switzer­land, Ger­many, South Korea, Slove­nia and Aus­tria topped the list.

Based on the 2016 Gard­ner Busi­ness Me­dia sur­vey re­port on world ma­chine tool con­sump­tion, which com­prised of 60 coun­tries, In­dia ranks 13th in pro­duc­tion (0.9%) and 10th in con­sump­tion.

At present the In­dian in­dus­try meets most of its ma­chine tool re­quire­ments through im­ports. In 2015-16 In­dia im­ported ma­chine tools worth Rs.5945 crore All types of machines CNC, non-CNC, metal cut­ting, metal form­ing, used and new machines are im­ported to In­dia from var­i­ous coun­tries. In­dia also ex­ported ma­chine tools worth Rs 296 crore dur­ing 201516.

There is a huge gap be­tween de­mand and sup­ply of ma­chine tools in In­dia. The grow­ing de­mand from In­dia’s ma­jor in­dus­trial sec­tors like au­to­mo­tives and com­po­nents, con­sumer durables, aero­space, of­fers tremen­dous op­por­tu­ni­ties for in­vest­ment. As the in­dus­try is mov­ing to­wards in­creas­ingly so­phis­ti­cated CNC machines, driven by de­mand from the ma­jor user seg­ments, tech­no­log­i­cal upgra­da­tion also be­comes an im­per­a­tive.

There is a good scope for ma­chine tool man­u­fac­tur­ing in In­dia by de­vel­op­ing new ca­pa­bil­i­ties mak­ing sub­stan­tial in­vest­ments, and by go­ing for joint ven­tures and col­lab­o­ra­tions.

In the Cover Story of this edi­tion, Auto Com­po­nents In­dia is tak­ing a close look at some of lead­ing play­ers in the ma­chine tool man­u­fac­tur­ing and dis­tri­bu­tion sec­tors in the coun­try that have scaled up to match the chang­ing man­u­fac­tur­ing needs.

The Ger­many-based EMAG Group cov­ers the en­tire spec­trum of machining pro­cesses in the met­al­work­ing in­dus­try. The com­pa­nies un­der the EMAG um­brella of­fer the lat­est tech­no­log­i­cal ad­vances to op­ti­mise a man­u­fac­tur­ing so­lu­tion for ev­ery cus­tomer’s re­quire­ment. Ac­tive in the au­to­mo­tive, oil field, power gen­er­a­tion, aero­space and large equip­ment in­dus­tries, EMAG is a trend­set­ter in the field of ver­ti­cal turn­ing cen­tres and multi-func­tional pro­duc­tion machines. In In­dia EMAG has bases in Noida, Pune and Chen­nai.

An­other Ger­man ma­chine tool com­pany Gehring Tech­nolo­gies of­fers hon­ing so­lu­tions for the au­to­mo­tive in­dus­try. With over 90 years of ex­pe­ri­ence, the com­pany man­u­fac­tures and sup­plies ma­chine tools in vary­ing di­men­sions from di­am­e­ter 0.8mm to 1000mm.

DMG Mori KTIENGESELLSCHAFT, one of Ger­many’s largest man­u­fac­tur­ers of cut­ting ma­chine tools and a lead­ing global man­u­fac­turer of CNC­con­trolled lathes and milling machines, has in­tro­duced a slew of new tech­nolo­gies in In­dia. It has in­stalled about 400 machines in the coun­try so far. The com­pany plans to in­crease its pen­e­tra­tion lev­els. To­wards this it had show­cased a host of new machines at the re­cently con­ducted IMTEX.

Ace Mi­cro­matic Group is a large ma­chine tool con­glom­er­ate in In­dia with mar­ket pres­ence in sev­eral other coun­tries across Asia, Aus­tralia, Mid­dle East, North and South Amer­ica and Europe. The com­pany which pro­vides its cus­tomers

a one-stop shop for all machining needs spe­cialises in the man­u­fac­tur­ing of CNC con­trolled turn­ing, milling and grind­ing machines along with sub­sys­tems like tool tur­rets, ATC etc. Ace Man­u­fac­tur­ing In­tel­li­gence Tech­nol­ogy (AMIT), the Ace Mi­cro­matic Group’s soft­ware com­pany, has been bring­ing the power of au­to­mated IT so­lu­tions and IoT to man­u­fac­tur­ing. Their prod­ucts syn­er­gise the Group’s deep man­u­fac­tur­ing do­main knowl­edge and IT ex­per­tise.

Ren­ishaw, a world leader in pre­ci­sion en­gi­neer­ing tech­nolo­gies, has launched new range of metrol­ogy and ad­di­tive man­u­fac­tur­ing equip­ment re­cently. The new prod­ucts an­nounced are de­signed to meet the re­quire­ments of the ad­vanced man­u­fac­tur­ing sec­tor in In­dia; from the need to pro­duce parts with in­creas­ing com­plex­ity and tighter tol­er­ances, to the drive to re­duce costs, to in­crease speed of op­er­a­tion and the re­quire­ment to im­prove the ease-of-use for new tech­nol­ogy.

Bright Bur­nish­ing Tools Pri­vate Ltd. is a lead­ing man­u­fac­turer and ex­porter of roller bur­nish­ing tools and machines. It is ISO 9001: 2000 qual­ity cer­ti­fied for de­sign, man­u­fac­ture, mar­ket­ing and ser­vice of all types of bur­nish­ing tools for the au­to­mo­tive and other in­dus­tries. By 2020 the com­pany wants to be a mar­ket leader and in line with that it is mod­i­fy­ing its prod­uct range.

SMK Turnkey So­lu­tions Pri­vate Ltd, the so­lu­tions provider for metal cut­ting ma­chine tech­nol­ogy, caters to the do­mes­tic and ex­port mar­kets with the work-hold sys­tems, tool-hold sys­tems and CNC pe­riph­er­als.

SKB Ma­chine Tools, a lead­ing ma­chine tool agency, rep­re­sents com­pa­nies like Nis­sei (Ja­pan), IMM Maschinebau (Ger­many) and Kataoka (Ja­pan) for sales and ser­vice of ma­chine tools in the In­dian mar­ket. The range of machines in­cludes dou­ble disc grind­ing machines, cen­tre­less grinders, pro­file grind­ing machines, gear hob­bers, gear grinders, cam grind­ing and milling machines and en­tire line of pis­ton rings. They are high pre­ci­sion machines and are used for highly spe­cialised op­er­a­tions.

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