Overview of Machine Tools Industry in India
Overview of Machine Tools Industry in India
Machine Tools
Industry in
India
INTRODUCTION OF MACHINE TOOL
A machine tool is a power-driven device used to shape, cut, grind, or otherwise alter
materials, typically metal. These tools are vital in manufacturing processes across
industries. They include lathes, milling machines, drills, grinders, and more. Lathes
rotate a workpiece while a cutting tool shapes it; milling machines use rotary cutters to
remove material; drills create holes; grinders smooth surfaces. Machine tools enable
precise production of parts, offering high accuracy and repeatability. They streamline
manufacturing, reducing time and costs while ensuring quality. From traditional
manual machines to modern computer-controlled systems, machine tools are
essential for shaping raw materials into finished products.
Machine tools in India refer to power-driven devices used for shaping, cutting, or
altering materials, predominantly metal. They are crucial in India's manufacturing
sector, supporting industries such as automotive, aerospace, and engineering. These
tools range from conventional to advanced CNC machines, driving industrial growth
and innovation.
3) Green Revolution and Economic Liberalization (1960s - 1990s): During the Green
Revolution in the 1960s and subsequent economic liberalization in the 1990s, there was
an increased demand for agricultural machinery and industrial equipment. This led to
further growth and modernization of the machine tool sector in India.
• 2. Milling Machine (late 18th to early 19th century): The invention of the milling
machine allowed for precise cutting of metal workpieces using rotary cutters.
This versatile tool facilitated the production of complex shapes and contours,
paving the way for mass production techniques and the machining of intricate
parts.
Milling Machine: Milling machines use rotary cutters to remove material from a workpiece.
They can perform a wide range of operations such as face milling, end milling, slotting, and
drilling. Milling machines are versatile and can produce flat surfaces, irregular shapes, and
complex contours. Types of milling machines include vertical, horizontal, and universal milling
machines
Drilling Machine: Drilling machines create holes in a workpiece using a rotating drill bit. They
can perform drilling, reaming, tapping, and counterboring operations. Drilling machines range
from simple bench drills to large radial drills. They are crucial for creating holes of various sizes
and depths accurately
Grinding Machine: Grinding machines use abrasive wheels to remove material from a
workpiece's surface and achieve the desired shape and finish. They are used for precision
grinding, sharpening, and finishing operations. Surface grinders, cylindrical grinders, and
centreless grinders are common types, capable of producing flat surfaces, cylindrical shapes,
and intricate profiles.
Boring Machine: Boring machines enlarge existing holes in a workpiece using a single-point
cutting tool or boring head. They are used to achieve precise dimensions and tolerances in
cylindrical holes. Boring machines can create through-holes, blind holes, and tapered holes.
Horizontal and vertical boring machines are widely used for various applications.
Hydraulic Presses: Hydraulic presses use hydraulic fluid to generate and control the force
applied to the workpiece. They offer high force capabilities and precise control over pressing
operations, making them suitable for tasks such as deep drawing, forging, and molding of
metallic and non-metallic materials.
Surface Grinding Machine: Surface grinders are used to produce flat surfaces on workpieces,
typically through abrasive grinding using a horizontal spindle and a reciprocating or rotary
table.
Bench Drill Press: This type of drilling machine is mounted on a workbench or stand and is
commonly used for light-duty drilling tasks in workshops and garages.
Hammer Forging Machines: Hammer forging machines, also known as power hammers or
drop hammers, utilize a weighted ram or hammer to deliver a sudden impact force to the
workpiece. This force deforms the metal, forcing it to conform to the shape of the die or
tooling. Hammer forging machines come in various types, including steam hammers, air
hammers, and hydraulic hammers, each offering different capabilities and advantages
Arc Welding Machines: Arc welding machines utilize an electric arc between an electrode and
the workpiece to generate the heat required for melting and fusing the metal. Common arc
welding processes include Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding
(GMAW), and Gas Tungsten Arc Welding (GTAW). These processes offer versatility, allowing for
welding of a wide range of materials and thicknesses
Gas Welding Machines: Gas welding machines, such as oxy-fuel welding and cutting systems,
use a mixture of fuel gas and oxygen to produce a high-temperature flame for melting and
joining metals. While less common than arc welding processes, gas welding is still used in
certain applications, such as repair and maintenance work
Hydraulic Riveting Machines: Hydraulic riveting machines use hydraulic pressure to deform the
rivet and join the workpieces together. These machines offer high force capabilities and precise
control over riveting operations, making them suitable for heavy-duty applications and critical
assembly tasks
Automatic Riveting Machines: Automatic riveting machines are fully automated systems that
can feed, position, and rivet multiple rivets in rapid succession. These machines are ideal for
high-volume production environments where efficiency and productivity are paramount.
Screwdriving Machines: Screwdriving machines are used to drive screws into workpieces,
providing a secure and durable connection. They come in manual, semi-automatic, and fully
automatic configurations, with features such as torque control, depth adjustment, and
automatic screw feeding for increased efficiency and precision.
Major players in the Indian machine tools market
1--HMT (Hindustan Machine Tools): Established in 1953, HMT is one of India's oldest
and most prominent machine tool manufacturers, offering a wide range of products
such as lathes, milling machines, and grinding machines.
3--Bharat Fritz Werner (BFW): BFW specializes in machining centers, turning centers,
and special purpose machines. Known for innovation, they cater to sectors like
automotive, aerospace, and die & mold industries.
4--Jyoti CNC Automation: Jyoti CNC Automation manufactures CNC turning and
machining centers, providing solutions for precision manufacturing. They have a
strong presence both domestically and internationally.
5--Doosan Machine Tools India: Doosan Machine Tools India, a subsidiary of Doosan
Machine Tools Co., Ltd., South Korea, offers CNC turning centers, machining centers,
and multitasking machines known for advanced technologies.
Rising industrial automation to increase the overall productivity and improve the
ergonomics represents one of the significant factors stimulating the market growth in
India. Apart from this, an increase in the number of small and medium-sized
enterprises (SMEs), along with stringent evaluation criteria on product quality, is
bolstering the market growth. Furthermore, due to lower labor and raw materials costs
and reduced tax rates, several foreign companies are setting up their manufacturing
bases in India. This is further providing growth opportunities to these manufacturers to
expand their consumer base in the country. Moreover, the escalating energy demand is
leading to the exploration of new oil and gas fields in India, which is expected to create
a positive influence on market growth.
The 2 images below show trend of India’s key manufacturing sectors investing in capital
infrastructure. It also approximates the share of machine tool sector investment by those
sectors in the same period. Data is gathered from Indian Machine Tool Manufacturer’s
Association (IMTMA)
On a sectoral level, some companies will do better and some worse off. A rule of thumb
is that if the overall sector is running consistently above 75% capacity for a sustained
period of time as well as registering growth, big capacity addition can be expected.
The chart below shows that manufacturing sector capacity utilization has been bumpy
over the past 5 years. Q1 FY 2020-21 saw a capacity utilization of below 50%
Machine tool industry
The machine tool industry is broad, but in the context of this it is restricted to mean only
the metal cutting and metal forming machine tools (together called metal working
machines). Annual consumption of machine tools is estimated to be about Rs. 20,000
crores in India and it has grown at a rapid pace over the past decade. The machine tools
are broadly classified as:
CNC machines: Stands for Computer numerical control. These machines are digitally
operated by entering relevant code onto a computer which is fed into the machine tool
where the machining/forming operation happens. These machines are highly accurate,
repeatable and also benefit from software upgrades and sophisticated technologies
such as automatic tool change, automatic tool centering, etc.
Non CNC machines: These are manually operated machines and can perform similar
operations to some of the less complicated CNC machines. While these are
substantially lower in cost, they need a highly skilled operator continuously operating
the machine. Manual intervention reduces accuracy and repeatability of parts as
compared to CNC machines. Productivity is low with non CNC machines.
The charts below give a depiction of how the industry is spread within India
It can be seen that this has been overall a high growth sector at a long term 18% CAGR
growth rate. One can also observe that half of the machine tool demand is filled by
imports, although domestic manufacturing has grown considerably in the last decade.
A majority of the manufacturers are either unlisted or private entities showing that
there is still a long way to go for this sector to mature. The only large listed companies
available are HMT, Laskhmi Machine works and Kennametal. Some important large, but
unlisted companies are Ace, Jyoti, Bharat Fritz Werner, Grind Master, MTAB, Makino,
DMG Mori and Fanuc.
The author having worked extensively in this field has observed the evolution of
domestic players such as Ace Micromatic, MTAB, Jyoti, BFW, Lakshmi tools, Grind
Masters, etc and can confidently say that the machines produced by these companies
are comparable in quality and in cost to many of the top imported technologies. India has
a good number of skilled engineers available to work in this field. Geographical clusters
for machine tool manufacturing are in Bangalore, Pune and Mumbai, Chennai and
Coimbatore, Hyderabad, Punjab, Rajkot, Ahmedabad, and Jamnagar.
As Indian manufacturers begin to bridge the quality gap, perceptions will slowly change
in favour of them (think of the mature auto sector where Indian brands are preferred by
customers). However, there is a long way to go to eliminate this trade deficit as
technology is rapidly advancing and it can get difficult to match pace with it. However,
with key components such as ball-screw drives, spindles, translation stages, hydraulic
systems, etc. now being indigenously made in high quality and low cost, there is
massive potential.
India has a huge appetite for domestic machine tools and the sector is still in the
developing stage. In recent years, competition has picked in the Indian market. With
technological and financial investments by global manufacturers in India, this sector
will soon unleash as Indian products become globally competitive.
Collaborations between academic institutes and industries are happening for the first
time in a major way in India which gives a research boost to such businesses.
Government of India’s Atmanirbhar Bharat program and the various schemes to fire up
manufacturing in India have the potential to revive the lost private capital formation and
confidence.
It has been a difficult last couple of years for machine tool manufacturers, but it is often
darkest before the dawn. In our opinion, India’s tryst with the machine tool sector is only
beginning
Technology
Emerging technologies in machine tools manufacturing
Several emerging technologies are shaping the future of machine tools
manufacturing, offering advanced capabilities and efficiencies. Some of the key
emerging technologies in this field include:
6--Hybrid Machining:
Hybrid machining combines additive manufacturing with subtractive processes like
milling, turning, and grinding. This approach allows for the creation of near-net shape
parts using additive methods, followed by precision machining to achieve final
dimensions and surface finish, resulting in reduced material waste and lead times.
1--Efficiency Improvement
Advanced Machining Processes: Emerging technologies like additive manufacturing
and hybrid machining allow for the production of complex parts with reduced setup
times and material waste. AI-driven systems optimize tool paths, reduce cycle times,
and minimize idle time by analysing machining data in real-time, leading to more
efficient use of resources and increased throughput
2--Precision Enhancement
Additive Manufacturing and Hybrid Machining: These technologies enable the creation
of highly precise components with intricate geometries, reducing the need for multiple
machining operations and improving overall accuracy. Digital twins simulate
machining processes, allowing for precise adjustments to parameters
before physical machining, ensuring high precision in the final product.
Applications
Automotive industry
Machine tools are indispensable in the automotive industry, where precision, efficiency,
and reliability are paramount in the manufacturing process. These tools play a crucial
role in producing the multitude of components that make up vehicles, ranging from
engine parts to body panels. Here's a brief overview of how machine tools are used in
the automotive industry
1. Engine Manufacturing:
Machine tools are used to produce various engine components, such as cylinder blocks,
cylinder heads, crankshafts, camshafts, and pistons. Processes such as milling, turning,
drilling, grinding, and honing are employed to achieve the required dimensions, tolerances, and
surface finishes for these critical components. CNC machining centers, lathes, grinders, and
specialized equipment are used to ensure the precision and quality of engine parts.
Aerospace industry
Machine tools are integral to the aerospace industry, where precision, reliability, and
safety are paramount in the manufacturing of aircraft components and systems. These
tools play a crucial role in producing a wide range of parts, from structural components
to engine parts and avionics. Here's a brief overview of how machine tools are used in
the aerospace industry:
1. Structural Components:
Machine tools are used to manufacture structural components of aircraft, including
fuselage sections, wings, empennage, and landing gear. CNC machining centers,
milling machines, and routers are employed to shape and machine metallic and
composite materials to precise specifications. These components require tight
tolerances and complex geometries to ensure structural integrity and aerodynamic
performance.
2-Engine Parts:
Machine tools play a vital role in producing engine components for aircraft propulsion
systems. Processes such as milling, turning, drilling, grinding, and honing are used to
manufacture components such as turbine blades, compressor blades, engine casings,
and shafts. CNC machining centers, lathes, grinders, and EDM machines are employed
to achieve the high precision and surface finishes required for these critical
components.
Construction industry
Machine tools play a significant role in the construction industry, where they are used
for various tasks ranging from shaping and cutting materials to assembling structural
components. These tools enable the efficient and precise fabrication of building
elements, infrastructure components, and construction machinery. Here's a brief
overview of their applications in the construction industry:
1-Metal Fabrication:
Machine tools are utilized for metal fabrication tasks such as cutting, bending,
punching, and welding structural steel components used in buildings, bridges, and
other infrastructure projects. CNC plasma cutters, laser cutting machines, press
brakes, and welding machines are commonly used for fabricating steel beams,
columns, trusses, and other structural elements to precise specifications.
2-Concrete Processing:
Machine tools are employed for processing concrete and other construction materials
to create components such as precast concrete panels, beams, columns, and blocks.
Concrete saws, drills, grinders, and vibrators are used for cutting, drilling, shaping, and
finishing concrete structures, while formwork systems and concrete mixers enable the
casting of custom shapes and sizes.
Conclusion
The machine tools industry in India is a cornerstone of the nation's manufacturing
sector, vital for various industries including automotive, aerospace, defence, and
general engineering. With a diverse ecosystem of manufacturers, both domestic and
international, the industry has seen significant growth and transformation in recent
years. Companies like HMT, BFW, ACE Micromatic Group, and Jyoti CNC Automation are
key players, known for their innovation and quality. India's skilled workforce and
government initiatives like "Make in India" further boost the industry. Emerging
technologies like additive manufacturing, AI, and IoT are driving productivity and
efficiency, enabling precision engineering and reduced lead times. However,
challenges such as infrastructure constraints and access to finance persist.
Overcoming these challenges will be crucial for sustained growth. Despite this, India's
machine tools industry holds immense potential. With continued investment,
technological advancement, and policy support, India can strengthen its position as a
leading manufacturer, contributing significantly to economic growth and industrial
development.