- M. S. Unnikrishnan, Co-Chairman, FICCI Capital Goods Committee

Capital goods industry contributes 12% to the total manufacturing activity & about 1.8-2.0% of the GDP

Capital Goods Sector registered a growth rate of 7.6% in April-March 2014-15

Capital Goods Sector needs to increase production to Rs.5,10,570 crore in 2022 so as to sustain targeted manufacturing growth rate of 13% CAGR

India is a net importer of capital goods

Capital Goods Imports are projected to be US $ 35.6 Billion in April-March 2015

India's Imports of Capital Goods ($ Million)

Commodity

Apr-

Mar 201

0

Apr-

Mar 201

1

Apr-

Mar 201

2

Apr-

Mar 201

3

Apr-

Mar 201

4

Apr-

Mar 2015(P

)

CAGR

(%)

Growth

(%) in

Apr-Mar

2015

Share in

Total Imports

Apr-Mar

2015 (%)

MACHINERY 24,657.1 30,312.9 38,684.6 35,700.1 31,103.4 32,018.8 5.4 2.9 7.2

Machine Tools 1,741.2 2,357.9 3,147.3 2,900.8 2,183.2 2,169.8 4.5 -0.6 0.5

Electrical

Machinery &

Equipments

4,403.2 5,614.7 7,291.7 6,353.5 5,492.3 6,064.4 6.6 10.4 1.36

Textiles

Machinery 1292.7 1629.5 2002.4 1705.5 1731.7 1638.6 4.9 -5.4 0.4

Machinery*oth

er than

Electrical

17220.1 20710.9 26243.2 24740.3 21696.2 22146 5.1 1.5 4.9

PROJECT

GOODS 4,704.0 6,151.8 8,764.6 6,554.3 4,551.0 3,620.6 -5.1 -20.4 0.8

Total Capital

Goods Import 29,361.1 36,464.7 47,449.2 42,254.4 35,654.4 35639.4 4 -0.04 8

Source: DGCIS, Kolkata

32,0

18.8

0

2,1

69.8

0

6,0

64.4

0

23784.6

1638.6

3,6

20.6

0

35639.4

5.4

4.5

6.6

5.1

4.9

-5.1

4

-6

-4

-2

0

2

4

6

8

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000M

achin

ery

Mac

hin

e T

ool

s

Ele

c.M

ach.

& E

quip

.

Mac

hin

ery

excl

. Ele

ct.

Tex

tile

sM

achin

ery

Proj

ect

Good

s

Tot

al

2014-2015 (P) CAGR (%)

CAGR: 2009-10 to 2014-15 (P) Source: Ministry of Commerce

In today’s globalized world, technology is increasingly essential for firms to compete and prosper

As per the Global Competitiveness Index of 2014-15 (World Economic Forum), out of 144 economies, India ranks:

121 in technological readiness

110 with respect to availability of latest technologies

102 in Firm-level technology &

95 when it comes to FDI and technology transfer

Sr.

N

o

Technology Application(s) Benefits Country (s) from

where the

technology can be

sourced

1 High pressure gas

insulated

transformer

For transmission and

distribution of power

Scarcity of land is becoming a boiling issue in India.

Indian cities are expanding and are in need of

increased power. In future substations will be a

part of city.

Gas insulated transformer along with GIS

equipment can be placed below underground,

beneath commercial buildings, parks and public

spaces.

Japan or to be

developed

indigenously

2 CO2 filled

distribution

transformers

For distribution of

power to consumers

Theft of insulating mineral oil from the transformer

is a burning issue in India. Gas filled anti-theft

distribution transformer can offer a better solution

against this.

Japan or to be

developed

indigenously

3 CRGO steel Used in manufacturing

of transformers

India does not have technology for producing

CRGO electrical steel.

In order to meet the huge projected requirement

of transformers and thereby electrical steel in

current and next planning year, indigenous

technology of producing CRGO is very much

essential.

Japan

Sr.

No

Technology Application(s) Benefits Country (s) from

where the

technology can be

sourced

4 Dynamically controlled

shunt reactor

Controlling power

system profile

Dynamically controlled shunt reactor offers less foot

print area and reduced losses as compared to

conventional shunt reactors.

There are several technologies available to realize

variable capacity reactors. Present day solution is to

use OLTC in shunt reactor.

Europe or to be

developed

indigenously

5 Micro Channel Heat

Exchanger manufacturing

technology

Steel metallurgy Advanced power plant cycles and low grade waste to

energy technologies demand a very compact heat

exchanger device and the technology of micro

channel for steel metallurgy will unleash 60 GW of

extra power at commercially viable cost

6 Supercritical C02 turbine

cum compressor cum

generator in a single

hermetically sealed barrel

with special bearings

Compact (one-third to one-fourth the size of

classical power plant)

Cost effective

Highly reduced water consumption

Many countries are

working on this new

and future

technology

7 Evacuated glass tube

technology with absorber

coating on inside and anti-

reflective coating on

outside (French)

Evacuated vacuum

tubes (EVT) are

widely used in low to

medium temperature

applications

By acquisition of this technology India will have the

manufacturing capability of low temperature EVTs

and then further develop medium temperature EVTs

which will give us a lead in the market. This

technology has the capacity to replace about 20%

fossil fuel by integrating it to boiler / heater

China has the largest

installed

manufacturing

capacity

Sr.

No

Technology Application(s) Benefits

1 LAZER Processing

Additive manufacturing, laser cladding

and high power laser welding

Enhance global

competitiveness Capital Goods

Industries

2 Robotic Welding

Wind energy & solar energy systems, aircraft sub-assemblies & development of low cost welding robots

3 Waveform controlled welding technology

Valve sub-assemblies, castings, aerospace components, compressor sub-assemblies and pumps

4 Welding Simulation and analysis

Alloy design for welding electrodes / filler metals, Metallurgical characterization of weld metals

5 Residual stress based validation Technology

Wind mill towers, textile machineries and valve assemblies

Cooling Sr

No

Process Proposed

up-gradation

Benefits expected

1 Welding of shells Robot Consistency in weld quality Reduction in weld leaks Better weld aesthetics Elimination of welder skill requirement Less fatigue & higher output

2 Tube-expansion Robot Less fatigue & higher output Consistency in quality Reduction in expansion leaks

3 Painting &

Paint booth

Robot Consistency in painting quality Less fatigue & higher output

4 Plate cutting & beveling CNC Plasma plate

cutting & beveling

machine

Higher productivity thru savings in manual efforts

5 Helium leak test Measuring gas

volume

Increasing process reliability

6 Performance test Temp sensors,

System generated

reports

Building customer confidence in test process thru minimal manual intervention

IT : Data capturing, Information Processing & Flow

Sr

No

Process Proposed

up-gradation

Benefits expected

1 Design Documents

distribution

Higher usage of Soft

copies

Reduced efforts & time for distribution, searching, printing etc.

Faster communication with suppliers Reduced paper wastage

2 Tracking order status Logging in stage

completion in ERP

Remote status check

3 Production Planning Scheduling software Better predictability on delivery Alerts on capacity constraints

4 Quality records and

Process data

Sensors, Bar coding,

Digitized records,

Photos / Videos

Component traceability Faster access to records Less space for record keeping Better evidence creation

5 Deliveries of out-sourced

items

JIT scheduling on real

time basis, automated

follow-up

Improved material in-flow Reduced follow-up efforts

Production Process Automation : Heating, Shell & Drum Type Boilers

Sr

No

Process Proposed

up-gradation

Benefits expected

1 L seam set up and welding

station

Auto L seam weld set up and

welding

Consistency in weld quality Better weld aesthetics Elimination of welder skill requirement Less fatigue & higher output

2 C seam weld automation Auto C seam weld set up and

Welding station.

Consistency in weld quality Better weld aesthetics Elimination of welder skill Less fatigue & higher output

3 Dish end flanging machine For drum dish end flanging Suitable for making dish ends for bi-drums Cold or hot operation

4 Tube plate knuckling Knuckled tube plates mfg Will support automation of C seam welding Improved weld quality

5 IRC welding, shell boilers Robotic welding with positioner Eliminate weld difficulty Better weld aesthetics Elimination of welder skill Less fatigue & higher output

6 Boiler component

fabrication

Robotic welding station Higher productivity Consistency in weld quality Better weld aesthetics Elimination of welder skill

Production Process Automation : Heating, Shell & Drum Type Boilers

Sr

No

Process Proposed

up-gradation

Benefits expected

7 Tube to tube sheet

welding

Robotic welding station Higher output Elimination of welder skill Consistency in weld quality

8 Shell type boiler welding Gantry robotic welding station for

full welding of boiler nozzles and

man holes

Eliminate weld difficulty Higher output Improved weld quality Eliminates welder skill

9 Shell type boiler full

welding

All position robotic welding

Of shell type boilers

Eliminate weld difficulty Better weld aesthetics Elimination of welder skill Less fatigue & higher output

10 Bi drum welding All position welding with gantry

and positioner

Higher productivity Consistency in weld quality Better weld aesthetics Elimination of welder skill

11 Bi drum nozzle opening

and welding

Vessel robot profiler with nozzle

opening cutting and welding

Higher output Elimination of welder skill Consistency in weld quality

Production Process Automation : Heating, Shell & Drum Type Boilers

Sr

No

Process Proposed

up-gradation

Benefits expected

12 Tube to tube welding of

coils and economisers

Orbital welding heads for

fusion welding

Eliminate weld difficulty Higher output Improved weld quality Eliminates welder skill

13 Serpentine coil

manufacturing

Complete auto line

manufacturing for super

heater and economiser

coils (welding & bending )

Higher output Better weld aesthetics Elimination of welder skill

14 Radiography On line radiography for

tube to tube welding

Quick results and hence higher productivity

15 Plate rolling CNC plate rolling machine Higher output Elimination of skill

16 IT : DNC with shop link

( Chinchwad+ Savali )

Connecting all machines to

ERP via DNC, Remote

monitoring & real time

reports

Remote monitoring, Real time reports Planning and predictability resulting in

OTP

Sr.

No

Technology Application(s) Benefits Country (s) from

where the technology

can be sourced

1 Forging

technology for

making heavy

rolls like

backup rolls

for steel

industry

Support super and ultra-super critical power

plants

Currently these rolls are

imported and have

historically required long

delivery period, so,

manufacturing them will

reduce the delivery

period

UK, US, Japan and

Korea

2 High

Performance

coated Sub-

Micron Grade

of Tungsten

Carbide cutting

tools

High speed machining of commonly used

ferrous alloys which are used in most of

the manufacturing industries

Dry machining, particularly gear hobbing,

gear shaping, milling of Cr-Ni-V-Mo based

alloy steels

Machining of exotic materials like Ti-Ni

based super-alloys which are work horse of

aircraft industries.

Machining of conventional Al alloys and Al-

Si alloys which are increasingly being used

in the automobile industries.

Augmentation in

productivity and

profitability

Environmental

friendly

Multi-axes, multi-function machines

Heavy duty machine tools

Servo presses

Machine tool and industrial electronics

Pneumatic, hydraulic and electro-based systems

CNC control systems, ball screw technology, linear motion guide-way technology, rotary table units, integral or motorised spindle units

Software for design / analysis / simulation, machining and manufacture

Metal-cutting Machine Tool Technologies Multi-axes machining centres – five-axes machining centres; six-axes machining

centres; and components requiring five-axes machining

Multi-tasking machines – turning centres with mill-grind-gear cut application; machining centres with turning capability; and vertical turning centres with machining-milling-grinding capability

High-precision machines – precision production grinder with 100 nano-micron (nm) accuracy

Large-sized machine – floor-boring machines; large-gantry machining centres; and vertical turning lathes

Gear-cutting and grinding centres – dry gear-hobbing machine; multiple diameter gear-shaping machine

Electrical and micro-machining – EDMs; wire-EDMs; and electro-chemical machines

Metal-forming Machine Tool Technologies

Higher press automation and transfer systems

Servo presses

Sheet-working machines – laser; and waterjet heads

Hydro-forming machines

Hot forming technology

Fine blanking

Precision forging

Flow-forming machine and components

Hot-forming press lines

Hydraulic forging presses

Explosive forming

Magnetic pulse forming

Supporting Technologies For Machine Tools And Manufacturing

Cutting tool technologies

Metrology and measuring technology

Alternate materials – epoxy granite casting

Thermally-stable welded structures

Hydrostatic spindles, guideways

Motorised and high frequency spindles

Smart machines and embedded sensors

Critical component-technologies for CNC machines

CNC controls / systems

Anti-friction linear guideways

Ball-screws

Precision spindle and ball-screw support bearings

Spindle and axes servo motors with drive controllers – motors and drives; integral motor spindles; and linear motors for feed drives

Feedback measurement systems – 3-coordinate measuring machines; digital metrology; precision gauging instruments and optics; open & closed linear measuring systems; and encoders & angle measuring transducers