AMT JUN/JUL 2016

Australian Manufacturing Technology

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Contents

Volume 16 Number 03 june/july ISSN 1832-6080

44

FEATURES

MINING & RESOURCES Breaking new ground Rotating output in confined underground spaces Internet of Mining Things – next wave of productivity

44 48 50

COMPOSITES & ADVANCED MATERIALS Composites, a key enabler for innovation Manufacturing breakthrough for Australia Ultrasound – 3D printing of composites Realising the competitive potential of composites Quickstep opens up South Korean automotive market

56 58 59 60 61

FORMING & FABRICATION New laser boosts development agility Jmar Engineering benefits from new fibre laser

62 64

BUSINESS MANAGEMENT Monitoring overall manufacturing efficiency Paying the price of poor project management Yacht mast manufacturer invests in ERP Big export success for small Engi-O

68 70 72 74

ADDITIVE MANUFACTURING The future of Australian additive manufacturing A unique interplay between technologies Lamborghini speeds workflow with 3D parts

76 78 81

CUTTING TOOLS Thread milling – ‘Tapping’ into the future The age of new materials - is the future now?

Machining success needs a productive balance Bolts & Industrial Supplies – Oz-made quality

84 86 88 90

MATERIAL REMOVAL Tiny bubbles cause troubles

92

MOTORS & DRIVES Gearing up for quick changes Siemens unveils new HTS technology

94 95

REGULARS

INDUSTRY NEWS Current news from the industry

20

VOICEBOX Opinions from across the manufacturing industry

30

PRODUCT NEWS Our selection of new and interesting products

36

ONE ON ONE Prof. Sam Bucolo - Professor of Design Innovation at UTS

54

COMPANY FOCUS Décor Engineering – A successful balance

82

AMTIL FORUMS Forum OHS Forum Finance Forum Import/Export Forum Logistics

96 97 98 99

MANUFACTURERS’ PAVILION

100

AMTIL INSIDE The latest news from AMTIL

110

MANUFACTURING HISTORY – A look back in time

118

54 Professor Sam Bucolo Sam Bucolo is Professor of Design Innovation at University of Technology Sydney and Director of their Design Innovation Research Centre. Prof. Bucolo’s mission includes improving the level of collaboration between industry and academia in Australia, which is low compared to other OECD countries.

82 Décor Engineering – A successful balance Décor Engineering is a classic example of an adaptable Australian manufacturing firm that has forged valuable opportunities by taking on new markets from its beginnings in the car manufacturing industry in 1970. From that time it has maintained the strategy of continuously developing new products while still retaining the expertise and years of experience.

Your IndustrY. Your

MagazIne.

jun jul

technology

8 10 12 14 16

Australia’s mining boom may be over, but Australian manufacturers and innovators are still making their mark on the industry globally and are well placed for the future. Responding to changing market conditions to ensure competitiveness is necessary for survival, as evidenced in case studies highlighted here.

AustrAliAn MAnufActuring

From the Editor From the CEO From the Minister From the Industry From the Union

Breaking new ground

Mining & ResouRces

Business Management

Materials Composites & advanced Forming & Fabrication additive Manufacturing Cutting tools Material removal Motors & drives

AMT Jun/Jul 2016

Cover The post-mining-boom years have forced the Australian mining & resources industries to change.

Through measures such as increased automation, costs at some Australian thermal coal sites were halved from 2010-15. Page 44

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008

From the Editor William Poole

The news story that won’t die

I was at an event a while back where I ended up talking to someone and inevitably the subject of our jobs came up. When I explained I edited a magazine about manufacturing, he snorted, saying: “I feel sorry for you mate. In a couple of years, that whole sector’ll be dead.”

Your Industry. Your Magazine.

Australian Manufacturing Technology

It’s hard to respond to such a blunt appraisal of your employment outlook. In the end, I just smiled and changed the subject. But it got me thinking: Hmmm. A couple of years…

Editor William Poole wpoole@amtil.com.au

That was almost four years ago now. And while those years have certainly been hard for the sector, and with continued challenges yet to come, here we still are. But we’re still beset by this generalised perception that our industry is doomed. If Australian manufacturing is the industry that refuses to die, its impending demise is the news story that refuses to die.

The latest example came from Jason Murphy, an economist and blogger whose article ‘Australia has reached the point of no return: It’s time to forget about making stuff’ made a few headlines last month.

Contributor Carole Goldsmith

Murphy begins by proclaiming “Making things is officially over. We are now a country whose economy is about doing things and helping people.” What follows is the usual roll call of overworked arguments: we can’t compete with China; automation means manufacturing can never be the mass employer of old; and that we should concentrate instead on service industries.

Murphy challenges the perceived lower status of service-sector workers compared with “makers”, citing such noble professions as firemen, nurses, doctors, and… er… cleaners, one point even likening them to the Man from Snowy River – a comparison no doubt inspirational to anyone who cleans toilets for a living.

This is not to diminish the importance of the service industries. But where Murphy really falls over is in his argument that this is grounds to get out of manufacturing – not least when so much of the world seems so keen to get in.

Take just a few headlines from the last couple of months. Pakistan, for example, has been courting foreign car makers, with Suzuki contemplating a $460m investment in the country.

In Nigeria, the government is under fire from the main automotive manufacturers association for procuring imported vehicles instead of locally assembled brands (sound familiar?).

Of course, Pakistan and Nigeria are developing economies, to which Australia should not be aspiring to be compared. But look elsewhere. In April, the UK’s Daily Telegraph – a paper traditionally aligned to financial services – ran an article entitled ‘We should spend less time on bankers and more on our ailing manufacturers’. And Germany, Switzerland or the Scandinavian countries don’t seem to be in a hurry to transition to service-led economies.

Then there’s the manufacturing superpowers. China’s government is grappling with rising labour costs and the competitive threat posed by even lower-wage nations such as Vietnam. Across the Pacific, the upcoming US presidential election has seen candidates across the political spectrum – Donald Trump and Bernie Sanders – pledging to bring back US manufacturing jobs that had been offshored to places like China (an easy pledge to make given that this process has been underway for some years now).

In our own, comparatively low-key election race, we’ve seen both Prime Minister Malcom Turnbull and opposition leader Bill Shorten talking up manufacturing as the campaign has progressed. It seems Australia is not about to “say goodbye to being a country that makes things”.

Murphy’s article should be taken with a pinch of salt – a provocative headline will always win your blog a few extra clickthroughs. And many of the points he makes are, indeed, true.

We can’t compete on high-volume production. Manufacturing will never employ the huge workforces of yesterday. Services will play a larger role.

But to talk down the sector on those grounds does a disservice to the many exciting and innovative companies working in this country. To argue that manufacturing has no place in our economy is just silly.

Sales Manager Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia using FSC® mix of paper from responsible sources FSC® C007821 Contact Details AMT Magazine AMTIL Suite 1, 673 Boronia Rd Wantirna VIC 3152 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright © Australian Manufacturing Technology (AMT).

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From the CEO Shane Infanti – Chief Executive Officer AMTIL

Are we positive about what lies ahead?

As we move more and more into election mode, I thought it would be a good time to speak positively about the manufacturing industry and the great news stories that exist.

It’s frustrating to me that many people still reference manufacturing as having an image problem and the mainstream headlines still proclaim the death of manufacturing because our passenger vehicle production is leaving our shores over the next year or two. It’s frustrating because I see great companies, great people and great opportunities every day and I wish the people who write negatively about the manufacturing sector had the same chance as I do to witness these stories.

I see companies that are leveraging the latest thinking in technology and design. I see companies transforming their business through innovation and leadership. I see young people that have chosen career paths for themselves in manufacturing and are going from strength to strength. I see major projects being announced that have great potential for Australian content.

I see effort being put into local supply chain management. I look ahead and see revolutions like Industry 4.0 and additive technologies and wonder what positive impact they will have on our future.

I recently attended the Smart Manufacturing Symposium that was held in Dandenong Victoria and it encompassed just about everything I have mentioned above. So I thought it was a good idea to share with you some of what I saw.

I spoke to Jason Petch, the inventor of Skynanny, who has spent four years developing a GPS tracking device the size of a credit card and mobile application that allows parents to maintain accurate and regular positional updates of a child’s location. A great example of where technology and design have created a product with great commercial prospects.

I heard from Jan Vydra, Managing Director of Australian Fresh Leaf, and his story of bringing technology and innovation into the agricultural production of fresh herbs. By incorporating hydroponic methods, vertical production and innovative computer programming he can cultivate up to 30 times more produce than using traditional methods.

I met Loulou Hammad. She worked for Telstra for many years before deciding to move into a career in the manufacturing sector. She is now the Communications and Marketing Lead at Bombardier Australia, one of the world’s leading manufacturers of planes and trains. She told a great story

AMT Jun/Jul 2016

of perseverance and love for her job. I also met Danielle Kazi-Shedden. What an inspirational young woman. Unsure of what she wanted to do after VCE, she finally found a passion in life and, in an industry dominated by males, she recently won the Master Builders’ Association Apprentice of the Year award. Her positive attitude and work ethic, I’m sure, will see her through life as a successful shopfitter and one day business owner.

One of the symposium sessions focused on projects in the Defence industry and had panel members from Thales Australia, Northrop Grumman Australia and BAE Systems as well as Dr Mark Hodge from the Defence Materials Technology Centre. The session gave a thorough understanding of existing major projects, what opportunities exist for the supply chain, how the procurement process works and what the key requirements to supply to defence primes are.

I attended a session presented by CSIRO and heard Chad Henry give us an overview of the exciting additive technologies available for use within CSIRO’s Lab22.

Their focus on bridging the gap between R&D and industry and utilizing 3D printing of titanium and metallic manufacturing technology is going to result in successful outcomes in the future. It was interesting to see companies like Jayco, one might call a traditional manufacturer of caravans, investing research dollars into how additive manufacturing can have a positive impact on their production processes.

I see great companies, great people and great opportunities, every day and I wish the people who write negatively about the manufacturing sector had the same chance as I do to witness these stories.

Finally I caught up with a good industry colleague, Jennifer Conley, from the Australian Advanced Manufacturing Council. They have just released a YouTube video that aims to tackle some of the misconceptions around our manufacturing sector and highlight that advanced manufacturing will indeed create exciting opportunities and growth across all industrial sectors in the future. You can view this video at https://www.youtube. com/watch?v=WW7ZW9g9y_8 or type AAMC Manufacturing is Misunderstood into the YouTube search browser.

If I can meet all these terrific people and hear all of these great stories about companies going places in just a few hours in the outer suburbs of Melbourne, then surely we have to be positive about what lies ahead.

012

From the ministry The Hon Christopher Pyne MP – Minister for Industry, Innovation and Science

Submarine boost for Australian advanced manufacturing

When our defence industry is flourishing, the nation’s advanced manufacturing sector reaps the rewards. Investment in defence represents a significant boost to Australian firms and, in particular, our advanced manufacturing sector.

The Government’s recent announcement that the nation’s next generation of submarines will be built in Adelaide is tremendous news for defence but also a very positive development for advanced manufacturing. At more than $50bn, it is the largest and most complex defence acquisition Australia has ever undertaken.

Crucially, it represents significant opportunities for Australian firms and workers across a range of sectors and professional and technical trades.

The Future Submarines will be superior in terms of sensor performance, stealth and endurance. There will be a new design to meet our defence capability requirements, drawing on the latest technology. In short the Future Submarine will be a highly complex and impressive piece of machinery.

Building it is going to take advanced skills, materials, engineering, systems and technology – but Australia is ready for the challenge.

We have a reputation for building cutting-edge defence capability.

Australia has developed computer systems for the Air Warfare Destroyer, manufactured high-technology sub-assemblies for the Joint Strike Fighter and the Super Hornet, and developed a ballistic protection system for the Bushmaster. That reputation is set to be enhanced as we embark on building the Future Submarine.

The Government anticipates the Future Submarine Program will create 2,800 high-tech and manufacturing jobs. An anticipated 1,100 direct jobs will be in Adelaide, where the submarines will be constructed, and a further 1,700 jobs will be created through the supply chain. We’ll need to utilise the skills of naval architects, mechanical, electrical and marine engineers, electricians and painters, as well as system integrators and project managers.

The program will be managed to maximise the opportunities for Australian firms to supply key materials, components and equipment, including the use of Australian steel.

Manufacturing matters to Australia’s economy – it remains integral to our nation’s economy. In 2014-15, Australian manufacturing employed around 900,000 Australians and contributed about $100bn in Gross Value-Added in real terms to Australia’s GDP. The Future Submarine Project is a shot in the arm for Australian manufacturing. The commitment to an Australian build will create a sustainable Australian naval shipbuilding industry and provide the certainty that industry requires to invest in innovation and technology and grow its workforce.

It complements initiatives in the Defence Industry Policy Statement, which was released in conjunction with the Defence White Paper in February 2016. Measures announced in the statement will transform the defence industry. They will also help us to continue to capitalise on our strengths and enhance our global reputation for developing breakthrough defence technologies.

The Centre for Defence Industry Capability, an investment of $230m, is at the cornerstone of the statement. The Centre’s

aim is to ensure the Australian defence industry is sustainable, internationally competitive, and aligned with our defence capability requirements. The Centre, which will be headquartered in Adelaide, will commence operations in the second half of 2016.

Advanced manufacturing is also one of six key high-growth industry sectors of competitive strength and strategic priority where the Government is concentrating its investment through the $248m Industry Growth Centres initiative. Growth Centres are working to lift the levels of collaboration between businesses, industry, research organisations and government in order to better capitalise on the excellent research and development undertaken and scientific knowledge generated in Australia.

The Future Submarine announcement, along with our other commitments in this area, means the road ahead for Australian manufacturing is rich with opportunity. Subject to further commercial discussions, the Department of Defence expects to commence design of the Future Submarine with DCNS this year.

We live in a rapidly changing world. Australia’s defence forces need the highest levels of capability as they work to protect our interests nationally and overseas. The Government has the right policies and programs to ensure that Australian firms can meet the challenges and provide defence with the best equipment to carry out its mission.

The Government’s continued investment in locally produced defence technology will generate benefits beyond local defence firms. It will also deliver jobs and encourage innovation for businesses and communities right across Australia.

“The Future Submarine announcement, along with our other commitments in this area, means the road ahead for Australian manufacturing is rich with opportunity.”

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From the industry Innes Willox – Chief Executive Australian Industry Group

Action needed on apprenticeships

Ai Group recently turned the spotlight on Australian Apprenticeships through the release of the ‘Making Apprenticeships Work’ policy statement, which highlights a severe decline in commencements and those in training.

The latest Apprentices and Trainees report from the National Centre for Vocational Education Research (NCVER), for the September 2015 quarter, highlighted that there were only 295,300 apprentices and trainees in training. This represented a decrease of more than 13% on the same period the previous year, and the lowest level of participation for a decade.

It is the same story for commencements. The proportion of Australian workers employed as an apprentice or trainee has fallen to a worryingly low 2.7% of total employment. Australian apprentices and trainees now only make up 9.7% of all those participating in the entire Vocational Education and Training (VET) system.

Without urgent and meaningful intervention, the apprenticeship system in Australia will continue to underperform and fail to deliver for business and the community.

Disappointingly, there persists a lack of commitment to implementing competency-based progression and completion, as well as minimal support for pathways to Australian Apprenticeships such as preapprenticeships.

The growth sectors in the economy and subsequent employment patterns are in areas not traditionally served by apprenticeships.

There is a challenge to expand and spread the benefits of this workbased learning model to new and different industries.

Many of the current arrangements lack national consistency and are unnecessarily complicated for key players including employers and the apprentices themselves. Competency-based progression and completion is not systematically implemented. Employers have told us that they are cautious about expanding their workforces through apprenticeships in the current climate.

A key challenge for Government is addressing these inconsistencies in the system, and making a commitment to facilitate greater engagement by industry and young people in this vital training pathway.

There is a need to find ways to improve and expand this workbased pathway into other industry and occupation areas, and to encourage young people to consider an apprenticeship as a viable career option. In the UK, for example, ‘higher apprenticeships’ have been introduced at a higher qualification level and in a wider range of different industries. This has boosted their numbers in apprenticeships. We should undertake some trials of similar arrangements and see if they work in Australia.

For our part, Ai Group has proposed an action plan. The adoption of these recommendations by all is essential to give the apprenticeship system the drive it needs: • Employer Incentives: implement incentives for those employers who are not currently engaged with Australian Apprenticeships to address the significant decline.

• Supporting New Employers and Completions: focus on supporting first-time employers of apprentices, and provide funding support through Joint Group Training Program Funding to group training organisations (GTOs).

“Without urgent and meaningful intervention, the apprenticeship system in Australia will continue to underperform and fail to deliver for business and the community.”

• Implement Competency-Based Progression and Completions: implement a national communication strategy to develop mechanisms to facilitate registered training organisations (RTOs) to promote the outcomes.

• National Consistency and Complexity: establish a national industry-led oversighting body to drive the national Australian Apprenticeships policy.

• Linking to Higher-Level Qualifications: trial a range of measures that link apprenticeships to higher-level qualifications in the VET and Higher Education sector.

• Participation in Apprenticeship Pathways: clearly define and support pre-apprenticeship programs as well as develop measures to support school-based apprenticeships.

• Expanding the Labour Market for Apprentices: investigate the introduction of ‘higher apprenticeship’ models, which provide this pathway to a wider range of industries.

With apprenticeship numbers at their lowest level in a decade, the Australian Industry Group is urging all parties to adopt these measures to address this dire situation.

AMT Jun/Jul 2016

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From The Union Paul Bastian – National Secretary Australian Manufacturing Workers Union

Manufacturing and the election

As we watch an epic election campaign unfold, it is a good time to take stock of the different approaches being taken towards the manufacturing industry.

The Coalition government’s approach is summarised in their pre-election budget; one dominated by tax cuts presented as a driver of growth, and a domestic build of Future Submarines, Future Frigates, Overseas Patrol Vessels and Pacific Patrol Boats.

The AMWU has been campaigning for this outcome on Australia’s shipbuilding projects for years and we naturally welcome it. It is a huge win that recognises the importance of a domestic shipbuilding capability, and it will see jobs, skills and business stay in Australia that otherwise would have gone overseas; both in the major yards and in the supply chain. But while this has been a huge win, it hasn’t been complete.

Replacements for Australia’s supply ships are still scheduled to go overseas rather than being built in Australia. In addition, the decision trumpeted in the budget came too late to save the jobs of 1,800 shipbuilding workers whose jobs have already gone due to a lack of work. What’s more, this decision doesn’t look like enough to save the Williamstown shipyard in Victoria from closure. And we shouldn’t forget, at the last election, Tony Abbott also promised a full domestic build for Australia’s Future Submarines, before changing his mind once coming to power. Just like shipbuilder Matthew Premio told Christopher Pyne on Q&A, we should see ink on paper before we totally accept the assurances of this government about Australian-built ships.

The Turnbull government’s proposed tax changes may lead the casual observer to think they will have a material impact on investment and employment, but detailed analysis doesn’t support this conclusion.

More than one economist, and notably the ACTU, have pointed out that other countries, most notably the USA, our largest source of foreign direct investment, have tax systems that charge their companies a rate of tax net of what they pay in other countries. This means that a 5% cut in our corporate tax rates just increases taxes paid to the US Treasury by 5%.

In addition, our dividend imputation system means that a corporate tax cut simply gets passed on to shareholders, rather than going to new investment which boosts productivity and jobs. And this is before we consider the opportunity cost of the $48bn budget cost of this tax cut. A cost that needs to be paid for, and will likely be paid for with further cuts to productivity-

AMT Jun/Jul 2016

boosting services like education, training and health.

On more than one occasion I have written on these pages that a central barrier to a stronger and more productive manufacturing sector is the systemic difficulty that manufacturing firms face in financing investment. This is something that manufacturers are aware of, as are industry associations like the Australian Industry Group. I have proposed a public Manufacturing Finance Corporation (MFC) to address these barriers, but at the time of writing, it seems that neither major party is willing to endorse a MFC. Whether it is a MFC model or some other option, without addressing the systemic hurdle manufacturing faces in accessing finance, it is hard to see how the sector can reach its potential; a potential that needs to be reached if the country is itself to reach its potential.

On the Labor side, at the time of writing, we have seen a promise to top up Victorian and South Australian programs aimed at helping automotive supply chain firms diversify their business and access new investment to make diversification plans a reality. This program will also specifically target investments in Victoria that will create new jobs for displaced automotive workers. While at $58m it is a modest proposal, it should nonetheless be welcomed. In particular, the extension of the South Australian Business Transformation Voucher program and the extension and expansion of the Automotive Supply Chain Diversification program will allow more

manufacturing businesses to position themselves for work on future shipbuilding projects in the state.

Labor’s proposed reforms to negative gearing and Capital Gains Tax will have a much greater economic impact, and likely in way that are almost entirely overlooked.

These are reforms the broader labour movement has been consistently arguing in favour of for years. That’s not only because of the inequity of spending billions of taxpayers’ dollars per year to subsidise the accumulation of investment property when basic services and industry training policies are cut in the name of fiscal repair. It’s also because negative gearing diverts precious investment funds away from the creation of new productive assets through business and infrastructure investment.

Negative gearing directly costs taxpayers $11bn per year, but the investment that it diverts into existing property is much greater. In the last year, $6.7 trillion worth of loans were provided for ‘investment’ in Australian property (not including owneroccupiers). If only 1% of this finance was re-directed to investment in small and medium-sized businesses or other jobs creating productive assets, that would be an investment boost for industry of almost $67bn, in one year alone.

Perhaps more than anything else we’ll see in this election campaign, Labor’s negative gearing reforms have the possibility of proving to be a real boost to the economy – and not in the way most people would think about it.

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Innovation focus needed to boost Australian manufacturing

The development of advanced manufacturing technologies, including smart, connected products and factories, predictive analytics, and advanced materials, are core to Australian manufacturing’s future competitiveness in the global market, according to the 2016 Global Manufacturing Competitiveness Index report from Deloitte Global and the US Council on Competitiveness, released on 21 April.

Whilst Australia’s manufacturing competitiveness ranking has slipped from 16th to 21st since 2013, Deloitte Australia Tax Partner and Manufacturing Group leader, Damon Cantwell, believes the country deserves to be ranked higher.

“We are simply not getting the message out – Australia is competitive in the majority of the global drivers of competitiveness such as talent, the supplier network and our innovation infrastructure, but this is not reflected in our ranking,” said Cantwell. “In fact, seven of the top 10 manufacturing nations, including the US, Japan, Germany and the UK, are all relatively high wage nations. Indications are a higher cost environment is becoming less important in regard to an economy’s manufacturing competitiveness.

“It is timely the Federal Government’s Innovation Agenda has been an area of focus over recent months in Australia, with global CEOs keeping a close eye on these settings in their investment decisions.

The key for Australian policymakers is how these policies rank against international competitors. We are in our own competitive market with other countries that are more advanced when it comes to innovation and research and development support, and the integration between the manufacturing and research sectors.”

According to the Index, the United States is expected to become the most competitive manufacturing nation over the next five years, with current leader, China, slipping into second position. The prediction is based on an in-depth analysis of survey responses from more than 500 chief executive officers and senior leaders at manufacturing companies around the world.

In the Index’s country rankings, regional clusters of strength emerge, with North American and Asia-Pacific nations dominating the competitive landscape. This includes the rise of Malaysia, India, Thailand, Indonesia, and Vietnam (MITI V, or the ‘Mighty Five’), all of which are expected to be among the top 15 nations by 2020 and could represent a ‘new China’ in terms of low-cost labour, agile manufacturing capabilities, favourable demographic profiles, in addition to market and economic growth.

“The role of larger, geographic manufacturing clusters is becoming increasingly important, with participating countries delivering different capabilities and skill sets in areas such as assembly, design, product development and testing,” Cantwell concluded. “With AsiaPacific identified as one of these regions, the challenge for Australia’s manufacturing industry is to determine which of these areas will be its main focus.”

Deloitte’s findings followed similar research from KPMG, released on 7 April, which saw Australia climb three places in an index of business competitiveness. KPMG’s biennial Competitive Alternatives report looked at ten countries and 111 cities around the world. A key feature of the report was the declining cost of doing business in Australia over the previous two years, which left Australia ranked fifth among the ten economies in the 2016 study, overtaking France, the UK and Japan, with a business cost advantage over the US of 10.6%. The improvement in Australia’s 2016 ranking has been primarily driven by a combination of the Australian dollar depreciation rate of 22.3% since 2014, below-average wages growth and disproportionately large falls in other business costs, such as electricity and natural gas.

Australian Chamber announces new leader The Australian Chamber of Commerce and Industry on 5 April announced the appointment of James Pearson to the position of Chief Executive Officer.

Pearson replaces former CEO Kate Carnell AO, who has moved on to a role as Small Business and Family Enterprise Ombudsman. Australian Chamber President, Terry Wetherall, said that the Board of the Australian Chamber was delighted that Pearson has accepted the position and will be a strong advocate for the Chamber’s membership.

“James comes to the Chamber with a wealth of experience in both the private and public sectors,” said Wetherall. “As a senior executive with Shell Australia and, previously, Chief Executive of the Chamber of Commerce and Industry Western Australia, he has represented business at the highest level and understands the needs of members.”

Pearson has held executive positions with Chevron Australia, the Australian Petroleum Production & Exploration Association,

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the Western Australian Department of Resources Development, and the Department of Foreign Affairs & Trade.

In addition he has also represented the Australian Government and businesses in trade negotiations in diplomatic postings overseas.

“James was selected from a field of high quality candidates, reflecting the significance of the Australian Chamber’s role in speaking on behalf of the business community to government and the community,” added Wetherall.

“We are fortunate to have a person of James’s calibre available to advocate the issues important to members. With a federal budget imminent and election looming, the Australian Chamber is soon to release our policy issues for all political parties to consider prior to the election.

“James will provide strong and direct leadership for our members.”

industry news

Austech 2017 – Start the countdown The countdown has begun for Austech 2017, Australia’s premier advanced manufacturing and machine tool exhibition, in Melbourne next May. Austech 2017 will take place at Melbourne Convention and Exhibition Centre from 9-12 May 2017. As always, Austech will include an exciting range of special features, including specialised areas such as the Additive and Digital Manufacturing Pavilion and Manufacturer’s Pavilion.

Preparations for the show are already in full swing. One of the first big milestones will be reached in the coming weeks, with the ballot for floor space to exhibitors to take place during July and August. To ensure that floor space for the exhibition is allocated fairly, AMTIL holds a ballot among exhibiting companies who have registered early. Once all companies participating in the ballot have chosen their space, the floor plan will be issued to other prospective exhibitors.

“The ballot is always really the starting gun for the build-up to Austech,” says Kim Warren, AMTIL Events Manager. “Keep an eye out for the launch of the ballot in coming weeks, and be sure to get your company’s name in the running, because that’s usually when some of the best spots on the exhibition floor get snapped up.”

An unparalleled showcase Held every two years in Melbourne, Austech is the place to be for suppliers of advanced manufacturing technology and related services. Exhibitors at Austech 2017 will have the opportunity to demonstrate their latest products, communicate their key message, reinforce their market position, and reach new prospects. Products on display will include: • CNC machining centres – horizontal and vertical.

• CNC lathes.

• Grinding, broaching, boring and milling machines.

• Forming, bending, punching and shearing equipment.

• Laser profiling, cutting, marking and engraving equipment.

• Waterjet cutters.

• Robotics • Digital and additive manufacturing.

• Cutting tools and hand tools.

• Cutting fluids.

• Finishing and coatings.

• CAD/CAM software

One key element of Austech 2017 will once again be the Manufacturer’s Pavilion. With a new focus and a new position within the exhibition area, the Manufacturers’ Pavilion will showcase the capabilities of this country’s advanced manufacturing industry. It provides Australian component manufacturers, precision engineering firms, toolmakers, advanced manufacturers and general engineering companies the opportunity to promote their unique capabilities.

Manufacturers’ Pavilion exhibitors can benefit from: • Face-to-face interaction with original equipment manufacturers (OEMs) and other major potential clients.

• Access to targeted prospects and buyers, all under the one roof.

• The chance to learn about opportunities in major projects.

• Participation in exclusive networking events.

• Opportunities for growth through new ideas and initiatives.

To support companies who exhibit in the Manufacturers’ Pavilion and help them get the most out of the event, AMTIL is able to provide pre-event trade show coaching at no added cost.

Opportunities for everyone Co-located with National Manufacturing Week, Austech 2017 promises a wealth of opportunities for all. Exhibitors will get to showcase their products and services to thousands of visitors including key decision-makers from across Australian manufacturing. Visitors will see demonstrations of the latest state-of-theart technology up close. And everyone will have opportunities to learn about what’s going on in the industry, network with potential new contacts, and catch up with business associates.

“A lot of work goes into the running of the exhibition,” says AMTIL CEO Shane Infanti.

“We manage it all in-house, and it’s always exciting to see the buzz build as the show gets nearer. We’re aiming to make Austech 2017 bigger and better than ever. I’m looking forward to it.”

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AMTIL PRODUCT E-BLASTS call anne samuelsson on 0400 115 525 or email asamuelsson@amtil.com.au for all enquiries.

For further information about Austech, contact AMTIL Events Manager Kim Warren. kwarren@amtil.com.au. www.amtil.com.au/Austech

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Some criteria apply regarding what products may be exhibited in Austech 2017. If you are unsure whether your products or services fit, contact AMTIL for further clarification.

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industry news

Industrial robots post a new sales record in 2015

The number of industrial robots sold worldwide surpassed the 240,000 unit mark in 2015 for the first time, according to research from the International Federation of Robotics (IFR).

The rise in sales corresponds to global year-on-year growth of 8%. The greatest demand was again registered by the automotive industry.

“Global robot shipments in 2015 confirmed that these are very exciting times to be in the robotics industry”, says Per Vegard Nerseth, Managing Director of ABB Robotics. “The traditional drivers in our industry are now being complemented by the tremendous demand for solutions related to the Internet of Things, Services and People, all of which lead me to believe that this year will be yet another record year for all concerned.”

In a comparison of global markets, China continues to exhibit the highest demand for industrial robots, with sales rising by 16%.

Despite the general perception of a ‘reluctant’ investment climate, China extended its leading position as the number-one sales market worldwide with unit sales reaching 66,000. This includes the units sold by local Chinese suppliers. Total sales in China, however, remained below the original IFR forecast of 30%. Demand in Asia, excluding China, remained at a high level with 78,000 units sold.

“The growth on the world robotics market is being driven forward at a rapid pace,” says Olaf C. Gehrels, CEO of FANUC Europe. “Along the way, two technological milestones have been set. Collaborative robots based upon standard robots equipped with tested and proven controllers have demonstrated their readiness for routine use in the industrial environment, and the introduction of high-payload robots capable of handling items weighing up to 2,300kg now allows the employment of totally new manufacturing concepts.”

Sales of industrial robots in Europe rose by a record of 9% to nearly 50,000 units. Eastern Europe, with growth of 29%, proved to be one of the fastest growing regions globally. The number of units deployed in North America also broke a new record: in the U.S., Canada and Mexico a total of 34,000 units were sold in 2015, representing yearon-year growth of 11%.

“In the age of Industry 4.0, the automotive industry is taking a leading role when it comes to flexible and state-of-the-art automation solutions and the direct collaboration between humans and robots,” says Stefan Lampa, President and CEO of KUKA Roboter. “Moreover, the demand for automation solutions is constantly growing in nearly all sectors. New markets are evolving where automation has not been a major topic until now. A particularly important market for us is the electronics sector: the electronics industry is confronted with an increasing number of new products, an accelerating pace of development and short product life cycles. Here too, flexibility is the be-all and end-all in the industry.”

Articulated robots are by far the most sold robot type. The diverse range of applications across which they are deployed, coupled with the broad range of models available, has helped to drive sales of this robot type across all regions to over 150,000 units in 2015 – a new high.

SAE-A names Mario Turcarelli as President

The Society of Automotive Engineers - Australasia (SAE-A) recently confirmed the appointment of Mario Turcarelli as the Society’s new President.

Turcarelli was appointed as President of the SAE-A at the Society’s 70th Annual General Meeting & Networking Dinner on 5 May. He succeeds Adrian Feeney who has completed his three-year term as President. Feeney will remain on the Board for 12 months as the Immediate Past President.

SAE-A CEO Dale Gilson welcomed the appointment of Turcarelli. He also thanked Feeney for his work over the past three years; for his continued loyalty to the SAE-A; and for being instrumental in driving the Society into the “good position” it is in today.

“With a newly appointed President and CEO, we have a lot of good ideas and enthusiasm to expand and act upon,” said Gibson. “The SAE-A is heading into a new season of growth, with renewed training programs, high-quality events and greater member benefits. Mario is passionate about his company, Dolphin Products, and I’m confident he’ll bring the same enthusiasm to his

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role as President of the SAE-A. I look forward to working alongside Mario as we see our vision for the SAE-A come to fruition.”

Turcarelli is the Managing Director of Dolphin Products as well as the Director of Dolphin Products Thailand.

He holds a Chartered Professional Engineer (CPEng. Mechanical) qualification with an extensive management background, which is complemented with diverse global auto and plastics engineering experience. Turcarelli also has international experience with automotive projects in Europe, the USA and the Asia Pacific Region, and has had extensive leadership roles in engineering, design, and program management.

“I would like to thank Adrian and the Board for electing me. I’m very passionate about what the SAE-A does, particularly with developing our young engineers” said Turcarelli. “Innovation is the answer to Australia’s manufacturing issues. We are going to progress the SAE-A, despite some turbulent times in the industry.”

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industry news

Innovation and collaboration headline NMW National Manufacturing Week (NMW) 2016 took place in Sydney with more than 200 exhibiting companies, 50 speakers and more than 5,000 attendees visiting the combined NMW-Safety First Conference and Expo event.

This year’s events were defined by the twin themes of innovation and collaboration: with several Seminar Theatre sessions focusing on opportunities for manufacturers to break down the barriers to innovation. Feedback to organisers, Reed Exhibitions, was that participants have gained new insights, information and all-important inspiration for growth in their businesses.

“The time for action is now,” urged Karen Andrews, Assistant Minister for Science, in a Keynote Address on NMW’s final day. “I know that SMEs have had some hesitation in the past around approaching the universities for partnership, due to barriers such as cost. But I invite businesses to come talk to the Department of Industry, or to me personally, because there are some real opportunities on the table, and we are keen to help business make connections that can support your growth.”

The Assistant Minister’s comments were reflected throughout the NMW Seminar Theatre program. In a panel discussion focusing on funding for business innovation, several SMEs including Marathon Targets and HMS Equipment joined AusIndustry to share examples of how government assistance can help connect growth-hungry businesses connect with potential partners, and new ideas for growth.

In a separate Day 2 session, Western Sydney University’s Dr Sasha Alexander challenged visitors with the observation that “Every time a stranger enters the business, innovation happens”. Dr Alexander went on to explain how an outsider’s view of your business – from industry partners, consultants and even competitors – can challenge your assumptions, opening your eyes to new markets and product development opportunities.

Throughout this year’s events, NMW and Safety First exhibitors made contact with existing and new customers from across the spectrum of Australia’s manufacturing industry. Among them was Robert Hamilton, Managing Director of Saint-Gobain Performance Plastics, who commented: “I was surprised by the number of people already waiting for the doors to open before NMW started, and

Dandenong showcases world-class manufacturing The centre of Dandenong in south-east Melbourne was transformed on 17 May into the manufacturing epicentre of Australia for Smart Manufacturing ’16, an expo-style event promoting the world-class capability and capacity of the region.

Smart Manufacturing ’16 – Dandenong and South East Melbourne on Show saw the main square taken over with locally manufactured products such as the VLocity train, Melbourne’s E-Class tram, and Jayco caravans; as well as leading innovations such as emergency housing that can be deployed in a flat-pack, and CSIRO’s 3D printed bicycle.

The event also hosted a cutting edge symposia with industry leaders and commentators at the forefront of industry trends speaking on smart manufacturing, innovation and commercialisation. Senator Kim Carr, Shadow Minister for Higher Education, Research, Innovation and Industry, gave the keynote speech, and there were also contributions from representatives of state and local government, leading manufacturers, educators and researchers from the region.

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throughout the event we made a number of strong contacts. We have found people in a market segment that we hadn’t thought of – and we’ve also made contact with people who are already using our product inside another product. It’s been terrific.”

NMW Exhibition Director Robby Clark commented that NMW has once again helped create real opportunities for participants: “There is a great deal of strength in Australia’s manufacturing sector.

The feedback from exhibitors is that visitors are looking keenly at opportunities to transform and expand their capabilities: an observation that is supported by strong attendance at our NMW Seminar Theatre events, which gave businesses opportunities to collect new information and ideas for growth.

“There was a real buzz across NMW 2016, which I am sure will translate into real opportunities in the weeks and months ahead.”

Reed Exhibitions has announced that NMW 2017 will take place in Melbourne from 9-12 May 2017, co-located with Austech and the Safety First Conference & Expo, as well as AUSCLEAN Pulire, the leading event for Australasia’s cleaning industry. NMW 2017 is expected to draw strong visitor numbers, and many of industry’s leading players have already booked exhibition space at the event.

New Deputy Chair for CSIRO board Shirley In’t Veld has been appointed as the new Deputy Chairperson on the CSIRO Board.

Announcing the appointment, Minister for Industry, Innovation and Science Christopher Pyne said In’t Veld, who has been a CSIRO Board member since June 2012, was well placed to assist the CSIRO Board Chair in ensuring the proper and efficient performance of the functions of the CSIRO. “CSIRO’s capacity to promote scientific endeavour and capture the power of science for the benefit of all Australians will be supported by this appointment,” Pyne said. “Ms In’t Veld’s substantial business leadership skills, industry links and connections will continue to benefit the Board as it furthers its collaborations between science and industry.

“Ms In’t Veld’s appointment ensures ongoing corporate knowledge that will benefit the CSIRO board. Her skills and experience complement those of the other board members. I warmly congratulate Ms In’t Veld on her appointment and thank Ms In’t Veld for her willingness to take on the additional responsibilities of the Deputy Chairperson position. “

open the door to great machinery and design

AWISA 2016

6-9 July 2016 Melbourne Convention & Exhibition Centre South Wharf Melbourne

the show for wood and panel processing AWISA 2016 is the international exhibition of machinery, materials, fittings and services for the Australian and New Zealand cabinet, joinery, furniture, fit-out, timber and panel industries.

www.awisa.com

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Industry news

Sandvik Coromant cements ties with Swinburne visit

Klas Forsström, President of Sandvik Coromant, was in Australia for a visit in early April, and his first port of call was Swinburne University of Technology.

The head of the Swedish cutting tools giant had only landed in Melbourne a few hours earlier when he arrived at Swinburne’s Hawthorn campus. Sandvik Coromant has a long-standing collaborative relationship with Swinburne’s Faculty of Science, Engineering and Technology, and the meeting was an opportunity to both cement those ties and explore ways to build on them.

Forsström was accompanied by Sandvik Coromant’s Oceania General Manager Peter Rollauer and Oceania Industry and Sales Support Manager Greg Bennett, while AMTIL CEO Shane Infanti was also invited along to participate. Swinburne was represented by: Professor Geoff Brooks, Pro Vice Chancellor, Future Manufacturing; Professor Bronwyn Fox, Director of the University’s Factory of the Future (FotF) facility; Doctor Suresh Palanisamy, Senior Research Fellow/DMTC Air Platforms Program Leader; and Janine Shearer, Senior Manager, Collaboration and Partnerships.

First on the agenda was a tour of Swinburne’s Advanced Manufacturing and Design Centre (AMDC). Opened last year, the AMDC is a $100m, state-of-the-art hub aimed at promoting manufacturing innovation and collaborative learning. Its centerpiece is the FotF, a purpose-built facility designed to provide cutting-edge tools with which to explore conceptual ideas for manufacturing next-generation products. Forsström was given a demonstration of an ongoing project between Swinburne and Sandvik Coromant led by Palanisamy. The tour also took in Swinburne’s Direct Metal Deposition Laboratory and its Robotics Laboratory.

Another highlight was the premiere of a new short film from Sandvik Coromant. This was the fourth in a series of “Trend” videos the company has produced that have looked at various trends affecting the industry. Previous Trend movies have looked at Hyperspecialisation, Industry 4.0 and Industrialisation, and can be viewed at the Sandvik Coromant website. The new film focused on Materials, bringing together insights from Sandvik Coromant’s own experts, as well as academics from around the world. It discussed some of the very latest advanced materials such as graphene and composites.

“Part of the reason why we’re producing those videos is telling the world we’re following these trends,” said Forsström. “So if you team up with us you’ll have access to this knowledge.”

This was followed by a wide-ranging conversation encompassing everything from material science to industrial automation, the history of Sandvik Coromant, and potential mechanisms for promoting collaboration between universities and industry. Brooks gave a brief presentation that provided an overview of Swinburne’s work in design, engineering, technology and manufacturing, and Fox provided an update into some interesting new research she has been engaged in on Industry 4.0 and carbon-fibre. There was also extensive discussion of how Sandvik Coromant and Swinburne can work together, along with AMTIL, to help industry get the most out of advanced manufacturing technology.

“I think one of the challenges in collaboration between academia and industry is the knowledge of each other,” said Forsström. “What I think is a very important thing to do is to promote manufacturing.

And it’s something that we definitely can support.”

Thales, Orica announce explosive partnership

Thales Australia and Orica have signed a ten-year contract for Thales to produce five million explosive boosters each year, in a deal that is good news for regional manufacturing.

Orica is an Australian-based multinational corporation that is one of the largest providers of commercial explosives and blasting systems to the mining and infrastructure markets. Boosters are small explosive devices that help detonate larger charges, and are used extensively across Australia’s mining and construction industries.

The new contract with Thales, a global technology leader for the aerospace, transport, defence and security markets, will replace imported products with Australian ones, and strengthens Orica’s leading position in this market. The order will increase manufacturing activity at the Benalla (Victoria) and Mulwala (New South Wales) facilities operated by Thales, including the establishment of a new multi-million dollar production line for the boosters, designed and built in Victoria. The boosters themselves are an advanced new product designed by Orica.

“The agreement with Thales will make Orica even more competitive

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in Australia, with better quality booster products,” said Orica CEO Alberto Calderon. “In addition, sustaining jobs in regional Australia as a result of this agreement is a very positive flow-on benefit for the broader community.”

The new contract will help to sustain around 100 jobs. Approximately 200 people currently work at Benalla, and 400 at Mulwala. Key Australian component suppliers will also benefit from increased annual orders from Thales as a result of the deal.

“At a time of ongoing economic uncertainty, this is a great result for manufacturing in regional Victoria and New South Wales,” said Thales Australia CEO, Chris Jenkins. “Not only are we increasing employment and production levels at the sites, we’re also giving a leading Australian company committed to technology and innovation the reassurance of a high quality supply chain based in this country. Credit to Orica for investing in local skills and local manufacturing.

industry news

Bosch Australia inaugurates new headquarters, tech centre Bosch Australia on 20 April inaugurated its new headquarters and technical centre, on its 120,000sqm campus in Clayton, Victoria.

The $40m development is the single largest investment by the Bosch Group in Australia since the company established its wholly owned subsidiary in 1954. Lily D’Ambrosio, Victorian Minister for Industry and Minister for Energy and Resources, inaugurated the newly redeveloped facilities, saying: “Bosch’s commitment to this project represents a great vote of confidence in the underlying strength of Victoria’s economic fundamentals.”

EuroBLECH 2016

The New Generation of Sheet Metal Working

“It is a special day for us,” said Gavin Smith, Bosch President with responsibility for the region of Oceania. “The new facility is evidence of Bosch’s long-term commitment to diversified activities in this region including sales and distribution, high tech engineering, advanced manufacturing and further investment into exciting new fields.” The new facility incorporates offices, workshops, testing facilities, training rooms and employee amenities. It has been developed to support the future of mobility with the installation of dedicated electric vehicle (EV) charge spots. The new headquarters have been designed to provide contemporary working conditions that encourage collaboration amongst the 800 Bosch associates in Clayton. The facility supports health benefits for all associates and encourages cycling to work with undercover bike parking and end-of-trip facilities for cyclists. It has a landscaped courtyard with semi-established trees, and an outside terrace with an alternative working space.

Further investment by Bosch in Australia is already underway. In addition to the new headquarters, Bosch is making a significant investment in manufacturing for the global automotive sector. The Clayton facility will see a further $6.2m invested to increase its diodes production capacity to support growth with international customers. The Federal Government has contributed $1m from the Automotive Diversification Programme (ADP).

“Australia is an important location for the Bosch Group,” said Peter Tyroller, member of the board of management of the Bosch Group responsible for Asia Pacific. “We have seen a positive development of our business in 2015 and we are confident of the market’s long-term prospects.” Bosch in Australia has a strong engineering competence and the automotive electronics engineering facility on the Clayton site is concurrently being upgraded. This will support approximately 200 engineers predominately working on projects for international automotive customers.

Bosch also continues to invest in future-oriented activities in this region, including direct investment in Australian start-ups – most recently ‘The Yield’, a company focused on micro-climate sensing technology in agriculture and aquaculture. Bosch’s recently established manufacturing solutions business has already supplied millions of dollars’ worth of production equipment and technology into a variety of manufacturing companies in the region.

24th International Sheet Metal Working Technology Exhibition Sheet metal, Tube, Sections Handling Forming Separation, Cutting Joining, Welding R&D Finished products, Parts, Assemblies Tools, Dies Flexible sheet metal working Machine elements Tube/Section working Additive Manufacturing Surface treatment Composites Safety at work Data capture/processing CAD/CAM/CIM systems Controlling, Regulating, Measuring, Inspection Factory and warehouse equipment

25 -29 OCTOBER 2016 HANOVER, GERMANY www.euroblech.com Organisers: Mack Brooks Exhibitions Ltd

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government news

New export loan to improve access to finance for small business

Small businesses will find it easier and quicker to access the finance they need to support their products and services exports, with the new Small Business Export Loan launched by Efic, Australia’s export finance agency.

The Small Business Export Loan is intended to improve convenience, increase approval speed and provide greater flexibility for Australian small businesses seeking finance to support export contracts. The loan product will enable small and medium-sized businesses with an annual revenue between $250,000 and $5m to access up to $250,000 to support an export contract. The loan will be available to small exporters when their main bank is unable to help.

The Small Business Export Loan has been developed to meet the needs of small exporters, with a focus on convenience and speed throughout the application and approval process. Small businesses can apply online via Efic’s online portal, EficDirect, in as little as 30 minutes and will receive an indicative offer immediately. Businesses can then receive a formal approval within seven business days, after which funds can be available to draw on within as little as two business days.

In assessing loan applications, Efic will focus on the small exporter’s ability to service the loan, rather than the level of security available.

Promoting careers in manufacturing Manufacturers have been given an opportunity to attract Australia’s youth to the sector under the Federal Government’s $752m Youth Jobs PaTH (Prepare-Trial-Hire) programme.

Announced in the Federal Budget, the programme is intended to enable the sector to attract and retain talent, promoting prosperous careers in a sector undergoing transformation.

“Australian manufacturing is changing,” said Mark Phillips, Manufacturing National Leader, Grant Thornton Australia.

“While original equipment manufacturing is exiting our shores, new advanced manufacturing is slowly taking its place. What’s been lagging in this transition is the development of the manufacturing workforce. The Government’s youth initiative provides a distinct opportunity to invigorate the sector’s workforce.”

The manufacturing industry has found it difficult to attract youth into the sector, with 41.2% of the manufacturing workforce classified as mature age workers, including 25% aged between 45 and 54 years, resulting in manufacturing having the oldest workforce in the Australian economy.

The programme includes internships matching job seekers and businesses, allowing young workers the opportunity to gain hands-on experience in a workplace while receiving a small payment. Businesses that take on interns will receive an upfront payment of $1,000, and will benefit from the opportunity to see what a young worker can do and how they fit in to the team before deciding whether to offer them ongoing employment.

In addition, there are further wage subsidies available from 1 January 2017, when Australian employers will be eligible for a Youth Bonus wage subsidy if they hire a young jobseeker who has been in employment services for six months or more. www.employment.gov.au/youth-jobs-path-infographic

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Being unable to provide securable assets is a barrier many small businesses face when seeking to access finance for export.

The Small Business Export Loan is consistent with the Government’s focus on Efic helping more Australian SMEs, particularly smaller SMEs, by reducing red tape and costs for SME exporters looking to access finance. The new product will increase the number of SMEs, particularly smaller businesses, which can now access Efic’s services.

“This new loan facility is the first of its kind designed specifically for small exporters,” said Andrew Hunter, Managing Director & CEO, Efic. “Moving the application online through our portal, EficDirect, has allowed us to significantly reduce the cost and time needed for small businesses to apply for and access export finance. The whole process could take less than two weeks.

“Small businesses are the heartbeat of the Australian economy, and Efic’s new loan facility will make it easier for small businesses to compete on a world stage.” www.efic.gov.au

Roadmap launched to double energy productivity The Federal Government’s new ‘2xEP’ Manufacturing Sector Roadmap aims to double Australia’s energy productivity in manufacturing by 2030.

Developed by the Australian Alliance to Save Energy (A2SE), and a steering committee of senior business leaders under its 2xEP project, the roadmap aims to establish what manufacturing can do to improve energy productivity, what policy support manufacturing seeks from government, and how sensible policies can unlock manufacturing productivity improvements in Australia.

“This is a great example of industry taking the lead in driving growth and innovation in the transition to a low carbon future,” Josh Frydenberg, Minister for Resources, Energy and Northern Australia.

“Improving energy productivity is about obtaining more value from the energy we consume.”

Manufacturing contributes 8% of the nation’s GDP and uses about $14bn worth of energy a year. The A2SE estimates that in doubling its energy productivity by 2030, the manufacturing sector could reduce the cost of its energy use by $5bn per annum.

The Government is committed to improving Australia’s energy productivity by 40% between 2015 and 2030. The National Energy Productivity Plan (NEPP), developed by the COAG Energy Council, brings together a wide range of opportunities into a co-ordinated, national plan to achieve this target.

To date, the Government has provided $260,000 to A2SE to support the development of five sector roadmaps, of which manufacturing is the first. As part of the NEPP, the Government is also supporting the A2SE to develop a proposal for the “2xEP Challenge”. The Challenge, outlined in the manufacturing roadmap, will recognise leading companies for their public commitments to greatly improve their energy productivity.

The roadmap is available at www.2xep.org.au/sectors/ manufacturing. To find out more about the NEPP visit www. industry.gov.au/Energy/Pages/National-Energy-ProductivityPlan.aspx

Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

It’s all about you.

Innovation Connections

The Entrepreneurs’ Programme (EP) is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. AMTIL is a partner organisation working with the Department of Industry in the delivery of the EP. The Programme forms a part of the Australian Government’s Economic Action Strategy and will deploy over 100 experienced Advisers and Facilitators, offering support to businesses through three key elements: 1. Business Management 2. Innovation Connections 3. Accelerating Commercialisation Innovation Connections is a facilitation service to encourage and assist small and medium businesses to access knowledge, engage with researchers and foster innovation. Access to the latest technologies and cuttingedge research and knowledge is critical to help Australian businesses innovate and remain competitive. However, finding the unbiased advice, research and knowledge specific to your business can be challenging.

Innovation Connections offers: • Support from experienced Innovation Facilitators to help you assess your technical, research or knowledge requirements. These Innovation Facilitators will provide you with unbiased recommendations to help you develop new ideas with commercial potential.

• Introductions to researchers, technology or knowledge providers to work with you on collaborative projects.

• Matched grants of up to $50,000 to engage a research organisation to undertake research projects in collaboration with your business.

• Introductions to researchers, technology or knowledge providers to work with you on collaborative projects.

Every business has different needs.

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To find out what the Entrepreneurs’ Programme can do for you, call 13 28 46 or visit www.business.gov.au or contact Greg Chalker 03 9800 3666 or email gchalker@amtil.com.au

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voice box Opinions from across the manufacturing industry

Can Australian industry successfully be part of Industry 4.0 and global digitalisation?

Announced in late April, the Prime Minister’s Industry 4.0 Taskforce has been established to support Australia’s transition to a new economy and connect the nation to the fourth industrial revolution, known as Industry 4.0. The group’s leader, Jeff Connolly, discusses the opportunities and challenges ahead.

Recently one of my German colleagues, who is working in Australia, shared an interesting observation with me. He said in many ways Australia operates as a number of different countries connected by land only. I asked what he meant and he started to talk about standards. Every state seems to have different standards for health and safety, different standards for rail, different standards for industry and so on.

He has a good point and it got me thinking… is it really possible for Australia to be part of something global, something much bigger like Industry 4.0, and connect into global supply chains which require adoption of global standards?

I’m pleased to say yes! However, this does come with some caveats.

In its simplest form, there are two critical prerequisites (apart from the commitment to continuous investment required). The first prerequisite is that as an industrial nation we will have to adopt global digitalisation standards – no matter how good we are. The second is around having skills and using tools that are commonly accepted globally. In terms of global standards, I can proudly announce that I’ve been leading what is called the Prime Minister’s Industry 4.0 Taskforce. This taskforce is designed to connect Australian Industry to the German and US industrial leaders who are setting the global standards for digital networking.

It will support Australia’s transition to a new economy and connect the nation to Industry 4.0.

At the world’s largest industrial trade event, Hannover Messe (German for ‘Fair’) in April, the Taskforce entered important roundtable discussions. We met with the two most powerful groups in industrial transformation: Plattform Industrie 4.0 of Germany, and the Industrial Internet Consortium from the US. Why is this important for Australia?

As we transition from an economy led by a mining and resources boom, we are now looking to innovation to help fire up economic growth and provide income so we can continue to enjoy the success and liveability we have come accustomed to. This taskforce directly supports the National Science and Innovation Agenda – what the Government is calling the ‘Ideas Boom’. It is also a direct outcome of the recommendations from the Australia-Germany Advisory Group that was co-chaired by Finance Minister Mathias Cormann and German Minister of State Dr Maria Böhmer. I had the privilege of being a member of this group.

The Australia-Germany Advisory Group was established to build closer ties between Australia and Germany and identify opportunities for increased trade and investment. Its final report contained 59 recommendations to strengthen bilateral relations and was presented to Prime Minister Malcolm Turnbull and Chancellor Angela Merkel in Berlin on 13 November 2015.

Minister Cormann welcomed the commitment and initiative of the Prime Minister’s Industry 4.0 Taskforce. “It is vital that Australia is connected to critical developments in industrial digitalisation being led by Germany and the US,” said Minister Cormann. “The Prime Minister’s Industry 4.0 Taskforce helps achieve one of the key Australia-Germany Advisory Group recommendations to initiate a collaborative approach to the development of global Industry 4.0 standards.”

AMT Jun/Jul 2016

Germany and the US are at the forefront of setting the standards for digital networking and if Australia’s brightest innovators are to take the global field, then we must be connected to what the future looks like in order to participate in that future. SAP and Siemens have been tasked with supporting Australia’s move towards Industry 4.0.

To understand the particular relevance to Australia right now, you have to understand that a significant global event happened in early March whereby two of the most advanced industrial nations, the US and Germany, announced that they will work together to set the global course for digitalisation standards. We saw this as a unique opportunity to action the recommendations of the AustraliaGermany Advisory Group, which includes the development of global Industry 4.0 standards.

In the roundtable discussions at Hannover Messe, the Taskforce was able to connect Australia with Plattform Industrie 4.0 and the Industrial Internet Consortium – a critical first step for Australia to get on the journey to Industry 4.0. To put the importance of Hannover Messe in context, this year the USA was the fair’s focus country.

Hannover is taken so seriously as the global technology benchmark, that US President Barack Obama visited the Siemens stand with German Chancellor Angela Merkel and Siemens’ global CEO Joe Kaeser.

I recently took part in a panel discussion with Lleyton Hewitt, discussing how businesses can learn from sport in Australia. For our local industries to punch above their weight globally, we need to think global and leverage the relationships and strengths of global partners. And there is no better place to do this than events like Hannover Messe, which is a fulcrum for technology and innovation.

So is it possible for Australia to successfully transition to Industry 4.0? Yes! Jeff Connolly is the Chairman and CEO of Siemens Australia and New Zealand, and is the leader of the Prime Minister’s Industry 4.0 Taskforce. www.siemens.com.au

“Germany and the US are at the forefront of setting the standards for digital networking and if Australia’s brightest innovators are to take the global field, then we must be connected to what the future looks like in order to participate in that future.”

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voice box Opinions from across the manufacturing industry

Protecting your business against competition from departing employees

The current fluidity of employee movement across different organisations, combined with the ease with which confidential information can be transferred from one electronic device to another in many of today’s Australian workplaces, highlights the need for businesses to have robust and up-to-date employment contracts in place with all its employees, writes Jeremy Cousins.

For many AMTIL members, and other organisations involved in manufacturing technology, employees will have access to sensitive client, product and/or supplier information. Employees will also often have access to confidential processes and techniques, equipment details, pricing information and typically for more senior employees, information about strategy and business direction.

Where this information could cause damage to an employer should it fall into the wrong hands, there are likely to be legitimate grounds upon which an employer may seek to protect it.

While employees will be bound by a series of implied contractual and statutory obligations in relation to the protection of confidential information, the extent of these obligations can be unclear. Without a properly tailored clause in an employee’s employment contract, there is likely to be significant doubt about the scope of the implied contractual and statutory obligations.

Further, Australian courts will not imply a post-employment restraint: where an employee’s contract does not provide such an obligation then (subject to the employee’s compliance with any obligations relating to confidential information) the employee will be free to compete with their previous employer immediately upon termination of their employment.

There is no doubt that post-employment restraints are difficult to craft effectively. However, where they are very carefully tailored to protect an employer’s identified legitimate business interest and go no wider than is reasonably necessary they will (subject to compliance with a range of other issues) be enforced by the Courts. The use of “boiler plate” restraint clauses is almost always an entirely ineffective approach.

In many cases, an employer may obtain short-term protection against competition by requiring an employee to take “garden leave” during the period of notice. Again, in this situation, the employment contract should include a properly tailored and relevant clause.

However, in many cases, a restraint applying after the employment ends will also be required.

A quick overview of the most typically relevant issues in relation to post-employment restraints is below: • The starting point is that restraints are presumed to be void.

• However, an employer can rebut this presumption where it can show that the restraints go no wider than is reasonably necessary to protect an identified legitimate business interest.

There must be some valid basis for the restraints; the Courts will not enforce a restraint simply to prevent competition.

Typically, a valid legitimate business interest might relate to: (1) confidential information and trade secrets; (2) customer connections and relationships; (3) supplier connections and relationships; or (4) protection of the employer’s stable and trained workforce against poaching from former employees.

• A Court will also consider whether the terms are certain and can be understood. It is typical for post-employment restraints to be drafted using “cascading” or “waterfall” clauses. The purpose of this is to allow a Court to strike out what it considers to be an unreasonable term and leave a lesser, but reasonable, term in its place. However, in some cases the restraints have included too many combinations and permutations and the Courts have refused to enforce them on the grounds of uncertainty. Indeed, in one case there were 82,152 possible combinations (of the restraints combined with the various geographical areas and time periods, etc.) and the Court refused to enforce the restraint on grounds of uncertainty.

• To be enforced, the scope of the restraints must be reasonable. The restraints must go no wider than is reasonably necessary to protect the identified legitimate business interest.

For example, if sensitive software and design information for a new CNC machine will become public information in six months’ time, a 12-month restraint to protect this information would be unenforceable.

• The validity of the restraints will be determined at the date that they were given. Where an employee has restraints in a very old employment contract this can be problematic, particularly where the nature of the business has fundamentally changed.

• Many post-employment restraints still seek to impose restraints by protecting defined geographical areas. In many modern workplaces where customer needs are met by email, telephone, video conferencing and with the use of other technology in place of face-to-face meetings, restraints preventing employees from physically engaging in certain activities within a defined geographical area may be largely irrelevant.

• The Courts will also consider whether it is in the public interest to enforce the restraints. A Court could find that whilst the restraint is reasonable between the parties it is not reasonable in the public interest.

In summary, post-employment restraints will be enforceable where they are carefully crafted and relevant to the particular issues. If they are not tailored to the relevant circumstances, it is likely that employees will be able to ignore the restraints in the employment contract entirely on termination of their employment, or as described in accordance with modern-day legalese “drive a truck through the restraints”.

Jeremy Cousins is a Principal of Whitehall Workplace Law. Whitehall Workplace Law is able to assist AMTIL employer members with all employment law, industrial relations and occupational health and safety matters. www.whitehallworkplacelaw.com.au

• For post-employment restraints to be enforceable, typically some form of consideration (payment or benefit) must be provided to the employee when they enter into the restraint (and not afterwards as often happens).

AMT Jun/Jul 2016

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voice box Opinions from across the manufacturing industry

Is Australian business serious about innovation?

With Prime Minister Malcolm Turnbull and his Minister for Industry, Innovation & Science Christopher Pyne beating the innovation drum and calling for an awakening of STEM (science, technology, engineering and mathematics) skills in our younger generation, Craig Hingston asks: who is really listening?

Turnbull and Pyne are right in what they say. Australia needs to be known as an innovation incubator in the Global Village in order to form a competitive edge and attract premium (read: highly profitable) projects from overseas. We have almost given up manufacturing, but we can retain our creative edge if we ensure that the next intake of engineers, technicians and designers have the right expertise.

One organisation has put its heart on its sleeve – a not-for-profit organisation founded by an engineer, Dr Michael Myers OAM, who has dedicated almost two decades to pursuing his dream to see Aussie children become world-class thinkers and producers of their ideas. His Re-Engineering Australia Foundation (REA) has placed space-age technology into the hands of over 400,000 students and encouraged them to think outside the square via a series of highly competitive national programs.

True, a few large companies in the engineering-manufacturing space have stepped up and assisted REA, but we’re really talking counting the fingers on both hands. Dr Myers has presented to everyone from governments to multinationals to local companies to industry organisations. His audiences are astounded by his achievements, and that is where it stops.

So, is Australian business ready to invest in innovation?

REA has tabled two litmus tests and is waiting to see what type of response they receive from the business community.

The first is a unique once-in-a-lifetime experience for students, teachers and parents. The REA STEM World Education Tour 2016 is the result of Dr Myers “talking to his mates” around the globe and organising a treasure chest of innovation experiences.

The four-week itinerary includes visits to the Mercedes Benz and Porsche headquarters in Germany, the Large Hadron Collider in Switzerland, a Siemens wind power site in Denmark, the Hyundai Heavy Industries shipyard in South Korea, Tokyo City in Japan, and in the US, the Daimler Chrysler and Ford Design Centres, NASA Space Centre, Microsoft, Boeing, Google, Stanford University, Disney Studios, Frank Gehry Partners and the Smithsonian Institute.

Each one of these landmark technology sites is persona non grata to us common folk, yet the REA tour will go right inside and meet the people responsible for the latest advances in science, aerospace, energy and architecture. Take the Large Hadron Collider. How else is an Australian teacher or student going to witness the world’s largest, most complex experimental facility? The single largest machine in the world, it is 27km in circumference, lies up to 175m beneath the surface, and took 10,000 scientists and engineers a decade to construct.

Imagine the world view of a young person coming back from that experience.

Of course something like this costs money and this is where REA appreciates the business community stepping up to the plate. For an investment of $10,000, it can sponsor a student on that trip.

You would have to say that that same person would be an A-grade candidate as a future employee.

We often hear businesses bemoaning the fact that they cannot find young, excited, self-motivated, can-do cadets. Therefore, it makes good sense for companies to provide scholarships to these young

AMT Jun/Jul 2016

people, full of ideas and confidence, seeking to embark on the tour. Begin the partnership now by allowing the kids to experience world-best technology. Expose them to the career opportunities offered in your company, and coach them into taking the relevant undergraduate studies whilst commencing their cadetships.

Litmus test number two involves three groups of outstanding high achievers.

These high schoolers have competed in three technology competitions operated by REA: F1inSchools, Subs in Schools, and the Land Rover 4x4 Technology Challenge – global competitions involving 10,000,000 students in more than 40 countries.

As the titles suggest, the kids aged between 10-17 have designed (using NASA-type engineering and analysis software) and made operational F1 cars, submarines and off road vehicles. More than 40,000 students were engaged in these programs and Team Australia represents our brightest and best STEM students. There are 27 in total, divided into seven teams. Interestingly, one-quarter of the contingent are girls, and three of the teams are managed by girls.

These 27 teenagers, from public and private schools in four states, need financial assistance in order to demonstrate to the rest of the world that we are in fact The Clever Country.

Australia is already revered. For example, F1inSchools teams from Down Under have become World Champions a record four times and been runners-up more times than any of the other 40-plus nations. We have a reputation to uphold.

Athena, the all-girl National Champions of Subs in Schools, are heading off to the NASA Neutral Buoyancy Facility in Houston in June to participate in the Marine Advanced Technology Education ROV Competition.

Wombat Warriors from Queensland is returning to England in July for the World Finals of the 4x4 competition, where they finished second in 2015, hopeful of going one better in 2016. This time they will be joined by Zircon from Dubbo Senior College in NSW. Austin, Texas, is the scene of Team Australia’s most recent triumph when it was named 2014 World Champion. In October, Team Australia will return there with the goal of winning world title number five. Four teams are involved: Zero and Fast Payce Racing from Sydney, Terminal Velocity and Negative Filter from Victoria and South Australia.

All these students have dedicated hundreds of hours outside the classroom to get to this level. Like the STEM world tour, these young people will make champion employees over the next few years.

For businesses it becomes a very viable investment opportunity to sponsor them. A sponsorship package of as little as $5,000 (which sees the sponsor’s branding exposed multiple times before, during and after the event) is a cost-effective means of forming a partnership with a future cadet.

There we have it. Two tangible investment options with longterm benefits. REA is watching and waiting to see if the business community is asleep at the wheel, or ready to engage.

Craig Hingston is the Strategic Director of The Industrial Agency. www.industrialagency.com.au

only in Melbourne Australia’s Premier Advanced Manufacturing & Machine Tool Exhibition

Back with more great ideas and more opportunity.

9th – 12th May, 2017 • Melbourne Convention & Exhibition Centre www.amtil.com.au/austech Austech proudly owned and operated by AMTIL

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Tech News

USA: Spider robots Researchers have developed prototype spider-like robots that can work collaboratively to print structures and surfaces, thus potentially accelerating production of large-scale, complex structures such as plane fuselages ship hulls. The spiders - known as SiSpis or Siemens Spiders - are essentially fully autonomous additive manufacturing devices with legs. The key is collaboration – enabled by algorithms that allow multi-robot task planning so that two or more devices can collaborate on the additive manufacture of a single object or area. To accomplish this, the robots use onboard cameras as well as a laser scanner to work out which part of an area it can cover, while other robots use the same technique to cover adjacent areas. When its batteries are low, a spider returns to a charging station after transmitting its data to another spider that has just been charged. Each spider is equipped with an extruder similar to those on traditional 3D printers, but is currently limited to poly lactic acid.

Siemens (Princeton)

ineffective for iron and steel: at high temperature carbon interacts with these metals and gradually collapses. To resolve this, scientists developed a composite coating based on diamond and cubic boron nitride - the hardest known material. Cubic boron nitride is not destroyed by contact with iron and steel, which makes the tool almost “invincible”. “Nobody has synthesised cubic boron nitride coatings in the form of polycrystalline carbon yet. “Our coating that integrates the properties of diamond and nitride coatings, will be applicable to most metals,”- explains Stepan Linnik, a research engineer.

Tomsk Polytechnic University

USA: Tougher plastic with 50% renewables One of the drawbacks of the common ABS polymer is that it is made using petroleum. Researchers have made a better thermoplastic by replacing styrene with lignin, a brittle, rigid polymer that, with cellulose, forms the woody cell walls of plants. Thereby inventing a solvent-free production process that interconnects equal parts of nanoscale lignin dispersed in a synthetic rubber matrix to produce a meltable, mouldable, ductile material that’s at least ten times tougher than ABS. The resulting thermoplastic — called ABL for acrylonitrile, butadiene, lignin — is recyclable, as it can be melted three times and still perform well. The researchers needed to address several issues including the toughening of lignin which is a very brittle natural polymer.

Oak Ridge National Laboratory

Germany: Nanoparticles offer reliable rust protection USA: World’s largest commercial jet engine The world’s largest commercial aircraft engine – the GE9X (undergoing testing) is the most fuel-efficient jet engine GE has ever produced. It spans 3.35m – a world record - and has 3D printed fuel nozzles and the most extensive use of parts made from lightweight and ultra heat-resistant materials called ceramic matrix composites (CMCs). CMCs are inside the combustor and the turbine, allowing engineers to keep the heat higher inside the engine while reducing fuel burn and emissions. The engine also includes 16 carbon-fibre fan blades that feed air into an 11-stage high-pressure compressor with a 27:1 pressure ratio. No other commercial engine in service has a pressure ratio that’s higher. With almost 700 engines on order, the GE9X will power Boeing’s new 777X aircraft.

GE Aviation/GE Reports

Russia: “Invulnerable” coatings for cutting tools A technology has been developed to produce diamond thin films and cubic boron nitride from a gas mixture. Diamond coatings are

AMT Jun/Jul 2016

Steel plates and girders must have extensive and durable corrosion-protection. Researchers have developed a special type of flake-like zinc-phosphate nanoparticles. These nanoparticles are 10 times as long as they are thick, so the penetration of gas molecules into the metal is slowed down. The result was that the corrosion process was much slower than with coatings with spheroidal nanoparticles. In tests, steel plates were immersed both in electrolyte solutions with spheroidal nanoparticles and with flaketype nanoparticles. After just half a day, the steel plates with the spheroidal nanoparticles were showing signs of corrosion whereas the steel plates with flake-type nanoparticles were still in perfect condition and shining. The researchers created their particles using standard, commercially available zinc salts, phosphoric acid and an organic acid as a complexing agent.

Leibniz Institute for New Materials

USA: New metallic glass ‘bounces’ Engineers have generated a bulk metal glass that is unusually strong, elastic and shock- resistant. It doesn’t fracture, instead retaining most of its original strength, making it potentially useful in a variety of applications from drill bits to body armour to satellite casings. The material was produced by heating a powdered iron composite up to exactly 630 deg.C and then rapidly cooling it.

Dubbed SAM2X5-630, the new material has the highest impact resistance of any “bulk metallic glass”. What makes it special is that it’s not entirely a glass – just mostly. The exact timing and temperatures used to create it leave just a few hints of structure – which seems to be the key to its unique nature. The material was produced using a spark-plasma sintering process in which the iron compound is powdered, placed in a dye, and then zapped with a current – superheating it to the point of binding without ever liquefying it.

University of Southern California.

Tech News

USA: 3D printed robots made of both solids & liquids

UK/USA: Humanoid robot to tackle space

Researchers have presented the first-ever technique for 3D printing tiny, dynamic robots that involves printing solid and liquid materials at the same time in a single step, with no assembly required, using a commercially-available 3D printer. Researchers 3D printed a 16cm six-legged robot that can crawl via 12 hydraulic pumps embedded within its body via a single DC motor which spins a crankshaft that pumps fluid to the robot’s legs. Among the robot’s key parts are several set of “bellows” that are 3D printed directly into its body.

Aside from its motor and power supply, every component is printed in a single step. The team also 3D printed a silicone-rubber robotic hand with fluid-actuated fingers. This technique is an important step to moving from printing passive parts to printing active integrated systems.

The NASA Valkyrie is one of the most advanced humanoid robots. Initially designed to complete disasterrelief manoeuvers and in assistive manufacturing; its main goal will be deep space exploration. It was constructed by NASA-JSC in 2015 and delivered to the University of Edinburgh in March. Weighing 125 kg and 1.8m tall, Valkyrie will enable breakthroughs in humanoid control, motion planning and perception. It is battery-powered, with sensors in its head, abdomen, arms, knees and feet. It has a ‘32 degree of freedom’ body (a waist that can rotate, a head that can tilt) and ‘6 degree of freedom hands’ each with three fingers and a thumb.

NB: there’s an impressive video clip of the robot “dancing”.

MIT (CSAIL)

University of Edinburgh

Mexico: Antibacterial geopolymer

Australia: Home battery – takes on Tesla Brisbane-based Redflow has launched its 10kWh ZCell into the Australian home battery storage market. With the number of home batteries tipped to rise rapidly, the ASX-listed company is taking on global giants such as Tesla and Panasonic by launching its Australian-designed energy storage system in what is predicted to become the first mass market for battery storage in the world. A single ZCell stores enough energy to keep most homes running overnight. Unlike its competitors, the ZCell zinc bromine flow battery does not use lithium. “ZCell is primarily made of plastic, aluminium and steel, elements that are easily recycled, while its fluid electrolyte can be reused or repurposed” said Redflow Executive Chairman Simon Hackett. “ZCell lets you discharge 100% of its stored energy every day, whereas other battery types must reserve a significant amount of their storage capacity to prevent battery damage”. www.zcell.com

Australia: The world’s largest telescope Technology developed by CSIRO will be central to one of the world’s biggest science projects, following an agreement with China’s leading astronomical research organisation – NAOC. The world’s largest single dish telescope – the Five hundred metre Aperture Spherical Telescope (FAST) – has a diameter of half a kilometre and will dwarf the current largest single dish telescope - the Arecibo Observatory in Puerto Rico. It will also be one of the most sensitive..

“This is a really exciting project and builds on 40 years of CSIRO collaboration with Chinese industry and research organisations.

Most radio telescopes use receivers that can only see one piece of sky at a time, but CSIRO has designed receivers with many separate, simultaneous beams”, said CSIRO Chief Executive Dr Larry Marshall.

Researchers have developed an inorganic antibacterial geopolymer called Antibac to repel pathogens. Used as a cement, it can adhere to metal surfaces, ceramics or glass. The material lasts approx.

100 years, is resistant to acids and water, and does not discolour.

Costing less than $10 per sqm, the product can be placed on any surface, setting in just 24 hours. It consists of clay and sea sand dissolved in an aqueous solution and a biocidal agent in the form of microscopic glass particles that inhibit bacterial growth. Once solidified, it traps the antibacterial microcrystals in a “cage”. The microorganisms are then removed by existing diffusion or any simple cleaner. In traditional polymers, if someone sneezes on the surface, the bacteria remain there and can transferred. The product is environmentally friendly because only water vapour is generated during the manufacturing process.

Investigación y Desarrollo

USA: Morphing metal Imagine an aircraft that could alter its wing shape in midflight and, like a pelican, dive into the water before morphing into a submarine.

The key is a hybrid material featuring stiff metal and soft, porous rubber foam that combines the best properties of both; it also has self-healing properties. The material combines a soft alloy called Field’s metal (which contains no lead) with a porous silicone foam.

The foam is dipped into the molten metal, then placed in a vacuum so that the air in the foam’s pores is removed and replaced by the alloy. The foam can be tuned to create a stiffer or a more flexible material. In testing of its strength and elasticity, the material showed an ability to deform when heated, regain rigidity when cooled, then return to its original shape and strength when reheated. In addition to a morphing-wing application, this material could be used in soft robots that must negotiate tight spaces.

Cornell University

“All you have to do is stick in a battery and motor, and you have a robot that can practically walk right out of the printer”.

MIT’s Computer Science and Artificial Intelligence Laboratory Director - Daniela Rus – on the first-ever technique for 3D printing dynamic robots. This technique enables printing solid and liquid materials at the same time in a single step.

CSIRO

AMT Jun/Jul 2016

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036

product news

Universal 3D metrology workflow

InnovMetric Software has launched PolyWorks 2016, the latest release of its universal 3D metrology platform.

PolyWorks 2016 fully supports probing and laser scanning on stationary CNC co-ordinate measuring machines (CMMs), and delivers a truly universal 3D metrology workflow that will allow users to operate any type of portable metrology and CNC CMM measurement device within a common framework, from a single software module, and using similar tools and methods.

the Play Inspection tool that automatically generates a step-by-step guided measurement sequence to capture 3D datasets of a new piece using portable metrology devices. PolyWorks 2016 expands the capabilities of the Play Inspection technology by allowing the customisation of its automatically generated sequence. Using the new sequence editor, users can now:

“Portable metrology and CNC CMM metrology devices used to be operated in very different ways,” said Marc Soucy, President of InnovMetric. “Offline CMM programming and online CNC measurements were traditionally performed in different modules using different tool sets. This time is now over. With PolyWorks 2016, the definition of what constitutes a universal platform takes on an entirely new meaning: a universal hub that interfaces with any type of 3D metrology measurement device, and offers a universal workflow for performing all inspection tasks. This innovative endto-end approach will significantly lower the total cost of software ownership for industrial manufacturers as it eliminates metrology workflow silos, decreases the cost of training, facilitates broader collaboration between teams, ensures consistency in measurement results, and increases workforce mobility.”

• Configure the order of measurement operations.

With PolyWorks 2016, portable metrology and CNC CMM operators are now able to: • Define a measurement plan without being physically connected to a specific measurement device.

• Specify geometry controls on measurement objects and prepare inspection reports.

• Connect to a non-contact or a contact-based portable metrology device, or to a CNC CMM controller (from Hexagon, Mitutoyo, Nikon, Pantec, Wenzel, and I++ servers), to play the measurement sequence.

• Review measured object geometry controls and reports, or multipiece inspection results through built-in SPC functionality.

Operating portable metrology and CNC CMM devices within a common framework is now possible with the introduction of two new major components in PolyWorks 2016: the measurement sequence editor and the offline simulation. Since 2012, PolyWorks has offered

• Control device position moves.

• Trigger CMM-specific operations, such as moving the probe head to a specific location or changing the orientation of a measurement tool.

• Easily add guidance messages and images.

• Create conditional blocks of operations.

• Insert macro scripts, opening up unlimited process customisation possibilities.

PolyWorks 2016 also delivers a new easy-to-use offline simulation functionality that automatically generates simulated point cloud data and probed points from a CAD model of the measured part, while going through a simulated measurement workflow. Offline simulation allows users to quickly create simulated measured object components, Data alignments, Data color maps, geometry control tables, 3D scene snapshots, and inspection reports before the real measurement task, without needing access to a measurement device. The PolyWorks 2016 offline simulation also fully supports CNC CMMs, allowing users to control the probing and laser scanning tool orientations and trajectories on a virtual device.

Thanks to the universal 3D metrology architecture of PolyWorks 2016, only minimal changes will need to be made to a PolyWorks inspection project so that it can be used with multiple hardware platforms to optimise object measurement methodologies and adapt them to different measurement principles. As a result, PolyWorks 2016 opens a new era for universal inspection projects and device interoperability, ensuring total flexibility for customers to select the appropriate measurement devices for their needs and maximise the return on their 3D metrology investments. www.hitechmetrology.com.au

Direct clamping on the micro-scale

Mapal has expanded its programme of narrow contour HTC clamping chucks, whose narrow shapes are produced without a restrictive brazed joint thanks to additive manufacturing.

These new chucks can directly clamp diameters of 3mm, 4mm and 5mm, now also allowing hydraulic clamping chucks to be used on the micro-scale, for example in medical technology or the timepiece and jewellery industry. Until now, reduction sleeves were usually required to clamp diameters below 6mm: with the new chuck, these are no longer needed. Moreover, the advantages of combining hydraulic clamping technology with the contour of a narrow shrink chuck can now also be enjoyed on the microscale. Like its counterpart for diameters above 6mm, the new HTC is made using additive manufacturing. The reason: as of yet, it has not been possible to produce either the narrow contour or diameters of 6mm or less for direct-clamping hydraulic clamping chucks using conventional manufacturing methods.

The clamping area is very close to the front of the chuck, which is not possible in conventional manufacturing. This provides an ideal concentricity of below 3 microns at the locating bore and below 5

AMT Jun/Jul 2016

microns at 2.5 x diameter, plus high geometrical accuracy along with good vibration damping. The damping built into the system reduces micro-outbreaks at the cutting edge, giving the tool a longer life expectancy and reducing wear on the machine spindle.

The HTC with a narrow contour offers all the advantages of the proven Mapal HTC (High Torque Chuck) technology, with the “T” standing not only for “torque” but also for “temperatureresistance”. The wide operating temperature range of up to 170 deg.Celsius ensures additional process reliability. The balancing quality is G = 2.5 at a turning speed of 25,000 min-1. The chuck is suitable for all machining in contour-critical areas. It allows the tool to be clamped easily and quickly. In other words, no training courses are required on its implementation, and no high set-up costs or expensive peripheral devices are needed. www.mapal.com.au

FACTORY TRAINED SALES & SERVICE STAFF FOR MITSUBISHI LASER.

Applied Machinery, one of Australia’s largest and most respected Dealers of new and used machinery is proud to be the authorised sales and service representative of Mitsubishi Laser in Australia.

Proof of Applied’s commitment to the brand is evidenced by a sales and service delegation that has just returned from Japan after intensive training at the Mitsubishi plant in Nagoya.

Applied’s team of laser sales and service experts are now fully factory trained

by Mitsubishi, so you can rest assured that when investing in Mitsubishi you have the local knowledge and support required to ensure that your transition to Mitsubishi is seamless.

Following on from this factory visit, one of Applied’s key customers who also made the trip to Japan placed an order for a Mitsubishi ML-3015 45CFR. If you’re considering upgrading your current laser, or adding laser processing to your production capabilities, Mitsubishi Laser will be an exceptional choice for your organisation.

Featuring laser power up to 6kW and sheet capacities up to 6000 x 3000mm, there’s a Mitsubishi laser for practically all applications.

NOW THAT’S APPLIED THINKING.

To find out more: Call: 03 9706 8066 YOUTUBE LOGO SPECS Email: sales@appliedmachinery.com.au PRINT on light backgrounds Visit: www.appliedmachinery.com.au main red

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product news

Titespot helps manufacturer out of tight spot Dimac Tooling is the exclusive agent for Eltool products and its range of Titespot angle heads.

For over 15 years Titespot angle heads have offered a cost-effective alternative to electrical discharge machining (EDM) and mechanically driven angle heads, particularly where multiposition radial machining and/or machining in small bores or cavities is required. Because spindle rotation is not required to power the angle head, the machine spindle becomes an indexer, allowing multiposition machining with one head and one set-up.

The smallest head in the range can machine radially in bores down to 15.9mm in diameter.

Recently, US-based CNC manufacturer Antron Engineering and Machine Co. came upon the challenge of milling a long interrupted slot in a smalldiameter bore for a prototype part. To further complicate things, they had to effectively and consistently machine features in a cylinder housing made of 7075 aluminium. The component was part of a pump unit that runs the hydraulics for the controls and engine in an aircraft – a crucial component that could not afford to fail.

The only option initially appeared to be planing or building a motorised head that powered a gear-driven tool and fit that into the machine tool spindle – not an ideal solution due to cost and question marks over its effectiveness and accuracy. After looking at other options, the company came across Eltool’s Titespot range, which relies on high-pressure coolant to drive an integral, positivedisplacement ball piston motor.

The motor powers a drive shaft, which in turn drives the head’s spindle while exhausted coolant is directed at and through the cutting tool. Because the angle head has its own power, a machine

spindle can function as an indexer allowing multiple-position machining with one head and set-up.

The product appeared to be the solution that Antron was looking for, so a Titespot angle head was purchased. It has performed perfectly, producing the required part in a short timeframe with absolute precision. A company spokesman said that not only had it provided significant cost savings, but crucially it provided process certainty – instead of 100% of the time not knowing if the machined part would be good or bad.

“Quite literally, Titespot angle heads can get manufacturers out of a tight spot when it comes to costeffective and accurate machining where multi-position radial machining and/or machining in small bores or cavities is required,” Dimac’s Managing Director Paul Fowler said. “The other major benefit is that we are confident the Titespot angle head will be able to be utilised for other jobs. You don’t need to purchase a completely new angle head for different applications. Instead you can buy a different drive shaft and tool assembly for about half the cost because the hydraulically powered motor is universal for all the different attachments.”

Dimac has more than 30 years experience in CNC machine tool accessories and are agents for brands such as Kitagawa, Cooljet, Reven and Eron. The company also manufactures soft and hard jaws in its own CNC-equipped machine shop.

“Like all the products we sell, Eltool Titespot angle heads are supported by the full back-up and support of Dimac technical personnel to ensure the right product is specified and operates at optimum performance,” Fowler concluded. www.dimac.com.au

AWISA 2016 – Set for Melbourne

AWISA 2016, Australia’s biggest ever trade show of machinery, materials and fittings for the woodworking and related industries, will take place at the Melbourne Convention & Exhibition Centre from 6-9 July.

The event, organised by the Australian Woodworking Industry Suppliers Association Ltd, is the largest AWISA show ever and occupies 20,000sqm of the venue. With extraordinary support from the major machinery and hardware companies, it is already a sold-out success. With the show being the biggest ever, the scale of some of the individual exhibits is also the biggest ever.

AWISA 2016 is not just a woodworking show. Much of the machinery on display is capable of processing aluminium and other non-ferrous metals, plastics, composite materials such as Alucobond, and in some cases even stone and glass.

The exhibition is the must-see event for everyone in woodworking and related industries and professions. Shop and office fitters, furniture manufacturers, cabinet makers, kitchen manufacturers, joinery manufacturers, architects, designers, builders, and other wood,

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timber, aluminium, plastics and panel processing industries are welcome to attend. AWISA 2016 is a trade-only exhibition; admission is free. AWISA’s website features extensive information about visiting the show, including links for hotel accommodation and for visitor pre-

registration. AWISA is running shuttle buses from Melbourne airport to the venue on show days. All visitors are asked to register. Visitors can register at the counters in the foyer prior to admission, but is it preferred that they pre-register online. www.awisa.com

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product news

HySpex – Hyperspectral imaging cameras Available in Australia through Raymax Lasers, the Hyspex range of hyperspectral cameras are robust, compact, highperformance and versatile instruments for a multitude of applications.

Hyperspectral imaging, or imaging spectroscopy, combines the power of digital imaging and spectroscopy. Put simply, for every pixel in an image, a hyperspectral camera acquires the light intensity (radiance) for a large number of contiguous spectral bands. Every spatial pixel in the image contains a continuous spectrum (in radiance or reflectance), which can be used to characterise the objects in the scene with great precision and detail.

Utilising a cutting-edge, actively cooled and stabilised scientific CMOS detector, the HySpex VNIR-1800 is ideal for high-end data acquisitions where high radiometric accuracy is required. The dynamic range of 20,000 ensures outstanding SNR levels even in darker areas of the image of highly dynamic scenes. With a maximum frame rate of 260fps, combined with aberration-corrected optics and high optical throughput (f/2.5), the VNIR-1800 offers a unique combination of data quality, high speed and sensitivity.

A wide range of close-up lenses allows the use of the camera at working distances ranging from a few cm with a spatial resolution of 24 microns, to infinity for example - airborne remote sensing.

The new HySpex SWIR-384 hyperspectral camera from NEO, is developed for field, laboratory, airborne and industrial applications.

The new MCT sensor with cooling down to 150K, affords low background noise, high dynamic range and exceptional SNR levels.

With a max frame rate of 400 fps, combined with an aberrationcorrected optical system with high optical throughput (f/2), the data quality, speed and sensitivity is truly state-of-the-art. A wide range of close-up lenses allows the use of the camera at working distances ranging from a few cm with a spatial resolution of 53 microns to infinity for e.g. airborne remote sensing.

HySpex ODIN-1024 is a next-generation state-of the-art airborne hyperspectral imager, covering the spectral range from 4002,500nm. Perfect co-registration between 1024 spatial pixels for VNIR and SWIR is achieved by employing a novel common fore-optics design. Along with the extreme resolution, the unique design provides high sensitivity and low noise, low spatial and spectral miss-registration (smile and keystone). With supreme data quality, HySpex ODIN-1024 includes real-time data processing functionalities such as real-time geo-referencing of acquired images.

It also features built-in on-board calibration system to monitor the stability of the instrument. www.raymax.com.au

Viper Plus and INOX: Class-leaders from Sutton New market-exclusive drill bit technology and application design has been used in Sutton Tools’ recently released Viper Plus and INOX drill bits, providing proven unrivalled performance when drilling into stainless steel.

The Viper Plus is a premium multipurpose drill bit catering for handheld drilling applications, while the INOX specialises in machine drilling of stainless steel thanks to a combination of features unique to the Australian market. Prior to their release, both the Viper Plus and INOX drill bits were independently tested on computerised (CNC) machines in identical conditions, including application material, downward pressure and drilling speed.

Results from CNC testing found 6mm Viper Plus drill bits saw a 45% increase in productivity (time taken to drill 100 holes) and double the tool life compared with other similarly priced and positioned competitor drill bits. Further CNC testing on 6mm INOX drill bits found they are 42% more productive and will last 70% longer than Sutton Blue Bullet HSS drill bits, for a price premium of only 30%.

“It’s a huge saving because it means increased productivity and less downtime changing the tool or heading off mid-job to buy a new tool,” said Sutton Tools technical manager, Jeff Boyd. “You’re getting around twice the lifespan for only 30% more money.”

The impressive performances are a result of world-leading ‘TiAlN Futura-Nano’ coatings combined with the latest design

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technology and the use of premium European High Speed Steel (HSS). “TiAIN Futura-Nano is a wear-resistant coating, which is a thin film applied to the cutting edges that keeps them sharp longer due to its wear resistant properties,” Boyd said.

The design and European HSS used in the Viper Plus and INOX drill bits are integral to their class-leading performances, while quality control is enhanced by being made at the Sutton Tools factory. In the Viper Plus, the 118-degree split point tip provides easier steel penetration while a 30-degree helix means the bits works well across a range of applications.

In the INOX, a 40-degree flute helix angle provides a higher cutting angle than is standard, which serves to reduce friction and therefore heat build-up. Furthermore, a shorter flute means the INOX construction is more rigid, allowing users to push the drill harder or increase the feed to maintain a higher chip thickness.

The unique point and stepped core design allows superb penetration and minimal work hardening.

It is INOX’s unique-to-market combination of a 40-degree helix, TiAlN Futura-Nano coating and shorter flute that enables its classleading performance when machine drilling into stainless steel. www.suttontools.com

Product news

Going vertical boosts efficiency

Amid rising real estate prices and limited space in built-up areas, finding the right solution to store products can be difficult. System Control Engineering had to grapple with this scenario, until it realised the benefits of going vertical.

System Control prides itself on supplying popular brands to customers throughout Australia. With close to 50 years in the industry, this family business distributes plumbing and gas supply parts and equipment to well-known businesses like Reece, Tradelink and more. Scott Rimes, General Manager at System Control, says the company focuses heavily on supplying the very best brands.

“Product quality and branding is important to us,” says Rimes.

“That’s why we chose Hanel – because it’s a reputable German brand.” As a wholesaler and distributor, System Control became concerned about space in its warehouse, in Blackburn, Victoria.

According to Rimes, “it was either relocate or go vertical”.

“We decided to implement a vertical storage system because we were limited with space,” he says.

“What’s great about Hanel is its ability to save space on our factory floor. The fact that we don’t have to use a forklift anymore is great, it means we can operate the machinery and pick our items in a safer way.”

Hanel vertical storage is renowned for its warehouse storage systems. They are high-tech, organisational systems that save time and costs. Some of the benefits Hanel vertical storage has provided System Control include: • Floor space savings of up to 80% by utilising room height.

• Ergonomic retrieval processes, bringing the item to reach level.

• Ability to expand and alter storage capacity at any time.

• Increased productivity.

• Increased product security and reductions in stock loss.

Noticeable improvements in pick speeds have also been seen at System Control, with Rimes estimating an increase of about 30%.

Another great benefit is a reduction in dust in the warehouse compared to older methods of racking.

“All items that come out of the Hanel are dust free,” says Rimes.

“Our older racking methods meant all of our products were out in the open and most of the time they would be covered in dust.”

Alan Barratt, General Manager of Storage at Headland Machinery, says working with System Control and providing them with the right solution for its needs has been fantastic.

“Hanel has been around for close to 60 years, so to be able to provide the company with technology that is reliable and has the benefits of saving space is great,” says Barratt. “System Control has been able to achieve its goal of increasing productivity because of the efficiency of the storage system.” www.systemcontrol.com.au www.headland.com.au

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product news

Laser surface texturing with Laserdyne

Laser surface texturing with the Laserdyne 795 and 430 BeamDirector is an important process capability of these flexible, precision 3D laser processing systems. With the precision and flexibility of these systems, texturing is accurate and easy to perform.

Laser texturing with a Laserdyne system is effectively another type of laser drilling process that involves producing “blind”, or partial depth, holes and indentations from a few micrometres to a few tenths of millimetre in depth. This process is currently used to form precise and detailed textures on the surface of metals.

For this reason, the use of laser for texturing is rapidly growing in automotive, medical device and mould-making industries, to name a few. In many applications, the laser surface texturing process is becoming an integral part of the product design process.

A unique feature of Laserdyne laser texturing is that it is particularly well suited to three-dimensional surfaces. Programming and process development are simplified with features of the Laserdyne S94P Laser Process Control such as CylPerf Cylinder Perforation Programming and Process Control and LinPerf Linear Perforation Programming and Process Control. Both CylPerf and LinPerf provide an easy way to program and visualise macro programming blocks that create complex rows of features on cylindrical and flat surfaces, respectively.

On-the-fly processing is well-proven for drilling small-diameter holes and features that create unique textures. The process makes use of the latest fibre laser technology and advanced control of laser parameters through the Laserdyne S94P and can be applied to virtually all metals and alloys, including mould steel, stainless steel, and titanium, as well as plastics that absorb the laser beam.

The capability of 3D laser texturing is based on the same characteristics of laser processing as for other applications. For example, compared to mechanical processes, laser texturing

Laser texturing can create patterns based on blind holes from a few micrometres to a few tenths of millimetre diameter and depth.

does not require specialised tools (drills) and involves no tool wear or breakage. The ability to focus the beam to small diameters creates the possibility for smaller features than can be produced mechanically.

Laser texturing does not involve toxic or corrosive chemicals used in the chemical etching process. Also, laser texturing does not require tooling (artwork) to define the pattern because the texture detail is created by the laser beam. An additional benefit of Laserdyne laser texturing using the 795 and 430BD systems is that these systems are capable of precise, high-speed cutting, welding and drilling.

These capabilities – all in one machine with the appropriate laser source – can reduce part handling, simplify operation, and save capital expense and floor space required for machines dedicated to a single process. www.imts.com.au

Kaeser launches next-gen Mobilair 57 Utility

Kaeser has launched its latest generation M57 Utility portable compressor. Compact, convenient and costeffective, the M57 Utility is now configured for even greater flexibility thanks to a number of new design features.

The latest generation M57 Utility retains all the popular features of the original series, including its compact size – crucial for truck-mounting, upward expelling exhaust gas outlet and allround intelligent design. The unit is configured as standard for an impressive temperature range from -10 to +50 degrees Celsius, whilst a version designed for even lower ambient temperatures is offered with pre-warming of the motor cooling water. In addition to the proven and renowned 7-bar version, which up until now delivered 5.4 cubic metres/min, a new model with a flow rate of 4.7 cubic metres /min at 10-bar maximum pressure is now available and ideal for applications such as sand-blasting. With the intelligent Sigma Control Smart (SCM) controller fitted as standard, pressure can be reduced down to 5 bar in precise 0.1 bar increments for perfect adjustment to onsite conditions. The appropriate pressure setting helps protect, for example hammer drills that operate at 6 bar for optimum performance, from wear. The colour display provides a convenient overview of all operating parameters, alarm notifications and upcoming required maintenance. Motor start-up is made easy with just the push of a button.

The service-friendliness of the Mobilair series has always been a key characteristic of all models in the range and this has never

AMT Jun/Jul 2016

been truer than with the compact M57 Utility.

The unit is designed in such a way that all maintenance points are easily accessible from the cargo bed side once the panels have been removed. Fuelling is performed from the front side. Operating fluids and liquids can be easily drained via externally mounted service connections without having to hoist up or lift the compressor unit. Also noticeable are the low-positioned compressed air take-off taps and the metal cover protected operating panel. This attention to detail makes operation especially easy, particularly when the unit is installed on a truck cargo bed. Furthermore, in combination with an integrated tool lubricator, the patented Anti-Frost control protects connected tools from potential damage caused by freezing and corrosion. For even higher compressed air quality requirements, the M57 Utility can be optionally equipped with a compressed air aftercooler.

The premium quality Kaeser rotary screw compressor block with Sigma Profile rotors is directly driven without transmission loss by an energy-saving Kubota diesel engine. Moreover, with its integrated fuel tank, the M57 is able to ensure over 10 hours of uninterrupted operation. The Mobilair M 57 Utility portable compressor from Kaeser is available in two pressure stages 7 bar (5.4 m3/min) and 10 bar (4.7 m3/min). www.kaeser.com.au

Product news

Moulding hard-to-cut materials by chasing with New Line

TaeguTec has launched two new five-cutting edge insert lines – RTMX and RTHX – with related cutters specifically dedicated for stainless steel and difficult-to-cut materials used in the aerospace, oil and gas and power generation industries, among others.

ChaseMold’s RTMX and RTHX inserts including the line’s optimal cutter design were born through rigorous trial and error as well as performance testing in order to attain excellent performance in stainless steel, difficult-to-cut materials and turbine blade machining under severe machining conditions and in unstable fixtures. The RTMX is a press-to-size type line for economy, while the RTHX ground type is dedicated towards high-precision machining, with both lines offering a high positive rake angle for low cutting resistance.

Both inserts come in 10mm and 12m sizes and their chip formers are available in three types: MM, ML and MLL. The MM chip former is recommended for unstable conditions, the MLL for stable conditions and the ML covers the middle range between the MM and MLL types. Furthermore, both lines are available in standard and special grades; the special grades are made for any machining environment, even under harsh conditions due to their high wear resistance and toughness capabilities.

Cutters are available in end mills (ø32mm), modular types (ø2540mm) as well as face mills (ø40-80mm) and all are coolant-

BAC releases special storage systems for Volvo Cars BAC Systems has released the BAC Volvo Special Tools Modules – a dedicated storage solution for the Volvosupplied special tools mandatory for Volvo-franchised service operations.

The system was recently introduced into the Volvo Car Australia training facility operated by Vantage Automotive.

Trainer Assessor, Jeremy Wilkins, has smoothly transitioned his special tools from the previously used peg-board to the new BAC Volvo Special Tools Modules. “Drawers run well and hold everything I need,” said Wilkins. “It’s easy to find tools, and the drawers and the cupboards all run fine.

And mate, they’re strong!”

The system uses partitioned drawers to provide a unique storage location for each individual tool. The system is clean and the tools are easily found. The cabinets are supplied in the appropriate Volvo colour and look impressive in a line along any workshop wall.

capable for easy chip evacuation.

During the product testing simulating real-world conditions, TaeguTec’s new ChaseMold lines achieved higher tool life and productivity than the competitors’ similar offering.

For tool life during the roughing operation of the airfoil, shroud and the root part of a blade component made from martensitic stainless steel (X20Cr13, AISI 420), TaeguTec’s new five-tooth RTMX line outlasted a leading competitor’s tool by 65%, while on a blade shroud and root roughing operation made from stainless steel (1.4923), the same RTMX line increased tool life by almost 30%.

In another test that emulated real-world machining conditions, TaeguTec’s RTMX completely increased tool life by 100% while performing a spiral roughing operation on the blade’s airfoil part of the component made from alloy special martensitic creep-resisting steel (1.4938 + QT, X12CrNiMoV12-3). With regard to productivity, TaeguTec’s tests using the ChaseMold RTMX line on an aerospace engine case made from Waspaloy and Inconel 718 increased productivity by 65% on a leading competitor’s similar offering. www.taegutec.com

Awards win for Okuma MU-4000-L Okuma’s Universal Center MU-4000V-L five-axis vertical machining centre has received one of the 2015 Best 10 New Product Awards from Nikkan Kogyo Shimbun (Business & Technology Daily News) in Japan.

The Best 10 New Product Awards are given to selected products for their contributions to the development of manufacturing and the strengthening of Japan’s international competitiveness. Winners are chosen from among all products developed and in practical use in a given year. This is Okuma’s twelfth product to receive a Best 10 New Product Award.

The MU-4000V-L completely integrates turning, grinding, and gear cutting in high-speed, high-accuracy five-axis machining. It is a fiveaxis machining centre that is ready for the age of the Internet of Things (IoT). Boasting features such as high-dimensional, processintensive machining with a high-speed, high output spindle, turning capacity equivalent to that of a medium-sized lathe, grinding, gear skiving and more, the machine offers shorter lead times in the machining of complex shapes.

BAC Systems accompanies its cabinets with a catalogue of tool locations. This makes it simple for users to set up and maintain their tool locations. The catalogue is in the form of a spreadsheet so it is easy to update with the release of new tools.

The MU-4000V-L is equipped with the OSP-suite Monozukuri controller that leads the IoT age. In addition to co-ordination with production control systems and CAM simulators, it records information including the load, vibration, and pressure on each axis with a “monitoring function” that visualises and logs utilisation status, as well as flow sensor signals and worker operation information. This makes it possible to track and analyse production processes.

www.bacsystems.com.au

www.okumaaustralia.com.au

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Mining & Resources

Breaking

New Ground

Australia’s mining boom may be over, but Australian manufacturers and innovators are still making their mark on the industry globally. By William Poole.

Mining, so long a key driver of Australia’s economic prosperity, has hit a slow patch. The boom of the 2000s is long passed. Following a wave of investment in construction and equipment, the industry has entered a production and sustainment phase, employing fewer workers and spending less. In 2014-15, revenue and exports both dropped substantially, as increased production resulted in global oversupply and depressed commodity prices.

Energy Quarterly for the March Quarter, Australia’s resources and energy sector enjoys broadly positive prospects in the medium-tolong term. Earnings from exports are forecast to decline by 7% to $160bn in 2015-16, but will average annual growth of 3% to 20202021, reaching $208bn in real terms. Although challenging market conditions are likely to persist in the short term, consumption of most commodities is projected to increase as Asian economies urbanise.

However, grounds for optimism remain. According to the Department of Industry, Innovation and Science’s Resources and

The post-boom years have to some degree forced Australian mining to up its game. Mining companies and manufacturers supplying

AMT Jun/Jul 2016

Mining & Resources

them have had to focus on efficiency, productivity and innovation.

Through measures such as increased automation, costs at some Australian thermal coal sites were halved from 2010-15, while labour productivity for the sector rose 33% in the last two financial years.

Nonetheless, the report stresses a need to find further ways to innovate and improve efficiency.

“Australian producers have in the past demonstrated their ability to respond to changing market dynamics,” says Mark Cully, Chief Economist at the Department. “They will need to continue doing so to ensure they remain competitive in what is expected to be an often volatile market.”

industries. Korvest’s Managing Director Alexander Kachellek believes this diversity is key to its strength.

“If you’re only in METS, when the mining is great, sales are great; when the mining is down, sales are down,” he explains. “To me it’s important that a business has a diverse product range or a diverse customer range. Businesses have to look at their internal capabilities and grow them, to safeguard against shocks.”

The company has four key divisions: Korvest Galvanisers, its core galvanising business; EzyStrut, Australia’s market leader in cable and pipe support solutions; PowerStep, which makes safety access systems for large mobile equipment; and Titan Technologies, which provides bolting solutions.

Korvest – Strength through diversification One company that has shown its ability to adapt is Korvest, based in Adelaide. The company actually began life as a goldmine, KiaOra Investments, which was ASX-listed in 1970. However, goldmining soon hit a downturn, so instead the company invested in a galvanising plant. Over the subsequent decades it bought and sold various businesses within the sheet metal and galvanising segments.

Today Korvest employs around 275 people including around 160 manufacturing personnel, with its headquarters and manufacturing plant in Adelaide, and sales and distribution offices nationwide.

In keeping with its gold-mining origins, the company remains significantly involved in the mining equipment, technology and services (METS) sector, but also operates across various other

All four divisions have some exposure to the mining and resources industries, but are also active in other fields. The galvanising business services clients across the structural steel industry in South Australia, Titan Tools has provided solutions in areas such as wind power and rail transport, while EzyStrut’s products are sold into all types of non-residential construction, including hospitals, power stations and commercial utilities. Even PowerStep, the division closest to a true METS business, is pursuing fresh prospects. Initially it operated entirely in mining, producing retractable step systems for installation on the big trucks and draglines utilised in the sector. However, it is now targeting markets such as rail and shipping.

Continued next page

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Mining & Resources Laureate Professor Graeme Jameson.

A Hitachi EX5500 excavator fitted with Power Step access system.

Contined from previous page

Due to the nature of the Australian economy and markets, and its small population, Korvest’s businesses tend towards lowvolume, small batches, with the company providing specialist Korvest services to meet specific Managing customer demands. Kachellek Director regards this as where Australian Alexander manufacturing overall should be Kachellek. heading, rather than trying to compete with low-cost nations in high-volume production.

“The next trick is how you make lots of small bubbles” he explains.

“A billion a second, on a very big scale, with equipment that’s lowmaintenance, won’t block up and performs well? That’s the task I set myself. I came up with a simple way of doing it. That’s what the Jameson Cell does.”

Jameson likens the process to when you wash your car: get a bucket with detergent in it, squirt water in from a garden hose, and you end up with a bucket of froth. However, his solution is somewhat more sophisticated, using a high-speed jet to produce bubbles with a diameter of 300-500 microns. Compared with more conventional processes, the Jameson Cell offers increased throughput while using less energy and taking up less space, and it can also much finer, higher-grade particles.

“Our focus here should be on bespoke, custom things that our expertise and our intellect or knowledge enable us to do,” he says.

“That is also more difficult for Asian volume-producers; they don’t want to be bothered with specials and one-offs. They find them difficult and costly to do. They’re not set up to do that.”

First installed in 1989, the Jameson Cell has been installed in 26 countries, with over 300 machines now operating at mines worldwide. Other applications have also been found, in the manufacture of everything from aluminium cans to ice cream, as well as the environmental clean-up of polluted waterways.

Alongside his role at Korvest, Kachellek is also Chairman of Austmine, the industry body for the METS sector in Australia. As such, he can speak with some credibility about the sector’s outlook.

Despite the recent downturn, he believes Australian manufacturers are well placed for the future.

“The biggest benefit to Australia has been in the coal industry, where it’s been used to recover very fine coal which would otherwise have gone to waste,” says Jameson. “The exports to date have brought in about $36bn to the economy, which is a lot of money. It’s been a big success and I’m very proud of that.”

“Mining 100 years ago used shovels and the wheelbarrow. We still use shovels and a wheelbarrow, just bigger!” says Kachellek. “I think this is where the Australian METS sector plays a part, because we do have innovative companies. We have the brains to think laterally.

The climate that we’re in now, it’s pushed the industry to think harder and come up with new ways of doing things. We’re seeing that.”

The Jameson Cell is a rare case of an Australian innovation effectively commercialised here, rather than the intellectual property going overseas. Jameson says he was very fortunate in finding the right partners to help develop his ideas.

Bubbles of inspiration When Kachellek talks about Australia having ‘the brains to think laterally’, he could probably find few better examples than Laureate Professor Graeme Jameson, the Director of the Centre for Multiphase Processes at the University of Newcastle. Last September, Jameson was awarded the inaugural Prime Minister’s $250,000 Prize for Innovation for his pioneering work on the Jameson Cell.

“It was a great thrill,” says Jameson. “It’s wonderful to see your work recognised after many, many years. The fact is you don’t work to get prizes, you do it because you like it and you’re looking for some sort of fulfilment in the work itself. But when you do get public recognition, it’s a great thrill.”

Invented in the 1980s, the Jameson Cell employs a floatation process to draw valuable minerals from raw ore. The ore is ground into small particles and suspended in water. Air bubbles are passed through the suspension, carrying reagents that make the valuable particles stick to them, forming a mineral-rich froth that can then be skimmed off the surface. Other flotation techniques exist, but Jameson recognised that the efficiency of the process lay in the size of the bubbles.

AMT Jun/Jul 2016

“Mount Isa Mines in Queensland had an unusual ore body which couldn’t be separated by normal means, so they became interested in what I was doing,” he recounts. “I was able to try my ideas in their plant, they worked, and Mount Isa Mines put a young metallurgist on it for a year to try out the machine in a concentrator and develop scale-up rules, that were very simple. It really took off from there.

Jameson says those opportunities don’t really exist anymore as mining companies have cut back on investment in research and innovation, and he believes Government could help: “Nobody will take on an invention unless it’s been developed to a stage where it’s been demonstrated at a realistic scale. There’s an old saying: the one-ten-100 rule. It takes $1 to make a discovery, $10 to develop it to the point of commercial take-off, and $100 to actually commercialise it. It’s the $10 part we lack. And that’s where Governments can step in.”

The Jameson Cell essentially comprises two elements: a large metal tank in which the process takes place; and the machinery that carries it out. The latter, more high-value components are produced in Australia, while the tank is produced in the location where the machine will operate. Jameson believes this is a good model for Australian manufacturing.

“It’s much cheaper to build a tank where the mine is, so if it’s in South America, the tank would be mostly fabricated locally. Those

Mining & Resources

A Jameson Cell in operation.

Elphinstone and Caterpillar have built more than 5,000 underground mining trucks and loaders in Burnie over the past 40 years.

things can be done more cheaply elsewhere. Where the future lies is in added value.”

Elphinstone grew steadily, and in 1987 it purchased William Adams, the Cat dealership for Victoria and Tasmania. In 2001, Caterpillar bought the remaining 50% of Elphinstone’s underground mining manufacturing business, and while the products were eventually rebranded Caterpillar, they continued to be manufactured in Burnie right up until the end of 2015.

Despite his achievements, Jameson is not sitting back and polishing his awards. His latest project is the NovaCell. Named in honour of his home town Newcastle, the NovaCell is a fluidised bed froth flotation cell that can efficiently capture larger particles, meaning ore doesn’t have to be ground so finely. This would bring major savings in terms of energy as well as the cost of the wear parts.

“But the real benefit comes by being able to reject most of the waste material early in the process, he adds. “It’s taken me a while to understand the process properly and to develop the design criteria, but I’m at the point where I’ll be looking for an industry partner to develop the idea. I’m pretty sure it will happen in the next year.”

Another prize from the Prime Minister could be pending.

Elphinstone – Putting its name on the line While the recent mining downturn might make some manufacturers wary of the sector, one iconic Tasmanian company is actively increasing its involvement, and putting its name behind it. Based on the north-west coast of Tasmania, the Elphinstone Group recently announced its return to the underground mining industry, manufacturing specialised support equipment using major Caterpillar components under the Elphinstone brand.

The move has resulted in Haulmax, an Elphinstone Group subsidiary that builds extended-distance off highway haul-trucks and technologically advanced road-rail excavators, adopt the Elphinstone Pty Ltd name. Elphinstone is also in the process of acquiring local underground equipment manufacturer Specialised Vehicle Solutions (SVS).

Although in part expedited by US machinery giant Caterpillar’s decision to relocate its Burnie-based manufacturing operations to Thailand at the end of 2015, the Elphinstone Group had somewhat been expecting this transition. Zak Brakey, Elphinstone’s Sales & Marketing Manager, is bullish about the prospects.

“The Elphinstone group has been manufacturing mining products in Tasmania for over 30 years, and successfully exporting these products all over the world,” he says. “What we’re finding is, in a low-commodity-price environment, our customers are very much focused on reducing costs. Miners are willing to spend money on products and new technologies that improve efficiency, increase productivity and reduce their operating costs”.

Dale Elphinstone started his business in 1977, modifying Caterpillar equipment to work underground, and the relationship between the two companies would prove pivotal in Elphinstone’s evolution.

The company went on to design and manufacture its own range of underground LHD’s and trucks, using Caterpillar major components that were sold and supported via Caterpillar’s global dealer network.

Throughout this time, Burnie has become somewhat of a centre of excellence in the manufacture of specialised mining equipment.

Haulmax was originally based in Brisbane, before its founders made the decision to move to Tasmania taking advantage of a skilled local workforce and state-of-the-art manufacturing facilities, Haulmax became a 100%-owned subsidiary of the Elphinstone Group in December 2014. SVS, meanwhile, was founded by two former Elphinstone employees in 2009, who have been successfully designing, manufacturing and supplying underground support vehicles to the global market.

Elphinstone Pty Ltd is genuinely committed to the North West Coast of Tasmania, the region that has been its home for almost four decades. To maintain operations in a relatively high-wage location, the company has had to embrace and foster a lean manufacturing culture, in terms of both technology (such as a vertical lift for storing components) and ongoing employee training – all manufacturing staff have undertaken their Certificate 4 in Lean manufacturing, while senior managers have completed Certificate 3.

“We have and will continue to invest in the layout of our fabrication shops, assembly areas and warehouses to ensure we eliminate as much waste as possible, improve safety, minimise downtime, and reduce costs,” says Brakey. “We know to remain globally competitive we have to be as efficient as possible which means we must continue to maximise and improve our productivity” Between them, Elphinstone and Caterpillar have 5,000 underground mining trucks and loaders in past 40 years. As Elphinstone Pty Ltd begins manufacturing underground support equipment Elphinstone Group remains fiercely proud of its specialised, high quality Australian manufacturer.

built more than Burnie over the a new chapter in Burnie, the reputation as a

“I guess we find it extremely frustrating when we hear people make the comment that manufacturing in Australia is a dying industry, because we definitely don’t believe that,” says Brakey. “Our view is that Australian manufacturing can and should exist. Yes, there are challenges and that’s business, however we honestly believe if we continue train and develop our people, invest in our facilities, and embrace new technologies we will remain globally competitive.” www.industry.gov.au www.austmine.com.au www.korvest.com.au www.newcastle.edu.au www.jamesoncell.com www.elphinstone.com

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Mining & Resources

Chute Technology – Rotating output in confined underground spaces

Australian manufacturing partnership Chute Technology has developed a multidirectional rotating underground coal chute system that can be installed in less than a single shift at a typical mine, in what it believes is a world-first.

The cost-saving universal chute – which can rotate output through 160 degrees left or right – can remove completely the need to custommanufacture individual chute types to fit the confined spaces and particular angles of individual mines. The versatile bolt-in system – comprising a complete integrated structure from head end to conveyor outlet – features a rotating outlet beneath the head that can be angled to any position required to facilitate product flow.

In addition to radically reducing the labour required for manufacture and installation, the chute’s ability to be installed in a fraction of the time of custom chutes minimises downtime by keeping production moving when chutes wear out.

“This is a brilliantly simple breakthrough in cost and time saving at a time when the mining industry needs it most to maintain production,” says Chute Technology partner Tom Woods, whose experience of coal chute manufacture through family company TW Woods Construction extends back more than 40 years. “The benefits are obvious when you look at the basic concept, but we don’t know of anywhere else in the world where it has been done.”

Chute Technology combines the local and international manufacturing experience of TW Woods, with the similarly broad engineering and technology experience of Engineering Consultant Dennis Pomfret of Dennis Pomfret Engineering, and Design Engineer Gary Telford of McKajj Services, which contributes extensive design engineering, detail drafting and project management experience.

Between them the three partners have a combined experience of more than 80 years in a wide variety of resource industries including coal, iron ore, alumina and limestone across Australia, the USA, South America and South Africa. The company’s technologies are also applicable to gold, nickel and other bulk minerals and ores.

“A great thing about the new system is that it is easily configured to flow with the hugely diverse geology of mines throughout the world, which have shafts joining other shafts at whatever angles the geology and conditions underground dictate,” says Woods.

“Instead of having to engineer custom-fabricated chute systems to

A trolley-mounted chute for rollout installation and maintenance.

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suit unusual angles, this system just bolts into place in a fraction of the time and at a fraction of the cost in time and money.

First examples of the design under construction.

“In addition to savings in extending mines and adding new production, the chute system is far more time and labour-efficient in replacement of worn-out chutes, when you usually have to dismantle the old and install the new piece by piece. This one just slots into production virtually overnight.

“It’s like comparing keyhole surgery with old-fashioned surgery – there’s far less disruption, is quicker and it’s neater. The system is a unique synthesis of the skills at Chute Technology, which is involved in materials handling projects ranging from individual mines to entire port facilities.”

A bonus of the system they have produced is that it is designed from the outset to solve spillage and conveyor bulking problems common in coal mining and coal handling facilities. The tough hardened steel design – built to easily outlast conventional types – features a conical head developed by mining specialist designers to maintain high-volume flow rates when conveyors change direction, either underground or on the surface.

“Frequently in underground mines you get 90-degree turns as coal conveyors emerge from one shaft and have to transfer into another within very tight spaces,” says Woods. “It is usually very difficult to get coal to turn that quickly without spillage and bulking up on the conveyor belts as coal is dropped from the belt above onto the one below while changing direction.”

The chute’s conical head is configured to provide a smooth transition through the turn for coal moving at typically three metres a second and dropping up to 1,500mm onto a belt below.

“Drawing on our designer’s highly respected problem-solving expertise and our own hands-on experience over scores of mines, we set out to eliminate the spills, splatters and bulking that can disrupt production in mines where time truly is money,” says Woods.

“Eliminating frustration, delay and cost is vital in today’s economic climate.” www.chutetechnology.com.au

Belt loading can be made on a variety of belt inclination angles.

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Mining & Resources

The Internet of Mining Things delivers the next wave of productivity The Internet of Things (IoT) is increasing the connectedness of people and things on a scale that once was unimaginable. One industry at the forefront of this revolution is mining.

The magnitude of the IoT’s evolution is momentous, with more than 80bn internetconnected devices projected to be in use in 2024, up from fewer than 20bn in 2014.

When we then couple the data produced, and processes involved in the interaction among things and with people, what results is a powerful model upon which to drive the digitisation and transformation of companies, industries and whole nations.

The ability to use standard internet technologies throughout an enterprise, right down to individual field devices, enables new levels of connectivity for people, processes, data and things, ultimately providing greater productivity, better utilisation of assets, and improved decision-making to industrial companies.

“The IoT is connecting people in more relevant, valuable, and meaningful ways, delivering the right information to the right person or machine in real time,” says Michael Boland, Distinguished Systems Engineer at Cisco. “Data is being leveraged in more useful ways for better decision-making.

It has applicability across all markets, the private sector and governments.”

The mining industry has a lot to gain from the connectivity that the IoT delivers. Mining operations around the world are on an automation curve, applying technologies processes to automate their key functions to gain efficiencies in production. However these initiatives are often focused and restricted within production silos. “We see a significant number of mines that have data locked away in individual systems but now want to federate that data together, instigate new processes, involving their people in new ways to achieve better outcomes,” says Boland. “Mining generates big data because the number of sensors are growing rapidly and systems involved are becoming more intelligent. The challenge ahead is to federate that data to gain insight and optimise operations.”

Productivity and safety are two key drivers.

Removing people from the mine site and into remote operating centres helps companies achieve both these objectives. By leveraging IoT technologies, the interaction between people, process, data and things can be securely and reliably monitored, modified and maintained remotely.

Making big data meaningful “The next big boom in mining is going to be connecting a lot more ‘things’,” says

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Boland. “There are going to be more wireless and mobile devices that will be able to be instrumented, sensed and controlled more effectively.”

is becoming apparent that mining systems that have been implemented to date have not been designed for this concept of integrated but outsourced services.

This results in a lot of data being generated that needs to be analysed to generate useful information. Data needs to be intelligently captured, correlated and analysed to optimise production systems. It also needs to be available as useful information in real time so the mine’s remote operating centre can modify processes, asset utilisation and maintenance to optimise production rates in relation to dynamic market demands.

Through IoT, this next level of optimisation can be achieved for a single mine or a federation of mines, rail and ports. IoT enables the digitisation of the entire mining supply chain for optimisation.

We need to have these roles inside the integrated operations systems, yet others may actually perform them in a secure and controlled way. Through well designed IoT infrastructure, the ability for remote experts to analyse information and real time systems securely from a plant and interact with local staff can be achieved.”

The complete mining operation, from pit to port, involves many functions with many specialist devices and equipment.

Centralising control allows mining operations to pool resources to optimise production and reduce costs.

“The other trend here is that we are arriving at a point where, instead of doing everything ourselves, we are starting to contract out particular roles that require specialist expertise provided it makes commercial and economic sense, and the miner is in full control,” explains Boland. “However, it

The next wave of productivity The IoT is taking the world by storm and opening new and exciting possibilities to businesses, government and industries.

The mining sector also has much to gain from the benefits that IoT can provide, particularly in light of the current market challenges.

Through IoT, mining operations can save energy, downtime and costs associated with production and transportation of resources.

Remote operations remove people from potentially hazardous situations, improving safety and productivity. The IoT provides the platform for the integration and optimisation of the entire mining supply chain.

“On a national scale, for Australia, the benefits that the IoT can deliver are most important because as a country we are not

Mining & Resources going to win on efficiency gains based on cheaper labour to drive down costs,” says Boland. “We are going to use our expertise and knowledge of mining and automation systems to continually improve the most efficient and cost effective mining capability in the world.”

Rockwell Automation and Cisco have developed a unique value proposition for mining customers to help bridge the gap between mining operations and business systems through network and security products, Converged Plantwide Ethernet (CPwE) reference architectures, training courses, services and solutions.

“By developing reference architectures for mining we are reducing risk for our customers,” explains Boland. “We are developing full guides on how to facilitate convergence of information technology and operational technology so that our customers do not have to do all the heavy lifting and have all the expertise themselves, yet still inherit the capabilities for safe, compliant and sustainable operations and performance.

“We are unique in that we develop solutions that leverage our expertise in operational technology, through the Rockwell Automation offering, and then combine this with the deep networking, datacentre and security capabilities of Cisco.”

Connections above and below ground A mine in Canada has established a new technology benchmark for future mines by applying IoT technologies throughout the site. A detailed evaluation process recognised that the Rockwell Automation and Cisco offering was capable of delivering the complete integrated solution. The central operations centre utilises IoT technologies and combines systems monitoring and control with remote equipment control and tracking.

The mine deployed the latest advances in controls and communications, including comprehensive Wi-Fi communications for surface and underground phone, data, asset and personnel tracking; and a Radio Frequency Identification-based wireless tracking system, used to create ‘ventilationon-demand’ underground.

Combining operational technology with networking and security capabilities provided the inherent flexibility for the mine to adapt to changing requirements in real time for enhanced optimisation and efficiency.

According to Geoff Irvine, Mining Industry Manager at Rockwell Automation, “using standard Ethernet components really adds significant value in being able to combine control, safety, voice over IP, video, people

tracking and also applications such as ventilation on demand”. IoT technologies provide the capability to integrate and analyse data from various processes such as remote sensing of objects and the environment, images from cameras deployed for monitoring and maintenance, scheduling preventative maintenance procedures and monitoring power usage.

“Together with Cisco we help customers leverage technology to better gather and analyse data, and transform it into actionable, real time insightful information,” adds Irvine. “By converging information technology (IT) with operational technology (OT) into a single unified architecture, mines can benefit from establishing a ‘Connected Enterprise’ and leveraging the power of this information to optimise operations and take their productivity to the next level.” www.rockwellautomation.com

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Mining & Resources

Mining machine crushes comminution costs

A new energy-efficient machine uses mineral waste products to create a more environmentally friendly cement product.

South Australian company IMP technologies (IMPTEC) has developed a super fine crusher that reduces comminution costs.

The company is currently trialling a semi-commercial unit at Hallett Concrete in Adelaide, South Australia’s capital. The machine is being used to turn the waste from black sand or iron sand into a replacement for Portland cement.

IMPTEC Director John Doherty said the crusher was a gamechanging invention that could eventually be at the forefront of the industry: “What we’re involved in is reducing the amount of energy, which is usually electrical, and the cost of media. You can also include lower maintenance costs because it’s just one machine.

The energy density of the crusher is greater than other machines and reduces around 30% of energy costs.”

Comminution is the essential processor of minerals into cement, more commonly Portland cement, a known producer of a number of greenhouse gases. It also accounts for almost 40% of total mining costs and 3% of the world’s energy consumption, prompting the search for a more efficient solution.

Conventional methods include breaking down large rocks to a few centimetres, crushing them further to fit into a ball mill, and grinding the minerals with the help of media and water till the material came out in slurry form. This machine shortens the process by merging the second and third stage. It is unique because it also able to run the process dry and without the use of media.

Doherty said the company plans to produce a fully commercial product by the end of the year.

“Our semi-commercial unit takes in orders of two tonnes per hour,” Doherty said. “If it approves itself over the next few months, it would be good. We’re looking at scaling up to 100 tonnes per hour.”

The transformation of black sand or granulated slag into cement is a world first. In April, IMPTEC was awarded the Statewide Super Innovation in Resources Award for its superfine crusher at the inaugural South Australian Resources Industry Awards. The judging panel included the leader of the Minerals and Energy strand at the University of South Australia’s Future Industries Institute, Bill Skinner, who said that as good deposits of high-grade minerals diminish, the need to grind more material finer was vital.

“Energy consumption is going to go up if we are trying to keep up with what is needed in terms of metals. So anything that is going to reduce the footprint of an operating plant is going to be good,” said Skinner. “Portland cement is very energy intensive to produce and produces a lot of CO2 in the process. If you are using something that is actually a waste product, that is what you want.

This (IMPTEC’s super fine crusher) particular technology offers much reduced energy consumption. Upscaling it is a challenge that needs to be overcome.”

UWA launches oil and gas training and research hubs

The University of Western Australia (UWA) has launched two new $20m hubs to be used for international research and training in offshore oil and gas.

The hubs are part of the Australian Research Council’s (ARC) Industrial Transformation Research Program, with two of the nine centres announced by the Federal Government in May last year coming to UWA. UWA Deputy Vice-Chancellor (Research) Professor Robyn Owens said the new hubs would add to the world-leading nature of Australia’s energy expertise.

“The hubs will be powerful tools for connecting research and industry with the partnership providing a competitive edge for products, processes and services,” Professor Owens said. “They will be a unique training environment and will provide a highly skilled workforce with the expertise to unlock Australia’s energy resources and strengthen our contribution to the global energy engineering business.”

With $9.6m in combined funding from ARC and nine industry partners, the ARC Training Centre for LNG Futures will be led by UWA’s Professor Eric May. He said the centre will focus on costeffective LNG production, at all scales, in remote or deep-water locations, with 11 industry-driven research projects planned across a five-year period and training for 12 PhD students and five research fellows.

“The centre’s legacy will be a globally-unique LNG research and training facility, designed for future integration into a micro scale

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LNG plant,” said Professor May. “We will be working over the next few years with our industry partners, including those from Korea, China, and the USA, to make a micro scale LNG plant in Western Australia dedicated for training and research.”

The ARC Research Hub for Offshore Floating Facilities, led by the University’s Professor David White, will help ensure Australia plays a leading role in future offshore energy developments across the globe. With $10m in combined funding from the ARC and four industry partners – Shell, Woodside, Lloyd’s Register and Bureau Veritas – Professor White said the centre will address the critical engineering challenges associated with Australia’s next generation of offshore oil and gas projects, which will require innovative floating facilities.

“Drawing on world-leading expertise, the hub will develop and deploy the new technologies and analysis methods required for safe and efficient projects,” said Professor White. “Our work spans ocean forecasting, vessel motion and offloading analysis, riser and mooring longevity and novel anchoring and subsea foundations.

The research will blend experiments and numerical simulations; backed-up by offshore field observations with our aim to devise innovative design solutions that will be adopted by our partners, changing current industry practice.” www.uwa.edu.au

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one-on-one

Professor Sam Bucolo is Professor of Design Innovation at University of Technology Sydney (UTS) and Director of UTS’s Design Innovation Research Centre (DI:rc). He spoke to Carole Goldsmith.

AMT: Let’s start with your career background before joining UTS. Sam Bucolo: I started as an industrial designer working as a consultant, mainly for SME manufacturers. My frustration was that I kept getting the wrong brief from clients from these firms. Often they just wanted me to focus on a better manufacturing process or improved product aesthetics. As a designer, I used to tell them, this product does not meet the needs of your industry. You need to speak to your customers and find out their requirements.

I worked in and out of academia and consulted to large multinational international companies in Europe for a while and learnt a lot about corporate strategy. When I returned to Australia, I worked for the Co-operative Research Centre (CRC) for Interaction Design.

It was interesting work but highlighted the challenges of getting good ideas and research to market.

If you look at traditional research commercialisation, it often starts with a product, then businesses seek investors and develop, promote and sell the product. I believe that a product and business model goes hand in hand, and design can be used for both. Good design can apply to the overriding business model, not just the product or service.

AMT: What does your current role entail?

SB: I am helping manufacturers to better understand their customers and through the design process, develop their business model. We do that to help companies and in turn, we can ensure industry capability in our new design graduates. I work with CEOs and they sometimes need to be challenged, as many are not listening to their customers, even though they believe they are.

We take SME CEOs to their customer’s premises and then we do customer interviews inviting CEOs to listen. Many CEOs say: “what have I been missing all these years through this process?”

In the Design Innovation Research Centre (DI:rc), we run customer engagement/business design programs over several weeks. The firm’s CEO, management team and workers attend these sessions.

Our design team assist in the interview of the SME’s customers and feed these comments back to the companies during the five-day sessions. We also aim to mentor the SMEs at their premises over several years.

This is part of a different way that universities and industries can better collaborate. There is limited contact between industry and academia in this country. In Germany for example, business turns to universities for expertise. Australia is placed at the back of the pack for industry – academic collaboration when compared to other OECD nations. Engagement models need to be reconsidered in Australia and through our research, we are trying to address this.

AMT: What facilities and programs does the DI:rc have and how can manufacturers access them?

SB: Our building has floor space for SMEs to meet as a single business or in industry groups. They are encouraged to work in a ‘safe’ space together and address key concerns about their businesses. We offer a range of intervention programs and/or industry-specific programs for SMEs, large corporates and nongovernment organisations. As part of this, we work with our industry partners to develop leadership capacity in design-led research that

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helps grow their products and services, business models and their employee engagement strategies.

Firms can get involved with our programs by contacting our centre at UTS, on 02 9514-8998. Senior management have to be ready to commit to the time involved and they need to have available resources to implement design into their business.

AMT: Tell us about some of the programs currently underway at the centre?

SB: With the SME engagement program we start with the fiveday program and we expect the CEO and leadership team to turn up, such as the heads of design, R&D and marketing, as well as employees. When we ask them to listen to their customers, some don’t know how to listen or they only hear what they want to hear.

Recently I went out to a 40-year-old manufacturing business and met with its CEO and one of its customers. The CEO asked the customer if a specific solution will solve the customer’s problem, which he had with the manufacturer’s product.

We did the interview, which was recorded, and the CEO took extensive notes of what he thought the customer said. After the interview, I asked the CEO for his notes and I had the audio version transcribed. From his notes, I could see that all the CEO could hear was the problem that his business could solve. He missed everything that the customer said. When I played him back the audio, he realised that he had not listened to the customer properly.

CEOs and management have to first stand back and listen to their customers, and this is part of the design process. It is also about understanding the customer’s problem and then looking at what solutions you can solve for them. We also encourage the firm’s management to examine every aspect of their business. This can range from people management, supply chain efficiency, marketing to export, and we look at how this will directly help their customer and the company to succeed.

AMT: You have co-authored several research reports on designled innovation in manufacturing. What does design-led innovation mean?

SB: Design-led innovation is about companies who have a vision for growth based on deep customer insights. Then they need to apply those insights to all parts of the business.

In my recently published book, Are We There Yet? Insights On How To Lead By Design, which was written for SMEs, I explain that becoming design-led is not just about designing products or services. You need to take an entire look at the business from a customer’s perspective and design all elements of the business from this understanding.

AMT: Can you provide some examples of Australian manufacturers who have embraced design-led innovation and how has this helped them to succeed?

SB: We have been working together with some Australian manufacturers for over three years. One of these is Centor, a multi award-winning designer and manufacturer of architectural hardware systems for folding and sliding doors, screen blinds and bi-fold door locks.

055 Centor’s global headquarters is at Eagle Farm in Brisbane’s industrial area. It also has branches across Australia, as well as regional headquarters in Birmingham (UK) and in the USA, plus branches in Nantes (France) and China. A third-generation Australian company, Centor employs around 160 people worldwide.

We helped Centor interview its customers, and at the time the company had around 180 different projects in action. Based on customer responses and joint research, we all realised that only four of the projects should be continued. All other projects ceased to operate and the four core projects that continued were made world-class.

Røde Microphones is another Australian manufacturing success story. Its western Sydney head office and its state-of-the-art plant has over $30m in precision machinery and a support staff of more than 140 people. It also has offices in the USA and Hong Kong. As I report in my book, Røde’s CEO Peter Freeman is an inspirational leader who demonstrates the quality that all business leaders need to succeed in today’s economy. He has led his company from a state of near-bankruptcy to a world-leading designer and manufacturer of microphones and audio equipment.

AMT: What are some steps Australian manufacturers can use to incorporate Design-led innovation in their business?

SB: Australian manufacturers need to listen to their customers.

Innovation is not about a product or a cheaper efficient way to make a widget. You need to give yourself enough time before a problem occurs and you have a crisis on your hands, such as your product is eroded by a competitor. You need to work through the key stages of design-led innovation. These described in more detail in my book, Are We There Yet?, and can be summarised as: customer value – who is your customer and what is the problem being solved?; strategic alliance – ensure that all your systems and products are aligned with your customer’s problems; and management mindset: build a new insight about your customer and then develop a new business strategy to match this new mindset. www.uts.edu.au

Peter has done this by not just focusing on the wonderfully designed products, but by looking at every part of the business, from a customer-focused perspective. It is the firm’s close connection to the customer that keeps Røde so competitive and successful.

Every staff member has a clear understanding of the company’s purpose and the multiple types of innovation that can occur.

Staff are encouraged to experiment and take risks, but these are managed by staying close to the customer.

AMT: What design lessons can Australian manufacturers learn from overseas?

SB: The UK has had design programs like we are teaching for at least 10 years and many UK companies practice lead by design.

The UK Design Council encourages design-led innovation and its website states that innovation is the most important driver of longterm prosperity. Design helps turn innovative ideas into profitable offerings that meet consumer needs and compete on the world stage. Over the last 10 years, the Design Council has worked with more than 4,000 businesses including British Airways and Thames Water. For every £1 businesses invested in design, they gained over £4 net operating profit, over £20 net turnover and over £5 net exports, the Design Council estimates.

We don’t have this data in Australia and we still believe that we should be investing in more technologies. What most Australian businesses need to do is to fundamentally change their business culture. Other countries like Denmark and New Zealand are leading by design.

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Composites & Advanced Materials

Composites, a key enabler for innovation and competitive edge

Composite materials are unleashing a wave of innovation across a plethora of industries, and Australian manufacturers are seizing the opportunity. By Kerryn Caulfield, Executive Officer at Composites Australia.

Australian Federal Governments past and present, as well as state governments in Victoria and Queensland, have one thing in common in terms of economic policy – they see composite materials as a key enabler for the product innovation required for Australia’s advanced manufacturing sector to be competitive and secure new export markets.

While composite materials are generally more expensive that traditional metals, timber and concrete, they offer distinct advantages that can make products competitive locally and globally. Composite materials give designers and engineers freedom to be creative; to think outside the square and design fluid, seamless shapes; integrate fittings; reduced weight; improve comfort and usability, leverage the high strength to weight ratio; heat and sound insulation qualities; anti-corrosion and low conductivity characteristics.

Rarely a month goes by without news of the release of a new product featuring carbon fibre. That’s because today’s marketers recognise carbon fibre products are highly desirable, their association with high-performance, elite sports giving their brand an edge in the marketplace.

Two Victorian advanced manufacturers are enjoying export growth on the back of their carbon fibre products. Geelong-based Carbon Revolution is delivering on a contract to supply its world-leading carbon fibre wheels on every Ford Shelby GT350R Mustang made in the USA. Quickstep, an Australian aerospace manufacturer is diversifying into the automotive market starting with a contract to produce innovative carbon fibre air intake system for the Ford Falcon XR6 Sprint.

Composite manufacturers in Australia are increasingly being called on by their clients to help them introduce carbon fibre features into their buses, trains, truck sleep cabins, bicycles, motorbikes, furniture and sporting equipment.

Enlightened Boats in Queensland has discovered a niche market for their lightweight composite fishing dinghies among “grey nomads” as well as keen fishermen who are attracted by the light weight, comfort, look and quiet when compared with the cheaper traditional “tinny”.

Similarly architects and sculptors in Australia and overseas are realising the cultural and commercial benefits composites can provide their clients and the surrounding streetscape. Today highrise apartment buildings made principally of composite materials can be prefabricated in a factory, and installed as complete individual units saving time and money on the build while limiting the time trades and equipment are working at heights.

The opportunity to prefabricate a strong, yet light structures in composites and transport and install with minimal onsite works and minimal disruption to the environment, traffic and neighbourhood is making composites the preferred solution for small bridges, wharves, marinas as well as major infrastructure refurbishment and strengthening projects.

Composite materials played a key role in the widening and strengthening of the Westgate Bridge – the world’s biggest project of structural strengthening by means of bonded, high-tensile carbon fibre reinforced polymers (CFRP) – a system developed by Swinburne and Monash University research engineers.

Victoria’s Yarra Valley Water is confident the GRP pipe system currently being laid for the $130m Amaroo Main Sewer in Melbourne

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Carbon Revolution is supplying carbon fibre wheels for the Ford Shelby GT350R Mustang.

northern growth corridor has the strength and durability to outlast its 100-year design. The 1.6m pipes are manufactured under license at RPC Technology’s Adelaide plant while the other GRP components are manufactured at their Corio plant near Geelong.

The pipes are engineered and designed to create a seamless join as they are jacked under pressure along the tunnel some 14-20m below ground.

The pipe system is being used in an increasing number of water and sewer main projects in regional and urban Australia. It is an excellent example of how composites can be cleverly engineered to provide a highly competitive solution to repair aging infrastructure and construct new infrastructure.

Recognising the opportunity to provide a solution for the chemical transport industry, Sydney-based Evolution Tankers invested in R&D to develop its patented Omni Tanks, carbon fibre chemical transport tankers seamlessly lined with polyethylene thermoplastic The award winning innovation is now going global in a market attracted by the commercial benefits presented by the lightweight tanks, enabling larger payloads, corrosion resistance and easy washout, leading in turn to higher returns for chemical transport companies.

The next-generation Australian defence land transport vehicle, the Hawkei, is about to go into production featuring several advanced composite components that help the vehicle achieve the weight and strength parameters required for helicopter deployment and the protection of our troops.

The sky’s the limit The above examples clearly demonstrate the diversity of applications possible with composite materials and it is by no means complete.

Composite materials are no longer the materials of the future. They are materials of the 21st century.

As futurist Geoff Manaugh of BLDG BLOG argues in a recent article for New Scientist’s New Urbanist column, skyscrapers of the future will be glued together.

“In fact, composite materials are more like rigid fabrics,” says Manaugh. “Sticking them together results in building-sized components that can sometimes be set hard in just a few seconds, depending on the adhesives used. Composite materials are already used to make high-performance yachts, wind turbine blades, large passenger aircraft such as Boeing’s carbon fibre Dreamliner, and even commercial spacecraft such as SpaceShipOne. Why not skyscrapers?”

Composites & Advanced Materials

About composite materials Quickstep is diversifying into the automotive market producing an innovative carbon fibre air intake system for the Ford Falcon XR6 Sprint.

Composites can and should be tailored to an application to achieve optimum results. This can mean it is far from straightforward to design and manufacture. However there is now a mass of global research to provide engineers and architects with the necessary knowledge to move beyond their classical training based on traditional materials, plus there is now ready access to composite engineering design, testing and analysis expertise in Australia to support manufacturers in the take-up of composite components.

Unlike most traditional manufacturers, composite fabricators have a diverse product range and can apply the same technologies, skills and processes to a myriad of end-uses. For example, Melbourne boat builder Composite Constructions is manufacturing helicopter search-lights for a client growing their global market with a lightweight, well-designed and engineered composite casing with integrated mountings. Queensland high-performance boatbuilders Mouldcam is building a global reputation in manufacturing architectural composite features and large-scale innovative public sculptures.

Queensland-based composite manufacturer Marky Industries supplies components for major truck companies; elevated work platforms helping clients innovate by leveraging the characteristics of composite materials to build their market share.

In Tasmania, Penguin Composites, founded on kayaks, now also manufactures a range of caravans along with igloo accommodation for remote scientific and research operations. It also undertakes commissioned projects for clients including bespoke seating for the Mona Gallery wharf; “igloo” offices for Google’s Geneva branch; roofing for a heritage building; and more.

Meanwhile the world’s largest car manufacturers, defence organisations and aerospace giants such as Boeing and Airbus are all investing heavily in R&D to maximise the advantages of composite materials in order to remain competitive.

Clearly, composite materials area key enabler for innovation and competitiveness in the global market. Advanced manufacturers looking for a step-change to break into new markets, might consider whether there is an opportunity to partner with a composite fabricator to develop a creative solution.

Kerryn Caulfield is the Executive Officer at Composites Australia. www.compositesaustralia.com.au

Penguin Composites has produced “igloo” offices for Google.

Advanced composites are a class of materials in which the basic properties of plastics (light weight, mouldability, resistance to chemical corrosion, and electrical insulation) are given mechanical reinforcement via the addition of fibrous materials such as glass, cellulose, synthetic fibres, carbon, Kevlar aramid and boron.

From the wide choice of plastics resin matrices, combined with a wide range of reinforcing materials and their various forms, the permutations are virtually unlimited. The concept of reinforcing a resin is as old as the first synthetic resin, which dates back to early 1900s when the Belgian-American chemist Leo Baekeland made the discovery that phenolic resin could be processed if filled (or reinforced) with wood flour. His invention of Bakelite, an inexpensive, nonflammable, versatile, and popular plastic marked the beginning of the modern plastics industry.

Often cited as frontier materials, the reality is that advanced composites as we know them today have grown up with the aircraft and defence industries, which needed strong lightweight materials. Resin-stiffened fabric was used as early as in the 1920 for propellers. Officially, the first airframe application is said (by SAMPE) to be a glass fibre sandwich for the aft fuselage skin of the Vultee B-15 trainer in the USA in 1945. However, the first use of primary aerospace application was probably the war-time construction of the fuselage for the Supermarine Spitfire fighter aircraft by Gordon Aerolite, ahead of a threatened aluminium shortage.

In the early 40s, allyl casting resins and the first low-pressure laminating resins were being used in the USA with glass cloth reinforcement, and a few years later resins similar to those used today became commercially available both in the USA and Europe. Chopped stand glass mat became available a few years later, along with technologies such as pultrusion and filament winding – ushering in enthusiastic utilisation of these materials in boat-building, automotive production and industrial applications such as chemical tanks and pipes.

Since that time, the global aerospace and defence sectors have spent billions researching all elements of resin matrices, reinforcing materials and the myriad of production systems.

The barrier of size was convincingly broken by the UK Navy over 40 years ago in 1972 when it launched the first allcomposite minesweeper, the HMS Wilton, with a 170m hull.

Advances in composite technologies have catapulted to stratospheric levels in recent years; indeed NASA is using composites as “crosscutting technology” for future missions including Mars precursor missions, advanced in-space propulsion, and space platforms (2020 to 2030).

While it is a specialised field, advanced composite technology is not a black art. While it may appear enigmatic, there are usually plenty of examples of prior use of advanced composites for any given application, be it aerospace, automotive, building & construction, marine, aquatic leisure, storage and pressure vessels, pipes, and transport including trains, buses and trucks. More importantly, there is a mass of global research available for the faint-hearted. Engineers and architects should no longer be bonded by their classical training disciplines.

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High-tech manufacturing breakthrough for Australia

Australia will become the first country in the world to use graphene in the large-scale manufacture of an industrial product, according to Chris Gilbey, the CEO of Sydney-based company Imagine Intelligent Materials (Imagine IM).

Gilbey announced on 11 April that Imagine IM, the leading Australian developer of graphene applications for industry, has entered into a licensing agreement with Australia’s largest geotextiles manufacturer Geofabrics Australasia. The groundbreaking agreement will see Geofabrics become the exclusive Australian licensee of Imagine IM’s graphene coating technology for applications in geotextiles.

Geofabrics will use the technology to offer Australian civil engineering companies significantly improved capacity to locate and remedy leaks with applications in landfill and mining construction. Gilbey said that the insights gained from working with Geofabrics, which is headquartered in Melbourne, were key to the development of the graphene manufacturing solution.

“Increased environmental regulations in Australia and around the world are driven by the need to address water safety and conservation and by the need for cost effective leak detection in the mining industry,” Gilbey said. “We estimate our technology will save customers around 20-40% on their current solution costs.

Our graphene coating technology has the potential to become a key element of the world’s geotextiles industry, which is growing at around 10% per annum and will be worth around $20bn by 2018.

“We have utilised graphene’s electrical conductivity to provide the means to detect pin hole sized leaks in geotextiles. Leak detection is important because, undetected leaks mean that there is potential for toxins to escape from tailings dams and landfills into ground water.

Graphene consists of a layer of carbon a single atom thick, extracted from graphite.

Geofabrics is scheduled to provide the marketplace with the first of its graphenecoated geotextile products in August.

The products will be manufactured at Geofabrics’ facility in Albury, NSW. “We are the leading geotextiles manufacturer in Australia and we entered into the agreement with Imagine IM because of our belief in graphene and our belief in Imagine IM’s ability to quality assure the product and the supply chain,” said Brendan Swifte, General Manager at Geofabrics.

“We believe that our bidim geotextile with graphene coating is a ‘game changer’ for the geotextile industry. It will be a high tech solution at an extremely competitive price.”

According to Gilbey, Imagine IM’s licensing agreement with Geofabrics follows his company’s announcement last month that it has commenced development of Australia’s first graphene manufacturing plant in North Geelong. The plant will commence production later this year and will supply its graphene solutions to Geofabrics.

Out of the laboratory

Chris Gilbey, CEO of Imagine Intelligent Materials.

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Widely regarding as the new ‘super material’, graphene consists of a layer of carbon a single atom thick, extracted from graphite. Graphene has many extraordinary properties. It is about 100 times stronger than the strongest steel, conducts heat and electricity efficiently, is nearly transparent, impervious to water and gases, and can stretch like rubber. Its discoverers, Andre Geim and Konstantin Novoselov from the University of Manchester in the UK, were awarded the Nobel Prize for physics in 2010.

Imagine IM was founded in 2014 to create disruptive solutions utilising graphene that can be integrated into existing manufacturing processes.

“The scientific and engineering team at Imagine IM is proud that we have taken graphene out of the research laboratory and transformed its potential into a genuine commercial application and in so doing boosted Australia’s ‘clever country’ credentials,” said Gilbey.

Imagine IM is in the process of developing additional products and solutions for the global geotextiles industry and is planning to migrate its platform technologies into other textile product lines where solving problems associated with water are highly valued. Gilbey said that Imagine IM is currently discussing international licensing agreements for its graphene technologies in the USA. “The race to commercialise graphene has seen the launch of numerous companies in the USA, Europe and Asia,” said Gilbey.

“The European Commission has established the €1bn Graphene Flagship Fund to help drive the commercialisation of graphene in Europe. In the UK, British Government support has helped establish the National Graphene Institute at the University of Manchester.

“However, up till now, no company has been able to develop a product that delivers at industrial scale the potential that has been indicated in research labs.” www.imgne.com

Composites & Advanced Materials

Ultrasound could transform 3D printing of composites

Researchers at the University of Bristol in the UK have developed a new way of 3D printing composite materials, using ultrasonic waves. Bruce Drinkwater, Professor of Ultrasonics at the University of Bristol explains.

The advent of 3D printers supposedly means we can manufacture anything in our homes. But in reality most existing home 3D printers can only make things out of certain plastics, while some industrial systems can print certain metals. What has so far been out of reach is a way to 3D print high-tech composite materials such as the carbon fibre composites used to build lightweight but extremely strong versions of things including tennis racquets, aerodynamic bikes and even aircraft parts.

When designed properly, composites have just about the best strength for their weight of any common material, making them perfect for applications that need to be very strong but light, such as aeroplanes. Composites are usually made from very long glass or carbon fibres set in a plastic matrix. It’s the presence and careful arrangement of the fibres that make these materials so impressively strong yet lightweight.

At present, composite products are made by forming the fibres into sheets that look a bit like stiff cloth. These are then cut to shape and assembled by hand, layer-bylayer, to create the final product. As a result, composites are expensive and not easily replicated with 3D printers.

However, my colleagues and I have found a way to transform existing 3D printers so they can also print composite material, by making a relatively simple addition to a cheap, off-the-shelf 3D printer. The breakthrough was based on the simple idea of printing using a liquid polymer mixed with millions of tiny fibres. This makes a readily printable material that can, for example, be pushed through a tiny nozzle into the desired location. The final object can then be printed layer by layer, as with many other 3D printing processes.

The big challenge was working out how to reassemble the tiny fibres into the carefully arranged patterns needed to generate the superior strength we expect from composites. The innovation we developed was to use ultrasonic waves to form the fibres into patterns within the polymer while it’s still in its liquid state.

The ultrasound effectively creates a patterned force field in the liquid plastic and the fibres move to and align with low pressure regions in the field called nodes.

The fibres are then fixed in place using a tightly focused laser beam that cures (sets) the polymer.

The patterned fibres can be thought of as a reinforcement network, just like the steel reinforcing bars that are routinely placed in concrete structures such as foundations or bridges. Our study used short glass fibres in liquid epoxy polymer that are formed into longer lines of fibres and can recreate the structure of a traditional composite.

But the process has huge flexibility and can also create patterns not possible with traditional methods. By adjusting the ultrasonic wave pattern we can steer the fibres as the print progresses, producing a complex 3D architecture of fibres rather than layers of 2D structures.

One of the particularly useful features of the ultrasonic alignment process is that almost any type, size or shape of fibre can be used. This will give product designers some completely new possibilities and allow the printing of smart materials that can repair themselves or harvest electricity from the environment. For example researchers are working on embedding networks of hollow tubes filled with uncured polymer into composites. If the material is damaged and the tubes are broken open they will “bleed” polymer that will then set and “heal” the product. These tubes could be positioned in the liquid plastic with our ultrasonic printing system.

The ultrasonic technology is still in its early stages, so don’t expect to be able to buy these printers next week. But 3D printing is a very fast moving field so these ideas could well hit the market in the next few years.

This article was originally published in The Conversation. www.bristol.ac.uk www.theconversation.com

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Realising the competitive potential of composites additive manufacturing Additive manufacturing or 3D printing is the fastest growing sector of manufacturing globally. Professor Milan Brandt and Professor Murray L Scott assess its potential in the design and production of composite parts directly from CAD. Companies such as Airbus, Audi, BMW, Boeing, Ford, General Electric, Hewlett-Packard and Nike, as well as many small and medium-sized enterprises globally, are using and exploring additive manufacturing (AM) technology for component and part production. Popular press, trade and technical journals are almost daily reporting on new and innovative printers; parts additively manufactured in both metal alloys and polymers; and component designs for AM that challenge the imagination.

The main driver has been globalisation, which is changing the nature and economics of manufacturing in high-wage countries such as Australia. On one hand, globalisation has led to new markets, but on the other, to new competitors, in particular from low-wage countries. Handling the challenge of product cost pressures, diversity and dynamics becomes the central focus for manufacturing companies in high-wage countries.

Advanced technology and research are seen as critical elements in addressing some of these challenges to deliver cost-competitive approaches to manufacturing for the companies in high-wage countries to remain profitable and in business. AM is seen as a solution to boost local manufacturing because of the many benefits it offers compared to traditional manufacturing. With additive technologies, parts can be built directly from computer models or from measurements of existing components to be re-engineered, and therefore bypass traditional manufacturing processes such as cutting, milling, casting and grinding. Benefits include:

The driveable Strati carbon fibre electric car printed in two days at IMTS 2014.

electronics, sensors, ball bearings, hard mounting points and more into 3D printed parts made with carbon, glass and/or aramid fibres.

Shown at right is a part manufactured on a MarkForged printer.

Below is a table listing some of the current companies and composite AM technologies, including fused filament fabrication (FFF), composite filament fabrication (CFF), fused deposition modelling (FDM) and selective laser sintering (SLS).

• New designs not possible using conventional subtractive technology.

• Dramatic savings in time, materials, wastage, energy and other costs in producing new components.

• Significant reductions in environmental impact • Faster time to market for products.

Ever since composite materials were first introduced, they have been pushing the boundaries of high-performance and lightweight designs in all branches of engineering. Composite manufacturing processes are in essence additive processes. In order to reduce the labour-intensive manual operations, and the need for a flexible automated composite process, organisations are investigating the feasibility of implementing AM techniques to aid the fabrication of composite parts.

There are several options for which AM can be implemented in the composite production process involving direct and indirect manufacture of composite parts. This article highlights the potential of AM in the design and manufacturing of composite parts directly from CAD in particular with fibre reinforced thermoplastics.

Growing applications The use of composites in AM is definitely growing, as evidenced by the number of companies looking to take advantage of the material properties due to continuous filaments and the size of parts possible. The latter was demonstrated at the 2014 IMTS show in Chicago, USA, with the printing of the Strati carbon fibre reinforced plastic car using BAAM (Big Area Additive Manufacturing), by US collaborators Local Motors (Chandler, Arizona), Oak Ridge National Laboratory and Cincinnati Incorporated.

MarkForged has developed a process for fusing carbon fibre to other thermosetting materials and is offering a small desktop printer for this. The Mark One MarkForged printer allows users to embed

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AM technologies relevant to composites have been around for a number of years, and some have been used for production, including the following: selective laser sintering (SLS); laminated object manufacturing (LOM); stereolithography (SL); fused deposition modelling (FDM); three dimensional printing (3DP); and ultrasonic consolidation.

AM techniques which have mainly been used with fibre composites, are SL, FDM and LOM. However, in a powder-based AM technique such as SLS, it is difficult to draw smooth layers of powder-fibre mixture. Long or continuous fibres, instead of short fibres, are difficult to incorporate into processing, therefore their use has been limited to LOM and SL techniques.

FDM, pioneered by Stratasys, is now one of the most widely adopted AM techniques. In the fused deposition process, a spooled filament of a thermoplastic polymer is fed into a liquefier, with the help of a pinch feed mechanism. The incoming solid filament acts as a plunger to extrude the material through a circular nozzle in the form of a molten bead of material. The extruded polymer is deposited according to a fill pattern established by software pre-processing onto the build platform or previous layer. After the layer is finished, the build platform is lowered and the cycle repeats.

The AM process using the filament-based extrusion technique of FDM requires the material to be processed into a filament form.

Composites & Advanced Materials Right: The Mark One MarkForged manufactured part with embedded sensor.

This filament is extruded to a very high diametric tolerance. Parts obtained from the FDM process have mostly been used for model visualisation and form/fit verification. However, in recent years many new materials have been investigated to enable FDM to produce fully functional parts by incorporating a reinforcing material into the polymer matrix.

In conclusion, AM technologies are rising in importance globally because of the benefits that they offer compared to conventional techniques. In the composites area, direct manufacturing of parts is being driven by the research into improving their structural integrity through the addition of reinforcing filler materials and new deposition technologies. It has been shown that the extrusion-based additive manufacturing technique has a positive effect on the fibre alignment in the resulting parts. The main weakness of extrusion-based polymer AM parts is the interlayer bonding strength between adjacent layers. Further research is being conducted with short fibres and fibre fillers to investigate the bond formation of polymer filaments and their properties.

Professor Milan Brandt is the Technical Director of Advanced Manufacturing Precinct and Director of the Centre for Additive Manufacturing at RMIT University. Professor Murray Scott is Managing Director of Advanced Composite Structures Australia Pty Ltd and an Adjunct Professor at RMIT University. Article reprinted courtesy of Composites Australia. www.compositesaustralia.com.au www.rmit.edu.au www.acs-aus.com

Quickstep opens up South Korean automotive market

Manufacturer of advanced carbon fibre composites company Quickstep Holdings has announced its entry into the South Korean automotive market through a sales contract with the Korea Institute of Science and Technology (KIST).

Quickstep will develop and supply composite manufacturing equipment, including its patented Resin Spray Transfer (RST) and Qure (Out-of-Autoclave) curing machine technologies, which KIST will use to develop prototype, demonstrator and niche-volume composite parts. Delivery is expected to be completed by the end of 2016 and will pave the way for further adoption of Quickstep’s technologies in the growing South Korean automotive sector.

“This contract opens up the South Korean automotive market for Quickstep’s process technology,” said David Marino, Managing Director of Quickstep. “Our patented technologies will enable medium-volume production of carbon fibre composite automotive parts, providing throughput of more than 10,000 parts per year.

KIST is very well positioned within the automotive industry in South Korea, a sector that has made it a priority to develop lightweight carbon fibre solutions for future vehicles.”

KIST is a well-respected, multi-disciplinary government research institute located in Seoul, with a significant role in the development of South Korea’s growing carbon fibre composite materials industry.

It specialises in supporting Korean companies in the research, evaluation and introduction of new technologies into production environments.

“This will be the first system of this kind in South Korea and we are very pleased with our decision to work with Quickstep to design and manufacture it for us,” stated Dr. Jun-Kyung Kim, Jeonbuk Branch Composite Material Technology Institute Director General of KIST. “The system will offer the complete capabilities that we need to continue and expand our research in the field of composite materials science, with our goal to become the world’s leading researcher in this area.”

The Quickstep manufacturing system supplied to KIST will be optimised for niche to medium-volume automotive industry production. This contract will drive further development of the RST and Qure systems for higher volume production, well above the current capacity of existing systems used in the aerospace sector.

KIST selected the Quickstep system after evaluating several processes. This provides a significant endorsement, confirming Quickstep’s competitiveness compared to other composite manufacturing technologies used for medium-volume automotive applications. Quickstep’s Qure and RST technology will enable KIST to produce Class-A surface quality parts at an overall lower cost, and will demonstrate the benefits of the system for industry uptake in the Korean market.

South Korea provides a number of opportunities for the uptake of Quickstep’s process capabilities in the future, both in its fastgrowing automotive market, as well as in its emerging aerospace manufacturing sector. The carbon fibre sector is seen as a major growth area in South Korea with significant government and industry investment going into major initiatives such as Carbon Valley Project in Jeollabuk-do province, creating an internationally focused region for research, development and industry in areas such as carbon fibre, artificial graphite, and carbon polymers. www.quickstep.com.au

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Integra Systems – New laser boosts development agility

Integra Systems opened up its headquarters in Broadmeadows, Victoria, on 15 April for an event to mark its acquisition of a state-of-the-art new fibre-optic laser cutter from Italian manufacturer Salvagnini.

The launch event was attended by customers, partners and suppliers of Integra, as well as various industry figures and representatives of the media. They enjoyed speeches from the leadership team at Integra as well as from Frank McGuire MP, Local Member for Broadmeadows and Parliamentary Secretary for Medical Research in lieu of Lily D’Ambrosio Victorian Minister for Industry, Energy and Resources, and Hume Mayor Cr Helen Patsikatheodorou. McGuire also did the honours in cutting the ribbon to officially launch the new machine, a Salvagnini L5 fibre-optic laser cutter. Along with refreshments and networking opportunities for the guests, there were opportunities for everyone to watch demonstrations of the new machine in action up close.

“This event is a celebration of the progressive thinking amongst everyone here today,” said Erika Hughes, Integra’s Marketing Director. “It is a demonstration of the power of disruptive technology to make things happen in a highly competitive world.

And with the number of people here today from all areas of industry, it is a celebration of the passion for collaboration amongst us to deliver the ultimate solution.”

At a time when the media bombards us with reports of how segments of the

manufacturing industry are in decline and under stress, Integra and businesses like it are moving forward by adopting a progressive and transformative approach.

The team at Integra believe their strategy, based around like-minded collaboration with Government, universities, industry advocates, suppliers and clients, will ensure it continued success in Australia’s manufacturing industry.

“Innovative thinking, space for creative experimentation and enabling technology to make it happen are essential ingredients to success,” said Paul Hughes, Managing Director of Integra. “This exciting acquisition will provide our clients with the responsiveness they need to remain competitive in a highly contested global market. Technology is advancing at a rapid pace and we make it our mission to ensure our clients are provided with the best technology and solutions available to enhance their business performance outcomes.”

A culture of innovation An award-winning, industry-leading family business based in Melbourne’s north, Integra was founded in 1991 by Paul Hughes. He was joined a couple of years later by his father Russell, who remains the company’s Director of Innovation.

Erika, Paul’s wife, then came on board as Marketing Director in 2001. From day one the company has operated on the basis that progressive thinking, disruptive technology, results-focused collaboration and speed to market are the key drivers to manufacturing success in Australia.

Innovation has consistently been at the cornerstone of Integra’s culture since 1991.

The company enables and empowers its clients by providing fully integrated solutions that cover the entire development process from the initial formation of ideas or concepts, right through to the ultimate execution, encompassing key areas of industrial design, product design engineering, mechanical engineering and prototyping. This is backed up through Integra’s highly efficient in-house advanced manufacturing and metal-processing systems, and the team’s renowned expertise in project management.

“We have provided clients with integrated product design and execution solutions to help them boost their business outcomes locally and globally,” says Erika. “Our design and manufacturing operation is co-located so that we can keep client projects lean, innovative and allows us to keep our finger on the pulse when it comes to product outcomes.

The Salvagnini L5 fibre-optic laser cutter.

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Forming & Fabrication Paul Hughes, Managing Director of Integra Systems.

Frank McGuire MP, Local Member for Broadmeadows, cut the ribbon to officially launch the machine.

“The glue to all this is our deep knowledge and insights from the diverse range of industries we work in, and our ability to project manage complex products using our own advanced manufacturing facility and components and services from our trusted network of supplies to ensure the optimum outcome.”

Inside the L5 laser cutter “At Integra we have always been very careful in introducing the most innovative technology that is available at the time,” says Paul. “Having come from the machine tool building industry and developed our own award-winning Punch-IT coil line, we know what to look for in machinery in terms of innovation, technical capability and value for money.”

Distributed in Australia by Machinery Forum, the Salvagnini L5 laser cutter offers highdynamic cutting due to its original compass structure, which assures dynamics of up to 5g, with low rates of power consumption thanks to its light weight. Driven by a pair of rotary motors, the compass structure allows the cutting head to be moved on the XY plane over a distance of 170mm.

The L5 delivers rapid throughput for high speed to market, with a relatively compact size and an upgradeable modular architecture. It boasts extremely high positioning and processing speeds, with a high-quality, burr-free cut. The machine has the ability to cut aluminium, copper, brass, and coated, uncoated and stainless steel, and can etch and engrave at high speed, even enabling the bar-coding of products.

The L5 offers low costs in terms of energy usage, consumables and maintenance.

The new technology will enhance Integra’s ability to experiment and co-create with

its customers, engaging them in the entire process from design through to manufacture. The machine can be used for rapid prototyping and validating new designs, significantly condensing the time from conceptual design through to full production. Moreover, it facilitates mass customisation rather than mass production, where products can be continuously changed and updated to accommodate emerging technology “Most importantly, we can combine the best manufacturing technology that is available with our Design for Manufacture and industrial design capabilities to provide fully integrated solutions for our clients in the shortest possible time frames,” says Paul.

“We often use the Abraham Lincoln quote ‘If you’ve got eight hours to cut down a tree, you should spend seven hours sharpening your axe’. We like working with a sharp axe. We believe in investing in the best to achieve the best results.”

WorkSmart – Desks with a difference A further benefit that the new machine brings is that it allows Integra to bring its own new designs to the market. The first fruits of this development were unveiled alongside the new laser cutter, with the launch of Integra’s flagship new WorkSmart collection of electronic sit-stand ergonomic solutions.

There’s been a lot of coverage of sitstand desks in the newspapers lately, as awareness has grown of the negative health consequences of spending long periods spent in a sitting position. Sitstand desks encourage sedentary office staff to spend a bit more time on their feet, raising or lowering the work surface so that workers can alternative between working while standing up or sitting down. Along with health benefits, enabling staff to stand at their desks has been found to improve productivity and general wellbeing.

Marketed under Integra’s new Integra

Erika Hughes, Marketing Director at Integra.

Transform division, and manufactured entirely at the company’s Broadmeadows facility, the WorkSmart collection comprises two basic lines: the BioSmart desk converter, and the AeroSmart workstation.

The BioSmart maximises the value of existing furniture assets, sitting on top of an ordinary desk where it can raise or lower your computer monitor, keyboard and other equipment. The BioSmart can be adapted to accommodate up to three monitors.

The AeroSmart is a more comprehensive solution, a full-sized desk that uses worldclass electronics to elevate the entire workstation surface. The AeroSmart can be easily customised according to customers’ specific requirements.

Assistance in growth To assist with its purchase of the new laser technology, Integra received funding from Melbourne’s North Innovation and Investment Fund (MNIIF). The Fund was established by the Victorian and Commonwealth governments, along with Ford Australia, to grow manufacturing and create jobs in Melbourne’s northern suburbs.

“Integra Systems is demonstrating its forward thinking by investing in the cutting edge new technology, which will enable it to expand its operations and provide an innovative service to manufacturers” says Lily D’Ambrosio, Victorian Minister for Industry, Energy and Resources.

“The support of all of these parties as well as our local Hume Council is greatly appreciated,” said Paul. “We are fully committed to expanding our operations and appointing five new people to support this innovative development.

“We are a passionate Australian family business and believe there is a bright future in design-led advanced manufacturing in Australia and we are proud to be part of these exciting times.” www.machineryforum.com.au www.integrasystems.com.au

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Jmar Engineering reaps benefits from new fibre laser

Applied Machinery recently installed a new fibre laser cutter at Jmar Engineering in Shepparton, Victoria.

Founded by Mark and Janice Hooper 22 years ago, Jmar specialises in component manufacturing and repairs across a broad range of industries including those associated with conveyor and package handling equipment. A commitment to providing outstanding customer service, staying abreast of local trends, and ongoing diversification has seen the company achieve steady growth and increase its customer base since its inception.

An example of that diversification has been the way the company now undertakes a considerable amount of ‘reverse engineering’ – fabricating many components and parts that clients may have previously bought from overseas suppliers. In addition to component manufacturing, the company has been a supplier to the agricultural industry for more than 20 years with a unique product called the Christopher Dairy Bails. This is a retrofit product suitable for herringbone dairies that allows the farmer to feed in the bail at milking time.

Nearly all Jmar’s business comes from around the Goulburn Valley area within a 50km radius of Shepparton.

Last year Mark spotted an opportunity to invest in a laser cutter to further grow his business and enhance the quality of his company’s end product. After extensive further research, a fibre laser cutter appeared to be the best choice. Fibre laser cutters offer a number of significant benefits, including extreme accuracy, high speed and consistency of cut, coupled with very low operating costs.

Mark’s interest in fibre lasers saw him issue a challenge to Applied Machinery: to supply him with a machine that would meet both his performance criteria and budget restrictions. It was a challenge that the team at Applied was pleased to accept.

After a detailed presentation, Mark became Applied’s inaugural fibre laser cutter customer with the supply and installation of a Hans GS LFD-3015 1kW fibre laser cutting system.

Paying quick dividends “The new Hans fibre laser installed in late February is already paying huge dividends for us,” says Mark. “Not only is it improving productivity and quality of our finished products, but it has also opened up new market opportunities. We’re seeing work that we would never have seen, and are quoting on jobs that we have previously not been able to quote on. The new Hans fibre laser is really helping to expand our business.”

Another benefit of the new machine is that the quality of the finished product coming out of the company’s press-brake is now far superior, due to the huge increase in quality of the pre-bend parts from the fibre laser when compared with the company’s plasma cutter. The Yawei pressbrake is coincidentally another product supplied by Applied Machinery.

“Quite simply the new Hans fibre laser ticks all the boxes,” Mark enthuses.

of Applied’s service both prior to making the purchase and during the machine’s installation process.

“Applied’s service is unquestionably outstanding,” he says. “I have been overwhelmed with the support and commitment of Applied’s staff. Their ability to resolve any issues that did arise was really pleasing. Throughout the process Matt Keogh, Applied Machinery’s Service Manager, has continually checked to ensure we were completely satisfied with the operation of the machine and the quality of the training.

“This new fibre laser is completely in keeping with the ethos of Jmar Engineering,” Mark concludes. “It not only allows us to produce the highest-quality components in a faster time, but also provides us with the opportunity to add to the diversity of products we produce.” www.jmarengineering.com.au www.appliedmachinery.com.au

Not only is Mark rapt with his new machine – he also raves about the quality

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AMT & AMTIL Digital Media Kit 2016 Call Anne Samuelsson at AMTIL on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

Forming & Fabrication

Kemppi launches new mechanised and robotic welding line Kemppi has unveiled a new range that it believes sets a new industry benchmark for quality and productivity improvement in welding production operations.

Kemppi’s family of Mechanised Welding Systems can be combined with Kemppi WISE software processes to increase productivity several hundred percent when compared to manual welding. This not only improves productivity but also ensures greater continuity in weld quality. Simple to operate and user-friendly, the Kemppi Mechanised Welding Systems allow the welder to weld remarkably quickly, safely. Plus, there is also a considerable saving in time and costs, not only because the Systems improve the speed of welding, but also because the need for rework is diminished.

The Mechanised Welding System range includes six systems for Mig and Tig options for both rail-mounted seam welding and orbital welding for tubes and pipework. Products range from simple, compact battery-powered systems, to advanced professional solutions for multilayer welding of pipes and tubes. The range includes the A5 Mig Rail System 2500, the A3 Mig Rail System 2500, the A5 Mig Orbital System 1500, and the A5 Tig Orbital System 75 and A7 Tig Orbital 150 and 300.

The Mig Mechanised Welding Systems can be further combined with Kemppi’s unique Reduced Gap Technology (RGT) software to take welding productivity and quality to an even higher level. Together, they further enhance reliability in the consistency of the weld, the quality of welding and speed, to further increase productivity.

For those involved in Robotic welding, the new A7 Mig Welder 450 is designed for robotic arc welding and can be easily integrated with any robot brand. It is ideal for any industry using robotic welding for mild steel, stainless steel and aluminium components.

A comprehensive and perfectly balanced process package, the A7 Mig Welder 450 guarantees reliable welding performance with no compromises. Together with Kemppi WISE software, the A7 significantly improves welding speed and boosts production efficiency. Designed with flexibility in mind, this same equipment can be used for a variety of welding tasks and offers extensive functionality.

The A7’s power source can be quickly accessed from an external computer via Ethernet with a regular web browser. No extra programs are needed and the system can be set up quickly and easily to help save on time. www.kemppi.com

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Precitec launches multi-axis laser-cladding head Precitec has launched CoaxCladder, a new, state-of-the-art multi-axis laser-cladding head distributed in Australia by Industrial Laser.

The coaxial welding cladding head allows complete X/Y/Z-direction independent cladding with filler wire. Based on a unique internal optical design, it splits in half, then rejoins the beam at the cladding position and is combined with the coaxial feeding of the additional filler wire material. The wire is then fused from all directions at the local melt pool to the base substrate.

In comparison to laser cladding with powder, a very high material efficiency is possible, since the additional material is introduced and processed at 100%. The process is also cleaner, highly stable and simple to integrate and adjust.

The homogenous energy distribution in the fully circular focus enables a large process window, which results in a stable process, even if the working distance fluctuates a little. This proves advantageous particularly for the construction of free-formed 2.5D structures.

The Precitec CoaxCladder allows application across a wide range of fields, such as the repair of high-value components, adding specialised wear-resistance coatings, or the building of high-volume structures. The efficient process allows very high processing speeds, up to 5m per minute or more. The ability to put down material with small radiuses also allows for more complex 3D structures.

To protect the CoaxCladder against splatters and dust, the head is integrated with a Crossjet gas shield and a serviceable protective glass. The head can be retrofitted to most fibre lasers up to 5kW

The CoaxCladder in action, with rotary axis and robot integration.

using passive fibres up to 600 micrometres. The filler wire diameter can range from 1.0 to 1.6 millimetres in diameter.

Due to the versatility of the coaxial head design, Precitec has also released a Coax Brazing head, making very high-quality brazed seams also possible. Combined with Precitec’s extensive range of add-on enhancements such as seam tracking, this is another example of a laser solution looking for an application. www.industriallaser.com.au

Plasma cutter becomes indispensable for SA gate manufacturer When Adelaide-based Secure Gates automated the cutting of square tube and plate steel with the installation of an HD plasma machine, the result was increased productivity, production times halved, and much shorter lead times in prototyping and fabricating.

Owned and operated by Simon Neil, Secure Gates works in the area of large, specialised industrial and highsecurity gates – including gates used in prisons. It’s a niche business with a repeat client list and new clients attracted by word of mouth. Neil currently employs one staff member.

Or two, if you count, as Simon does, the Advanced Robotic Technology (ART) plasma cutter he installed in 2013, and which he sees as absolutely pivotal to the success of his business.

“The business hasn’t looked back since I installed the machine,” he says. “It’s absolutely pivotal to the business.”

Neil had been looking for some time to install a cutting machine to help with the workload. When he contacted ART, they were quick to analyse the needs of the business and suggest solutions that would work best for him. Neil says he was very impressed with the team at ART and consultation was soon followed by installation at Secure Gates of an ART HPR130XD plasma machine with a drill/tap head.

The machine was customised for Neil’s need for a large working area – in his case a working area of 14.5m x 2.5m – and the ability for cutting long length of square tube – up to 12.5m in length – as well as steel plate. The result for Secure Gates has been an increase in

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speed and accuracy, greatly lowered lead times and reduced production costs. With the ART plasma cutter, productivity has increased by 50%, and the product is of higher quality.

In particular, Neil likes the fact his machine is a high-quality Australian product and that support comes from people on the ground in Australia familiar with the Australian business environment. This has huge benefits, Neil says: “After-sales support has been very good. ART is able to deal with most problems by logging on remotely and getting me back on track quickly.”

The plasma cutter has made a considerable impact on output. In the past, having to have material cut offsite caused problems with lead times but now Neil is able to prototype quickly, and achieves faster fabrication of orders. Productivity has increased by 50%, and the product is of higher quality.

Moreover, the increased productivity has freed up time for Neil to plan for his company’s growth, which has already paid off. The ability to tap into other markets, combined with the machine’s efficiency, saw Secure Gates grow by 70% over the last three years. www.advancedrobotic.com

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BUsiness Management

Monitoring overall manufacturing efficiency Production efficiency monitoring is important to sustain profitability and competitiveness of a manufacturing company.

Alexander Berdyshevski of Manufacturing and Design Solutions discusses how manufacturers can benefit from monitoring Overall Equipment Efficiency.

Overall Equipment Efficiency (OEE) is commonly used for efficiency estimation. OEE is a function of Equipment Availability (A) and Equipment Performance (P), both expressed as percentages, and is calculated as follows:

OEE = A x P Availability (A) reflects the impact of production time losses, and can be calculated as the ratio of the actual availability (the production time when equipment is making products) against the target availability (the production time originally scheduled):

A = Aactual / Atarget Target availability is calculated as a time interval (usually in minutes) between the start and the finish of the scheduled production time, minus planned breaks for set-up, preventive maintenance, cleaning, lunch breaks and so on. Actual availability is calculated as the target availability, minus unplanned production time losses (such as equipment downtime and breakdowns). When actual time for planned activity (e.g. set-up) exceeds the allocated time, excess becomes a downtime. For example if 15 minutes is allowed for the line set-up and it actually took 20 minutes, five minutes for excessive setup is downtime (DT).

Aactual = Atarget – DT

around and assist their team members. In this case there is a need to estimate and monitor the labour efficiency (L), which is calculated as follows:

L = Lactual / Ltarget Ltarget is the target amount of allocated labour hours (labour recovery) calculated as allocated labour hours for the product (Lstandard) multiplied by the actual output:

Ltarget = Lstandard x Pactual With addition of the labour performance indicator, OEE becomes Overall Manufacturing Efficiency (OME), which is calculated as follows:

OME = A x P x Q x L or

OME = OEE x L The main challenges for any efficiency monitoring system implementation are: • Data collection and analysis. If it takes too much time for production personnel to enter and analyse data on a regular basis, then it would be very hard to maintain the system over any long period of time

It is important that downtime causes are classified and captured from the pre-defined list to be suitable for statistical analysis. Downtime data collected over a certain time period can be an excellent basis to justify continuous improvement projects and associated capital and tooling investment.

• Flexibility. The system has to accommodate required changes dictated by improvement activities, such as introduction of new KPIs, addition of visual indicators, generation of special reports, and so on. If the system is too rigid or incurs considerable cost with every change it may lose its value.

Performance (P) shows the ratio of the actual production output (Pactual) against the standard or target output (Ptarget) when equipment is operational:

• Visual presentation. If results are not easily grasped (for instance if too many numbers on the display), some necessary corrective actions can be overlooked.

P = Pactual / Ptarget

One of the easiest and the most flexible ways to implement OEE or OME monitoring is to use MS Excel, but formula-based spreadsheets quickly become quite complex specifically with a wide range of products with multiple changeovers over a day.

Target output is calculated as a standard hourly rate (R) over available production time:

Ptarget = R x Aactual Actual production output is the units made over the scheduled production time.

Performance is a characteristic of the production rate and it makes sense to classify and collect data for the causes of the slower than required production rate. Performance slowdown is estimated in minutes of lost production time similar to the downtime. In some cases, a quality indicator (Q) is also included in OEE calculation, as follows:

Visual Basic can be used as a solution to overcome increased computational complexity in Excel. User forms with drop-down menus simplify manual data collection (product, downtime or quality issue selection). Product and process data are pulled from the database. Downtime and slowdown causes are selected from the predefined lists.

OEEq = A x P x Q Q is calculated as the actual production output minus the rejected units made or units requiring rework, divided by the actual production output. In some cases the reject/rework calculation is more complex if there is a requirement to reflect the cost difference between rejects and reworks. Sometimes reworks have to be split into separate types to capture difference in associated time losses. It is important that reject and rework types are pre-defined and classified for the statistical analysis to support quality improvement activities.

Quite often being competitive means utilising flexible teams of operators, where the number of operators can vary from one run to the next, or even during individual production runs. This parameter is particularly important if there are a few products that are made on a few lines or cells each day, and operators have freedom to move

AMT Jun/Jul 2016

Example of a manual data collection sheet.

Actual process data can be transferred from the equipment control system or any other external database. In this case the amount of manually entered data is minimised or completely eliminated. Figure 2 shows a data collection sheet where all the data, including downtime and slowdown causes as well as quality issues, are transferred from programmable logic controllers (PLCs). In this example standard

BUsiness Management

set-up time depends on the previous job parameters. That is why it is necessary to enter the initial line status (previous job) to calculate the allocated setup time. Operators can also enter comments to clarify production issues in detail.

A performance database dashboard.

Example of a data collection sheet with data transferred from PLC.

Some PLC manufacturers have developed special packages to establish communication between PLCs and MS Office. For example, Omron offers special software called CXLite that provides excellent integration opportunities between MS Excel and Omron PLCs. In this application PLC memory areas can be read from and written to with a few lines of Visual Basic code. This technology allows users to update production performance practically as often as required.

Performance calculation for a single product.

Pareto chart for downtime causes.

Overall performance over a day.

Production personnel often prefer a gauge-type dashboard of a monitoring display over the digital one as the first one is easier to grasp.

Downtime cause run chart.

A gauge-type performance dashboard.

All routine tasks including periodic and end-of-shift (day) analysis and reports are automated, which gives production personnel more time for corrective and improvement actions. Daily performance data is transferred to the database to monitor performance over the longer than one-day time interval (from beginning of the month, year). Routine long-term statistical analysis tasks such as Pareto or production issue trends can then be generated automatically.

MS Excel-based efficiency monitoring systems can be easily fine-tuned to various manufacturing environments, such as different production types or line/cell configurations, as well as to accommodate specific customer requirements.

I would like to express my gratitude for the pleasure of working with the following individuals and the opportunity to tap into their vast knowledge and expertise during implementation of these systems: Kevin Robson and Darren Webb from Chassis Brakes International Castings; Bobs Reyes, Tony Zullo and Gerry Miller from Fletcher Insulation; Greg Gulley and Voltaire Nacorda from Tyco (Scott Safety); and the Omron team for their ongoing support. www.manufacturinganddesignsolutions.com.au

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Paying the price of poor project management Dwindling standards of project management are having an impact on innovation and efficiency in Australian manufacturing. By Craig Hingston.

prepare for a new product or how to follow it through with us along the design, analysis, manufacturing and testing phases. This is obviously not something that can be solved overnight, but companies need to be aware that when they let valuable technical and project management expertise go, it is detrimental to their future.”

Long-time AMTIL member Archer Enterprises, a precision engineering firm based in Somersby, NSW, is one company that has observed a noticeable drop in the standard of project management across a number of industries, and it is having a negative impact on product development.

“We’re aware that companies have been downsizing since the GFC and now we are seeing the consequences of that change,” says Archer’s Operations Director Russell Byrne. “The people who drove product development and managed it properly, the technicians and the project managers, are missing.”

Byrne adds that without people filling those strategic roles, the quality of project scopes of work has worsened.

“We are seeing junior staff, project officers and in some cases senior executives who don’t have the right technical or management skills being given responsibility to run projects,” he explains. “They approach us with ill-informed intentions and minimal information. We do step in and guide them; that is a normal part of our technology relationship. But the added assistance they require from us has sometimes meant rewriting the scope of works.

Given the general lack of expertise of those involved, it also takes a lot longer for people to make decisions. A few years ago Archer would be handed a solid scope of works

Archer Enterprises’ premises in Somersby.

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Anyone can do it?

Yvonne Butler, Chief Executive Officer of the Australian Institute of Project Management (AIPM), says that some companies have been deploying project management for so long that it has become a generic business capability and there is a belief that anyone can do it.

Archer’s Operations Director Russell Byrne.

and be able to start work on it immediately.

However, according to Byrne, it is now more common to make a start, have someone make changes, start again, see further changes, start yet again, make even more changes, and so on. Besides being a waste of time and resources, this delays the product development cycle and the time products take to get to market.

“Some companies attempt to develop new intellectual property from the board room,” says Byrne. “They don’t understand mechanical and electronic technology or properties of raw materials. Nor do they understand what it takes to plan and

“It is great that elements of project management are embedded in the organisation – we applaud and encourage them for doing that,” says Butler. “But the double-edged sword is that they have the wrong perception of project management and the value it brings to the enterprise. The project management role is handed over to people without formal skills or certification which demonstrates their competency and currency, and the organisation becomes less sustainable.

“Project management protects the value of a company. If you don’t use the disciplines of project management across the organisation you are giving its value away.”

BUsiness Management

on the others and the way to create change where everyone is on the same page is to have project managers involved.”

Butler understands the frustration being experienced by companies like Archer.

Yvonne Butler, CEO of the Australian Institute of Project Management.

As an example, Butler cites the large IT and telecommunications companies that implemented project management cultures a few years ago. Because the initial implementation wasn’t handled very well, those companies then had to embark on multi-billion dollar transformation programs in order to redress the problems so as to become sustainable.

“Effective project management requires professionally trained people who ‘get stuff done’ and bring about positive change to processes and culture,” says Butler. “Not just in a few siloed areas but right across the organisation. At the time of the GFC, boards said we need to prune costs off our bottom line and each department manager had to make head count decisions. There was no regard for their portfolio of projects, what they had in their books, the pipeline. It was a siloed approach. They asked themselves what can we afford to delay? The question should have been what do we need in order to still be competitive when we come out of this?”

Butler believes that process oriented industry sectors, such as manufacturing, often fail to comprehend the value of project management, arguing that they tend to be more asset-focused than project-focused.

She says that project management is highly necessary in manufacturing because it is outcome-focused: it has to deliver an outcome, and when it does this it delivers enduring benefits for the organisation. This includes oversight of current outcomes – the projects being manufactured today – as well as what happens in the future.

At a time when the sector is being told to embrace advanced manufacturing, Industry 4.0, collaboration, automation, innovation and so on, it is going to take skilled project managers to help to facilitate this evolution.

“Project management is needed to integrate change in a business,” says Butler. “There are many disciplines within an organisation that must evolve together. Each one impacts

“We need to make sure that if organisations consciously decide not to retain a project management competency then the layer below needs to know how to govern projects and value risk,” she says. “They need to see the correlation between technical expertise and project management. There is a direct connection between project managers and shareholders because dividends increase when a company continually delivers its work on time and within budget. because We don’t need every managing director or general manager to become a project manager but they need to understand what project managers do. This requires a return to the simpler language that boards understand.”

According to Butler, the future is about making people more aware and improving skill sets: “When you have people in project management roles and they are not competent – in other words they don’t have qualifications that reflect our Australian standards, they don’t understand the balance within an organisation of technical competency with behavioural competency.

It is about so much more than Gant charts.

We have to make sure that business leaders are equipped with knowledge, if not the expertise, of the value of project management and the contribution that certified project managers make.”

“I want Government to come to us first, not the consultants, so that we can show them what is required and what they need to deliver success,” Butler adds. “It’s not all gloom and doom. We are starting to see at state level with the big infrastructure projects that project management is being written into the scope of works. It is not mandated but it is good all the same to see it mentioned. Government tenders

Dr Michael Myers OAM, Founder and Executive Chairman of the Re-Engineering Australia Foundation.

don’t insist on having project management capabilities included so this is one area that we need to look at. The AIPM plans to work with recruitment companies to initiate the promotion of project managers in companies. If they can define what value the project manager brings to their clients they can become ambassadors for our members.”

Everything is a project Dr Michael Myers OAM is the founder of a social enterprise Re-Engineering Australia Foundation, which inspires students regarding careers path opportunities in engineering and manufacturing via a series of hi-tech competitions. One of these is the F1 in Schools Technology Challenge, involving 40,000 young people.

“Manufacturers have deleted soft skills without considering the strategic direction of their companies,” says Myers. “If you ignore or de-value project management you stop innovating, you lose customer service, and you fail to manage your people.

“Everything is a project and has to be managed properly from teenagers designing and making an 80kph model F1 car to home owners building a deck or laying a driveway.

All of us engage in projects in different areas of life without even knowing it. Project management has become so discrete that it is ignored.” www.aipm.com.au

Left: The F1 in Schools Technology Challenge is a global competition aimed at encouraging students to choose careers in engineering and manufacturing.

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Go-to manufacturer of yacht mast invests in ERP to beat the tide

How did a manufacturer of spars and rigging for racing yachts improve business efficiencies and enhance its access to valuable, real-time data to inform its critical business decisions? By Vince Randall, Regional Vice-President at Epicor Software, ANZ. According to a recent survey, nine out of ten organisations across the globe were left exposed to significant business dangers in 2015 due to the impact of unplanned growth. The business leaders surveyed readily admitted that they often fear the consequences of growth.

Some 45% said that they worry their business might take on large or complex projects they do not have the skillset and technology to deliver effectively, as a result of growth that hasn’t been planned for properly. A majority of business leaders believe that in order to adequately prepare for growth they need to have an effective and integrated IT infrastructure in place. This holds true in Australia, with 70% of businesses believing a solid technology system is essential.

These statistics reflect recent comments from, and discussions Epicor has had with, business leaders across a range of industries.

One particular customer, a wholesaler that was a ‘power user’ of one of our legacy enterprise resource planning (ERP) platforms dating back to the mid-1980s acknowledged the software had outlived its purpose as far back as 2002. He finally upgraded in 2014.

What this business owner would tell you today is, had he replaced his ERP platform four years earlier it would have already paid for itself multiple times over through increased efficiency, reduced labour and inventory expenses, and improved customer satisfaction.

The adoption of new technologies plays a critical role in placing organisations in a position to reap the benefits of newfound efficiencies and pave the way for growth.

Southern Spars, a manufacturer of a unique kind, has a similar story to tell. Headquartered in Auckland, New Zealand, Southern Spars’ operations extend to the USA, Denmark, South Africa, Spain and Sri Lanka. ©iStockphoto.com/nikitje.

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Preparing for growth With more than 25 years in business, Southern Spars is a hightech spar and rigging manufacturer for top racing yachts and the company prides itself on being at the leading edge of technology within its industry. Its expertise was forged during a major industry transition in the early 1990s from aluminium to carbon fibre spars.

Southern Spars was quick to make use of the strong yet light material and has since built its company upon an ethos of pushing the boundaries and continuing to innovate.

A few years ago Southern Spars realised it was at a critical juncture and needed to take steps to properly prepare itself for future growth.

At the crux of this was a technology upgrade. “Our old ERP solution was good at the time we selected and implemented it, but we hadn’t upgraded to the latest and greatest available,” said Daniel Malherbe, Group Chief Financial Officer for Southern Spars.

The business had grown to a stage where the management team wanted to leverage the capabilities of new business management tools on the market with more sophisticated features and functionality. Virtually every aspect of a Southern Spars rig is handled in-house, beginning on the design floor where 27 designers and engineers work on each project, so it was critical that they were able to access information as and when needed to operate as efficiently as possible.

“We were making decisions based on the information we were able to get from the outdated system,” said Malherbe. “It allowed us to do our job well and we were still getting it right for our customers, but we needed to be able to make better informed decisions for our own business.

BUsiness Management

“We found we were basing our decisions on a ‘gut feel’ about certain areas of the business because we didn’t have easy access to all the data. There was information we couldn’t readily access and analyse, or at least to do so was unnecessarily time-consuming and laborious.”

Time to upgrade The catalyst for the upgrade was combined feedback from across the company. The CFO wanted to delve further into the numbers and records to obtain a thorough overview of operational and financial information but this was taking longer than it should. The wider employee base also fed back that they wanted a new ERP system, as the old one had become a struggle. With employees now asking for a modern ERP system, the push to upgrade was even stronger.

“We investigated a range of options,” said Malherbe. “Epicor was serving us well but we invited a few vendors to do demos, spoke to external consultants to seek their opinions and the general consensus was in favour of continuing with Epicor and upgrading to its latest ERP offering. Deciding that we will continue to use Epicor ERP was a no-brainer for us. It’s not an old legacy-based system. Epicor is always pushing the boundaries and adding more technology to take its customers and their businesses to the next level.”

Unlike transaction-based legacy systems, unlimited access to business data in a modern, open database environment can give employees the ability to analyse, providing real-time information to make better decisions and call out exceptions. This can lead to improved customer service and growth.

“Since the implementation, we’ve been working through phases of automating activities, modernising procedures, and buying additional modules like Advance Print Management (APM),” said Malherbe.

“We’re also planning to integrate mobility options in 2017.”

Epicor ERP has given Southern Spars the ability to access the data it wants, when it wants. That, coupled with automation capabilities, has already saved over 400 man-hours a year. The benefits of the upgrade have been enjoyed across the organisation. The design team is excited about what the new system can do for them. The accounts payable team now has a more simplified workflow thanks to a traffic light system showing the status of each line item on a purchase order so they know whether or not to process a specific invoice, saving time and effort. And the finance department is able to create reports and dashboards without needing a programming background.

As for future plans, Malherbe knows that in order to realise the full benefits of its new ERP system and ensure maximum return on investment, Southern Spars needs to continually work with, and explore its capabilities.

“There are components and modules we plan to add over time, when it makes sense to do so,” he explained. “The system is flexible enough to allow us to capture data in a way that is familiar to us; in a way that makes sense for our day-to-day business. Now we know accurate, relevant information is available to staff from the shop floor to the back office.”

Collaboration the way to build innovation

The Federal Government has made a pledge to build Australia’s reputation as an intelligent country with innovation taking the lead. By Shermine Gotfredsen, General Manager, Universal Robots APAC The Government’s National Innovation and Science Agenda aims to encourage businesses to embrace risk, entrepreneurship and innovation, to develop new products and services, and to back good ideas and learn from mistakes. The plan is to develop industries that will help to wean Australia off its reliance on the mining sector.

A number of global companies are working in collaboration with governments and business to create innovative solutions that meet the need to work more efficiently and competitively.

One such company is Danish firm Universal Robots, which produces flexible, robotic solutions that automate and streamline repetitive industrial processes while reducing costs and boosting productivity. In an example of organisations working collaboratively with governments committed to innovation, Universal Robots has formed a partnership with the Singapore Government to develop cost-effective robotic applications and solutions for a range of industries.

The Singapore Economic Development Board (EDB) and SPRING Singapore (a government agency responsible for helping enterprises grow) offers grants to support SMEs in tech innovation and adoption. The EDB and SPRING have backed Universal Robots and with one of its local distributors to develop new robotic applications for Singaporean SMEs. A grant from SPRING will cover 70% of the distributor’s project qualifying costs in an effort to spearhead the development of the robotics industry and promote enterprise development, increased accessibility to technology, competitiveness and productivity. Working with end users, the Universal Robots research & development team are working to create specialised solutions to help make the end-user companies into market leaders. The model provides the means to create a commercially viable solution that can be installed quickly into the end-user’s operation. Andrew Pether, Head of Regional Tech Support for Universal Robots, APAC, showcased the company’s newly developed robotic solutions to key stakeholders at its Singapore office in January.

“With the support of SPRING and EDB, we are thrilled to be offering efficient and convenient applications that can palpably offer enhanced productivity for organisations across a range of industries within Singapore,” said Pether. “This model for innovation is one that provides tangible benefits to businesses and results in building sustainable and competitive organisations within the long term.”

In a very real, tangible way, Southern Spars is leveraging upgraded, modernised technology to help it grow effectively and in an intentional way, and in the process the company is becoming better prepared for growth.

With Singapore’s EDB and SPRING joint initiative facilitating national technological innovation in areas such as robotics, it provides a strong case for the Australian Government to explore the potential to institute similar grants. This is particularly pertinent in light of the Federal Government’s pledge to help companies and industries embrace technology and innovation as part of its “Ideas boom” agenda.

www.southernspars.com www.epicor.com

www.universal-robots.com

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Big export success for small Engi-O

Remarkably, this four-year-old business is exporting its home-engineered and home-manufactured products to Europe, the US, Canada and Asia, along with a handful of sales within Australia. By Wendy McWilliams.

Engi-O was established by Andrew Ogilvy in 2012 and after 18 months is nicely settled into its third location in Macquarie Place, Boronia. The company designs and manufactures sophisticated filling solutions for the aseptic and the ESL (Extended Shelf Life) bag-in-the-box industry. The bags/ bladders come in a range of sizes and fitments from two litres to 2000 litres.

Customers come from a variety of industries and filling applications, including wineries, dairies, pharmaceutical, olive oil, juice, syrups and water. The company employs six casuals and has just taken on its fourth permanent employee, a fitter and turner.

“Going from three to four permanents is a hard thing to do,” said Andrew. “The nature of our business is that it has the potential to be very roller coaster. Because individual made-to-measure aseptic filling machines can take a few months to complete, we need to ensure that everyone has work to do every day.

“It’s been an extraordinary journey so far and orders are way above our expectations. I’m fortunate to have a fantastic team of people including the inventor of the bag-in-the-box technology and another person who also worked at the company who owned the patent.”

Inventor on board When the patent expired and the company who had owned it decided to go offshore with their manufacturing, Andrew, who was Technical Manager with this company, saw an opportunity to keep the technology in Australia and build a business, utilising the services of the inventor, Ian Anderson, and a fellow employee.

Investing heavily in R&D is paying off and demonstrating how a small business can take advantage of opportunities; a new order has led Engi-O to becoming a contract packer with two shifts a day. Being a small business means working smarter, which is what Andrew and his Macquarie Place neighbours do when it comes to solving problems.

“When we need a forklift we borrow one from Martin Marine and provide services in return,” Andrew said. “Another neighbour makes soups and purees and we are helping each other with our different expertise, and another business owner is a good machinist so we are looking at utilising his skills.”

Andrew’s advice for other start-ups is to be careful and never outlay too much without testing the water; and value your suppliers,

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Above: An Engi-O model A5 aseptic low-acid bag in box installation in Canada showing the materials handling and centre platform.

keeping their payments up to date so they will look after you. Another tip is to take advantage of government assistance.

Andrew has taken part in the Victorian Government’s Business Development Plan and Strategic Review where half of the cost was met by the government.

“We are also going to apply for R&D tax incentives as we are doing quite a lot of research,” Andrew added.

Kindly reprinted with permission from Knox City Council’s Economic Development Unit, KnoxBiz. www.engi-o.com

Right: Andrew Ogilvy

You do what?

One of Engi-O’s strangest orders is to manufacture Beacon detectors that are placed on the back of cows to detect if they are in season so dairy farmers know when to have them fertilised. The first year, Engi-O made 600,000, and last year it made two million of these little detectors, becoming more popular in New Zealand as a result of the lower Australian dollar. The making of the detectors machine fits Engi-O’s bespoke, customised engineering service. An added bonus was the in-house contract packing of the detectors that was not expected but provides a nice cottage industry.

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Additive Manufacturing

The future of Australian additive manufacturing

With Australian manufacturers undergoing rapid change that is transforming the industry, additive manufacturing is an area of enormous potential, but the opportunities it offers are often misunderstood. By Dev Anand Dorasamy.

With the mining boom having come to an end, manufacturing will carry a greater share of the load as the economy turns to other industries for growth. Over the past decade, the rising prominence of imports in the domestic market has placed significant pressure on the industry.

However, the depreciation of the Australian dollar has provided some support for our manufacturers, making the products made in this country more affordable abroad, as well as making imported products less competitive.

Nevertheless, the domestic manufacturing sector continues to face strong headwinds.

With labour costs that are among the highest in the world, Australia is not strategically suited to compete in the mass manufacturing industry against low-cost manufacturing bases such as China. On the other hand, Australia is very well equipped to cater to the manufacture of products that require complex and customised designs. Additive manufacturing is an ideal tool in facilitating such forms of production.

Frost & Sullivan’s recently completed research report – Strategic Analysis of the Additive Manufacturing (3D Printing) Market in Australia – analyses the overall trends

in the additive manufacturing market in Australia, as a first step in demystifying this rapidly growing yet often misunderstood industry. Key insights presented in this study were obtained from primary data gathering, through telephonic and face-toface interviews with additive manufacturing system manufacturers and distributors as well as key academics in the space in Australia using a structured discussion guide. The discussion guide included closed and open-ended questions, to obtain quantitative data, as well as qualitative feedback.

The transition to “smart manufacturing” is driven by global industry structural changes, aiming to move the sector away from low-cost, high-volume production towards high-margin, low-volume models.

Advanced manufacturing technologies, such as additive manufacturing or 3D printing, are revolutionising the industry, with new capabilities to design and manufacture complex, customised products with short lead times, minimal tooling and wastage, and low labour input.

However, at the moment the pace of adoption of innovation technologies such as additive manufacturing among most traditional Australian manufacturers is still low.

Large Australian firms perform relatively poor on innovation on average, ranking 21st out of 32 OECD countries in 2014.

In contrast, Australian small to mediumsized enterprises (SMEs) are deemed to be more innovative, ranking fifth out of 32 OECD countries, according to the Australian Innovation System Report 2014.

However, due to the high cost of many of the advanced manufacturing technologies, these tools are often out of reach for smaller Australian companies.

The most apparent benefits of additive manufacturing compared to traditional subtractive methods are well known: reduced cycle times (with up to 90% time savings); reduced parts count; lower design costs (with savings of up to 75% ); and Just In Time (JIT) delivery, resulting in little or no finished inventory in stock. Nevertheless, it is important to remember that traditional manufacturing still holds an unassailable position in mass manufacturing that additive manufacturing is unlikely to ever unseat. That is, until the focus of production and products shifts from cost to performance. The most significant, and often least understood, benefit of additive manufacturing is in its ability to produce shapes and designs that cannot be made using traditional subtractive methods.

Amaero Engineering recently succeeded in producing components for the world’s first 3D-printed jet engine.

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Additive Manufacturing The aerospace industry is already reaping the benefits of additive-produced parts that are significantly lighter than their traditionally manufactured counterparts.

Subtracting boundaries

manufacturing systems and consumables at their retail stores, the consumers of these products seem limited to hobbyists and designers.

The average person may not be aware of the simplification process through which a designer’s vision is distilled and reiterated in order to make a component or product “viable” for traditional manufacturing. More often than not, this involves significant changes in the design and functionality of the original concept, leading to compromised aesthetics and performance.

This phenomenon is so prevalent that it is not uncommon for designers to “selfcensor” in order to meet manufacturing requirements.

In much the same way that the personal computer gained mass acceptance due to improved accessibility of its applications, it is expected that home-based additive manufacturing systems will need significant efforts in making design software accessible to the average person in order for it gain mass acceptance.

Adelaide-based Maker’s Empire is tackling the issue of design software complexity by tailoring it so that it can be used as part of primary and secondary school programs.

The company is experiencing strong growth both domestically and internationally, with its program being deployed across schools in Australia and the US.

Additive manufacturing technology, on the other hand, has almost no restrictions on what can be produced, and hence gives designers the freedom to explore the boundaries of what is possible. The most significant impact this phenomenon has had is in the improvement of part performance.

The aerospace industry is already reaping the benefits of additive-produced parts that are significantly lighter than their traditionally manufactured counterparts.

Overcoming cost barriers

Australia is well placed to take advantage of this trend given that it provides 51% of the world’s titanium ore—a material considered vital for aerospace innovation. The Monash Centre for Additive Manufacturing was built to drive the establishment for high-end, waste-free, tailored manufacturing for the aerospace industry. The commercial arm of this centre, Amaero Engineering, recently succeeded in producing the world’s first 3D-printed jet engine components.

The high cost of additive manufacturing systems, particularly metal-based systems, still proves to be a major barrier to the mass adoption of this technology, particularly among SMEs. One Australian company working on making metal-based additive manufacturing technology more accessible to manufacturing firms is Perth based Aurora Labs, who claims to have developed the world’s cheapest additive manufacturing system for metals.

It is expected that other industries that have relatively low-volume production needs and that place a significant premium on performance or aesthetics will reap benefits learned from catering to the aerospace industry, and will witness increased penetration of additive manufacturing technology in their supply chain.

While the widespread application of additive manufacturing technology in commercial manufacturing is merely a question of time, the proliferation of home-based additive manufacturing systems in Australia is another matter. Even though this year has seen mainstream retailers such as OfficeWorks and Aldi offering additive

Dev Anand Dorasamy

Nonetheless, even with significant improvements in usability of design software, it is doubtful that the average household will ever need a dedicated additive manufacturing system at home.

The more likely scenario would be that the number of additive manufacturing service bureaus will increase dramatically, and will be located in more accessible retail spots.

After years of promising to revolutionise the world, it is easy to understand why additive manufacturing technology has many sceptics. However, perhaps part of the problem has been the focus on the wrong benefits of additive manufacturing, with not enough attention to what it makes possible. Additive manufacturing will not only change “how” the world makes but more importantly “what” it makes. And Australia cannot afford to come late to this party.

Dev Anand Dorasamy is a Consultant – ANZ at Frost & Sullivan. www.frost.com

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Additive Manufacturing

A unique interplay between technologies In the market of additive manufacturing technology, DMG MORI is concentrating on the integral combination of laserassisted material build-up and chip removal, while promising unrestricted freedom of design with the utmost precision and surface quality.

In times of increasingly complex and individualised components, additive manufacturing processes with their high degree of geometrical freedom regarding component design are an effective way of escaping the complexity trap. However, the technology is slow, inaccurate and expensive which, up to now, has made it difficult to make inroads, particularly in the field of metal processing.

Against this background, the combination of laser deposition welding by means of a powder nozzle with chip removal opens up fully new perspectives. As a pioneer and trendsetter, DMG MORI is already offering two groundbreaking hybrid machines.

We spoke to Friedemann Lell, Sales Manager of SAUER, who is responsible for additive laser technology in the DMG MORI Group, about the advantages and areas of application of the combimachines.

AMT: What is the difference between the LASERTEC 3D machines and other additive metal processing systems?

Friedemann Lell: In the field of additive manufacturing, we are focusing on powder deposition welding using lasers, a technique which has basically long been used for carrying out repairs, for example in tool making and in engine construction. In this process, the powder is melted onto the base material by the laser beam. On the other hand, other laser-based additive manufacturing processes work using the layer principle, in which a component is built up from powdered material layer by layer.

AMT: What advantages do powder deposition welding using lasers offer compared with layering?

FL: First of all, I would like to point out that we also build up components layer by layer, but only use powder where it is necessary. As a result, the use of powder is significantly less than with classical powder bed systems. In addition, with powder deposition welding, the material can be built up around 10 times faster than in the powder bed. But even more decisive for us is that the process is ideal for incorporating into our high-tech machines, thus enabling an integral combination of additive manufacturing and chip removal. In this way, we offer the customers the best of both worlds!

AMT: What are the customer benefits?

FL: Although additive manufacturing may be fascinating with regard to the almost unrestricted geometrical freedom in design, all processes are painfully slow. In addition, the components generated bear no comparison with the excellent results of conventional machining with regard to accuracy and surface quality. By combining additive manufacturing and chip removal, we achieve geometrical freedom while chip removal brings the precision and quality for the component.

AMT: Couldn’t you just use two separate machines in tandem?

FL: Sequential manufacturing would cancel out an elementary advantage of our LASERTEC 3D machines.

Friedemann Lell, Sales Manager of SAUER.

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Firstly: In component design, geometrical freedom is the strongest argument for the use of additive manufacturing

because it is unique. Otherwise, as a single technology, the process is too expensive, too slow and too inaccurate, at least as far as our target market in metal processing is concerned.

Secondly: Geometrical freedom means that workpieces have altogether new levels of complexity. Internal cooling channels for injection moulding tools or freely formed geometrical elements in turbine and engine manufacture are just two concrete examples. If these components were to be produced sequentially, it would no longer be possible to achieve many of the contoured areas of the workpiece using a lathe, milling machine or grinding machine after additive manufacturing.

And thirdly: By combining the processes in our LASERTEC 3D machines, the user is able to first build up the component to a certain height using laser-assisted powder deposition welding and subsequently to machine certain areas where necessary.

Especially large components are built cost-efficient in that way. As a result, freely formed workpieces in the truest sense of the word are produced with the utmost precision and excellent surface finish thanks to a unique interplay between technologies.

AMT: As well as the LASERTEC 65 3D, DMG MORI has launched a second machine – the LASERTEC 4300 3D. What are the differences between these products?

FL: In its basic form, our LASERTEC 65 3D is a classic fiveaxis machine for high-precision milling operations up to five-axis simultaneous machining. For additive manufacturing, it is equipped with a 2.5kW diode laser. As well as the complete hybrid production of components, the machine is also suitable for carrying out repair work and applying partial or full coatings, for example in tool and mould-making.

As well as laser deposition welding and five-axis milling, the LASERTEC 4300 3D, which was launched during the Innovation Days event in Chicago in June and will go into serial production at the beginning of next year, also brings turning into play. This now enables rotationally symmetrical components to be produced using the hybrid process. Fitted with a mirrored C-axis, workpieces can even be fully finished on the rear and therefore on a total of six sides by means of the counter spindle. Even longer workpieces

Additive Manufacturing

are no problem, as in this case, the lower tool turret supports the component during the manufacturing process.

With both machines, the laser, including the powder build-up head, is optionally mounted in the Capto or in the milling spindle HSK tool holder and introduced automatically as required. Another special feature of the LASERTEC 4300 3D is that up to five powder build-up heads are available for different operations – for example for internal and external coating of cylindrical components. This provides additional degrees of freedom for the manufacturing strategy.

AMT: You have several LASERTEC 65 3D machines in the market.

What has been your experience and, an associated question, is additive manufacturing already a standard process?

FL: Practice confirms our expectations and, even more importantly, those of the customer. However, I would not go so far as to describe additive manufacturing as already being standard technology.

That would awaken false expectations. Additive manufacturing, particularly in the field of metal processing, is a complex process where the result depends on the perfect interplay between machine, material and process like nowhere else. For example, it follows from this that the process must be redeveloped in all its parameters for every material. In this regard, we provide intensive support for our customers. We also co-operate very closely with research institutes in the field of material and process development.

AMT: What does this mean for the further spread of additive manufacturing in the metal processing industry?

FL: Driven by the fascinating possibilities of the process and based on ever more frequent and more imposing successes currently, particularly in aircraft manufacturing, engine and turbine technology, and medical engineering, additive manufacturing is one of the technologies for the future in the metal processing industry.

This is also true particularly against the background of the digitised process chain in the Industry 4.0 age and the trend towards individualised products. Anyone wanting to manufacture finished products directly from CAD data will need additive manufacturing.

And if they also want excellent surface finish and high precision, they will need our hybrid machines. www.dmgmori.com

Right: Complete generation of 3D-parts: Turbine Casing (A) and Blisk (B) for the aerospace industry.

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Wysiwyg 3D – Raising awareness of Parkinson’s Wysiwyg 3D scanned Parkinson’s Disease sufferer Bernie McGrath and 3D-printed him as a miniature wobbly dashboard doll, as part of a project to raise awareness of the illness.

It’s Not Funny (INF) is a collection of people with Parkinson’s disease celebrating the positive aspects rather than dwelling on the negatives. The INF team thought it would be a great idea to make a dashboard wobbly doll, as a good representation of a positive attitude to living with the condition.

“We wanted to create a wobbly doll, Australian-made and with a genuine look to it, somehow linking it back to real people and Parkinson’s,” says John Peplow of INF. “I investigated getting a doll made but soon realised this was a mammoth exercise. I soon realised that getting a 3D scan and a 3D print was not that easy.

Not because of the technique, but because I was confronted with a maze of unsuccessful attempts until I found someone who knew what they were talking about.”

That someone was Shane Rolton, Managing Director from Wysiwyg 3D, who listened to the idea with interest, in part because his grandfather had Parkinson’s. Rolton saw an opportunity to use Wysiwyg’s expertise to contribute to a good cause.

The whole process was completed at Wysiwyg’s offices in Peakhurst, in southern Sydney. It only took around ten minutes to scan Bernie with an Artec portable 3D scanner, with the data aligned with Artec software. Post-processing was undertaken using Geomagic Software, before the model was printed on a 3D Systems Projet 4500 printer.

“It was fascinating to see how quickly the 3D model appeared on the computer screen,” says Peplow. “And Bernie had fun looking at his digital ‘mini-me’.”

Using 3D printing allowed Wysiwyg to print various smaller versions, which were subsequently modified with a little spring so that the figure would wobble when moved. Using the Projet 4500 printer meant Wysiwyg could ensure parts were strong enough to

be attached to a car dash, yet light enough to achieve the right wobble. It could also be printed in full colour.

“The thing that’s special for us is its realism,” says Peplow. “This was very important for our project because INF is about real people with a larger-than-life challenge, coping with Parkinson’s.”

Parkinson’s is recognised as one of the worst degenerative illnesses, but it is not considered a national health priority. By raising funds through the sale of the Bernie Dashboard Doll and an accompanying book, INF hopes to raise public consciousness about the disease in a light-hearted way. www.itsnotfunny.com.au www.wysiwyg3d.com.au

3D Vinyl PVC: An Aussie world-first

Sydney-based Chemson Pacific has announced the launch of 3D Vinyl PVC, a groundbreaking invention 100% conceived, developed and tested in Australia. It is believed to be the first of its kind in the world.

By pioneering a PVC formulation with true “thermoplastic” 3D printing properties, specifically designed for use as a 3D printing filament feedstock, the Chemson invention broadens the options available for users of 3D printing: from cottage-industry makers and hobbyists, to advanced manufacturing.

3D Vinyl’s unique qualities remove the constraints formerly imposed on the majority of accessible 3D printing platforms. The product will enable users of these systems to move beyond rapid prototyping and develop end-use parts and products in a variety of low-run production deployments.

3D Vinyl is weatherproof, UV and solvent resistant, and is Group-1 fire retardant, capable of AS3837 compliance. It boasts low embodied energy content compared to incumbent polymer-based filaments, with a sustainable footprint requiring 50% fewer fossil fuel inputs, using natural gas rather than being derived from crude oil. It features improved rigidity, eliminating bottom layer warping and poor bed adhesion, and is excellent for generating support structures, which are easily removed. Benefits of 3D Vinyl for industrial 3D printing include low melt viscosity, excellent flow properties, heat stability, excellent layer adhesion and enhanced durability.

Regional alliances with PVC industry leader Welvic, CSIRO and tertiary bodies will bring 3DVinyl to market for Australia, New

AMT Jun/Jul 2016

Photo: Chris Dunn (www.orangeorbphotography.com.au)

Zealand and ASEAN. A strategic partnership with US-based Functionalize will co-develop conductive, electrostatic dissipative and other specialised formulations of 3D Vinyl, and expand its market reach in North America, Europe and beyond.

“3D Vinyl is a definitive new 3D printing material that will bring a combination of physical properties not available with the current incumbent polymeric materials,” said Dennis Planner of Chemson Pacific. “3D Printing is currently one of the fastest growing, valueadding industries internationally and will be an important source of mentally-stimulating career paths and new business growth for the future, which I’m absolutely proud to be a part of. 3D Vinyl brings a new era for the PVC Industry and Advanced Manufacturing, here in Australia and worldwide.” www.3dVinyl.com.au

additive manufacturing

Lamborghini speeds workflow with 3D printed production parts

From its base in Sant’Agata Bolognese, Italy, Automobili Lamborghini can lay claim to being a manufacturing epicentre for some of the world’s most sought-after super sports cars.

Lamborghini prides itself on a 50-year heritage that has seen its brand become synonymous with extreme and uncompromising automotive design. The company has created a series of extraordinary cars that include the 350 GT, Miura, Espada, Countach, Diablo, Murciélago, Gallardo and Aventador, as well as several limited series such as the Reventón, Sesto Elemento, Aventador J and Veneno.

Lamborghini meets this objective partly through 3D printing, which the company uses throughout the entire lifecycle of its parts, from rapid prototyping applications to production parts. Today Lamborghini is owned by Audi, part of the Volkswagen Group. With its image and value proposition as important as ever, the company relies upon pioneering technologies to uphold its reputation for automotive excellence.

Fabio Serrazanetti of Lamborghini’s car body technical department says the company’s engineers first explored FDM technology and Fortus 3D Production Systems in order to meet demand for highstrength production parts tough enough to endure the rigors of highspeed racing, as well as the need to create complex geometries in a very tight timeframe.

“We use Stratasys technology to produce FDM-printed production parts because, quite simply, it meets all the requirements demanded of it,” he explains.

Serrazanetti adds that the 3D printer fulfills the need to create highperformance aesthetic parts like profiles and air conduits: “In the motor racing world, the capability to very quickly output highly durable parts and components within a seemingly unlimited design scope offers an unprecedented advantage.”

Beyond the racetrack, 3D printing has also accelerated Lamborghini’s rapid prototyping applications by slashing costs and enhancing workflow efficiencies. Having previously outsourced its prototyping requirements, operations were brought in-house in 2007 with the installation of a Dimension 1200es 3D Printer. This was followed by a Fortus 360mc Production System in 2010 and a Fortus 400mc in 2013.

As Serrazanetti explains, the in-house FDM printing systems quickly delivered a raft of important and tangible benefits.

“Outsourcing our rapid prototyping operations proved both a lengthy and costly exercise,” he says. “Today we have overall greater control of projects and have optimized lead times and reduced costs in the process.”

Serrazanetti and his team use 3D printing predominantly to produce scale models and advanced functional prototype parts for design verification and fit and form suitability. These include an array of different exterior parts – from section bumpers, grills, aesthetic frames and those in the engine bay – to various interior parts that span door panels, seat covers and steering wheels, along with aerodynamic components such as conveyors and air heaters.

FDM eliminates tooling, which keeps costs down and allows rapid iteration on new designs without manufacturing constraints.

Within these applications, the choice of materials varies according to high temperature requirements and the level of stress subjected upon the model during assembly, dimensional and mechanical testing.

“We aim to use materials that mimic the material properties of the final product,” explains Serrazanetti.

For example, Lamborghini uses ULTEM 9085 resin for the grill, since that part A 3D-printed air aspiration will be subjected to high engine conduit. temperatures from the engine compartment. Serrazanetti says the ULTEM material helps field urgent requests from Lamborghini’s Advanced Composite Research Center: “It allows us to quickly and confidently produce extremely strong complex parts when the timeframe leaves the technicians with no other option.”

He adds that the company also uses PC-ABS since it’s perfectly suited to producing certain interior parts due to the material’s excellent feature definition and surface finish.

Serrazanetti and his team typically test functional prototype parts on static scale model cars, as well as mount 3D-printed parts onto working prototype versions of the company’s next launches. These cars then undergo more intensive track or road testing to gauge a more realistic performance evaluation of specific parts during the development phase.

With the ability to dramatically improve cost and production efficiencies within Lamborghini’s rapid prototyping operations, Serrazanetti says that 3D printing makes his and his team’s life easier.

The Fortus 400mc 3D Production System produces parts that include Nolders, an aerodynamic profile installed under vehicle bumper.

“At the moment Stratasys’ technology delivers the fastest and most economical means of constructing prototype parts for us,” he concludes. www.stratasys.com

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Company Focus

Décor Engineering – A successful balance Décor Engineering is a classic example of an Australian manufacturing firm that has shown its ability to forge valuable opportunities by taking on new markets. By Nina Hendy.

The real stalwarts of the manufacturing industry have a clear understanding that there is always a fine balancing act between being a well-established brand that is known to many, and being recognised as sitting at the cutting edge of innovation. A privately owned company, Décor Engineering has managed to achieve this delicate balance, elevating it to an enviable position as an industry leader within its own specific niche.

Based in the bayside suburb of Seaford, in Melbourne’s south-east, Décor has strong, long-established foundations in the Australian car manufacturing industry. The company began life in 1970, back in the days when there were no fewer than five car manufacturers operating in Australia.

Those five car-makers all required hundreds of different parts that needed masking and painting, so Anton Derlet set up Décor to meet that need. Derlet began his business operating out of his garden shed in the early days, before moving to a factory site a year later as it became clear the fledgling company would need to begin scaling up production. Over the course of the next decade the company continued to enjoy strong growth providing spray painting services and manufacturing paint-masks.

In the 1980s, George Reisacher, a skilled tinsmith and engineer, came onboard and bought into the company, further developing its capabilities with regard to highly accurate masking for painting complex shapes, delivering a degree of precision that had previously been almost impossible to achieve. He designed and built copy routers for the machining of the wood trims for a variety of models of cars,

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as well as all production tooling and fixtures.

Reisacher’s arrival was followed in the mid1990s by Cedric Lazarus, who also took a stake in the company and brought with him a wealth of experience in manufacturing and business management. The company purchased its first two vacuum metallising machines soon after that, as it began to supply metallised products for markets such the homewares and signage sectors.

Décor also started the manufacture of decorative wood trims for higher-end car models, such as the Ford LTD, the Ford Fairlane and others.

In 2006 Tim Dash and wife Natalie purchased Décor and maintained the strategy of continuously developing new products, while still retaining the expertise

and years of experience present within the company. Tim brought with him more than a decade of automotive experience accrued during his time with GM Holden, along with an extensive background in information technology and electronics. Natalie has also been heavily involved in the business, bringing with her 15 years of experience in the printing and scanning industry.

The company has enjoyed a strong record of success in terms of low staff turnover, with most of Décor’s personnel having worked for the company for more than 15 years. This ability to retain its people has been to Décor’s advantage, as they have regularly proven themselves to be multiskilled, dynamic and adaptable to the changing needs of customers.

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In more recent years, Décor began to realise that the Australian car manufacturing industry was in trouble, and that it would eventually cease to exist. In readiness, it has focused heavily on developing new markets. It developed spray and metallised conductive coatings for the electronic industry in conjunction with top aeronautical companies. It was also one of the first companies to introduce the physical vapour deposition (PVD) plating process into Australia. This process is an environmentally-friendly process that involves no chemicals and is a direct replacement for the electro-plating process.

Décor now derives less than 2% of its sales from the automotive sector.

services well before Décor decided to make the commitment and make it available in Australia. Ecochrome is the only company in Australia with this technology available to the broader market. While it has been available in the US and Europe, this is the first time it has been available on Australian shores.

A talent for adaptation

“Our limitation is only the size of the part we can fit into our vacuum chamber, which is close to a metre square,” says Tim. “However, they are able to process many hundreds of parts in one day.”

Décor has utilised its capabilities and areas of expertise across a wide variety of different products over the years, including wood trims, upholstery, door trims, glue and fabric components. In recent times, it has established a new venture, Ecochrome, introducing an environmentally friendly chrome plating arm to its business.

Ecochrome was set up to address the growing demand for chrome-plating services, which had been attracting strong interest from the market. Tim says that he could see that the local market was clearly showing a strong need for chrome-plating

The process enables Ecochrome to coat any type of plastic with real metal inside a vacuum chamber. This is a cutting-edge process that is a greener and significantly faster alternative to electro-plating chrome.

It has a further advantage, in that other metals such as stainless steel, brass, titanium and various other metal alloys can also be used.

Unlike electro-plated chrome, with the Ecochrome process, the coatings do not lift, peel, blister or bubble. Moreover, it is a dry process with no use of chemicals, instead employing plasma to metallise the products.

“This is a decorative PVD process that’s quicker and less costly than electroplating,” says Tim. “With the use of different metal alloys, we can achieve a wide range

of colours and gloss levels, and a full or translucent finish. Being a low-temperature process, most plastics can be done without any warpage, and glass and metal parts can also be coated.”

Tim explains what occurs in the vacuum chamber during the Ecochrome process.

At high vacuum, a plasma is created using argon gas, which displaces metal from a sacrificial target and deposits it onto the parts that are to be plated. By changing the gas to nitrogen, a nitride of the metal can also be deposited.

“This technology is used for cosmetic, conductive and reflective coatings,” he explains. “These industries include automotive, marine, lighting, signage, homewares, furniture and others.”

For example, the Ecochrome process has been used on glass and sunglasses for many years. It can coat plastic mirrors for cars, or the face shields of an astronaut’s helmet. The process is also, Tim adds, ideal for the gaming industry, in areas such as the coating of LED chaser lights.

Current customers for this process include the automotive and marine industries, and manufacturers of products ranging from lighting, signage and lighting reflectors, through lawn mowers, perfume and cream bottle caps, to garden pots and office furniture, just to name a few.

As for the future of Décor? Tim already has plans to purchase another PVD machine to meet the needs of other emerging markets and keep in the forefront with the latest PVD technology. The future is looking bright, that’s for sure.

“The growth potential for both Décor and our Ecochome service is growing all the time,” says Tim. “And we look forward to servicing the market here into the future.” www.decorengineering.com.au www.ecochrome.com.au

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Cutting Tools

Thread milling – ‘Tapping’ into the future Thread milling has become increasingly popular within the global metalworking industry. Today’s CNC machine tools provide effective cutting by helical interpolation, and this advantageous feature ensures a growing trend of thread generation by the milling process.

Although tapping remains the most common internal threading generation process, the highly efficient thread milling technique has ended tapping’s dominance of as the main method of cutting threads in relatively small diameter holes.

Even though tapping is considered highly productive with some obvious pros, this traditional method also has evident cons.

The main problem encountered when performing tapping is chip evacuation. A long chip can clog the flute of a tap, which may cause the tap to break in a hole, and possibly cause an entire machined part to be scrapped. However, when performing thread milling, effective chip evacuation is achieved without difficulty.

Material hardness is another common impediment to efficient tapping. Although the majority of today’s taps are not suitable for machining hard materials, thread mills produced from solid carbide considerably expand the range of hard materials that are able to be tapped.

Thread milling delivers outstanding versatility. For instance, a single multipleform thread mill is able to produce screw threads with the same pitch in holes of different diameters. In addition, a single point thread mill of a partial profile is also suitable for machining threads in accordance with various standards, for example, both ISO metric and American National. In comparison, the dedicated nature of a tap means that it can only be applied to a thread of a specific diameter and pitch. Also, a thread mill is an excellent tool for making threads in blind holes.

Thread milling enables the ability to overcome a range of tapping problems, such as tool bending, wear and material “springiness”.

Despite the growth of thread milling, the traditional tapping method has important advantages (ease of operation, minimising

the work of a machinist, etc.), which explain its continuing widespread use. However, industry has so widely accepted thread milling as a preferred option that it is simply impossible to imagine manufacturing without mills that make threads.

In response, cutting tool producers now offer customers a wide choice of different thread mills. Iscar has developed a wide range of advanced thread milling products, including indexable and solid carbide tools.

An indexable tool that carries replaceable carbide inserts may have a design configuration such as a mill with shank or a shell mill with a central bore for mounting on an arbor. The main advantage of indexable tools is great versatility. By changing the inserts, the tool can turn into a cutter for milling external or internal threads which meet the requirements of different standards. Moreover, this process may enable users to find a more effective cutting geometry depending on the material of a machined workpiece. Each of these tools has internal channels to enable the delivery of an effective coolant supply into the cutting zone. An ingenious solution is to use helical threading inserts in MTSRH indexable tools.

The helical cutting edge of the inserts, as in solid carbide endmills, ensures an easy, light cutting action, significantly improving the performance of the tool. In addition, inserts with smooth helical cutting edges can be mounted onto the tools. Therefore, the MTSRH tools may also be applied to the finish milling of square shoulder, and as a result, they can successfully compete with 90° milling cutters.

Iscar’s family of solid carbide thread endmills feature a comprehensive range of cutters that have a range of profiles for the generated various threads, diameters, overall lengths and neck lengths. In addition, two separate coolant supply arrangements are available: one central hole, or coolant outlets located in flutes. Largely, Iscar’s design approach to thread milling tools is based on indexable or solid carbide cutters. However, Iscar also

AMT Jun/Jul 2016

supplies a unique product – a replaceable, solid carbide Multi-Master head for thread milling.

Launched more than 15 years ago, the Multi-Master range is a family of modular tools that comprises shanks and interchangeable carbide heads. Although originally intended mainly for die & mould applications, MultiMaster’s versatility ensured it soon became popular in many other industrial sectors.

This popularity inspired the introduction of thread milling heads to the range, further extending Multi-Master’s flexibility.

Today, Multi-Master provides customers with many more options, including single point milling heads for a 60°and 55° partial thread profile. Also, Multi-Master successfully adopted the cutting geometry of solid carbide multiple-form thread endmills for interchangeable cutting heads.

These heads are designed for milling internal and external threads in accordance with ISO, UN, UNF, UNEF and BSP specifications.

For the customer, the availability of a wide variety of Multi-Master shanks significantly simplifies the assembly of optimal tool configurations for specific threading operations. The use of Multi-Master also allows users to slash tool stock and remove the need for special (tailor-made) thread mills. The introduction of the new thread milling heads allows more effective use of the shanks that are already in operation in other processes, and increase utilisation rates. When compared to solid carbide thread mills, Multi-Master provides more reasonable and sustainable utilisation of cemented carbide. Therefore, by further expanding its applications into thread milling, Multi-Master has become the ideal multi-functional tool family. www.iscar.com.au

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Cutting Tools

The age of new materials - is the future now?

Throughout history, materials and advances in material technology have influenced humankind. Now we might be on the verge of the next shift in this type of technology, enabling products and functions we never believed possible. By Mark Teague, Business and Communications Specialist at Sandvik Coromant.

Industry is demanding that materials be lighter, tougher, thinner, denser and more flexible or rigid, as well as heat- and wear-resistant.

At the same time, researchers are pushing the boundaries of what we imagine is possible, seeking to improve and enhance existing materials and at the same time come up with completely new materials that, while years away from day-to-day use, take us down entirely new technological pathways.

Based on the research we’re seeing today, the field of applied material science is set to move in new, almost science-fiction-like directions. Looming resource scarcity is demanding innovations and out-of-the-box thinking. On the materials front, composites with desirable attributes such as low weight, high strength and high durability look likely to take a larger market share, and more of these materials will likely be based on renewable resources, as the need for this becomes greater. The most promising jewel in this arena is graphene.

Heading for the graphene revolution Graphene is a single atom thick (a million times thinner than a human hair) but 200 times stronger than steel by weight, extremely flexible, super light and almost transparent, with great heat and electricity conductivity. In fact, researchers at Nankai University in Tianjin, China, recently found that a graphene sponge can turn light into energy, thus taking humankind one step closer to a fuel-free spacecraft, one that runs by the light of the sun.

Graphene was discovered almost accidentally when professors Andre Geim and Kostya Novoselov at the University of Manchester in the UK experimented with pencils and sticky tape in 2004. In 2010, Geim and Novoselov won the Nobel Prize in physics for their graphene research, and the European Union subsequently

committed 1 billion euros to fund the Graphene Flagship, a research initiative aimed at speeding up the development of commercial applications.

Potential areas of application range from water purification and energy storage to household goods, computers and other electronics. Meanwhile, although graphene-related patents are increasing by the thousands, widespread industrial adoption of graphene is limited by the expense of producing it – but that may be about to change. Researchers at the University of Glasgow have found a way to produce large sheets of graphene at a cost some 100 times cheaper than the previous production method.

Synthetic skin, capable of providing sensory feedback to people with limb prostheses, is one of the many possibilities that could grow out of this development.

“Graphene could help provide an ultraflexible, conductive surface that could provide people with prosthetics capable of providing sensation in a way that is impossible for even the most advanced prosthetics today,” says Dr Ravinder Dahiya, who led the research team at the University of Glasgow.

The death of metals?

Metals have dominated industry, defining entire periods of human history. Such long-term use has created a wealth of information and expertise, but scientists and researchers continue to work to extend the boundaries of these materials. Nanomaterials figure prominently in this research, enhancing metals and opening up new application areas. Developments in metal matrix nanocomposites – composites that partially consist of carbon nanotubes or nanoparticles – could usher in a new era of weight reduction in the aerospace industries, with added strength and stiffness.

CoroMill745 – Double-sided, multi-edge milling Offering high productivity and a low cost per edge, the CoroMill 745 has a double-sided, multi-edge design that is ideal for large batch productions. With its tilted insert positioning system and sharp cutting edges, this milling cutter offers a light cutting action at low power consumption.

With a total of 14 cutting edges per insert, the CoroMill 745 is a cost-efficient choice for face milling. The assortment includes three pitch versions. The differential pitch design of the MD pitch is best when vibration is a factor and is radially compensated to ensure equal chip thickness for every insert. The M pitch is best for general applications and the H pitch has a higher number of teeth making it the best choice for higher productivity. The M and MD pitch both have the same number of teeth.

Designed to make insert indexing quick and easy, the unique insert positioning system in the tip seat and heptagonal insert design keep the inserts securely in the pocket when mounting.

The inserts are tilted in the tip seat to create a positive cutting action. Inserts geometries and grades are available for steel and cast iron materials. For roughing to semi-finishing applications,

AMT Jun/Jul 2016

the strong and light cutting inserts provide reliable face milling in all types of milling machines.

“You might see other multi-edge concept milling cutters on the market but none have the performance of the CoroMill 745,” says Matts Westin, Global Product Manager for Milling. “The science behind it is impressive. The unique double-sided, multi-edge insert design has 14 positively tilted cutting edges which are spaced out at different positions resulting in a milling cutter that is quiet and soft. For our customers, that means that they get a highly-productive milling cutter, increased tool life at a lower cost per component.”

Cutting Tools

If it’s broken, let it fix itself Nanocomposite research is opening up the possibility of materials that fix themselves, much the way the human body heals itself.

Researchers at the Beckman Institute’s Autonomous Materials Systems Group at the University of Illinois in the US are working on fibre-composite materials with self-healing properties that involve the integration of healing agents that are released to mix and polymerise when a defect is detected.

“Materials that heal themselves are coming,” says material scientist Mark Miodownik. For now, what’s technically possible isn’t close to being reasonable economically, but the possibility of fixing anything on the fly, from airplane wings to bike frames to car parts crucial to the safety of vehicle and passengers, is on the horizon. And it will have massive impact on product development, life cycle and sustainability. Researchers are even working on materials that will allow a roadway to repair itself instead of waiting for an overworked, understaffed maintenance crew.

Outperforming nature For thousands of years, material science moved forward through a series of accidental discoveries of materials that existed in nature.

Today researchers are looking beyond what’s in the natural world, combining multiple conventional materials or parts of materials and focusing on the inherent structure or pattern, to create properties that do not exist in nature – or at least haven’t been discovered thus far.

One such development is an arrangement of ridges formulated to resemble a shark’s skin. The micropattern, named Sharklet, protects against the harboring and transmission of bacteria and is being developed for use in hospital and health-care settings.

Another materials development involves invisibility. Physicists in several countries are working on metamaterials that hold the promise of rendering objects invisible by cloaking them with a material that can bend the electromagnetic radiation, such as light, around an object, creating the illusion that it isn’t really there.

Material science and the development of new materials, as well as improvement of existing ones, look likely to play a crucial role in such areas as resource scarcity and sustainability. New materials – for example, light-absorbing building materials – could help counter global warming.

We seem to be on the verge of a new age, characterised not only by digitalisation and the Internet of Things but also, importantly, by new materials – materials that can make our future easier, safer and more sustainable. The sky really is the limit. www.sandvik.coromant.com

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Cutting Tools

Machining success requires a productive balance

Regardless of the part, material or process, all manufacturers create a certain number of workpieces of a desired quality, in a specified time and at an appropriate cost. By Patrick de Vos, Corporate Technical Education Manager, Seco Tools.

Many manufacturers achieve this by following a narrow-perspective model that begins with tool selection and application and solving problems on a reactive basis.

Reversing that approach, however, can reduce costs and increase efficiency.

Instead of waiting for problems to arise and then making adjustments, manufacturers should focus first on proactive preplanning aimed at eliminating rejected parts and unplanned downtime.

Once a stable, reliable process has been established, applying the concepts of production economics can help manufacturers find a balance between production rate and manufacturing costs. Building on the foundation of secure, economically strong operations, manufacturers can select tools and cutting conditions that will fully optimise the machining process.

Production economics Before taking steps to optimise metal cutting, it is essential that processes are secure and reliable, minus defective parts or unplanned downtime. Process security requires a stable production environment.

Manufacturers must analyse machine tool maintenance, CAM programming, tool holding systems and coolant application.

Work-handling automation such as pallet or robotic part load/unload systems could also be part of the evaluation.

Production economics focuses on assuring maximum security in, and predictability of, the manufacturing process, while maximising productivity and minimising production costs. When the metal cutting process and environment are secure and predictable, production economics becomes a two-dimensional pursuit: finding a balance between production output and manufacturing costs that is appropriate for a manufacturer’s situation.

For example, in mass production of simple parts, maximising output at minimal cost may be the primary consideration. In highmix, low-volume manufacturing of valuable complex parts, the emphasis must be on total reliability and accuracy.

Minimising downtime Maximum utilisation of manufacturing resources requires minimisation of downtime. Some downtime is necessary and planned, including time spent programming and maintaining the machine tool, installing fixturing, loading

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and unloading workpieces, and changing tooling. Manufacturers account for planned downtime in their production schedules.

However, production of unacceptable parts results in unplanned downtime. When a rejected workpiece must be remachined, the time spent originally machining it is wasted.

Traditionally, shops take a reactive approach to reducing downtime. When a problem halts production, the search for a solution begins. Rather than waiting to react to a negative situation, a better approach is proactive planning that recognises key targets and steers the process toward them from the beginning. Most shops spend 20% in preparation efforts followed by 80% implementation and testing. The ideal would be to invest 80% in preparation and the rest in implementation and adjustments if necessary.

In preparing for machining, a shop should analyse its targets and develop reliable processes to achieve them. The primary target is not always increased production.

Although some examples of highvolume mass production remain, such as automotive part production, manufacturing

in general is moving more towards highmix, low-volume scenarios.

In mass production, losing 50 or 100 parts developing a machining process that will turn out hundreds of thousands of parts over a long time represents a tiny percentage of overall volume and can easily be absorbed. However, in a high-mix, lowvolume situation, the process must be as fully developed as possible before partmaking begins. High-mix, low-volume scenarios can involve small batches, single-digit lot sizes or even custom onepart runs. In these cases, rejection of a few parts represents the difference between a profit and a loss.

Micro versus macro The traditional approach to maximising metal cutting output involves a narrowperspective micro model based on optimisation of individual tools in individual operations. Macro models, however, consider processes from a broader perspective, concentrating on the total floor-to-floor time required to produce a workpiece.

Cutting Tools

The relationship between the micro and macro models can be compared to an artist’s perspective when creating a painting. The micro model concentrates on individual details, or individual brush strokes. The macro model steps back and views the overall process, as in viewing a painting in its entirety. Attention to detail is necessary, but not at the price of ignoring overall purpose.

Fixation on detail can distract attention from the final outcome. For instance, it is a disadvantage to reduce cutting time by ten seconds when it is achieved with an extra tool that adds ten minutes in setup and indexing. Similarly, working to achieve product quality beyond customer requirements will increase costs and production time. Almost seriously, one could ask: “How long would it take, and how much would it cost, to produce the worst workpiece possible that is still functionally acceptable?”

Operating costs Models for machining costs can also represent micro- and macro-perspectives.

Micro models consider processes from a narrow viewpoint, linking cutting conditions directly to costs. Macro models work from a broader perspective, emphasising the overall time to produce a workpiece.

Manufacturers measure production rate in various ways, from workpieces completed over time, to the total time required to finish an operation. Many factors affect production rate, including workpiece geometry requirements and material characteristics, product flow throughout a facility, personnel input, maintenance, peripheral equipment and environmental, recycling, and safety issues.

Some cost elements are fixed. Workpiece complexity and material generally dictate the type and number of machining operations required. Acquiring, maintaining and running machine tools are basically fixed costs. Labour costs are somewhat more flexible, but effectively fixed for the short term at least. These costs must be offset with revenue from the sale of machined components. Raising production rate – the speed at which workpieces are converted into products – can offset fixed costs.

Individual optimisation After the overall productivity and cost efficiency of a process are balanced and optimised on a macro basis, manufacturers can achieve further improvements by

“Production economics focuses on assuring maximum security in, and predictability of, the manufacturing process, while maximising productivity and minimising production costs.” optimising individual operations. Cutting conditions play a key role. Depth of cut, feed rate and cutting speeds can contribute to reductions in machining time, but the impact of each on reliability varies widely. Depth of cut essentially has no effect on tool life. Feed rate affects tool life slightly. However, the impact of cutting speed on tool life, and on process reliability, is significant.

Many shop managers believe that simply increasing cutting speeds will produce more parts and thereby reduce costs.

Usually that is true, but trade-offs are involved. In general, the faster an operation runs, the less stable it becomes. High speeds generate more heat that affect both tool and workpiece. Tool wear occurs faster and is less predictable, and tool wear or vibration can cause part dimensions to vary and surface finish to decline.

A tool may break and mar the workpiece. In addition, a process operating at the outer boundaries of reliability is typically unable to run untended or semi-tended, eliminating potential labour savings. Extremely high cutting speeds and aggressive machining parameters can increase machine maintenance costs and even downtime from machine failures.

At the beginning of the 20th century, US mechanical engineer FW Taylor developed a model for determining tool life. For a given combination of depth of cut and feed there is a certain window for cutting speeds where tool deterioration is safe, predictable and controllable. Taylor’s model makes it possible to quantify the relationship between cutting speed, tool wear and tool life, balancing cost efficiency and productivity, and providing a clear picture of optimum cutting speed.

In general, manufacturers should select the largest depths of cut and highest feed rates possible for each operation, subject to the stability of the tool clamping, workpiece fixturing and machine tool, as well as the machine tool’s power. Operational safety, in regard to chip formation and evacuation,

vibrations and workpiece deformation, also must be considered. A balanced approach involves reduced cutting speeds matched with proportional increases in feed rate and depth of cut. Utilising the largest depth of cut possible reduces the number of cutting passes required and thereby reduces machining time. Feed rate should be maximised as well, though workpiece quality and surface finish requirements can be affected by excessive feed rates.

In most cases, increases in feed rate and depth of cut while maintaining or lowering cutting speeds will produce metal removal rates equal to that achieved by higher cutting speeds alone.

Production costs are the sum of tool costs and machine costs. With increasing cutting speeds, machining times become shorter and machine costs decrease. However, from a certain point overall costs rise because shorter tool life increases the cost of tooling and tool change times enough to surpass the savings in machine cost. When a stable, reliable combination of feed rate and depth of cut has been reached, cutting speeds can be used for final calibration.

The target is a higher cutting speed that reduces machine time costs but does not excessively raise cutting tool costs via tool wear.

Non-cutting issues Environmental and safety issues are increasingly important in production economics. Manufacturers are under pressure to conserve energy. Use and disposal of coolants and oils are increasingly regulated and expensive. A balanced approach to cutting conditions can help manufacturers deal with these and similar concerns. Lower cutting speeds combined with increased feed rate and smaller depths of cut require less energy.

Balanced conditions also increase tool life, reducing tool consumption and disposal issues. Lower energy consumption results in reduced heat, offering opportunities for minimal- or zero-coolant machining.

Adopting production economics concepts requires an overall analysis of the machining environment and ways of thinking that are counter to many established practices.

Carrying out the recommended strategies can improve cost savings and workpiece quality and enable more environmentally friendly production, while maintaining productivity and profitability in a stable, reliable overall process. www.secotools.com/au

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Cutting Tools

Bolts & Industrial Supplies – Australian-made quality

After more than four decades in business, Bolts & Industrial Supplies is still breaking new ground, recently opening a new store in Dandenong South, Vic. We spoke to the company’s Managing Director Andrew Rodgers.

AMT: How did Bolts & Industrial Supplies start out in the industry?

Andrew Rodgers: Bolts & Industrial Supplies has been in business for over 40 years. Incorporated in 1973 by founding partner John Rodgers, the business is still in the Rodgers family to this day. Since then we’ve served the engineering community of Australia with a strong sense of pride and customer service that simply cannot be beaten.

The company has been moulded into what it is today by providing high-quality Australian-made products at a respectable price, top-notch service and reliable, timely delivery. No matter which industry you’re in – aerospace, automotive, die & mould, general engineering, construction or just day-to-day hardware – we’ve got you covered with a tool to suit your needs.

We have over 60 staff specialising in various fields, working hand in hand with over 200 suppliers, providing the best technical information possible to enhance performance and productivity.

AMT: And what about more recent developments?

AR: The future for us is in engineering supplies, particularly cutting tools and associated products. Over the last two years we’ve become the major distributor for Kennametal Metalworking. For over 10 years Kennametal Metalworking have been moving worldwide towards a distributorfocused supply chain, and have recognised the benefit of the end user being able to purchase a range of products from one supplier, minimising paperwork and adding value. Added to this is that we can offer technical support through our sales engineers, in person or by phone. It’s my expectation that more and more suppliers will move this may – the savings and valueadded benefits far outweigh the costs.

Sutton Tools will be a big focus for us this year as well. We’ve always been a strong supporter of Sutton Tools. They export a world-class product to the major players in the cutting tool world. Frustratingly, they don’t enjoy the same recognition in their home country, and we plan to change that.

Through technology and technical support, we’ll be opening up every end user to the biggest stock and range in the country.

Online ordering directly through web portals direct to the end user. We’re very excited to be driving this. With Sutton Tools now

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Bolts & Industrial Supplies Managing Director Andrew Rodgers.

directed once again by the Sutton family the future is looking very bright.

One area of focus for us is the ability to supply SMEs just as we would large organisations.

We’ve achieved this by negotiating stock levels, implementing stock management systems and adjusting our sales engineers’ call plans to actively encourage growth with our customers’ businesses.

AMT: Tell us how you approach delivering value for your customers.

AR: This is one area we have built the company around. All of our sales engineers have a trade background and all of them have at least ten years’ experience. Our phone sales staff and counter staff have the support of an internal network of 60 people to call on from various industry back grounds and are always willing to help each other. We place a lot of value on training and education and regularly conduct in house courses in everything from products to management!

Value for money is always a difficult area in our industry because there are always so many variables. Everyone has a different idea of what is value for money, so we do stringent market testing on quality, backup supply, reliability and price, and then offer what we believe is the best-value product of its type. However, we listen to our customers and if they want a particular item, from a particular supplier, that’s what we supply. It’s very straightforward.

Ethics is without doubt the most important part of running a business. It must filter

through every part of the business and will affect everything the company does.

With me personally, it not only affects the business but must extend outside work as well. All our managers surpass the levels I expect in ethics both at and outside work.

AMT: How do you see the future for engineering and manufacturing in Australia?

AR: The million dollar question. I believe two key areas will be collaboration and innovation. And innovation isn’t just inventing a new product. It’s changing and developing an existing product to bring something better to the market. Companies joining together to collaborate will go hand in hand with innovation.

The Support Australian Manufacturing (SAM) Campaign is a project we started to show people outside the industry that Australian manufacturing isn’t dead. I kept hearing people comment that we don’t make anything in Australia any more, and if you don’t work in manufacturing or aren’t directly involved, it would be easy to believe that. Our campaign is to show people not only do we still manufacture but we lead the world in many areas.

Over the last few years we have seen the industry diversify and expand into areas not traditionally focused on. The future for Australian manufacturing is definitely new industry and innovation. We strongly support this at all levels, and with over 40 years in business we have a lot to offer. www.bolt.com.au www.samcampaign.com.au

Hotspots is proudly owned and managed

by AMTIL

All we think about about is manufacturing.

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You need a specific component made, but don’t have the capabilities in house.

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Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

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Your business is diversifying into an area where the expertise available within the company is not sufficient.

HotSpots is a service designed to connect AMTIL members with opportunities to help their businesses grow. That piece of work that you need done might be just the sort of opportunity they’re looking for. And by featuring that opportunity as a HotSpot, you gain access to a wealth of Australian manufacturing capability and expertise.

Our regular AMTIL HotSpots email goes out to over 1,000 people every month, making HotSpots an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector.

Provided your opportunity meets our criteria for listing, inclusion in AMTIL HotSpots is free. If you have something you feel will meet our criteria, please forward it to AMTIL for assessment by emailing info@amtil.com.au with the subject line HOTSPOT. www.amtil.com.au/Membership/Hotspots

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092

Material Removal

Tiny bubbles cause troubles

Foam can impede performance of high-pressure, high-volume, high-velocity machine tools and lead to machine downtime and tool breakage. Before turning to non-foaming solutions, determine whether the foam is caused by a chemical or mechanical problem, writes David Foster.

The dictionary defines foam as a mass of small bubbles on a liquid’s surface. It doesn’t sound threatening, but in metalworking, foam can be a real challenge. The problems stem from several characteristics of foam.

It does not lubricate or cool well, often actually serving as an insulating blanket.

Because foam may float chips and fines, it affects filtration and the fluid’s ability to settle the fines. Foam contributes to chemical odour and mist difficulties. If sucked into pumps and machine plumbing, it can cause substantial damage. When you pump foam to a tool, you are mostly pumping air with a tiny amount of liquid. This raises cutting tool temperature, and occasional splashes of coolant create thermal shock and tool breakage.

Several conditions contribute to the formation of foam. The application must involve agitation and/or fluid movement.

The fluid must have surface active characteristics, containing surfactants or emulsifiers. The moving fluid must be exposed to a gas (typically air). Finally the fluid must trap or entrain some gas.

If it is possible to engineer out one or more of these conditions, foam control becomes easier, and will typically alleviate problems.

Like any manufacturing or engineering problem, fixing the root cause is always preferable to treating the symptoms. The bottom line is to always try the engineering solution before resorting to adding an antifoam (defoamer) solution. Consider using low-foaming fluids specially developed to work with today’s high-pressure, highvolume, high-velocity machine tools.

Such coolants are designed to work in high-pressure, high-volume applications without generating foam. If coolants are not designed for these applications and foaming occurs, it is a chemical issue, and an antifoaming coolant may solve the problem.

Chemical or mechanical?

Most metalworking fluids must be in motion to do their job, and higher velocities and volume frequently improve fluid performance. At times, however, this movement exposes the fluid to more air entrainment opportunities than necessary.

Antifoaming fluids have been optimised to resist entrainment and foaming, allowing you to fully exploit the machine’s capabilities, including high-pressure coolant delivery.

Mechanical problems that cause foaming need an engineering solution. Examples include:

AMT Jun/Jul 2016

is caused by the coolant. As coolants age and become contaminated with tramp oils and dirt, the tendency to foam decreases.

Fresh, clean coolants exhibit the greatest tendency to foam.

Keep in mind that antifoam solutions, once added, will eventually be carried out of the system, so periodic additions may be required. The over-addition of antifoam solutions can contribute to foam problems because they contain large quantities of emulsifiers.

Adjustments to some CNC machine tools with installed drum filters can fight foaming caused by the flow of the coolant over the filter. Try reducing drum filter flow to the lowest level possible to clean the drum. The filter is like a mesh aerator. When coolant flow is too high, it blasts past the individual fibres and introduces air into the coolant (think kitchen sink aerator). If flow is too low, the filter will clog.

• Leakage in valve stems, from loose packings; by pump shaft packings; or in piping, rotary unions, or other connections.

• Pinholes in hose.

• Bypass valves are closed too much, producing excessive back pressure.

• A pump oversized for the job or throttled back so that it churns the system.

• Sump too shallow or pump set too high so air is sucked into the intake.

• Coolant pump running in the wrong direction.

• Excessive cascading, or drop, of the coolant to the tank surface.

On the chemical side of the equation, foaming problems can be caused by: • Fluid and concentration selected.

• Tramp oil contamination.

• Washing or floor soap contamination.

• Water and how the fluid was mixed with it.

• Misuse or overuse of topical antifoams.

• Carryover from preceding operations – e.g. rust inhibitors, other oils.

You can easily determine if foaming is a chemical or mechanical problem by doing a 30-second shake test. Fill a bottle with two ounces of coolant and shake it vigorously for 30 seconds. If the foam drops in under 30 seconds it is a mechanical problem. If it takes more than 30 seconds to dissipate, it

Some drum filters are visible through a window; others are covered by a metal plate. They have an easily identifiable, 90-degree valve. A fully open valve will be parallel with the coolant line; a closed valve is perpendicular to the coolant line.

This valve should be about 50% open.

Experimentation will be required. On machines with pressure gauges near the control valve, it has been noticed that when the valve is wide open, it runs at about 15psi. When partially closed it runs at 5-7psi, does not foam over, and keeps the screen clean.

Tank capacity needs to be three times the flow rate for low pressure and one times the flow rate for high pressure to control foaming. Ideally, a 60psi, 50 gallons/minute flow rate will have a 150-gallon (568 litres) tank; a flow rate of 1,000psi, 50 gallons/ minute will have a 500-gallon tank. In today’s modern machine tools, this is not always the case so selecting a coolant designed to be low-foaming is imperative.

Making sure the sump is not full of chips or sludge is also very important because this reduces tank capacity. Low sump volume can allow the pump to whip the surface of the coolant and generate foam, similar to the way a hand mixer whips egg whites with air into a fluffy foam. The impeller should always be completely submerged.

David Foster is a District Sales Manager at Master Chemical Corp. This article originally appeared in CIM - Canadian Industrial Machinery. Reprinted with permission. www.masterchemical.com

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094

Motors & Drives

Gearing up for quick changes

They might not yet be matching the times of Formula One pit crews, but railway maintenance teams are set to exchange bogies – sets of four wheels at each end of a railway carriage – in record time.

This is due to new processes made possible by equipment developed specifically for the purpose by Andrew Engineering.

Driven by the flexibility and precision of the SEW-Eurodrive Movidrive B drive inverter, the latest bogie exchange system (BES) enables faster, safer and more economical turnaround in railway maintenance sheds throughout Australia.

Changing bogies is a demanding business.

According to Neil Boehringer, Project Manager at Andrew Engineering, when traditional methods are used, it takes a team of maintenance workers an hour and a half for each changeover. Using the new BES, a single operator can remove and replace a set of bogies and have the train ready within 45 minutes! This makes it easy to carry out maintenance on the wheels or other components away from the train.

Precise movements The older methods rely on jacking the whole train up or working from below in specially constructed pits, but thanks to the precise movements controlled by the Movidrive B drive inverter, the car need only be lifted by 50mm. The bogie is then easily removed and brought out sideways. This combination of movements requires a complex set of drives, motors and gears, working in all three axial directions (X, Y and Z), with lifting and positioning movements requiring

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great precision. When equipped with an absolute encoder feedback mechanism, the inverter can be configured for fine or course movements in any direction, says Mauro Castiello, Sales/Application Engineer at SEW-Eurodrive.

“The absolute encoder gives us the ability to lift and position with a tolerance of 0.1mm, in real time,” he says. “In other cases, when we don’t need that level of precision, it’s more like manually operating a crane. You press the button and the motor runs, and then you release the button to stop it.”

During the system design phase, Boehringer and his team enlisted their supplier to assist.

“If it’s a complex design that you can’t do yourself, they support you,” he says.

SEW-Eurodrive employed its Workbench software in producing the designs. Castiello says that by feeding in parameters like the speed of movements, the weights lifted and the type of friction to be encountered, the designers could easily select appropriate motors and drives. To cater for the range of movements, the system design included a combination of helical bevel and helical worm gearboxes.

“After the equipment selection was made, we reviewed the calculations together with the Andrew Engineering designers. Once approved, a three-dimensional CAD model of the system was provided and then used

directly into their own design software,” says Castiello. “Their skilled designers could use this input to engineer a complete BES, with no additional information from us.”

Because the movements are sequenced when the bogies are changed over, the designers requested a single inverter, to control the individual movement of four different motors. This resulted in considerable savings for the overall project.

“Rather than asking you to buy a Rolls Royce version, SEW-Eurodrive optimises its designs to suit our needs every time we work with them,” says Lincoln Oxer, Senior Electrical Designer at Andrew Engineering.

Field bus flexibility Oxer says another major advantage of the design was the ability to control the motors and drives via a field bus, with acceleration times, deceleration times and other parameters easily managed. Similarly, any adjustments that become necessary as conditions change during the lifecycle of the machine can be carried out remotely or by the operator at the human-machine interface (HMI).

The complete system controls 15 different motors through seven drives. Some of the motors have brakes; some have absolute encoders for extra precision and others Continued next page

Motors & Drives Continued from previous page

don’t. Consequently there is a wide variety of power and current requirements during the bogie changeover and it is essential that all the parameters can be switched simply.

“You get complete parametrisation and adjustability at your HMI without having to connect up a laptop to do the tweaks,” says Oxer. “You can limit the current if you need to do a soft stop. And it also has the grunt to lift heavy weights.”

Delivery time was an important factor in the success of the project. According to Oxer, the industry norm is to deliver this kind of equipment in 12-16 weeks, whereas SEWEurodrive could deliver in one week because its local operation holds stock. The ability to source all components from one supplier was also important, says Boehringer, who has selected gears, motors and drives from SEW-Eurodrive for complex projects over many years. It simplified the design process and there were no concerns about different suppliers arguing over warranty responsibilities.

Safer, cheaper and faster While the cost, speed and labour-saving advantages of the BES are clearly important, improved safety is the number-one benefit.

The two traditional methods of exchanging bogies – working from a pit beneath the train car, or working beneath the jacked-up train – require special precautions. This is not the case with the new system.

When a pit is installed in a maintenance shed – an expensive exercise – special work practices must be put in place to maintain the trains. Working in a pit beneath the train means working in a confined space. Occupational health and safety (OH&S) regulations for confined spaces include requirements for quick and easy exit in case of emergency. At the same time though, the maintenance crews are working at height to change the bogies, and there is a requirement for scaffolding to ensure their safety.

“These two requirements are fighting against each other, and maintenance might be delayed because the issue is too hard to resolve,” says Oxer, adding that working under a heavy jackedup train is not pleasant either, regardless of the precautions in place. “It always makes me nervous.”

In stark contrast, the new Andrew Engineering BES, powered by the SEWEurodrive Movidrive B drive inverter, overcomes this safety dilemma. In railway maintenance sheds around Australia, it is now possible for a single operator to carry out bogie exchanges in a safer, faster and more cost-effective manner. www.andeng.com.au www.sew-eurodrive.com.au

Siemens unveils new HTS technology under new research partnership Assistant Innovation Minister Wyatt Roy and Siemens Pacific CEO Jeff Connolly on 19 April unveiled new prototype high-temperature superconductor (HTS) technology, which Siemens has transferred from Germany under a new partnership with Defence Science & Technology Group (DSTG) and Queensland University of Technology (QUT).

The announcement took place at QUT and marks a significant step forward in Australian innovation via global partnerships. The $2.5m investment includes Siemens’ equipment, which will be used to explore applications for Australia’s maritime defence and industrial power requirements. The intent is to transition research findings into technology that can be trialled at sea.

Minister Roy commended the initiative and its positive implications for an array of Australian industries: “This partnership between QUT, Siemens and the DSTG highlights the meaningful, worldchanging innovation that can come from collaboration between research, the private sector and government. It’s also a strong sign of the confidence in Australia’s innovation ecosystem.”

Connolly said the partnership reinforces Siemens’ legacy of Australian investment and exemplifies the benefits of defence knowledge transfer and strong bilateral relations between Australia and Germany.

“This is a proud moment for Siemens,” said Connolly. “We have invested over 15 years HTS knowledge from Germany and together with local industry partners we are transferring that knowledge to Australia and helping the nation revolutionise how power is used in maritime defence, shipbuilding, power and transport.”

HTS technologies under development today in superconducting motors, generators and magnets can carry highdensity currents with virtually no loss and have the potential to reduce the size and weight of conventional motors by more than 30%. For the Australian Navy, the partnership opens a pathway to more energy-efficient vessels with significant leaps forward in size, weight and capacity.

HTS will also mean less environmental impact and reduced operating costs.

According to Connolly, the application of HTS technologies is not limited to defence industries and could renew other high energy-use sectors such as power and transport. He said the partnership is aligned to the Federal Government’s vision for the future of the domestic manufacturing sector to be increasingly based on local R&D. QUT Deputy Vice-Chancellor, Research and Commercialisation, Professor Arun Sharma said the university was purposebuilt to undertake this R&D because of its expertise and facilities, including the Banyo Pilot Plant Precinct, a leading specialist research centre for structural, mechanical and electrical engineering.

“Our partnership with Siemens and subsequent R&D puts QUT at the international forefront of superconducting motor research, an area of research that has the potential to radically transform many industries including maritime propulsion and transport drive systems,” Professor Sharma said. “As the world strives to find more efficient and cleaner ways to power ships and other forms of large-scale transport, QUT will be testing this superconducting motor and at the same time looking at the other potential uses and benefits.”

DSTG has strategic alliances with 12 defence companies and research agencies. They partner with 28 universities across Australia to deliver game-changing capability for the future of the Australian Defence Force and continue to seek opportunities to expand this network. Chief Defence Scientist Dr Alex Zelinksy said the partnership focuses on transitioning research to outcomes that can deal with real world problems, starting with its potential applications to defence. “The research is in line with our strategic goal to partner with the best talents in industry and academia to achieve a capability edge for defence,” Zelinsky said. www.siemens.com.au www.qut.edu.au www.dsto.defence.gov.au Left to right: Rob Hickey (QUT), Jeff Connolly (Siemens), Assistant Innovation Minister Wyatt Roy MP, Prof Carol Dickenson (QUT) and Mr Robert Jarvis (DST).

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Forum OHS

Working with angle grinders

This article from the Queensland Government seeks to highlight the risks associated with removing guards and using incorrect discs on angle grinders. Although the authorship is Queensland-based, the information contained is relevant Australia-wide.

In early February 2016, a Queensland worker received fatal injuries while operating a 230mm (9 inch) angle grinder. The worker was killed when part of a broken disc struck the worker’s chest. It appears that due to the high impact of the projectile, it caused fatal internal injuries.

In another incident the disc jammed and the angle grinder kicked back and cut the worker’s wrist.

Contributing factors One major contributing factor is the use of cutting discs that are too large for the angle grinder. In some cases the guards have been removed and the grinder fitted with a 356mm (14 inch) cut-off disc.

Cutting discs are usually designed for a maximum outside edge speed (i.e. peripheral speed) of approximately 70m/second (250 kmph). Larger angle grinders are manufactured with lower revolutions per minute (RPM) speeds than smaller angle grinders, so that the edge speed of the disc always remains around 70m/s.

Fitting a 356mm (14 inch) cut-off disc to a 230mm (9 inch) angle grinder will increase the edge speed excessively to at least 120 m/s (430 kmph). Image 1 shows an angle grinder with the wrong size cutting disc fitted and the guard removed. Discs are not designed for the higher speed, and if used, risk the possibility of the disc shattering and striking the user and others.

disc (see Image 2). If the disc hole is too big for the spindle flange, the disc may be off centre, become unbalanced, vibrate excessively and rapidly lead to it shattering.

Action required Always: • Use the angle grinder with the correct guard supplied by the manufacturer.

• Fit the right sized disc that has a hole matching the spindle flange.

• Use the tightening tool supplied by the grinder manufacturer to tighten the disc. The use of another device (i.e. punch and hammer) can damage the disc and grinder.

• Hold the angle grinder with both hands ensuring the side handle is inserted on the side of the unit that gives the best grip for the work activity.

• Use a grinding disc for grinding. Grinding with a cutting disc damages the disc and increases the likelihood of the disc breaking during use.

• Ensure the maximum RPM disc speed marked on the disc is higher than the maximum speed of the angle grinder.

• Ensure damaged discs are thrown out and not re-used.

• Allow the grinder to run to speed before cutting or grinding.

• Use the correct spindle flange and lock nut for the disc and make sure these are fitted the way the angle grinder manufacturer shows in the instruction manual. The type of flange or fitting method may vary for cutting and grinding discs.

If the incorrect flange and lock nut combination are used, the disc can be damaged and lead to premature failure.

Image 1: Unsafe 230mm (9 inch) angle grinder with 356mm (14 inch) disc fitted and guard removed.

Guards should be provided and used on all power tools where there is a risk of the disc ejecting, disintegrating or cutting the worker. If the guard has been removed: (a) There is nothing to stop the broken pieces hitting the user. (b) The user’s hand will be closer to the unguarded moving blade and (c) There is a greater risk of the blade being damaged when the angle grinder is put down and the weight of the grinder is resting directly on the disc.

Note: 230mm (9 inch) angle grinders have been banned on some work sites due to the increased risk of injury. The increased power and size of the unit will cause more severe kickback and gyroscopic effects (i.e. makes the grinder difficult to manoeuvre). A risk assessment to identify alternative methods and tools should be carried out prior to selecting a 230 mm (9 inch) angle grinder.

Workplace Health and Safety Queensland (WHSQ) is responsible for improving workplace health and safety in Queensland by enforcing work health and safety laws and investigating workplace fatalities and serious injuries. It also prosecutes breaches of legislation and educates on legal obligations.

Ph: 1300 362 128. www.worksafe.qld.gov.au

Another factor that increases the risk of disc failure is when the central disc hole size is too large for the spindle flange on the angle grinder. As the disc diameter increases so will the hole size. For example, the hole size of a 356mm (14 inch) cut-off wheel is typically 25.4mm compared to 22.3mm on a 230 mm (9 inch) cutting Image 2: Unsafe excessive clearance for the central hole on 356mm disc on 9 inch spindle flange.

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Image 3: 230mm (9 inch) angle grinder with guard and right sized disc fitted.

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Forum Finance

Year-end tax planning

As we approach the end of the financial year, many manufacturing businesses start thinking about strategies to minimise their tax liability. Damian Sutherland explains.

While tax planning should be part of a year round strategy, there are a number of specific issues that should be considered prior to the end of the financial year which may help to reduce your tax liability.

Some of the most important tax issues for this year have been summarised below. Please note that this list is by no means exhaustive and is designed to start you thinking about your tax affairs prior to year-end.

Business structure Some tax planning techniques differ depending on whether the business is a “Small Business Entity” (SBE). The SBE Provisions are available for any individual, partnership, company or trust that has carried on a business for all, or part of the financial year and has less than $2m in aggregate turnover. The provisions offer small business owners a number of generous concessions in relation to prepayments and depreciation. Among other features, eligible businesses may choose to use any of the following concessions: • Small business CGT concessions.

Defer income/bring forward expenditure Where you delay some invoicing until July, that income will only be assessable in the next financial year. Bring forward expenditure prior to 30 June and get the deduction this financial year. Items would include marketing materials, consumables and repairs and maintenance.

Trading Stock Prior to year-end, all trading stock should be valued at the lower of cost price, replacement price or market selling value. Consideration should also be given to obsolete stock that should be written off prior to year-end.

Directors’ fees and bonuses A deduction is only available where there is a firm commitment to pay fees or bonuses by passing an authorised resolution. Any bonuses claimed as a deduction cannot be subject to any discretion or conditions that need to be met after year end.

• Cash flow accounting.

Motor vehicle expenses

• Simpler depreciation rules.

Where applicable, motor vehicle expenses are claimed based on a business use percentage from a logbook kept for 12 continuous weeks. Such a logbook needs to be prepared every five years.

• Simpler trading stock rules.

• Deduction for certain prepaid business expenses.

• Accounting for GST on a cash basis.

Broadly, a SBE must carry on a business and its annual turnover (excluding GST) cannot exceed $2m. Turnover will also be aggregated to include the annual turnover of certain affiliates and entities connected with the taxpayer. While meeting the $2m turnover test automatically entitles SBEs to choose certain concessions such as simplified rules for both tax depreciation and trading stock, there are additional eligibility tests that may allow you to claim the small-business CGT concessions even if you do not meet the $2m turnover test. Business owners should be aware that the May Federal Budget proposed an increase in the small business entity turnover from $2m to $10m from 1 July 2016. This will apply for the 2017 year for the purpose of accessing many of the income tax concessions.

Maximise depreciation deductions now Small Business Entities can get an immediate tax deduction for nearly all individual assets they buy costing less than $20,000 which are used to produce an income. For business assets first used, or installed ready for use prior to that time, SBEs can claim an immediate deduction where assets cost less than $1,000 each, and which are used to produce an income. For businesses that are registered for GST, the threshold is calculated on a GST–exclusive basis. For businesses not registered for GST, the threshold is calculated on a GST–inclusive basis. A depreciating asset that is not immediately deductible – that is an asset costing $20,000 or more from 7.30PM AEST on 12 May 2015, or an asset costing $1,000 or more prior to that time – and which is used to produce an income, will be automatically depreciated at a flat rate of 15% in the year of acquisition. Other considerations for ALL manufacturing businesses is delaying income and bringing forward expenses. This opportunity could have greater impact if the proposed reduction in the new company tax rate to 28.5% from 30% for companies that meet the SBE test (remembering that the threshold for SBE increases to $10m next year if the budget proposals go through Parliament).

Bad debts Any debts that are unlikely to be collected should be written off prior to the end of the financial year. Remember to claim a GST adjustment for write-offs.

Superannuation It is important to review the superannuation contributions made by your business to ensure that the 9.5% Superannuation Guarantee Charge limit has been met for all relevant employees. Superannuation contributions must be paid by 30 June to obtain a tax deduction in the current year and by 28 July in order to avoid additional charges and penalties.

Consider the maximum concessional (deductible) contributions as an owner of the business.

For the current financial year the caps per person are: • $30,000 if less than 50 years of age; and • $35,000 if between 50 and 75* years of age. (*Between the age of 65 and 75 you currently must meet the works test prior to making a contribution) As noted, this is not an exhaustive list but as a business owner you should be reviewing the possibilities to do some year-end tax planning. With potential changes to the threshold for meeting a Small Business Entity and a reduction in the company tax rate, further opportunity to minimise tax exists for business owners.

Damian Sutherland is a director of William Buck (Vic) Pty Ltd Chartered Accountants which specialises in the manufacturing industry particularly in assisting businesses progress. William Buck is a leading network of Chartered Accountants and advisors with offices across Australia and New Zealand, wholly owned and operated in Australasia.

If you would like to arrange a complimentary appointment please contact Damian on 03 9824 8555. www.williambuck.com.au

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Forum Import & Export

Export technology or software? What you need to know to avoid fines or prison.

A recent flurry of activity among exporters of technology or software as the new provisions under the Defence Trade Controls Act 2012 (Act) become operative (after a trial period of some 12 months). Jenni Lightowlers explains.

The purpose of the Act is to strengthen controls on the transfer/ export of sensitive technologies so Australia meets its international obligations under various treaties. From 2 April 2, goods in intangible form which - if they were in a tangible form (the actual goods) would require a permit to export - will also require an export permit.

Are your goods affected?

The Act applies to technology or software (in hard copy or intangible form) (DSGL technology) that is on the Defence Strategic Goods List (List). The List is divided into two parts. Part 1 is the Munitions List which describes goods that are developed or adapted for military purpose. Part 2 of the List details goods that are “dual purpose”, that is, the goods described have been developed for commercial purposes but could be repurposed or componentry could be used for military applications. This article only deals with requirements in relation to dual purpose goods.

The List divides dual purpose goods into categories as follows: Category 0 – Nuclear Materials Category 1 – Materials, Chemicals, Microorganisms and Toxins Category 2 – Materials Processing Category 3 – Electronics Category 4 – Computers Category 5 – Telecommunications and Information Security Category 6 – Sensors and Lasers Category 7 – Navigation and Avionics Category 8 – Marine Category 9 – Aerospace and Propulsion If your company exports goods under these categories, and particularly if those goods are at the “high tech” end of the spectrum, we recommend that you check whether an export permit is required.

Are you exporting without the requisite permit?

Goods that may require an export permit Export permits may be required for: • some types of composite materials (Category 1); • machine milling tools (Category 2); • some carbides and coating technologies (Category 2); • various lasers (Category 6); • decryption algorithms (Category 7); and • technology for machining propellers to reduce underwater noise (Category 8).

How do you get a permit?

If you have determined that you need an export permit, you must apply on-line (http://www.defence.gov.au/deco/forms.asp) for a licence to export your DSGL technology. When making the application, you will be required to nominate the countries to which you wish to export.

Sanctions regimes There are further export restrictions under Australian laws and as part of Australia’s international obligations under the UN Sanctions regime. UN Sanctions prohibit exports of DSGL technology to a number of countries and Australia imposes its own additional sanctions. As the list of prohibited countries changes, you should check the DFAT website regularly.

But wait – there’s more!

If your export incorporates any tangible or intangible goods that you acquired from the US under conditions where the US exporter was required to obtain a permit to supply, you may well need export permits from both Australian and US authorities. The Defence Export Control Office (DECO) is unable to grant any authorisations with respect to US requirements.

The Act makes it an offence to supply, without a permit, DSGL technology (in hard copy or intangible form) that is on the List. There are some exceptions which relate to DSGL technology already in the public domain or which can be considered to be basic research.

Specifically, the Act provides that a supplier commits an offence if the supplier supplies DSGL technology to another person and either:

Penalties

(a) the supply is from Australia to a place outside Australia; or

Francis Abourizk Lightowlers (FAL Lawyers) advises directly on compliance issues arising out of export requirements and can assist with applications for DECO registrations and applications for export licences. FAL Lawyers also works with John Gaunt at FAL Consulting and Doug Tozer at TradeFox, who assist with Customs queries. FAL Consulting are experts in Customs consulting, including Customs duty management systems and compliance. TradeFox runs a software program to assist with assessing the correct Export Control Classification Number (ECCN) required for exports and imports. The Customs (Prohibited Exports) Regulations 1958, which are also referenced in the TradeFox program, are a useful reference for checking goods against dual use categories nominated above.

Jenni Lightowlers, Partner FAL Lawyers Member of AI Group (Defence) Member of Australian Industry & Defence Network www.fal-lawyers.com.au

(b) if the supply is the provision of access to DSGL technology – at the time of the provision of access, the supplier is in Australia and the other person is outside Australia…

For the purposes of the Act: • supply is defined to include the provision of access to the DSGL technology, as well as the more traditional forms of supply such as sale or lease.

• the supply must be to another person located outside of Australia, that is, to a different legal entity or natural person to the person supplying the DSGL technology.

• Australia is used in its geographical sense.

Intangible form means that the information relating to the goods or services is supplied via electronic communications such as by email, or file transfer. The Act sits alongside the Customs Act 1901 which regulates the export of various goods.

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There are quite significant penalties for failure to comply with the Act. The penalties apply to any person (body corporates as well as individuals) who exports without a permit, goods or services (including in an intangible form) that appear on the List. The penalties are tough – 10 years prison and/or $450,000.

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Forum Logistics

Service provider relationships across your supply chain.

The contracts which customers typically have with various service providers are often based on personal relationships or experience with those service providers. This can lead to problems when for example, the service provider leaves the business. An important role of the supply chain manager is to ensure that all parties involved in their supply chain are “on the same page” through having clear information and communication access and a detailed framework of roles and responsibilities. Lawrence Christoffelsz explains.

We all understand that in any international business, there are a number of service providers involved who are responsible for specific tasks and milestone deliverables.

One common area of frustration and additional costs for importers and exporters is when all of these service providers have a break down in communications and/or relationships.

A truly effective and efficient supply chain encompasses a detailed framework of roles and responsibilities from start to finish.

Customers typically have contracts or simply rate cards with various service providers and then attempt to keep all the pieces together themselves. However, this is often a result of an individual’s knowledge, experience and relationship with each of the service providers and this can lead to serious consequences when this individual goes on leave, or worse yet, leaves the business.

An important role of any supply chain manager is to ensure that all parties involved in their supply chain are fully aligned and have adequate visibility of information and communication access.

Some of the best ways to achieve this is to have in place the following; SLA’s (Service Level Agreements) with each and every service provider. These should include deliverables, reporting and KPI’s Process Flow Diagrams which incorporate each step and the respective service provider’s actions.

Communication Matrix – simply a list of key contacts for each service provider, made available to all.

After all is said and done, the end customer doesn’t know (or for that matter, care), who is dropping the ball and causing them any grief or inconvenience – they simply attribute any poor customer experience to the company they pay their money to.

Therefore all contracts, service agreements and related processes with your service providers MUST be with a single-minded goal or focus… “what will be the experience of our end customer?”.

Old school distribution models have dramatically changed in recent times and will continue to put more and more pressure on companies and their service providers.

Today, your customer’s engagement isn’t just in a simple retail environment, where the stock is replenished from an off-site warehouse. Instead, they want a range of flexible options when purchasing your product/s…

‘Omni-channel’ is a recent ‘buzz’ phrase used by many small and large companies alike. This means that customers can purchase products through a direct retail environment, a retail experience (with a touch ‘n feel) selection with subsequent home delivery, online direct transactions, as well as other marketing platforms (vouchers, etc.).

These are all positive and innovative engagement opportunities with customers, however in order to provide such a variety of flexible options, it must have a sound and robust supply chain infrastructure to deliver it.

Working issues log; the customer should continually monitor and capture supply chain issues and which service provider is responsible for improvement action/s.

Each of your individual service providers should be an ‘expert’ in their field. Therefore, combining expertise in each function of your outsourced supply chain should (in theory) provide you and your customers with the very best cost-effectiveness, efficiency and service experience.

Regular stakeholder meetings; Quarterly at a minimum or more frequently as circumstances dictate for the business.

Like Henry Ford once said, “I don’t need to know everything – I just need to surround myself with the people who do.”.

A good service provider should not resist any of the above initiatives and instead should be constantly seeking ways to ensure that they are increasingly perceived as an active extension of the customer’s business.

Lawrence Christoffelsz is International Trade & Supply Chain Advisor. He is also Managing Director of Logistics Results Pty Ltd - an Australian-owned and operated company. This team of supply chain, logistics and international trade experts will increase your efficiencies and reduce the costs to your organisation. The team is able to capture all the information on your international trade movements and then develop a tailored optimisation plan for your organisation. This initial review is more than just ‘freight rates’, it begins with the very first step of order placement and ends with final delivery to your end customers. With its latest supply chain technologies, the company has developed a proven track record for high-quality and continuity in outsourced Supply Chain Optimisation around the world. Ph: 1300 13 17 18 www.logisticsresults.com.au Lawrence is also Director and Board Member of the Australian Chamber of International Trade - www.acit.org.au

In today’s competitive business environment, it is more and more common for importers and exporters to rely heavily on outsourced service providers instead of the previous ‘norm’ of layered, in-house supply chain infrastructure, labour and management functions.

There are a number of benefits to outsourcing, however without a robust foundation of processes across each function and provider, it can be a very negative and frustrating experience for not only the owners and managers of the importer or exporter, but more importantly, their end customer.

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100 Manufacturing matters in Australia.

Our manufacturers lead the world in numerous products and industries.

Australia’s manufacturing industry is a major contributor to our economy each year, and our manufacturers employ large numbers of people, offering them challenging, rewarding work, and providing the basis for stable, diverse communities.

Welcome to the Manufacturers’ Pavilion, the section of AMT Magazine dedicated to celebrating some of the best, most dynamic, most innovative manufacturing companies working in Australia today.

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The Manufacturers’ Pavilion highlights the capabilities of Australia’s precision engineering and advanced manufacturing industry. Over the following pages, we will look at companies delivering products and services across a variety of industrial sectors, and employing a diverse array of processes.

It builds on the successful Manufacturers’ Pavilion exhibition area within the Austech trade show and is sure to enhance the profile of the leading edge manufacturers in our sector.

If you feel your company should be featured in a future edition of the Manufacturers’ Pavilion, please contact AMTIL Sales Manager Anne Samuelsson, on 03 9800 3666, or by emailing asamuelsson@amtil.com.au

Manufacturers Pavilion

Custom components for clients across the globe Victorian-based repetition engineering company Jodek manufactures a wide range of custom machined components to customers worldwide.

The family-owned business has more than 25 years industry experience and uses the latest in CNC technology specialising in machining components to its customers’ designs and drawings. Jodek provides its clients with the very best products and customer service.

Jodek Managing Director Derek Hyde says the company is one of the bigger component manufacturers in their field, with a total of 21 CNC machines, most of which run 24 hours a day, seven days a week.

“Running 24/7 enables us to offer our clients quick turnaround times on products whilst also keeping our running costs to a minimum,” says Hyde. “Our main strengths are in the high-volume repetition field where we can run jobs in the quantities of 3m plus per annum.”

Jodek has supplied components either directly or indirectly into many of the major projects worldwide including mining, construction, rail, oil and gas over the past 20 years. Recent projects have seen almost 50 tons of finished machined components shipped to Hong Kong for use in the

construction of the Hong Kong–Zhuhai– Macau Bridge.

“Without a doubt, you would be hard pressed to find a completed major project within Australia that does not contain something manufactured at Jodek,” adds Hyde, who believes the dedicated team at Jodek is what gave the company its competitive edge.

“We have a workforce of 23 people, most of whom have been with the business longterm,” he says. “They have the experience and the knowledge required to produce the goods.”

At present, around 60% of Jodek’s components are exported. Jodek is ISO 9001 accredited and every item shipped is fully traceable. The components are made from various materials including mild and high tensile steel, stainless steel, brass and copper, aluminium and alloys, tool steels, machining of castings and engineering plastic. For more information on Jodek and how it can cater to your next project visit www.jodek.com.au

Jodek 17 Mills Road Braeside, Victoria 3195 T: 03 9587 4677 F: 03 9587 4977 W: www.jodek.com.au E: info@jodek.com.au Derek Hyde Managing Director T: 03 9587 4677 E: derek@jodek.com.au Jodek is a leading manufacturer of precision machined components situated in the south-eastern suburbs of Melbourne. The company is a familyowned husband and wife team who have each spent more than 25 years in the industry. Jodek currently has 21 machines in a manufacturing operation of 2,400sqm with 20 employees.

Precision CNC Machining Jodek has forged a reputation that can be truly envied. Our attention to detail and innovative approach enables us to deliver precision componentry reliably, within budget and on time – getting it done right first time.

• CNC Turning & Milling • Multi Axis Machining • CAD CAM • Finished Product Assembly • All industries serviced 17 Mills Road, Braeside, Victoria 3195 • T: 03 9587 4677 • F: 03 9587 4977 E: info@jodek.com.au • www.jodek.com.au

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Manufacturers Pavilion

World-class turning/milling products Dimac hosts its own in-house CAD design and CNC manufacturing capability to provide customised workholding solutions for owners of CNC milling and turning machines.

The combination of skilled, passionate and experienced staff and the service support offered, coupled with quality CNC machine tool accessory suppliers across the world truly sets Dimac apart.

Since part of Dimac’s business model includes importing accessories from overseas, the company adds value by customising off-the shelf product, offer support and initiate the best solutions for customers. Dimac listens to customers’ manufacturing issues and requirements, attends international tradeshows and blends this with its expertise to provide a value solution. It does that successfully and only supplies well-supported, quality products.

Manufacturing an extensive range of soft jaws in-house for more than 30 years, coupled with direct sales and distributor network, has given Dimac the market reach and product range to provide prompt delivery of a quality product. Customers can choose a type and size of soft jaw that closely meets their needs, usually from stock.

Following the recent move to a newer production facility in Dandenong South (Vic), Dimac will continue to focus on assisting customers to be more productive and environmentally capable in their machining areas.

Over 30 years of innovation designed to improve your bottom line, enhance productivity and improve machining safety and efficiency.

NEW PREMISES 69-71 Williams Road, Dandenong South VIC 3175 sales@dimac.com.au • www.dimac.com.au

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Dimac Tooling Pty Ltd 69-71 Williams Rd Dandenong South VIC 3175 T: 03 9561 6155 F: 03 9561 6705 W: dimac.com.au E: sales@dimac.com.au Paul Fowler Managing Director T: 03 9561 6155 E: paulf@dimac.com.au Dimac Tooling is a provider of CNC machine tool accessories and workholding systems for the Australian & New Zealand markets. A strong focus is given to productivity-enhancing accessories and in-house manufacture of its own products as well as offering solutions tailored to customers’ needs.

Manufacturers Pavilion

BAC modular workbenches and storage – A flexible fit for any workplace

BAC Systems

BAC Systems has been manufacturing industrial workshop and storage equipment in Australia for nearly 40 years now, and in this time has seen the changing needs of workshops, laboratories and warehouses.

One of the reasons that BAC equipment is used so prolifically across nearly every industry sector is that it is so easy to configure the BAC range into a system that meets all of your functional needs in the most efficient way possible.

The secret to this is the fact that BAC Storage Systems are modular. The modular concept is a key aspect of the range and the team of BAC technicians and design engineers carefully integrate this modularity in all new product development to ensure this timeless element is always part of the award-winning range.

The modular concept means that each BAC unit can be considered a building block for a greater, complete system. This is evident in some of the company’s recent projects.

For the Australian Astronomical Observatory in Northern Sydney, different BAC storage modules and workbenches were combined to form a functional storage system that fitted ergonomically into their existing stores and laboratories, preventing them from outgrowing their facility. Similarly, at the

Gladstone LNG Facility operated by Santos, BAC combined a series of tall warehouse BAC storage modules with a series of BAC workstations to create a very functional combined workshop/warehouse with quick access to parts near to where they will be used. In each instance this was only possible because each element of the BAC modular range can interact with the other in such an efficient way that the resulting BAC modular system is a true enhancement for the workplace.

To learn more about how the BAC range of modular workshop and storage equipment can enhance your own workplace, please don’t hesitate to contact the BAC Technical Sales team on 02 9832 2777.

193-195 Power Street Glendenning, NSW 2761 T: 02 9832 2777 F: 02 9675 3645 W: www.bacsystems.com.au E: bacsales@bacsystems.com.au Robert Griffin BAC Technical Sales T: 02 9832 2777 E: Robert.griffin@bacsystems.com.au BAC Systems is an Australian manufacturer of quality workshop and storage equipment. For nearly 40 years it has been providing customised warehouse storage, industrial workbenches and high-strength storage solutions to industry in Australia and world-wide. Contact BAC’s Technical Sales team to arrange a complimentary site visit where we can survey your storage requirements or workshop layout needs.

BAC Drawer Storage & Industrial Workbenches World-Leading Warehouse Drawers & Workplace Systems

Support AUSTRALIA N Innovation and manufactu ring

Fully Modular Systems customised to suit your space and Inventory

BAC Systems Pty Limited 193-195 Power Street, Glendenning NSW 2761 Tel: (02) 9832 2777 www.bacsystems.com.au AMT Jun/Jul 2016

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Manufacturers Pavilion

Integra Systems - Make your vision real Empowering you to ‘Make Your Vision Real’ is what drives Integra Systems.

Breakthrough product and engineering design, followed by world-class execution is the method.

Since 1991, Integra Systems has worked with hundreds of Australian businesses and helped them enjoy prosperity in both local and export markets with product designs that blow their competition out of contention. Integra Systems is proud to be a 100% Australian-owned family business, supporting customers globally.

With innovation as the cornerstone of Integra’s culture, Integra enables and empowers clients in key areas of industrial design, product design engineering and mechanical engineering, followed by empowerment through highly efficient inhouse advanced manufacturing systems and project management expertise.

The company focuses on working collaboratively with clients to enable them to secure new market opportunities and overcome complex design challenges in a highly diverse range of industries. Overlaying a unique design process across a diverse range of industries is what distinguishes Integra, and provides you with the ultimate solution. Industry recognition for this is supported by the many awards Integra has received.

Enhanced business outcomes are the key focus of solutions that are driven by: • User centric design, utilising deep knowledge and insights.

• Improved productivity and reduced labour on-costs, resulting in total cost savings.

• Enhanced product appeal and sales turnover.

• Agile and flexible production processes.

• Design for manufacture which achieves bottom line results.

• Reduced cost of deployment.

Integra Systems 197 Northcorp Blvd Broadmeadows, Vic, 3047 T: 03 9359 3133 F: 03 9359 3166 W: www.integrasystems.com.au E: enquiries@integrasystems.com.au Paul Hughes Managing Director T: 03 9359 3133 E: paul@integrasystems.com.au For over 25 years, Integra has empowered clients to achieve their aspirations through integrated solutions – innovative, creative and break-through product design engineering and advanced manufacturing from ideation to delivery.

• Attention to production precision.

• Increased speed to market.

• Enjoyable product experience.

Business relationships are centred around Integra’s ability to ‘Make Your Vision Real’.

AGILE. PROGRESSIVE. REVOLUTIONARY. Empowering you to Make Your Vision Real is what drives us.

Break-through product design, followed by world-class execution is how we make it happen. We work with you to collaboratively deliver an integrated solution from ideation through to production and delivery, which creatively solves your challenge.

The result of this is revolutionary, award winning products that will enhance your business outcomes.

www.integrasystems.com.au Integra is proudly a multi-award winning company

AMT Jun/Jul 2016

Manufacturers Pavilion

Quality fasteners for Australian industry Australian-owned and -operated, Fuji Fasteners has the capability of producing most fastener types from 3mm to 16mm in diameter and in materials such as high- and low-carbon steel, alloy steel, stainless steel, copper, brass and aluminium.

More than 40 years of fastener manufacturing experience have driven Fuji to become one of the largest fastener producers in Australia, with production capabilities equal to any fastener producers in the Australasian region. The company’s growth over the past decade has been mostly attributed to a strong policy of customer service supported by a quality product and a firm focus on quick turnaround of production jobs.

Fuji now exports to counties such as the Philippines, New Zealand, Vietnam and Thailand. Low-volume runs, quick turnaround and assistance for the customer to make the most efficient and viable decision on their fastener requirements have proven a good formula in Fuji’s growth and recognition as major supplier to Australian Industry.

The acquisition of additional machinery in 2013/2014 has broadened Fuji’s range and capacity, plus the linking with specialist manufacturers in Asia basically means Fuji

can supply a fastener of any type, size, material and/or head/thread configuration in any grade and plating/coating.

Fuji Fasteners is also the Australasian distributor for the world-renowned Japanese-produced Fuji Lock Nut. These nuts are top of the range in quality and ability and when the application requires a nut with high vibration resistance, high or low temperature rating and/or is reusable, the Fuji Lock Nut is a proven reliable fastener.

These nuts are available in the U-Nut type and also the fine and twin U-Nut range.

The fastener range supplied by Fuji Fasteners includes tapping screws and metric set screws, metric and imperial bolts, cup head bolts, coach screws, sems assemblies (captive washers), wheel studs, weld studs and weld nuts, solid rivets, headed pins, double-ended studs and the Fuji Lock nut. Certification to ISO 9001 standard ensures products produced are to the highest standard.

Tapping Screws Metric Set Screws Metric & Imperial Bolts Cup Head Bolts Construction Bolts Sems Assemblies Screws with Captive Washers Weld Studs & Weld Nuts Wheel Studs Solid Rivets Headed Pins Double Headed Studs Fuji Lock Nuts

Fuji Fasteners 5 Swift Way Dandenong South, Victoria 3175 T: 03 9706 6652 F: 03 9706 6651 W: www.fujifasteners.com.au E: sales@fujifasteners.com.au Ross Tidswell Director E: ross@fujifasteners.com.au Nathan Salske General Manager E: Nathan@fujifasteners.com.au Advantages of cold forming Material cost savings Enhanced product Characteristics Higher-quality surface finish Reduced production costs Consistent and improved Tolerance control

Fuji Fasteners 5 Swift Way, Dandenong South Victoria 3175 T: 03 9706 6652 • F: 03 9706 6651 www.fujifasteners.com.au

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Manufacturers Pavilion

Flexible manufacturing of thin parts, signs and custom shim packs are our speciality.

Mastercut Technologies is the industry leader in the manufacture of precision thin metal parts.

Specialising in thin stainless steel, copper and brass, Mastercut has a variety of cutting techniques to suit the application. One of the most flexible is photo chemical milling (PCM). This method is the closest thing to photocopying of metal and is a great intermediate step between laser cutting and stamping. Mastercut also has lasers for cutting and marking and these methods can be combined for specific requirements.

In addition to precision parts, PCM is used for half etching ID plates and signage from stainless steel which will remain perfectly readable in all conditions.

Mastercut also manufactures a range of building signage including fascia signage, door numbers, elevator plaques and directional signage – for apartment buildings, office buildings, hotels and high-rises.

Signs are generally made form marine grade 316 stainless steel; copper and brass are also available. These signs can last decades and can be colour-filled or powder-coated for an added finish.

AMT Jun/Jul 2016

Mastercut serves the following industries: electronics assemblers; mining, oil & gas; medical devices; defence industry; RF shielding designers; model makers; sign, trophy & plaque makers; jewellery, gifts & souvenirs; and the architectural sector.

Mastercut is a major stockist of stainless steel shim off 600mm wide coils in both grades 304 and 316 in thicknesses starting from 0.025mm. Supplying to mining, oil and gas, Mastercut produces shims in a ‘pack’ of thicknesses to meet a customer’s specific design requirements. Mastercut can assist with drawing the shape if electronic files are not available.

Commenting on the benefits his company has to the mining industry, Managing Director Jim Cove says: “We often get calls from miners needing shim packs for operations in remote locations. Because we carry in stock a broad range of stainless shims starting from 0.025mm, we can get the job cut and despatched pretty fast. All we need is a drawing of the required shape and the required thicknesses.”

Mastercut Technologies Pty Ltd 22 Leda Drive Burleigh Heads, Queensland 4220 T: 07 5576 1900 F: 07 5576 1910 W: www.mastercut.com.au E: sales@mastercut.com.au Toby Poulsen Sales Consultant E: toby@mastercut.com.au Based on the Gold Coast in Queensland, Mastercut specialise in deep acid etching and laser cutting of thin metals. Operating for over 20 years, we are OEM suppliers to many manufacturers throughout Australia, New Zealand and SE Asia.

Manufacturers Pavilion

All-Australian experience TRJ Engineering is an Australian-owned and operated business that has been providing steel fabrication and engineering services to customers throughout Melbourne for over 40 years.

Terry Murphy started the business in 1974 with a small factory in Dandenong.

David Murphy (Terry’s son) is the owner of TRJ, which today has grown to over 30 employees occupying a 4000sqm factory in Hallam. Experienced in meeting the needs of private and government clients, TRJ is a leading Victorian supplier, dedicated to providing excellent service and engineering solutions for all applications, from truck chassis manufacture to street furniture, shop fit-outs and stainless steel components.

TRJ has expanded its services over the years and updated its capabilities by purchasing state-of-the-art machinery and assembling a team of skilled and qualified workers. This enables the company to offer laser and guillotine cutting, welding, general engineering and metal fabrication, and brake pressing. TRJ provides products across areas such as:chassis manufacture; street furniture; vandal-covers and safety hand-rails for earth-moving equipment; steel fabrication; and shop retail fittings.

TRJ’s approach is founded on core values of quality, commitment, diversity and innovation

TRJ has been involved in chassis manufacture for over 25 years. It started building B-Double chassis for FTE back then and only built five chassis in its first year. It currently builds over 140 chassis per year for a number of different clients and still for FTE. With the experience gathered in this field (nearly all of the TRJ team share a passion for cars), the company has branched out into custom automobile chassis building. It has built Cobra chassis for Python Vehicles, modified a number of race car chassis, and manufactured a number of different parts for the hot rod sector.

In 2015 TRJ decided to start building its own hot rod chassis and is now ready to sell them to the public. It has 3D drawings for most of the popular hot rods from the 1930s and has been able to design and manufacture the entire chassis to its manufacturing strengths. The company is looking at 4x4 custom work and has several designs for front bull bars, rock sliders and rear bars with tire mounts. With its team and its state-of- the-art machinery, TRJ believes it can custom-build almost anything for the automotive sector.

TRJ Engineering Group 17-19 Apollo Drive Hallam, Victoria 3803 T: 03 9703 1701 F: 03 9702 3288 W: www.trjengineering.com.au E: sales@ trjengineering.com.au David Murphy Managing Director T: 03 9703 1701 E: david@trjengineering.com.au TRJ Engineering has been involved in the engineering and manufacturing business for over 40 years, and now maintains a fully equipped modern workshop in Hallam. TRJ’s range of services includes: laser and guillotine cutting, welding, general engineering and metal fabrication, and brake pressing. It is experienced at meeting clients’ needs in a wide variety of industries.

Corporate Identity for TRJ Engineering group

TRJ Engineering Group…

earthmoving

All designs are copywrittien to webfirm ©2008

tranSport

Your first choice for precision metal fabrication and general engineering.

TRJ Engineering has been providing steel fabrication and engineering services throughout Melbourne for 40 years – Australian owned and operated. Experienced in private and government projects, TRJ Engineering is a leading Victorian supplier, dedicated to excellent service and state-of-the-art engineering solutions for all applications, from truck chassis manufacture to street furniture, shop fit-outs and stainless steel components.

Street Furniture

17-19 Apollo Drive, Hallam, Victoria 3803 T: 03 9703 1701 • F: 03 9702 3288 • E: sales@ trjengineering.com.au www.trjengineering.com.au

AMT Jun/Jul 2016 Corporate Identity for TRJ Engineering group

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Manufacturers Pavilion

Precision forging dies, gauges and componentry Australia-wide since 1990 Waddell Engineering is a quality manufacturer of precision components dedicated to customer service, exceptional and consistent quality and advancements in technology, equipment and infrastructure.

Based in Melbourne’s south-eastern suburbs, Waddell specialises in dies and tooling for the brass forging industry, and componentry and precision gauges for the packing/can manufacturing, prototype medical and aftermarket automotive industries. The Waddell team has more than 25 years of experience in the manufacturing of highly complex parts, aided by state-of-the-art CNC equipment, CAD/CAM software and co-ordinate measuring machinery. From simple to complex five-axis machining, Waddell Engineering has the team, the systems and the infrastructure to create the precision components required by businesses, and has invested in the best technology to provide highly precise, high-speed machining, with extremely tight tolerances.

The company was founded by David Waddell in 1990, with its roots in the design and manufacture of special purpose machinery for the LPG gas cylinder industry. Eventually the company moved into forging dies and peripheral tooling for the manufacture of

brass fittings and door hardware, and more recently acquired a precision grinding business specialising in gauges and tooling for the packaging and canning industries.

Waddell Engineering is a company that prides itself on a quick response time to any question proposed and efficient delivery for all the parts needed. Recently Waddell Engineering became ISO 9001 accredited, ensuring the company always delivers more than what clients expect. Whether at the tail-end of the design process, or just about to commence production, Waddell Engineering will help turn your concept into reality. Waddell Engineering’s qualifications include: • • • • • • • •

CNC milling – Three, four and five axes CNC high-speed machining CNC mill-turn CNC wire electrical discharge machining (EDM) Cylindrical grinding Surface grinding Co-ordinate measuring (CMM) Low-volume production.

Best Technology High Precision High Speed Machining

Waddell Engineering is a precision CNC machining company, specializing in dies and tooling for the brass forging industry, precision componentry and gauges for the Packaging/Can manufacturing industry, prototype Medical and aftermarket Automotive.

2 Commercial Road, Highett, Victoria, Australia 3190

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T: +61 3 9555 8971

Fax: +61 3 9555 9637

Waddell Engineering 2 Commercial Road Highett, Victoria 3190 T: 03 9555 8971 F: 03 9555 9637 W: www.waddellengineering.com.au E: enquiries@waddellengineering.com.au David Waddell Managing Director T: 03 9555 8971 E: david@waddellengineering.com.au Established in 1990, Waddell Engineering is a quality manufacturer of precision components situated in south-east Melbourne. Currently with eight employees, it is expanding to accommodate new customers. Waddell offers highly sought after workmanship at competitive prices, building a business around strong, long-term relationships and a loyal, experienced and dedicated team.

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AMT reaches over 40,000 readers. It provides detailed coverage of all aspects of advanced precision manufacturing, with a special focus on metal machining, cutting and fabrication.

Features covers various areas of the industry, news, interviews and much more. AMT assists to develop your business interest.

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Amtil Inside

Effectively communicating with our members

Member communication is probably the single biggest issue that faces most non-profit industry associations. At AMTIL, we face the same dilemma. How do we effectively communicate with our members so that they are aware of what we are doing for them, take up the opportunities when they arise, are kept up to date with current information and see value for money in their membership fee?

We are fortunate to have this magazine as a flagship method of communication. In particular, the AMTIL Inside section enables us to promote events and activities that we have planned and our members can get a certain level of information from us via this medium. If you are reading this article I would say that the AMT magazine works well for you and I would encourage you to keep yourself informed of AMTIL services through the publication.

Email communication and social media are two other ways in which we can communicate. Email is becoming more and more difficult to do effectively. There is just so much “white noise” out there we would be silly to think that AMTIL emails are treated any differently to the hundreds of others that appear in a person’s Outlook file.

I must admit that we send out too many emails each month and this is something we are working on. The challenge is to make the email relevant enough that it is opened and not just seen as another email from that group.

We have two regular emails each month that we need people to look at. Our Monthly Hotspot email goes to around 800 member delegates and contains information on business opportunities, industry information, special events and member services.

Most of the time it directs people back to the member section of our website for full information. We have found this to be a very effective member tool and surveys indicate that this is a valuable service. The second regular email is our monthly AMTIL e-News.

This goes more broadly to around 8,000 industry people and is our primary method for letting people what we are currently doing for our sector. Please look out for this email if you are at all interested in what AMTIL is up to.

Social media is an interesting one. We have accounts with Twitter, LinkedIn, Facebook, Instagram and YouTube. Currently we have a number of twitter accounts. You can follow me @AMTILCEO and our editor William Poole can be followed @AMTEditor. If your particular interest is in 3D printing you can join our Additive Manufacturing Network on Twitter @AMN_AUS or our general AMTIL information is available @AMTIL_AUS. If you are on LinkedIn maybe you can consider joining one of our groups. We have an AMTIL members group which is called, funnily enough, AMTIL All Members. This is exclusively for member companies and their employees. We will be using LinkedIn a lot more in the future for networking, connecting and informing - so look us up if you haven’t already done so. We also have a LinkedIn group for our Additive Manufacturing Network which is open to anybody to join for free.

Facebook, in my opinion, is more of a family and social media rather than business media but we do have a Facebook page that you can “like” if you are so inclined. And feel free to subscribe to our YouTube Channel as well. We currently have a number of interviews up on the channel that were taken at our Austech exhibition over the years that may be of interest to you.

So whatever communication mechanism takes your fancy, I think we have you covered.

One of the communication issues I am most interested in though is that it is a twoway street so I am just as interested to hear what is going on with our members and industry in general so please keep in touch with me.

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Amtil Inside

Make It Cheaper – Delivering savings for AMTIL members For over a year, AMTL has been partnering with Make It Cheaper to continue bringing energy saving expertise to our members, and the results thus far have been fantastic!

Make it Cheaper has looked at power bills for 33 customers and a total of 56 meters. Those 56 meters were split across Commercial & Industrial, SME and Residential – Make It Cheaper is capable of offering advice and quotations across all three of these markets.

Where it is possible to make an actual prediction of retrospective savings based on usage and the availability of the bill to perform a full bill comparison, the company has been able to save AMTIL members a total of $18,793 per year. Across the SME market this averages at $1,708 per meter switched where a better deal has been identified, and the highest estimated savings come in at a whopping $7,218.

The even better news is that there are still many, many members of AMTIL that haven’t yet taken advantage of this great service. Remember this service is free, and realistically it will take five to ten minutes of your time.

Of course, time is always tight, and your profit margins are tighter – it’s likely to have been a while since you last had a chance to review your energy spend. Now could be a great time for your business to get in touch with our partner to ensure you aren’t paying over the odds for your business’ electricity or gas bills.

Are you being overcharged?

Between October 2015 and March 2016, Make it Cheaper analysed 10,400 business bills and identified that 80% of Australian businesses pay too much for their electricity. Four out of five businesses is a huge majority, and both AMTIL and Make It Cheaper want to decrease this figure and ensure that manufacturing

businesses are within the 20% who are paying a fair amount for their gas and electricity bills.

So why are energy bills so high for businesses? Often this overpayment on energy occurs due to business owners not having enough time, or enough information, to know when or how to negotiate better energy rates.

Power bills are often neglected by business owners and left to fester, and as such, this means that they are placed on standard rates by energy suppliers, rather than the market rate for a company’s individual energy usage needs. It is this neglect in terms of reviewing energy rates that can lead to companies overspending on their power bills, and this is what AMTIL hopes our members will avoid, thanks to our partnership with Make It Cheaper.

The service offered by Make It Cheaper aims to bring some clarity in the often murky world of business by giving you - the business owner - crystal clear advice regarding your energy supplier options. Switching with Make It Cheaper couldn’t be simpler. They do all the hard work for you! Once you give them a call, a member of their energy savings team will take a look at your current energy usage and conduct a comprehensive comparison against other rates available to you. They will even sort out your new contracts, so that you don’t have to!

AMTIL has a service partnership with Make It Cheaper as an exclusive benefit to our members. To begin saving your business money on its energy bills, talk to an expert at Make It Cheaper about switching gas or electricity supplier, by calling 02 8880 5523 or emailing your bill to amtil@makeitcheaper.com.au. www.makeitcheaper.com.au 1271AMTIL

At your service.

AMTIL supports its members through its select range of AMTIL Service Partners.

www.amtil.com.au/Membership/Service-Partners

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Amtil Inside

ERP selection – a process not a journey Enterprise resource planning (ERP) software can be a valuable tool for manufacturers, but many companies struggle when it comes to choosing the right system and implementing it correctly. Richard Penman offers some pointers.

A previous edition of AMT magazine included a first-rate article on how software systems such as ERP platforms assist businesses in driving innovation. Done correctly they do; and I am sure that the majority of business today would agree with this. However, most business are also faced with conflicting messages and confusion in regard to ERP success.

To add to the drama, in 2013 Gartner told us that 75% of all ERP projects fail and more recently have stated that until 2018 that 80% of enterprises will lack the capability to successfully deliver a “postmodern” ERP strategy – “postmodern” representing a fundamental shift away from a single-vendor (on-premise) megasuite, toward a more loosely coupled, federated and cloud-based ERP environment.

Consequently, when businesses embark on an ERP project the fear of choosing poorly has a profound effect on both the length of time and quality of the ERP selection and evaluation process –so much so that we actually have a term for this: ‘paralysis by analysis’.

Understandably, selecting software is not an easy task, there is no ‘one-size-fits-all’ solution, regardless of what vendors tell you.

Each business differs in terms of technical and business maturity, size, workflow, functional requirements, context, activities, culture, budget and so on. As such the dreaded word ‘customisation’ will eventually be raised.

(RFI) stage and is aimed at receiving a written response from each shortlisted vendor in regard to their capabilities, experience, product fit, reference sites, etc.

Without a proverbial magic wand, the selection and evaluation process can be a lonely and confusing place. There are however a broad set of steps that, if followed, assist in the approach and may go some way to filling that hollow feeling you have when selected to manage an ERP project. By having a structured process you are increasing your chances of a successful implementation that you and the business can be proud of. This is a rather large topic to cover in a single article, so bear with me if it seems a little condensed.

Once responses are in, it’s time to evaluate the vendor, a process just as important as evaluating the ERP product. Hopefully you can whittle the list down to two products/vendors and can move on to the proposal stage. If you are not down to two or three vendors, you may ask for ballpark costings from the shortlisted vendors. They will be extremely reticent to do this and quote the old ‘too many factors’ argument. This step also doesn’t tend to work too well with ERPs and their pricing models which mostly range from the convoluted to the outright absurdly complicated.

So you have gone through the strategy meetings and the outcome is an ERP project! The project team has been created, the action plan generated, the gap analysis completed, and the business needs prioritised. The outcome of all these steps is a requirements document, which defines the functionality requirements for each of your processes and the criteria they have to meet. This document can and should be used to create a shopping list of useful features to use in pre-qualifying ERP vendors.

Once down to two or three products/vendors, share your requirements document with them and arrange for demonstrations of their products – note they have a pre-set presentation agenda, so prior to the presentation, send through a list of functionalities you want them to demonstrate. Score each demonstration against your requirements document and your vendor evaluation criteria. When down to the last two standing, ask for formal proposals.

Most businesses get to this point OK, but struggle with their options in terms of creating a shortlist of ERP vendors that could suit their industry and organisation? There are three choices. First you can do your own research, both online, direct calling vendor sales departments, and approaching businesses in your sector. Second you can hire an independent consultant to facilitate, which can be hard as most consulting entities are not independent but are affiliated with particular ERP products – they have to earn money too. Or thirdly, you can utilise Government-funded services such as the Entrepreneurs’ Programme, which provide a light-touch advisory service.

Regardless of the route chosen, it’s important to remember that selecting and subsequently implementing ERP is one of the most resource-intensive activities a business will undertake and you only get one chance to do it well. So no cutting corners.

Having chosen a shortlist route, the aim is to have no more than three after the initial pre-qualifying or shortlist stage. To assist in cutting down the list you could ask for general vendor information in a format that you can score or weigh each response. In a formal world this stage is often known as the request for information

AMT Jun/Jul 2016

Pricing can be notoriously complex with ERP vendors, so ask for a plainly worded costing sheet that clearly identifies the costs for each project element (software licences, training, data migration, support, ongoings, etc.). Make sure the vendor proposal includes a full total cost of ownership (TCO) analysis for the number of years you reasonably envisage owning the software. Such an analysis attempts to uncover all the obvious costs and hidden costs of ownership across the anticipated lifecycle of an ERP. After this you should have a pretty good idea of the frontrunner that best meets your industry, activity, culture, business and budget requirements. Move on to final negotiations and ensure you have a thorough scope of works (detailing each party’s responsibilities) in place before moving to the implementation stage. Implementation is another discussion entirely, but by having undertaken a wellstructured approach to selecting and evaluating ERPs, you can move forward with confidence.

Richard Penman is a national IT Systems Innovation Facilitator with the Federal Government’s Entrepreneurs’ Programme (EP). AMTIL is a partner organisation working with the Department of Industry in the delivery of the EP. www.business.gov.au/ep

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More events coming up from AMTIL

AMTIL’s events program continued in April and May with a tour of the Australian Synchrotron and two Business Mastery breakfast seminars.

And there’s more to come.

On 13 April, around 30 guests enjoyed a two-hour tour at the Australian Synchrotron in Clayton, Victoria, a world-class facility supporting research in sectors ranging from medicine and nanotechnology to manufacturing and mineral exploration. The AMTIL party received a presentation on the Synchrotron’s history and case studies of the research work undertaken there, as well as a tour of the facility. Details were also provided for how companies can apply for access to the Synchrotron to assist in their own projects, and the costs associated with “beam-time”.

The first of the two breakfast events took place on 20 April at Riversdale Golf Club in Mount Waverley, with Mike Anderson of Anderson’s Business Facilitation Services giving an informative talk on ‘Marketing Essentials For a Profitable Business’. This was followed on 5 May by the ‘Show Me the Money’ seminar, at The Centre Ivanhoe in Ivanhoe, with AMTIL service partners William Buck Chartered Accountants giving presentations on how to determine a manufacturing business’ value, and the best practice for structuring your business to legitimately minimise tax. At all three events, there was also plenty of opportunity for discussion and networking afterwards.

Three more Business Mastery breakfast seminars have now been scheduled over the coming months, covering a diverse array of topics. Attendance is free for AMTIL members, and $35 for non-members, with breakfast provided. Details are as follows:

Lean Thinking in the office Thursday 16 June, 7.30-9.30am The Centre Ivanhoe, VIC Speaker: Tim McLean, TXM Lean Solutions Lean is a great tool for improving manufacturing processes through eliminating waste. However in modern advanced economies, a shrinking proportion of economic value is still produced on the factory floor. Even in manufacturing businesses, the majority of costs and much of the value creation is now found in the design office, the sales department, accounting and administration and service. Therefore applying Lean away from the factory floor is becoming more and more important.

The federal election: What will it mean for industrial relations in Australia?

Thursday 28 July, 7.30-9.30am Riversdale Golf Club, Mount Waverley, VIC Speaker: Jeremy Cousins, Whitehall Workplace Law What are the likely effects of the Federal election on industrial relations law in Australia? Attendees will learn about any likely changes to the laws and how best to prepare your business for the new political era. We will discuss “Big Picture” issues, and provide a take-away checklist of things businesses can do to better enable them to operate at optimum performance. Attendees are invited to email questions they would like addressed during the session in advance to j.cousins@ whitehallworkplacelaw.com.au.

The Importance of leadership in a high-performing manufacturing company Wednesday 17 August, 7.30-9.30am Riversdale Golf Club, Mount Waverley, VIC Speaker: Linsey Siede, Automotive Supplier Excellence Australia The management and leadership of any company affects everything they do, and their importance to the business’ performance cannot be ignored. Business strategy, customer focus, operational excellence and company culture are just some factors that determine success.

This presentation will look at the data, results and outcomes of working with 150 companies over an eight-year period, and provide key information to help companies focus on achieving greater success.

For information on any of AMTIL’s events, visit the Events page of our website.

To discuss any aspect of our events calendar or to suggest topics for future events, contact Kim Warren, Events Manager at kwarren@amtil.com.au. www.amtil.com.au/Events

Damian Sutherland of William Buck at the ‘Show Me the Money’ breakfast seminar.

AMT Jun/Jul 2016

AMTIL FOOTY TIPPING 2016

Nine rounds into the season and it’s our first chance to welcome everyone back to the AMTIL Footy Tipping for season 2016 – and what a season it’s alreading proving to be. One day a rooster and the next a feather duster, especially for Freo – what the hell are ya doin’ Ross! The AFL’s expansion project are looking like the force all the smart heads were worried about with the GWS boys fast becoming solid and seasoned men – strap on for the ride to hear the theme song a few more times this year. Sanchez ROUND 9 1 Craig Linssen 2 The Axe 3 Waverley Reds 4 Kweenslanda 5 Matthew Ferguson 6 Raff - (Parish Eng) 7 Mal 8 Daniel Fisher 9 SKN 10 Vineet Ahuja

62 (237) 60 (156) 60 (168) 59 (150) 59 (234) 58 (184) 58 (209) 58 (211) 58 (239) 58 (244)

Australian Manufacturing Technology Institute Limited

Keeping it Simple.

One Membership, Many Benefits.

connect.inform.grow.

MeMbershIp pAckAges AvAILAbLe AMTIL membership for companies, individuals and supporters within the precision engineering and advanced manufacturing sector.

For more information visit www.amtil.com.au or contact corporate services Manager greg chalker on 03 9800 3666 or gchalker@amtil.com.au

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Industry Calendar

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event

INTERNATIONAL Guangzhou Intl. Metal & Metallurgy China, Guangzhou 12-14 June 2016 Includes sheet metal machinery, metal processing, robotics, die casting. www.julang.com.cn/english ATX Automation Technology USA, NY 14-16 June 2016 Motion control; robotics; assembly and inspection equipment.Co-located events: Atlantic Design & Manufacturing, EastPack, HBA Global, MD&M East, Pharmapack NA, PLASTEC East and Quality Expo http://atxeast.designnews.com Amerimold USA, Michigan 15-16 June 2016 Mould manufacturing for the plastic injection mould manufacturing industry. www.amerimoldexpo.com ACMEE India, Chennai 16-20 June 2016 Includes cutting/machine tools & accessories, CNC, CAD/CAM, sheet metal presses, laser cutting, robotics, welding, measurement, material handling and associated products . www.acmee.in IndExpo Industrial Exhibitions India Jaipur: 17-19 June 2016 Hyderabad: 1-3 September 2016 www.ind-expo.com Metal Mineracao Brazil, Criciuma 21-24 June 2016 Metalworking and mining innovations in the mining sector, ie: sensors, robotics, and a growing emphasis on safety and sustainability which are changing the face of the sector. www.metalmineracao.com.br M-Tech Japan, Tokyo 22-24 June 2016 Mechanical parts including bearings, fasteners, mechanical springs and metal and plastic processing technology. www.mtech-tokyo.jp/en Manufacturing Expo 2016 Thailand, Bangkok 22-25 June 2016 Comprehensive event for the manufacturing and supporting industries. Includes InterMold Thailand, (for mould & die); Automotive Manufacturing, Assembly & Automation; Surface & Coatings. Colocated with NEPCON Thailand, (electronics manufacturing). www.manufacturing-expo.com CIMES China, Beijing 22-26 June 2016 13th China International Machine Tool & Tools Exhibition. Includes the latest highend metalworking and industrial automation technology. Will showcase the world’s top

AMT Jun/Jul 2016

industry giants and international pavilions from key manufacturing countries.. www.cimes.net.cn/en MTA Vietnam Vietnam, Ho Chi Minh 5-8 July 2016 Precision engineering, machine tools & metalworking exhibition & conference.

Metrology Vietnam, Tool Tec Vietnam, Automation Vietnam and Weld Tech Vietnam. www.mtavietnam.com/en/home Interplast Thailand Thailand, Bangkok 7-10 July 2016 Plastics and petrochemical manufacturing machinery and technology. www.interplasthailand.com Aluminium China 2016 China, Shanghai 12-14 July 2016 Complete aluminium industry chain. www.aluminiumchina.com MTT Expo Indonesia, Jakarta 2-5 August 2016 Machine tools, metalworking & precision tooling, automotive engineering, and related manufacturing technologies. http://10times.com/mtt-indonesia-jakarta Manufacturing Surabaya Indonesia, East Java 3-6 August 2016 12th international manufacturing machinery, factory equipment and supplies exhibition. www.manufacturingsurabaya.com IMPE China, Tianjin 11-14 August 2016 Metals processing exhibition in north China’s economic centre. www.chinaimpe.com.cn Euromold Brazil Brazil, Joinville 16-19 August 2016 Mould-making, tooling, design and application development. Co-located with Interplast www.euromoldbrasil.com.br Automation Expo India, Bombay 22-25 August 2016 Automation technologies. Includes industrial & process automation; control systems, robotics, pumps/valves, hydraulics www.iedcommunications.com CIMIF Cambodia, Phnom Penh 26-29 August 2016 Textile & garment, agriculture, plastics, printing, packaging, food processing, automation, building materials, tools & hardware, auto parts and medical. www.camboexpo.com/CIMIF Taipei International Mold & Die Industry Fair Taiwan, Taipei 31 August – 3 September 2106

Exhibition will include a special area for ODM on product design & development, Design & PDM/CAD/CAM and design & production of mould, sub-manufacture (OEM). Concurrent show: Taipei Industrial Automation Exhibition. www.odm-dmi.com/en www.autotaiwan. com.tw/en IMTS USA, Chicago 12-17 September 2016 Technology show in North America. Over 2000 exhibitors and more than 15,000 new machine tools, controls, computers, software, components, systems and processes. www.imts.com Metalform China China, Beijing 21-24 September 2016 Chain of metal stamping, fabricating and forging. www.chinaforge.com.cn/en Industrial & Tool show USA 5-6 October 2016, Kansas 26-27 October 2016, Missouri Showcase of industrial products and services. www.expoindustrialshows.com Global Manufacturing & Industrialization Summit (GMIS) UAE, Abu Dhabi 10-12 October 2016 World’s first GMIS. Identify fundamental challenges in the manufacturing sector and provide transformational ideas that support and benefit the private and public sectors and advance inclusive and sustainable industrial development. Organised by the UAE Ministry of Economy and the UN Industrial Development Organization. http://g-mis.com AMTS USA, Ohio 12-13 October 2016 Advanced Manufacturing Technology Show. The latest manufacturing solutions, technology, and machinery www.daytonamts.com Mining & Engineering Indonesia, Indonesia, Jakarta 12-14 October 2016 International mining expo which delivers significant opportunities for local and international suppliers to launch latest products, technologies and services and network with mining professionals from Indonesia and the surrounding region www.miningandengineeringindo.com Euroblech Germany, Hanover 25-29 October 2016 Presents the entire sheet metal working technology chain. Sheet metal, semi-finished and finished products, handling, separation, forming, flexible sheet metal working, joining, welding and surface treatment, processing of hybrid structures, tools, quality control, CAD/ CAM systems & R&D. www.euroblech.com

Industry Calendar local International Forum on Additive Manufacturing Melbourne, RMIT University (Carlton) 23 – 24 June 2016 Opportunity for national and international practitioners to discuss and explore challenges and progress in additive technology and applications in the context of defence, aerospace and medical requirements. http://camrmit.eventbrite.com.au Food Technology Queensland Brisbane Convention & Exhibition Centre 26-28 June 2016 Queensland’s food processing industry – a showcase of new products and manufacturing equipment www.foodtechqld.com.au Adelaide Boat Show Adelaide Event & Exhibition Centre, Wayville 30 June – 3 July 2016 Recreational marine and boating event, large & small boats and accessories. www.adelaideboatshow.com.au AWISA Melbourne Convention & Exhibition Centre 6-9 July 2016 Australian Woodworking Industry Suppliers Association Ltd for the cabinet, joinery, furniture, timber and panel industries. www.awisa.com CeMAT Melbourne Convention & Exhibition Centre 12-14 July 2016 Trade fair for intralogistics and supply chain management. Leading technology and service providers in the materials handling and warehousing industries. www.cemat.com.au Queensland Mining & Engineering Exhibition, Mackay Showground 26–28 July 2016 Mining products, technologies & services. www.queenslandminingexpo.com.au Sydney Boat Show Darling Harbour & Glebe Island 28 July–1 August 2015 The largest recreational marine event in the southern hemisphere www.sydneyboatshow.com.au Australasian Waste & Recycling Expo Sydney 10-11 August 2016 Waste services companies, landfill owners/ operators, independent contractors, government, compost professionals,

organics recycling, waste generators, recycling firms, trucks, machinery and equipment manufacturers, healthcare distributers, legal, insurance, financial firms. www.awre.com.au Melbourne Home Show Melbourne Exhibition Centre 18-21 August 2016 Latest products, services and innovations for home improvement. www.melbournehomeshow.com.au Land Forces 2016 Adelaide Convention Centre 6-8 September 2016 Land defence exhibition and forum for Australia, Asia and the Indo-Pacific region.

Equipment, technology and services, conferences and seminars. Showcase for manufacturers, systems integrators, maintenance and logistics specialists. www.landforces.com.au All-Energy Australia Melbourne Exhibition & Conference Centre 4-5 October 2016 Australian Sustainability Conference. Solar, alternative technologies, energy efficiency and storage. Coverage to all sectors of the clean and renewable energy industry. www.all-energy.com.au Perth Technology Expo Process & Instrumentation Trade Show Perth Convention Exhibition Centre 13 October 2016 Instrumentation, Control and Automation Industry. www.iica.org.au/info/events Sydney (Western) Technology Expo Sydney, Marconi Club 26 October 2016 Instrumentation, Control and Automation Industry. www.iica.org.au/info/events Launceston Technology Expo TAS. Launceston 9 November 2016 Instrumentation, Control and Automation Industry. www.iica.org.au/info/events Ausrail 2016 Conference & Exhibition Adelaide 22-23 November 2016 Largest rail event in Australasia and is supported by the leading industry associations. The conference theme is: Rail – Moving the economy forward. The agenda will address rail’s role in effectively enhancing Australia’s productivity, liveability and international competiveness. www.ausrail.com

Advertiser Index 3D Systems Asia Pacific 79 ADFOAM 87 Alfex CNC 18-19 AMTIL AMT 109 AMTIL AUSTECH 33 AMTIL E-Blasts 21 AMTIL Entrepreneurs’ Programme 29 AMTIL Hotspots 91 AMTIL ManufactureLink 113 AMTIL Membership 115 Applied Machinery 37 AWISA 25 BAC Systems 103 Bolt & Industrial Supplies 85 Complete Machine Tools 49 Compressed Air Australia 23 Dimac Tooling 102 DMG MORI 11 ECI Solutions 67 EuroBLECH 2016 27 Fuji Fasteners 105 Guhring 17 Hare & Forbes 9 Headland 120 Hi-Tech Metrology 59 IMTS 39 Industrial Laser Cover flap, 15 Integra Systems 104 ISCAR 2-3 JODEK 101 Kaeser Compressors 51 Machinery Forum 119 Mastercut Technologies 106 MTI Qualos 41, 65 Okuma 7 OSG Tooling 4-5 Sandvik 53 SECO Tools 13 SEW Eurodrive 93 TRJ Engineering Pty Ltd 107 Waddell Engineering 108 Whitehall Workplace Law 75 Your Industry. Your Magazine.

aug sep

Australian Manufacturing Technology

MEDICAL We examine how innovations in precision manufacturing are revolutionising the medical world and creating fresh opportunities for Australian manufacturers.

CONSTRUCTION & INFRASTRUCTURE CUTTING TOOLS FORMING & FABRICATION

Advertise in Australia’s No. 1 precision and manufacturing magazine

MATERIAL REMOVAL

Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asameulsson@amtil.com.au

SOFTWARE

ROBOTICS & AUTOMATION WORKHOLDING

AMT Jun/Jul 2016

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history

Big wheels & little wheels – the story of Sir Laurence John Hartnett (1898 – 1986)

A LIKING BY THE VIKINGS

Part 13

UK-born Sir Laurence Hartnett arrived in Australia in 1934. The visionary Sir Laurence became known as Australia’s ‘Father of the Holden’ – and much more. But before Sir Laurence sets foot in Australia, GM’s Swedish & Finnish automotive enterprises must be established. There’s plenty of ice to break – literally; drivers (NOT divers) to fish out from the freezing Baltic sea and 15,000 cars to sell. The year is 1929.

T

he severe Scandinavian winter puts most things to sleep – except for impatient Finnish carbuyers.

This meant frantic sales and production activities for about seven months of the year and then down to semihibernation for five months. An example of this was that in the first year of operation we sold 15,000 vehicles, and 12,000 were sold in seven months of that year. To aggravate things, and apart from lack of buying urge by the public, it was difficult to transport cars, especially to Finland, as shipping would close down because of ice in the Baltic and the Gulf of Finland. We were so delightfully “young” that we were like young whippets straining at the leash. Just what could be done to ship over to Finland quantities of new model cars as the thaw came? If we could “beat the gun” there was a pent-up demand for cars.

In anticipation of the thaw we had a huge quantity of cars built awaiting shipment to Finland. Days passed and the cold weather-and the ice-still held.

The wharf in Stockholm (Sweden) became more and more congested with our cars, and the dealers in Finland became more and more anxious to get their orders. I heard of an enterprising character in Germany, one Albert Bernstein, who had brought some old German warships to use as cargo-carriers. Bernstein, I was told, would take any kind of chance in any kind of weather. He could be the answer to our problem.

“Will you use your ships as ice-breakers?” I asked him. He said, “Well, I’ll try. There’s ice half-way across the Baltic, but I think I could get close enough to the Finnish coast to drop the cars over the side and they could drive the rest of the way on the thick shore-ice.”

He sent one of his old German cruisers over to Stockholm, loaded 350 cars, and crashed through the ice towards Abo, a city on the southwest coast of Finland. The ship got reasonably close inshore before the ice became too thick to break, and then the crew lowered the vehicles on to the ice in slings. We had told the Finnish dealers what was happening and they came from everywhere to Abo. One by one the cars were unloaded, driven across the ice and delivered to the waiting dealers. We lost four cars through the ice; the drivers got a ducking, but they were all wearing life-jackets and were hauled out to safety. The dealers sold the other 346 vehicles overnight, and immediately asked for more.

Albert Bernstein’s delivery voyage made headline news in Scandinavia. He deserved all the good publicity he got for the sporting chance he took.

Come to think of it, we took a chance, too. If Albert’s old cruiser had gone down in the ice-field, it would have taken our 350 cars. GM (New York) wouldn’t have been happy about that!

Those two years in Scandinavia with GM Nordiska were among the most exciting and important of my career. The experience of going into a strange land with one other fellow and setting up a brand new company, building factories, hiring, directing and guiding a small army of men and women-and turning out a record number of cars in a record time seldom comes to a man of twenty-nine or thirty.

The success of the operation sent my reputation within GM soaring, and opened the way to bigger and more important posts within the organization. I was fortunate that a background of training in Vickers Engineering during World War 1 gave me a deep appreciation of so many technical requirements of the manufacturing and assembly side of Nordiska, and experience in my own business at Wallington (UK) and with Guthrie’s in Singapore and GM in India had equipped me to handle the sales operation. And I had the training in GM organizational procedure in the head office in New York.

Nordiska, I feel, rounded off my education. It fitted me for whatever lay ahead and gave me the confidence born of experience to tackle some of the biggest, toughest jobs in the industry. But more important than any previous technical experience I had, more valuable than any of the lucky business breaks I got in Sweden, was the fact that I had a wife (Gladys) who pulled her weight, who never grumbled once about my long absences from home, and who was always there with a word of sound advice and much-needed encouragement. Sweden was a great challenge for me, and a lot of fun. But to my wife it must have been terribly hard at times. She had a young baby, she knew no Swedish and she had to put up with many long periods of loneliness. I know I could not have carried off the job so successfully if Gladys had not been Gladys.

To be continued…

Above: This sketch of Laurence appeared in a farewell tribute from the staff at GM Nordiska (Sweden)

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT Jun/Jul 2016

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