AMT DEC 16/ JAN 2017

Australian Manufacturing Technology

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006

Contents

Volume 16 Number 06 December 2016/January 2017 ISSN 1832-6080

44

FEATURES AGRICULTURE, FOOD & BEVERAGES Growing markets Food, agriculture and robots: Next-gen solutions Regional agritech company: Big export punch Enmin Vibratory Equipment for food processing Lasers meet agribusiness head on Safe bulk handling of biscuits South Australian innovators tap global agri-markets

44 48 50 52 53 54 56

FORMING & FABRICATION “Englishman” boosts productivity The fastest coil handing and cutting system

60 62

MATERIAL REMOVAL Water supplier goes with the flow

64

CUTTING TOOLS Production stuck in the groove?

A tale of two cutting tools – Rotary vs. Indexable Advanced software and tools for rough milling

66 68 70

BUSINESS MANAGEMENT Effective professional development Annualised salary arrangements – compliance Building an omni-channel experience The hidden costs of offshore manufacturing

72 74 76 77

ROBOTICS & AUTOMATION EU takes pole position in global automation race NZ-based manufacturer automates processes Automation can really be so simple

80 84 86

ADVANCED MATERIALS & COMPOSITES Steel from old tyres and ceramics from nutshells Cutting down harmful chemicals in coatings & composites

87 88

MATERIALS HANDLING Demo3D – Simulating & testing material handling Konecranes – real time monitoring for lifecycle care

91 93

Growing markets Australia is in an exciting position to take advantage of the growing middle class in Asia, as they demand more nutritious and healthy foods. To capitalise on that, innovative Australian food and agribusinesses are working together with product designers and local manufacturers.

58 Jens Goennemann - Managing Director, Advanced Manufacturing Growth Centre The Advanced Manufacturing Growth Centre was formed to raise the competitiveness of our Australian manufacturing sector to a global level. Jens believes that in many cases, Australia has not sufficiently prepared itself for the technological changes inherent in the manufacturing sector.

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 Jens Goennemann

58

COMPANY FOCUS Romar Engineering – Prospering through partnership

78

AMTIL FORUM Forum Training Forum Import/Export Forum LAW Forum OHS

94 95 96 97

MANUFACTURERS’ PAVILION

98

AMTIL INSIDE The latest news from AMTIL

106

MANUFACTURING HISTORY – A look back in time

114

78 Prospering through partnership Having transitioned successfully from automotive tooling into medical devices, Romar Engineering has shown its ability to diversify over the years. Its latest venture sees it partnering with CSIRO in the brave new world of additive manufacturing. Romar’s success in transitioning is partly attributable to its emphasis on R&D and retaining skilled staff.

Your IndustrY. Your

Dec Jan /17

Agriculture, food & BeverAget Business Managemen

Cutting tools Forming & Fabrication Material removal robotics & automation Materials Composites & advanced Materials Handling

AMT Dec 2016/Jan 2017

Cover

MagazIne.

technology

8 10 12 14 16

AustrAliAn MAnufActuring

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

Byron Bay company – Flow Hive - has developed an innovative bee hive system that delivers honey directly on-tap . Exported to 128 countries, the demand is increasing globally. Page 44

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008

From the Editor William Poole

Looking back, and forwards

Your Industry. Your Magazine.

So goodbye to 2016 then. At risk of understating things, it’s been interesting.

It’ll go down as the year that saw Donald Trump elected as President of the United States of America. It’ll go down as the year the UK shocked the world by voting to leave the EU. There was the Zika virus, a failed coup in Turkey, and the passing of what has often seemed an unprecedented number of high-profile figures from every sphere of public life, from Muhammad Ali to Nancy Reagan, David Bowie to King Bhumibol Adulyadej of Thailand.

In a year where global events have been accompanied by great waves of hysterical overstatement, it’s been something of a relief that for Australia the news highlights reel has remained relatively muted. Federal elections were held in July, with a distinct absence of the sort of garish spectacle that was unfolding in the US. Prime Minster Malcolm Turnbull and his Coalition Government secured a narrow re-election. Other than that, it’s been quiet. Australian came tenth at the Olympics. There were surprise title wins for Western Bulldogs and Cronulla. Anything else?

It’s been similarly low-key for Australian manufacturing. It was of course a sad day when Ford finally wound down its manufacturing operations here, with GM Holden also beginning its planned closures. But better news came with the announcement that Australia’s Future Submarines fleet would be built in Adelaide, along with numerous stories about innovative Australian manufacturers winning major deals in the defence space, as well as in aerospace, medical, clean-tech, and more.

The Australian Performance of Manufacturing Index notched up a year of almost unbroken growth, underlining the impression the team here at AMTIL have been getting from talking to our members: that conditions are looking more positive for our industry than they have in some time.

So now we move on to 2017. The year ahead will see Holden and Toyota finalise the cessation of car-making in this country, with challenging implications for Australian manufacturers in their supply chain. But there’s no reason to believe that the companies that have been making the right sort of headlines this year won’t continue to do so, and that others will join them. Certainly excitement is already starting to build ahead of the upcoming Austech exhibition to be held in Melbourne this May. Across the globe, next year promises to be every bit as… interesting as this year. Trump will move into the White House; the UK will continue its tortuous Brexit process. Who knows what else lies in store? Let’s just hope Australian manufacturing can strike a note of stability. ***

It’s been a year of change for AMT Magazine as well, with our move from a ten issues a year to six. We took the decision last year to shift to a bi-monthly schedule because we felt the move would enable us to deliver a more diverse, substantial magazine.

So far the feedback from our readers has suggested it was the right decision, and we look forward to continuing the evolution in 2017.

So finally, I’ll just round things off by thanking our readers, contributors and advertisers for their support throughout 2016. On behalf of myself, Anne, Gabriele and Franco, and all of the AMTIL team, I’d also like to wish AMT readers and all involved in our industry a Merry Christmas and a Happy, Prosperous New Year.

Australian Manufacturing Technology

Editor William Poole wpoole@amtil.com.au Contributor Carole Goldsmith 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).

All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher.

Contained specifications and claims are those supplied by the manufacturer (contributor)

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes.

AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published monthly.

Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $165 (inc GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

1330AMTDecJan2017

AMT Dec 2016/Jan 2017

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

010

From the CEO Shane Infanti – Chief Executive Officer AMTIL

What will change under a Trump administration?

It was predicted by The Simpsons back in 2000 that Lisa Simpson would be elected President in 2030, following Trump’s tenure in office. However, that would mean The Don would have to be President for 14 years and we know, at best, he can only do eight!

Wow! We didn’t see that coming! Even with the Simpsons’ prediction and the fact that it was a two-horse race and the second horse had some significant hurdles of her own to overcome, it still sent shockwaves around the globe when the US voted Donald Trump as President-elect on 8 November. So when the inauguration of Donald Trump finally takes place on 20 January 2017, what can we expect?

At the time of writing this article, only a few days after the election, we had seen three days of share market volatility, gold price variations, exchange rate dips and rises and wide and varied condemnation and commendation. This, for me, is one major challenge Trump will have in the short term. How do you unite a country that has over 50m people voting so strongly for you NOT to be in office?

There are some key issues and political decisions that President Trump will have to make that could change America’s relationship with the rest of the world. He has been hugely critical of NATO (the North Atlantic Treaty Organization) which has been a cornerstone of American foreign policy for more than 60 years. He has attacked the organisation as being obsolete and said that America can no longer afford to protect countries unless they pay up. The world waits to see how this will play out. Will he be able to ease tensions with Russia and how strongly will he back up his promise to defeat the so-called Islamic State? And what does this mean for Australia?

The US has always been our strongest ally when it comes to matters of national security. Is that about to change?

Donald Trump’s trade policies, if he imposes them, would amount to the biggest change to the way America does business with the rest of the world that we have ever seen. He has threatened to scrap the North American Free Trade Agreement (NAFTA), withdraw from the Trans Pacific Partnership (TPP), and impose a 35% tariff on imports from Mexico and a 45% tariff on imports from China. It is hard to see any of these threats actually being carried out, such is the risk of the trade war that may follow, but then again it is what he has said he will do. Even though he has not specifically mentioned the Australia-US Free Trade Agreement, it will be interesting to see what

AMT Dec 2016/Jan 2017

impact any changes to the way America trades in the future will have on Australia. Will his open confrontation with China threaten to put Australia in a compromising position with our economic trading partners?

Climate change is another significant global issue that will be impacted by the US if Trump has his way. He has promised to cancel the Paris Climate Agreement within 100 days of taking office and says he will do everything in his power to reverse the climate change regulations introduced by President Barack Obama. He has pledged to stop government funding of clean energy projects and climate change initiatives and push ahead with coal and fossil fuel as the prime energy source production. What impact will his view of “affordable energy” versus “renewable energy” have on global warming and climate change?

Trump’s views on immigration have the potential to impact on Australia. The world needs compassionate and decisive leadership that is able to manage the mass humanitarian problem relating to immigration and refugees. Trump has vowed to stop immigration from the southern borders. He has called for a complete shutdown of Muslims entering the US until his representatives can figure out what impact this will have. Australia rightly prides itself on its multiculturalism. But humanitarian and refugee issues remain an important political issue here and are we likely to be impacted by what stance America finally takes?

These are issues that will have global impact. Then, of course, there are the questions that America waits to have answered internally. Will he build “The Wall” and who will pay for it? Will he scrap “Obamacare” and what will he replace it with? Will he deport the “hundreds of thousands of immigrants” that he says arrived as children illegally with their parents?

As you can see, there are many questions waiting to be answered.

One thing we can be certain of – President Trump will make change.

History will show us whether it is good or bad for America and the rest of us.

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012

From the ministry The Hon Greg Hunt MP – Minister for Industry, Innovation and Science

Australian manufacturers prospering in the US I recently travelled to the United States to meet with industry representatives to promote the enormous opportunity the Australian manufacturing sector has to offer.

I also saw first-hand how successful Australian businesses are exporting their products and expertise overseas, generating investment and creating more jobs. One of those is Australian company ANCA. While keeping its Melbourne manufacturing base in Bayswater, the company has also expanded its offering to Detroit, Michigan.

ANCA is an Australian-owned computer controlled tool grinding manufacturer, which exports almost 98% of its product globally.

Its clients include many global companies such as Boeing, General Motors, Rolls Royce and Samsung. The products the company sells are used by some of the most advanced manufacturing companies in the world – from the aerospace industry to car manufacturing to medicine.

ANCA has a history of investing heavily in research and development in order to ensure it provides the best technology in its field. ANCA’s success is based on giving its customers innovation, precision and quality along all points of the value chain.

In addition to providing highly sought-after products, the company has a strategy of using a worldwide team of technical specialists to service its diverse range of customers in traditional manufacturing regions such as the US, Japan, Germany and China. It is matching its advanced technology with a solid business operation strategy. When you see the strides made

by Australian firms like ANCA, it’s clear that, through advanced manufacturing, we as a nation can continue to be highly competitive on the world stage and create highly skilled, high-value jobs for Australians. ANCA’s success also demonstrates how crucial it is for Australian companies to gain access to global supply chains.

Access to worldwide supply chains and the development of advanced manufacturing technologies, and how they can be applied in Australia, were among the key reasons for my recent visit to the US. I also visited the headquarters of GE, toured the research and development labs at both General Motors and Ford, and met with the team from Dow Chemicals.

The experience gathered from these visits will be invaluable as the Federal Government continues to support Australia’s manufacturing sector to be world-class in terms of competitiveness, and in doing so, to create more jobs and better jobs.

AMT Dec 2016/Jan 2017

Minister Hunt at ANCA’s Detroit facility.

When you see the strides made by Australian firms like ANCA, it’s clear that, through advanced manufacturing, we as a nation can continue to be highly competitive on the world stage and create highly skilled, high-value jobs for Australians. ANCA’s success also demonstrates how crucial it is for Australian companies to gain access to global supply chains.

As we know, manufacturing in Australia is transforming – the long-term health of the sector lies in developing new and innovative ways of working. Companies like ANCA have set the standard and demonstrated that innovative, skilled and competitive Australian manufacturers can be among the best in the world.

The future of manufacturing in Australia lies in value-adding activities from product concept, research and development, design and production, to distribution and after-sales service. That’s why the Turnbull Government is committed to ensuring that our manufacturing industry is internationally competitive.

014

From the industry Innes Willox – Chief Executive Australian Industry Group

Australian manufacturing: recovery and restructuring in 2016. Where is the growth?

Australian manufacturing has staged a small but extremely welcome comeback in 2016, after suffering a sustained period of shrinkage since our most recent peak in 2008.

This partial recovery has been evident across a number of key industry-wide metrics: • Ai Group’s Australian PMI indicated stable or expanding activity in every month from July 2015 to July 2016. This was the longest positive run of results since 2008.

• Manufacturing value-added output improved by 1.0% in the June quarter of 2016, after declining in each of the previous seven quarters. However, it remains 14.5% lower than our previous peak in June 2008.

• Manufacturing employment recovered by 10,200 people in the year to Aug 2016, after losing 190,000 jobs between 2008 and 2015 (18% of its 2008 workforce).

• Aggregate corporate profits for manufacturers recovered in the June quarter 2016, to be up 10.9% from a year earlier and reaching their highest nominal level since 2011.

• Manufacturing capital investment spending (CAPEX) strengthened in the June quarter 2016, to be up 3.9% from a year earlier (although at $2bn, it remains well short of the $3.5bn that was typically being spent per quarter by manufacturers from 2005 to 2011).

• Even more positively, the latest estimate of CAPEX in 2016-17 indicates that manufacturers plan to invest about the same amount this year as they did last year. If they do, this will be the first year since 2011-12 in which their CAPEX has not fallen.

This partial recovery is all the more remarkable because it is happening even as Australia bids farewell to the automotive assembly sector, which has arguably been the lynchpin of Australia’s advanced manufacturing and engineering activities for at least 70 years.

So why is this recovery happening? What is driving it? Feedback from manufacturers via the Australian PMI and other sources indicates that the contributing factors include: • The lower Australian dollar, which is making it easier to export and to compete with imports across a range or product classes – probably the single most significant swing-factor.

• Increased interest and awareness of export markets among Australian manufacturers as a result of key trade agreements being finalised, including with China. While these agreements may not yet be facilitating easier and cheaper trade per se, they appear to be stimulating interest in exporting and willingness to attempt to crack new markets.

• Increased demand for Australian manufactured goods from key Asian markets and especially China, due to rising demand from middle-class Asian consumers.

• Increased demand for manufactured building materials and other products that feed into local residential construction, due to the strong upswing in the home building cycle happening across Australia, especially in Sydney and Melbourne.

• A partial recovery in global commodity prices and especially black coal prices, with the IMF’s global commodity price index up around 26% from the recent trough of January 2016, as of September. This is enabling Australia’s coal miners to resume their maintenance programs and to upgrade plant and

AMT Dec 2016/Jan 2017

equipment – benefiting manufacturers who supply or maintain plant and equipment for the miners, or who are involved in resources processing or transport.

More importantly, where is this recovery happening? And how can we keep this positive momentum going? In 2016, the growth segments of Australian manufacturing can be roughly divided into two large groups.

First, the ‘consumables’ and ‘consumer-oriented’ products, which collectively make up around one-third of our manufactured output: • Food products, e.g. confectionery, snack foods, dairy, baked goods, prepared meals.

• Beverages, e.g. wine, beer, soft drinks, bottled water, energy drinks.

• Pharmaceuticals, vitamins, health supplements.

• Toiletries & cosmetics.

• Medical appliances, devices and equipment.

These products are benefiting from: the low dollar; growing demand from middle-class Asia; growing demand from ageing populations; growing awareness of the importance of product quality, safety, efficacy and reliability; established trust in Australia as a reputable producer; verifiable supply chains; access to high-quality agricultural and other raw ingredients; and growing product ranges due to new technologies, production methods and product types.

All these factors can and should be actively promoted and marketed by business, industry and Government. New products, production methods and technologies must also be more actively fostered by business, industry, Government and the academic sectors if we are to get serious about innovation, collaboration and competitiveness that is not cost-based.

The second growth trend is centred around specialised and advanced construction, engineering and industrial applications: • Specialised, scientific and technical machinery and equipment.

• Transport parts and equipment other than cars, e.g. trucks, trains, buses, caravans.

• Building materials and components including wood, steel, glass, ceramics and others.

• Building & surface treatments, e.g. paint, adhesives, coatings.

These products are benefiting from: the low dollar; growing demand from the booming local residential construction sector; resurgent demand from Australian and international resources developments; growing awareness of the importance of product quality, safety, efficacy and reliability; established trust in Australia as a reputable producer; access to highly skilled employees and excellent engineering education facilities; growing product ranges due to new technologies, production methods and product types.

As with the first group, all of these factors can and should be actively promoted and marketed by business, industry and Government.

Also required is a stronger and faster emphasis on enabling innovation, better STEM skills development, and a serious reduction in the regulatory barriers and regulatory costs associated with new technologies and industrial production methods.

We hope to see continued growth in 2017.

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016

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

Questions linger over Future Submarines Readers of AMT might recall that in October 2014 my column was dedicated to calling on AMT readers to support the campaign for Australia’s Future Submarines to be built in Australia. We have been successful so far, but the battle continues.

All of the arguments in that column (which can be found online on the AMTIL website) remain relevant today: • The Abbott and Turnbull Coalition Governments made successive election commitments and should honour them.

• The skills, technology and know-how will boost manufacturing in Australia generally.

• The unique Australian security requirements mean that local knowhow is necessary for selfreliance.

• A strong statement of support by the Government for Australianmade submarines would provide a significant boost to manufacturing and strengthen the broader economy.

The Turnbull Government made the announcement on 26 April this year that DCNS of France had been selected to build the submarines and also made the necessary re-announcement that “the next generation of submarines for Australia will be constructed at the Adelaide shipyard”.

The announcement was necessary as the Abbott Government had for a period refused to confirm its pre-election commitment that the Future Submarines would be built in Adelaide.

However, there have been some troubling developments, which raise the prospect of a change in the Government’s position.

They raise questions about the Turnbull Government’s long-term commitment to the Australian build of the Future Submarines and importantly, its genuine commitment to building Australian industrial and shipbuilding capabilities.

A week before the announcement on 20 April, the contents of “confidential Defence documents” were reported in The Australian newspaper, which contained “modelling” that assumed it would cost 30% more to build the ships in Australia than it would to buy direct from the foreign shipyards. The basis of the assumption was not reported.

However, another interesting part of the article was an assumption in the modelling about how much of the build would actually be in Australia.

The article stated that the modelling also presumed that the 30% figure “assumed about half the cost of the project would be spent in Australia while major components,

AMT Dec 2016/Jan 2017

such as the motors and electronics, would be wholly imported”. In addition, the article’s reported 3,000 local jobs (including subcontractors) was slightly higher than the 2,800 jobs figure used in the Government’s official media release a week later.

At the October Senate Estimates hearings the Government was repeatedly asked why the ASC appeared to have no role in the building of the Submarines after it had been restructured. The ASC has been restructured by the Government into three entities: shipbuilding, submarine maintenance and support, and infrastructure.

Senator Nick Xenophon asked the Finance Minister about the new structure: “Minister, you don’t find it curious that Future Submarine building is omitted from the new structure?”

The Finance Minister responded: “You know those submarines will be built in South Australia, you know they will be built in Osborne, and you know they will be built on ASC infrastructure, and any contracting arrangements between ASC and DCNS are a matter for the Defence portfolio to essentially pursue.”

These developments raise serious questions about what parts of the submarine will be built in Australia and who will be building those parts that have been determined to be built in Australia.

The skills and capabilities needed to build the submarines will only have a flow-on effect if they are developed and retained in Australian workers and Australian companies. A fully functional workforce arriving from overseas on 457 visas who return to their home country in France will be unlikely to transfer knowledge and skills to the Australian economy.

As we enjoy time with our families and friends over the summer break, I urge AMT readers to continue actively supporting the Future Submarine project being built in Australia. It is plain from recent developments that the Government’s commitment to maximising Australian industry engagement in the project is not rock solid.

In addition, there are still people opposed to the renaissance of Australian manufacturing who continue to argue that manufacturing is an “old world industry”. The increasingly ideological Productivity Commission used its annual report on the Government’s “industry subsidies” to uncritically quote the 30% figure and predictably rail against the decision for a local build. Columnists in various publications have been using their columns to push their mischaracterisation of the decision to build the submarines in Australia as protectionist.

We know there are significant advances being made in manufacturing technology, process and product innovation across our industry. AMWU members are continuously involved in improving production processes that secure their jobs. A look on the Australian Made campaign’s website reveals tens of thousands of Australian made products, from daily-use consumer products to specialist trade sound engineering equipment. Organisations like Boeing Australia and the CSIRO continue to push the boundaries of what we know is possible.

The Future Submarine project directly challenges the propaganda about manufacturing being an “old world industry.”

The Future Submarines will be made from the latest deep sea naval technology and represent Australian manufacturing as a technologically advanced industry – an industry, that’s critical for a modern diverse economy.

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020

industry news

Ballarat hosts Manufacturing Showcase More than 350 manufacturers from across Victoria gathered in Ballarat on 18 October for the 2016 Victorian Manufacturing Showcase.

Themed Leveraging Opportunities in Growth Sectors, the annual event featured some of Victoria’s most successful manufacturing firms, held for the first time in regional Victoria. Ballarat’s manufacturing sector employs more than 4,600 people with approximately 600 manufacturing businesses in the area.

The Showcase was officially opened by the State Minister for Industry and Employment, Wade Noonan, who said in his foreword for the event’s programme: “It is fitting that this year’s event is being held in Ballarat, which has a thriving manufacturing industry that has been the bedrock of the local economy for over a century.”

Minister Noonan’s opening address was followed by a talk setting the scene from the Showcase Ambassador, Gerry Ryan OAM, Chairman of Jayco, Australasia’s largest manufacturers of recreational vehicles. This was followed by presentations from some of the state’s most innovative manufacturing businesses.

Chris Jenkins, Country Director and CEO of Thales Australia, talked about opportunities in Australia’s defence sector, where some $195bn is set to be spent over the next 10 years, emphasising the importance of innovation and the need to be globally competitive.

Rodney Walton of Haymes Paint then offered a case study of how companies can compete with the biggest in the business, in Haynes’ case due to a strong brand, a great product, and the ability to identify opportunities and deliver value.

Paul Chapman of the Australian Turntable Company gave a fascinating account of how his company secured a contract to build a revolving restaurant at the top of a tower in Tehran, thanks to attention to detail, and the belief among his team that they could match the best in the world. He was followed by Elizabeth LewisGray of Gekko Systems, which has become a leader in mineralprocessing technology through a focus on people and culture, astute marketing, and constant innovation.

Next up was Stephen McDonald, CEO of Albins Performance Transmissions, which has evolved from simply “making stuff”, to delivering something of more intrinsic value to his customers: a competitive advantage. Ross George of Austeng provided another story of transformation, detailing how his company has shifted from a business that was acutely exposed to the automotive sector, to new partnerships with both universities and start-ups, at the cutting edge of advanced engineering.

This was followed by Jim Le Sage of True Foods, who showed again how small companies can thrive against much larger competitors, in this case through a willingness to invest in innovation and focus on people. Finally, the day’s panel discussion featured Erika Hughes of Integra Systems, Ron Weinzierl of Australian Precision Technologies (APT), and Jeff Malone of SRX Global. The three panel members discussed how collaboration between their businesses had delivered real benefits.

“The Andrews Labor Government is proud to support this year’s Victorian Manufacturing Showcase in Ballarat, a testament to Victoria’s strong regional manufacturing sector,” said Minister Noonan. “Despite the closure of Ford, manufacturing is one of the largest industries in Victoria and will continue to support our high growth sectors that will create jobs and power the state’s economy.”

Melbourne’s 3D jet engine technology flies into production in France

The Monash University-led team which 3D-printed a jet engine last year on 8 November announced a new venture for manufacturing aerospace components in France.

Melbourne-based Amaero Engineering – a spin-out company from Monash’s innovation cluster – has signed an agreement to print turbojet components for Safran, the French-based global aerospace and defence company. The collaborative agreement is between Monash, Amaero and Safran Power Units.

“Our new facility will be embedded within the Safran Power Units factory in Toulouse and will make components for Safran’s auxiliary power units and turbojet engines,” said Barrie Finnin, CEO of Amaero. The world’s first 3D-printed jet engine was revealed at the 2015 Melbourne International Airshow. Safran, Monash University and Amaero, in collaboration with Deakin University and the CSIRO, took a Safran gas turbine power unit from a Falcon executive jet, scanned it and created two copies using customised 3D metal printers, as part of a project supported by the Science and Industry Endowment Fund (SIEF). This research is now being extended through the support of Australian Research Council’s (ARC) strategic initiative ‘Industry Transformation Research Hub’ and industrial partners including Safran and Amaero.

AMT Dec 2016/Jan 2017

“We proved that our team were world-leaders,” said Professor Xinhua Wu, Director of the Monash Centre for Additive Manufacturing. “I’m delighted to see our technology leap from the laboratory to a factory at the heart of Europe’s aerospace industry.”

Amaero will establish a new manufacturing facility on the Safran Power Units site in Toulouse using the 3D printing technology known as selective laser melting (SLM). Amaero will bring the know-how and intellectual property developed in partnership with Monash, and will also relocate two of the large printers they have customised for this precise manufacturing task.

Safran Power Units will test and validate the components the team makes, and then the factory will enter serial production, producing components that Safran Power Units will post-process, machine and assemble into auxiliary power units and turbojet engines for commercial and defence use. The project team expects that production will commence in the first quarter of 2017.

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industry news

Parish expands with Longworth takeover Parish Engineering has announced a major expansion of its business with the acquisition of Longworth Engineering, based in Nunawading, Melbourne.

Founded by John Longworth in the 1950s, Longworth specialises in repetition engineering as well as manufacturing air fittings for the truck industry. Established in 1932 and today owned and run by father-and-daughter team Graeme and Nicole Sinclair, Parish manufactures precision components for clients in industries such as automotive, defence, aerospace and mining. For Paul Rafferty, Business Development Manager at Parish, the Longworth takeover makes good business sense.

“With the demise of the automotive industry, we’d been looking at options to expand,” he explains. “I knew John, and a few years ago he mentioned he was looking at getting out of the business. I knew the business would be a good fit, so I had a chat with Graeme and Nicole and said ‘Shall we have a look into it?’ And today, here we are moving everything over.”

The key benefit for Parish will be the opportunity to have its own product line, in the form of Longworth’s extensive range of air fittings. Prior to the takeover, Parish had been largely confined to contract work as a components supplier. This, according to Rafferty, leaves one dependent on customer demand, so having a product line provides a degree of independence and stability.

“Before we relied on everyone else, so you’re at the mercy of what your customers do,” he says. “This gives you a bit more control if you’ve got your own product. Most repetition engineers, that’s their aim, to find their own product they can sell.”

Longworth’s operations will be moved from Nunawading to Parish’s facility in Moorabbin, with Rafferty estimating that the move will be completed by mid-December. The more modern, computerised equipment will be transferred, and though some of the older machines will be scrapped, a few will also be retained to keep up with ongoing demand for Longworth’s products.

“There’s machinery here that Parish scrapped off about two years ago,” says Rafferty. “But because the business is so vast, we want

to take that machinery while we’re getting a handle on the volumes.

We don’t want to throw out the baby with the bathwater and then find we haven’t got the equipment to cope with the volume.”

The plan is for the Longworth brand to continue under Parish’s name, as Longworth Air Fittings. At present the fittings are only sold to customers in Australia, but Rafferty sees considerable potential to market them further, possibly targeting export markets eventually. Indeed, as the purchase of Longworth has progressed, Rafferty has been increasingly impressed by the possibilities the takeover opens up.

“We were pretty well aware of the business and what they did, but actually more so when we got down here and got into the nuts and bolts of it,” he says. “It’s actually a lot bigger and better than I thought. We see the potential for this business to be bigger than Parish. The potential for this business is very good.” www.parishengineering.com.au

Seco and RMIT explore Industry 4.0 Seco Tools teamed up with RMIT University on 11 October for a special educational event that looked into the machining implications of ‘Industry 4.0’.

Held at RMIT’s Advanced Manufacturing Precinct in Melbourne, Seco’s NEXT STEP seminar was presented by Patrick De Vos, Seco’s Corporate Technical Education Manager and Global STEP Expert, along with David Morr, Regional STEP Expert – Asia Pacific, and was attended by representatives from some of Victoria’s most prominent advanced manufacturing companies. Seco held a similar event in Sydney later that week.

content, as well as a discussion about the actual meaning of Industry 4.0. This included some examples of manufacturing operations here in Australia, such as the Royal Australian Mint, that are already putting these ideas into practice– showing that Industry 4.0 is not just a vague idea of what might happen in the future, but something that is already happening here and now.

According to Seco, the Industry 4.0 concept is to create a “Cyber Physical Manufacturing System” that is capable of running itself without any input from human labour. Such a system would incorporate extensive use of robotics and automation, networked computers, sensors and monitoring technology, and constant analysis of high volumes of data. However, Seco’s focus in the seminar was more on the physical aspects of this system, in terms of the challenges it presents with regard to machining processes.

Morr opened up proceedings with an outline of the seminar’s

AMT Dec 2016/Jan 2017

Morr then handed over to De Vos who gave an extensive, far-reaching presentation that examined the implications of Industry 4.0 for cutting tools and machining processes.

De Vos’s talk covered varieties in materials, tool types and cutting strategies, and the need to apply the correct model to combat issues that arise during machining processes.

Patrick De Vos, Seco’s Corporate Technical Education Manager and Global STEP Expert.

“How can we implement Industry 4.0 in a machining operation?” said Morr. “As any experienced machinist would know, things can happen, things can go wrong. It’s not just about robots and big data. For us as machinists to introduce these Industry 4.0 concepts, it’s a lot more involved.”

The Truth About Compressed Air! If you think compressed air is too expensive and noisy - read this. The facts will surprise you!

Compare these Blowoffs

Facts about Blowers

source), and a blower supplied air knife (using an electric motor as a power source). Each system

Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of

Here are some important facts:

Filters must be replaced every one to three months.

Belts must be replaced every three to six months.

edges, we took sound level measurements in free air (no impinging surface).

Typical bearing replacement is at least once a year at a cost near $1000.

Drilled Pipe

Blower Air Knife

and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed

option. As noted below, the purchase price is high. Operating cost was considerably nozzle, but was comparable to EXAIR’s

is overshadowed by its high energy use.

its two 3" (76mm) diameter hoses requires

level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

the others. Noise level was high at 90 dBA.

•

Blower bearings wear out quickly due to the high speeds (17-20,000

•

Poorly designed seals that allow

•

environments above 50°C decrease the one year bearing life.

Many bearings can not be replaced to send the assembly back to the manufacturer.

with downtime were also negative factors.

Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air

Flat Air Nozzles

EXAIR Super Air Knife

As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminium and stainless steel from

job of removing the moisture on one pass due to the uniformity of the laminar low. For this application, energy use was slightly higher than the blower but can be

from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers

to control since mechanical adjustments are required. To discuss an application, contact:

is possible. Safe operation is not an issue since the Super Air Knife can not be deadended. Maintenance costs are low since there are no moving parts to wear out.

be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

Blowoff Comparison Comp. Air Type of blowoff

PSIG BAR

SCFM

SLPM

Horsepower Sound Purchase Required Level dBA Price

Annual Electrical Cost*

Approx. Annual Maintenance Cost

First Year Cost

$5,478

Drilled Pipes

60

4.1

174

4,924

35

91

$50

$4,508

$920

Flat Air Nozzles

60

4.1

257

7,273

51

102

$208

$6,569

$1,450

$8,227

Blower Air Knife

3

0.2

N/A

N/A

10

90

$5,500

$1,288

$1,500

$8,288

Super Air Knife

60

4.1

55

1,557

11

69

$1,188

$1,417

$300

$2,905

*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

024

industry news

thyssenkrupp Australia opens new facility in Dandenong

thyssenkrupp Materials Australia, on 8 November opened a new facility in Dandenong, Victoria.

The Dandenong facility will offer materials in both rolled and extruded aluminium products, cut to size using CNC plate – band – and dropsaws, continuing to build on thyssenkrupp’s commitment to its customers in Australia. Aluminium rolled and extruded products in the 2000, 5000, 6000 and 7000 series will be among the materials that the facility will supply to customers in Victoria. The new facility allows thyssenkrupp to bring quality products and services closer to customers in the region and provide them with added value in terms of streamlined sourcing and reduced lead times.

“The opening of our facility in Dandenong is an opportunity for us to bring our quality products closer to where customers need them the most, and for us to establish a key footprint in the Victorian market,” said Brad Foster, General Manager, thyssenkrupp Materials Australia. “This strategic expansion signals our commitment to furthering and growing our operations in the country.”

With the Victorian economy growing strongly and a range of highprofile infrastructure and construction projects underway, the Victorian Government has introduced several key initiatives focused on developing the state’s advanced manufacturing capabilities.

These include the Futures Industries Program that helps local companies implement new manufacturing technologies and processes in their operations.

Just as important in promoting advanced manufacturing is access to specialised and innovative materials. Raw materials are a key component in the manufacturing supply chain, and according to

thyssenkrupp, it is important to not only meet customers’ exact specifications, but also to introduce them to innovations that will help transform their ability to deliver projects on time and to budget. thyssenkrupp has built a diverse product portfolio and nurtured relationships with customers across Australia for the last two decades. It supplies an extensive range of quality raw materials into key manufacturing sectors within Victoria, such as aerospace, defence, hydraulics, motorsport & general engineering. Its ability to support these industries is backed by a reputable supply chain.

Its product range and stock holding continues to grow with the demands of the industry.

Greg Hunt visits ANCA’s US plant

Greg Hunt, Federal Minister of Industry, Innovation and Science, visited ANCA’s US facility in Wixom, Michigan, on 28 October. plans to expand the Wixom plant by 50%, increasing inventory and spare parts warehouse capacity, adding a dedicated customer focus and training centre, and doubling its machine demonstration area. It will also include enhanced machine rebuild and configuration areas for preparing the machines for customer delivery. The expansion also adds to ANCA’s spindle rebuild area and electrical repair facility, permitting the company to respond quickly to customer needs, and includes larger employee accommodation.

Minister Hunt met with Russell Riddiford, President of ANCA, Inc. (the North America branch of ANCA). Riddiford’s team provided the Minister with a demonstration of the Wixom plant’s capabilities. From Wixom, ANCA also services Mexico and Brazil.

“I was pleased to visit ANCA’s showroom today in Detroit and see first-hand the success that can be achieved by a business when they keep their eye on innovation,” said Minister Hunt. “ANCA is an Australian-owned manufacturer which exports almost 98% of its product globally but remains committed to its high-end production and main R&D team in Melbourne.

The building expansion will total 1,096 sqm According to Riddiford, it will allow ANCA to add employees to Russell Riddiford (left), President of ANCA, Inc., its warehouse, spindle rebuild, and “ANCA has a history of investing heavily and Greg Hunt, Federal machine configuration areas to provide in R&D to ensure it provides the best Minister of Industry, faster customer service. Work began in Innovation and Science. technology in its field and focuses on October with completion expected in creating a product that is sold into some the second quarter of 2017. of the most advanced manufacturing companies in the world, “This expansion represents ANCA’s commitment to the Americas from aerospace to car manufacturing to medical. ANCA is a true and to servicing our customers promptly and fully,” Riddiford said. success story in harnessing the power of innovation.”

Headquartered in Bayswater, Victoria, ANCA recently announced

AMT Dec 2016/Jan 2017

www.anca.com

industry news

TRJ expands with move to new facility

TRJ Engineering has expanded its capabilities with a move to a new, larger site in Hallam, Victoria.

TRJ began operations in Keysborough in 1974, but moved to Hallam around 20 years ago, eventually occupying three adjacent sites on the same street. The new facility is only round the corner from the old premises, but at 3,800sqm, it is 600sqm larger than the three old sites combined.

“We’ve moved from three factories into one big factory, so we’ve got it all under the one roof, which will make everything more efficient and increase our productivity,” says David Murphy, TRJ’s Director and Owner. “We’ve got more floor space, we’ve the ability to grow. The whole landscape has changed.”

Apart from being significantly larger, the new site represents a major upgrade in numerous areas. Boasting more than 400 amps of power, it includes a purpose-built machining shop, and is equipped with 16-ton and 10-ton overhead cranes, whereas previously TRJ only had access to 5-ton machines. The factory boasts eight dedicated general fabrication bays, as well as six welding bays, compared with four in the old premises. Murphy has also had gas lines plumbed in throughout the factory, meaning there’s no need for gas bottles in the bays.

“We do a lot of truck chassis work,” he says. “And now we’ve got six dedicated welding bays where we can build B-doubles and semi-trailers. I’ve also got laser cutters and folders and all the other bits and pieces in proper areas now. We’re not moving from one factory to another to keep our work going through, so we won’t have to deal with forklifts being on the road.”

The new site allows TRJ to become more efficient in the way it runs its work. Around 60% of Murphy’s team have done Lean manufacturing to Cert 3 or Cert 4 stage, and the new facility is an opportunity to put that into practice more rigorously.

“In the end, we now can produce bigger stuff,” says Murphy.

“Having a 16-ton crane, we can pick up heavier stuff, we can build heavier stuff, we can manoeuvre heavier stuff. I’ve got a lot of flexibility in those welding bays now, with screens moving in and out that change for the size of the jobs. Air lines are everywhere, power’s everywhere.

“There’s a whole lot of stuff that ticks boxes up here, and all under one roof. It’s pretty much a state-of-the-art workshop for us.

There’s no excuses anymore.”

AMT Dec 2016/Jan 2017

025

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Industry news

Advanced Manufacturing Growth Centre partners with Thales

The Advanced Manufacturing Growth Centre (AMGC) has announced the signing of Thales in Australia as the founding member.

As a member of the AMGC, Thales will be able to play a pivotal role in influencing the future trajectory of Australian manufacturing and will directly benefit from the Centre’s upcoming Sector Competitiveness Plan.

“The signing of Thales is a positive outcome for the Australian manufacturing industry,” said Dr Jens Goennemann, Managing Director of AMGC. “Fostering collaboration and connecting our local manufacturing firms and scientific research community with large multinational manufacturers is key to growing the sector and improving our global competitiveness.”

Thales is a global technology leader for the aerospace, transport, defence and security markets. Thales in Australia is a trusted partner of the Australian Defence Force and is also present in commercial sectors ranging from air traffic management and ground transport systems to security systems and services. Employing around 3,200 people, Thales in Australia recorded revenues of more than $1bn in 2015. Thales has a strong commitment to manufacturing and innovation in Australia. The company has invested millions of dollars in manufacturing over many years, in areas such as sonar systems for navy ships and submarines, plus life-saving protected vehicles and soldier systems for the Army.

“The Australian manufacturing industry is undergoing a transformation to become globally competitive on many fronts,” added Thales Australia CEO Chris Jenkins. “By becoming a member of the AMGC, we strengthen our position and build on

what we have been doing at Thales for years – investing in local relationships with industry to benefit customers here and overseas.

This will help boost local manufacturing, and show what Australian industry has to offer.”

The AMGC is a not-for-profit company established through the Australian Government’s Industry Growth Centres initiative. The vision for the AMGC is to develop an internationally competitive, dynamic and thriving Australian advanced manufacturing sector that is critical to the long-term health of the economy and the nation.

Australia slips in global competitiveness rankings

Australia’s ranking in the World Economic Forum’s (WEF) Global Competitiveness Report slipped one place to 22nd in 2016-17, indicating a slight deterioration in national business competitiveness compared with last year.

The performance equalled Australia’s worst ranking of 22nd, reached in 2014-15, and leaves it lagging behind peers including Canada (15th), New Zealand (13th), Japan (8th), the UK (7th), the US (3rd) and Singapore (2nd). Australia’s largest trade partner, China, was ranked the 28th most competitive economy, the same as in 2015-16. The top three competitive economies in 2016-17 are Switzerland (1st), Singapore (2nd) and the US (3rd), unchanged from 2015-16.

measures. It ranks poorly on hiring and firing practices (118th), flexibility of wage determination (111th), and taxation incentives to work (111th). Other outstanding areas of concern are cooperation in labour-employer relations (54th), female participation in the labour force (54th) and redundancy costs (43th). A number of these measures improved significantly, notably pay and productivity (from 66th place to 26th) and co-operation in labouremployer relations (from 70th place to 54th).

Ai Group is the WEF partner organisation in Australia and collects the bulk of the local data for the survey. Ai Group Chief Executive, Innes Willox, said: “The key policy message for Australian business, governments and the broader community arising is that Australia must work harder just to keep up with the improvements to competitiveness among our peers. For both businesses and governments this requires looking for innovative solutions and, critically, building community ownership of and support for the required business and policy directions.”

While innovation is crucial to successful participation in the latest global wave of technological advancement, Australia is falling further behind its developed nation peers, as measured by the WEF’s innovation pillar. This key ranking slipped three places to 26th place in 2016-17. Ongoing deficiencies for Australia in this area are government procurement of advanced technology (63rd), lower company spending on R&D (24th) and universityindustry collaboration in R&D (33rd), although Australia does better on the quality of our scientific research (12th).

Australia continues to rank relatively poorly on ‘labour market efficiency’ despite climbing eight places to 28th place. Australia still trails behind other economies on many labour market

“More can be done by government, business and universities in collaborating on research and in successfully commercialising new technologies and R&D,” said Willox.

AMT Dec 2016/Jan 2017

028

Government news

Building better incubators to support new Australian start-ups

The Federal Government has launched an initiative to support a new wave of Australian businesses, based all around the country, to achieve global success and boost their ideas.

The Incubator Support initiative includes $23m to assist with the creation of new business incubators which will help startup companies access advice, capital and valuable connections. Business incubators will increase innovation capacity in Australia’s urban areas, as well as regional and rural Australia and in university precincts by bringing communities of entrepreneurs together to increase the flow of local knowledge and foster collaboration.

Applications are now open for matching grants between $10,000 and $500,000 for the creation of new incubators in regions or business sectors with strong links to international trade, and for

existing, high-performing incubators to expand their services. Incubators can also access matching grants of up to $25,000 to engage experts-in-residence from Australia and overseas. This ensures start-ups have access to the top-quality research, managerial and technical talent they need to develop their capabilities and commercialise their ideas.

Announcing the initiative, Greg Hunt, the Minister for Industry, Innovation and Science, said: “I am delighted to launch the Incubator Support initiative today at Sydney-based fintech hub Stone & Chalk – a new initiative which already has an impressive track record. In its first year,

Stone & Chalk has attracted 95 start-ups on board, representing over 290 residents in financial services and fintech technology, has launched 21 start-ups and raised over $101m in capital.”

The Incubator Support initiative is a new element of the Entrepreneurs’ Programme and is one of the measures under the Government’s National Innovation and Science Agenda. Originally announced as an $8m initiative, the Government has committed a further $15m over four years to ensure innovative businesses, especially in regional and rural areas, can access resources and networks to help them grow. www.business.gov.au/incubator-support

Up to $1m available for rail R&D projects Rail Manufacturing CRC has announced a new funding cycle for its Rail Innovation Gateway project submissions.

The Rail Innovation Gateway is open to applications from businesses either working in the rail industry or with the potential to do so, who are asked to submit research and development project proposals focused on increasing competitiveness, capacity and productivity in Australian rail manufacturing.

The Centre will fund up to $1m per project, which is to be matched dollar-for-dollar (1:1) by the business/businesses involved.

The funds will be paid to a leading Australian Research Institution, who will be matched to the business/businesses and undertake the research project in partnership. Rail Manufacturing CRC Managing Director Dr Stuart Thomson voiced his excitement about the opportunity the program will bring in attracting manufacturing businesses into the rail supply chain and increasing innovation in the rail industry.

“The rail industry has significant opportunities through recent increases in government spending on rail rolling stock and infrastructure projects to embrace innovation and develop new business opportunities for Australianbased companies,” said Dr Thomson.

“By welcoming these opportunities, rail businesses will be contributing to the delivery of future economic growth, export opportunities and job creation.

“The Rail Innovation Gateway extends our engagement to include manufacturing businesses that may not currently be part of the rail supply chain, thereby generating a

AMT Dec 2016/Jan 2017

new pool of research projects that will boost innovation in the sector.”

All Rail Innovation Gateway project proposals must address one of the Rail Manufacturing CRC’s rail research priority areas – which are Power and Propulsion, Materials and Manufacturing, and Design, Modelling and Simulation.

More information on the two-stage application process, along with the application form, is available on the Rail Manufacturing CRC website. Applications close on 13 January, 2017. www.rmcrc.com.au

Rail Manufacturing CRC Managing Director Dr Stuart Thomson.

Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

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At no charge to you, a Business Adviser will: • develop a Growth Plan to help you reach your growth opportunity • provide support, advice and mentoring to build the necessary capabilities, culture, strategies and connections for growth • facilitate access to relevant advice, networks and knowledge • help maintain your growth momentum through regular meetings and follow-up.

Supply Chain Facilitation Supply Chain Facilitation offers your business practical ways to: • connect with, and supply existing and new markets • provide you with project opportunities.

At no cost to your business, a skilled Business Adviser or Business Facilitator will work closely with your suppliers and customers to: • strengthen your supply chain • improve your ability to access new markets.

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voice box Opinions from across the manufacturing industry

The Ford plant closure is sad loss of manufacturing know-how

The closure of Ford’s casting plant in Geelong does make you wonder how losing the ability to make our own engines can be a step forward. Australia should take stock and contemplate what kind of society we are becoming, writes Geoffrey Brooks.

Critics of the decision to allow the car industry to leave would argue that governments should subsidise their local car manufacturing industries because of the benefits the industry brings in terms of employment and raising the general technological level of that country.

treatment of the cast structure) continue, as the push for even higher quality and better properties drives research and investment in new technology.

In An Economy is not a Society, Dennis Glover argues that we are making a tremendous social and economic mistake in allowing such industries to close in the name of global competition. Glover outlines how the support for manufacturing in the post-Second World War era provided a base for many ordinary people to lead better lives, leading to many positive social and economic outcomes. He argues that the type of economy we have developed since the 1980s favours a few over the many.

Our tour guide said that our group was probably the last tour through the plant before it is closed and the site is bulldozed. As he tried to make light of the situation, the good-humoured banter between the engineer and the students evaporated and we all stood stone-faced outside the plant, feeling like something worthwhile was about to disappear.

Certainly, the current Government has shown more enthusiasm for making submarines than it did for car manufacturing. How does that extraordinary $50bn investment stack up, in terms of jobs and flow-on effects?

With the closing of the automotive industry, our knowledge of metals casting will clearly dive. Those employed at Ford and similar employees at Toyota and Holden don’t have equivalent jobs to take their deep knowledge to.

The opportunities in the metals industry in this country are thin on the ground. The large casting plants are now in Asia, though the high-technology end still prospers in part of Western and Northern Europe. The Chinese are currently known more for the lowvalue end of metal castings, but they are likely to follow the South Koreans and Japanese into the high-value end as their economy develops.

Recently, I took a group of engineering students to visit the Ford casting plant. After donning high-visibility orange vests, we were given a tour of the plant by an amicable Ford engineer. He showed us the various details of how engine moulds were formed, steel scrap melted, alloy elements added and engine blocks cast. It was clear that a lot of expertise had been developed over the decades to ensure that tight quality requirements were met.

I was also interested to see how much technology had been developed to recycle the sand used in the moulds, and our tour guide joked that he had spent as much time cleaning sand as did making engines.

Casting is one of those technologies that it is so successful, we barely notice it. We take it for granted that millions of objects can be cast each year with excellent physical properties and durability. New technologies such as 3D printing can outdo the same in terms of versatility and detail, but currently lag far behind casting in terms of quality, cost and productivity.

The materials science that underpins this technological triumph was mainly developed in the post-Second World War era, when new techniques in microscopy and analysis allowed us how to control the structure of cast materials with greater precision. New developments in casting and thermo-mechanical processing (post

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Our safe arrival at work each day, whether we travel by car, rail or plane, relies on this knowledge.

The plant isn’t closing down because casting technology is no longer important, but because our car industry has become uncompetitive in a global market and our Government is no longer willing to prop it up on the promise that it will one day become more competitive.

At a more immediate personal level, we have all got used to the idea of buying cheap cars produced in Asia. The thought of returning to the era of our parents, where there was limited choice and the local made cars were protected by tariffs and government policy, has little appeal.

We may want to blame the Government for the end of the car industry in this country but there are literally millions of individual choices underneath that decision.

Simply put, most of us prefer a cheap South Korean or Japanese car over a locally made equivalent from Broadmeadows, Altona, Geelong or Elizabeth.

Perhaps, the loss of skills in casting will be offset by jobs in new industries. Certainly, opportunities for skilled jobs in 3D printing, carbon-fibre composites, biomedical equipment and automation are likely to emerge over the next decade.

Australia has a number of impressive technology-based companies who specialise in high-precision machining, and the Boeing works in Melbourne, where carbon-fibre technology developed in Australia has been successfully applied.

Perhaps, new casting industries will also emerge in Australia. The AW Bell company in Dandenong South has recently prospered by combining traditional casting with new digital-based technology. It must be said that these are all relatively minor successes compared to the closure of an entire major industry.

There is a real danger that an important skill base will disappear from our country, as the furnaces are turned off for the last time in Geelong.

Professor Geoffrey Brooks is the Pro-Vice Chancellor (Future Manufacturing), Swinburne University of Technology. This article was originally published on The Conversation. www.theconversation.com www.swinburne.edu.au

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voice box Opinions from across the manufacturing industry

How to manage risk in a changing climate The climate is changing. Whether or not that makes you think of the weather is beside the point. The implications for your business could be profound, writes David McEwen.

The Paris Climate Accord struck last year, came into force on 4 November, having been ratified by sufficient countries including major greenhouse emitters the US, China, India and the Eurozone. The international aviation sector is set to get tighter emissions standards, transport is moving towards automation and electrification, and there is increasing pressure to tackle the use of the highly polluting marine diesel oil in international shipping. Meanwhile in October nearly 200 countries reached an agreement to amend the Montreal Protocol (which phased out ozone-depleting CFCs) to deal with HFC refrigerants and propellants, which were found to be extremely potent greenhouse gases.

And the physical climate is changing too, with 2014, 2015 and likely 2016 each breaking the hottest global average temperature record.

While there is still natural variability in the climate system, the longterm warming trend is clear.

All this points to a crescendo of change for many manufacturers: opportunity for some, particularly those in renewables and cleantech; but risk for many.

Firms whose operations, supply chains or end products embody or produce relatively higher levels of greenhouse emissions than their competitors and substitutes will increasingly be slugged with a rising carbon price, other government sanctions, or consumer boycotts led by Green groups. In Australia, where per capita emissions are amongst the highest in the world and our electricity grid is still highly dependent on coal, our exports may begin to look less attractive, or will become relatively more expensive if other countries impose a carbon tax on imports.

Consumers, including corporate procurement managers, will increasingly factor products’ emissions and environmental credentials in purchasing decisions. Governments are already ratcheting up existing minimal environmental or energy efficiency standards; this has already happened in some markets such as air conditioning systems and commercial property, where many Australian state and federal governments now require minimum NABERS Energy ratings for the lease of departmental office premises.

Manufacturers should review their environmental credentials and those of their suppliers. Measurement and baselining of greenhouse emissions should be undertaken, covering direct operations, upstream supply stream, and downstream distribution, use and end-of-life impacts of your products. Science-based targets for emission reduction should be set, aligned with the collective goal of keeping global warming to less than two degrees Celsius (and ideally under 1.5 degrees).

A

wide range of emissions reduction opportunities are generally available, many with a positive ROI due to the energy efficiency improvement they yield. Low hanging fruit includes behavioural or process changes that improve efficiency, and short payback projects such as LED lighting refurbishments and HVAC adjustments. Purchase energy from renewable sources where practical. Production processes and technologies should be reviewed, with improvement investments staged in line with

capital depreciation cycles.

At a more strategic level, a key question is whether particular products will be in continued demand given changing consumer attitudes and the availability of more environmentally friendly substitutes.

Companies should review their portfolios and plan to phase out less attractive products while transitioning to more suitable alternatives, taking advantage of the organisation’s core competencies where possible.

Anticipating milder winters and warmer summers, for example, a soup and sauces manufacturer applied similar technology to launch a range of desert toppings. Suppliers to threatened industries such as the coal industry may need to repurpose their products for alternate markets.

Product designs should be reviewed and re-engineered where possible to reduce so-called “embodied emissions” and those created in use or at end of life, including designing for future disassembly and separation of components. This includes careful consideration of product obsolescence: durability is likely to be favoured more by future purchasers.

Supplier contracts should be reviewed and emissions reduction ratchet clauses imposed where possible. Opportunities to increase recycled content in product designs should be explored (providing the emissions associated with recovery and reprocessing do not outweigh the benefits of reduced use of raw materials). Investigate facilities to harvest end-of-life products and move towards closedloop designs or partner with appropriate waste specialists.

Then there are the direct effects of climate change, with increasing droughts, heat waves, extreme weather, sea level rise and ocean acidification to contend with. Climate-sensitive businesses such as coral reef tourism, wine producers, alpine sports operators and those with coastal-exposed assets are already feeling these effects.

But so are manufacturers whose supply chains are disrupted by extreme weather. Information technology giant Hewlett Packard was not immune when floods ravaged Thailand in 2011/12, knocking out key suppliers’ manufacturing facilities, causing production delays and a reported 20% spike in input costs.

Freight logistics are also sensitive to extreme weather, and even the small amounts of sea level rise experienced to date (about 20cm in the past century) have had a significant magnifying effect on storm surges, particularly when combined with high tides. Some low-lying coastal logistics sites are starting to experience so-called “sunny day flooding”. While most organisations’ enterprise risk assessment processes consider the loss of key suppliers, in many cases the analysis of supply chain risks is relatively superficial.

Managing climate risks involves a structured identification, assessment and treatment process applied strategically across the organisation. Treating sustainability as not much more than a marketing bolt-on is no longer going to cut it as the full implications of the Paris agreement and related disruptions begin to be felt.

Directors may be liable in the event they fail to identify climate/ transition risks and plan appropriately.

David McEwen is a Director at Adaptive Capability, providing strategic advice to help businesses create and preserve value in the face of climate change. He is also the author of the new book Navigating the Adaptive Economy. www.adaptiveeconomybook.com

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voice box Opinions from across the manufacturing industry

Visiting Precision Valley

After the IMTS exhibition in Chicago in September, Paul Philips took a little time out to travel in the US. One of the highlights was a visit to the American Precision Museum in Vermont.

I first became aware of the American Precision Museum (APM) through its participation in IMTS some years ago. I had never been to New England, but I was aware of its natural beauty, so visiting that part of the world, and the APM in particular, was firmly on the bucket list.

The American Precision Museum

After this year’s IMTS I had one day spare before I was due to travel to Germany, so I finally had a chance to make the trip. It was well worth it. My expectations of both the APM and New England were exceeded. It really is a very beautiful part of the world.

I have always had a keen interest in the history of manufacturing technology. In the past, amongst other museums, I’ve visited the Smithsonian in Washington DC, and the Henry Ford/Greenfield Village in the Detroit suburb of Dearborn.

Located in Windsor, on the banks of the Connecticut River, the APM preserves the heritage of the mechanical arts, celebrates the ingenuity of our mechanical forebears, and explores the effects of their work on our everyday lives. Housed in the original Robbins & Lawrence Armory (which was the US’s first armory), the museum holds the largest collection of historically significant machine tools in the US. Being involved with machine tools for most of my life, I probably wasn’t quite the average member of the public who may visit APM. I am keenly aware of the importance of machine tools and the massive contribution that a tiny group of key people have made to the standard of living of the world’s population over the past 250 years; a subject of which most people are blissfully unaware.

Windsor and its surrounds became something of a manufacturing hub within Vermont in the 1800s, becoming the equivalent of how Silicon Valley influences today’s society and economy. The Robbins & Lawrence Armoury provided an environment that enabled companies such as Jones & Lamson, the Fellows Gear Shaping Company and Bryant Grinders to emerge and flourish. Precision machine work went on to spread throughout the region, until the Upper Connecticut River became known as “Precision Valley”.

Given the significance of so many of the exhibits, it would be difficult for me to single out any of the machines in particular, but I guess the most memorable for me were the planers, due to the key role that they played in the manufacture of other machine tools. I have now joined the APM, as I am happy to lend my support in any way possible to the most valuable function that this museum performs.

There is a Machine Tool Hall of Fame accessible online at the Museum’s website.

Paul Philips is Managing Director at Sydney-based Benson Machines and an AMTIL board member. www.bensonmachines.com www.americanprecision.org

AMT Dec 2016/Jan 2017

Real Business Real People Real Members Apart from any financial benefit what other reason is there to be a member of AMTIL? The world is getting smaller and globalisation provides an abundance of opportunities and threats. AMTIL provides us with tools and support to stay connected and collaborate with businesses who are driven to harness the opportunities and counteract the threats together, and retain a strong manufacturing footprint here in Australia.

Erika Hughes, Integra Systems

Since 1999, AMTIL has been connecting business, informing of opportunities and growing the manufacturing community.

To be become an AMTIL member contact our Corporate Servcies Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

amtil.com.au 1311AMTIL/EH

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Tech News

Japan: Working up a robotic sweat

Australia: Laying bricks at 1000 per hour

Researchers from the University of Tokyo’s JSK Lab, used the metal frame of their 1.7m tall robot – Kengoro – as a watercoolant-delivery system. This allowed water to seep out through the frame around the motors to cool them evaporatively – akin to “sweating”. The frame is laser sintered from aluminum powder (additive manufacturing ). This enabled selective variation of the metal’s permeability, where microchannels embedded in the metal components allow water to flow. The water seeps from an inner porous layer into a more porous region near the surface of the frame, from where it evaporates into the air. Kengoro can run for half a day on a cup of deionized water – although redydration is necessary. This cooling method works three times better than air cooling. Kengoro can do push-ups for 11 minutes without burning out its motors.

Work is underway on the construction of the updated commercial bricklaying machine, the Hadrian X, which is set to revolutionize the bricklaying industry. Once commercially available, this robot will lay approx.1000 bricks per hour (ie the entire shell of a building in just two days). This is the second iteration of the robot from Australiabased Fastbrick Robotics Ltd. that could disrupt the $1.3 trillion global construction market and slash the cost of construction.

Hadrian X will assess the 3D layout of the structure and calculate the location and size of each brick. The bricks will be cut as needed and treated with adhesive. The bricks then travel along the conveyor belt within the robot’s telescopic arm and are placed with great precision (0.5mm laying accuracy), thanks to a laser guidance system.

Fastbrick Robotics

IEEE Spectrum

Australia: Ford buys up big on Australian mirrors As automotive manufacturing winds down in Australia, Adelaide scientist Colin Hall has won an inaugural new innovators award for creating a process that allows manufacturers to replace glass components with light-weight plastic. He and his colleagues at the Uni. of South Australia’s Future Industries Institute have combined micron-thin layers of plastics to develop a material that can replace glass in cars, aircraft, spacecraft, and whitegoods. It’s shatter-proof, low-vibration, and can be moulded into quite complex shapes. Car makers have long searched for ways to reduce the body weight of vehicles and the car-wing mirror design weighs a fraction of the conventional glass product. In five years, 1.6 million have been exported to the US to be used in a Ford truck. “We hope to be able to roll out this technology, doorhandles, grills, badges or even the wing-mirror housing as well,” Dr Hall said. The product is being made by SMR Automotive Australia, which has created 20 jobs.

The Lead and ABC

USA/Finland: Electric current tracks water in concrete Researchers have developed a new technique for tracking water in concrete structures – allowing engineers to identify potential issues before they become big problems. The technology allows the identification and tracking of water movement in concrete using a small current of electricity that is faster, safer and less expensive than existing technologies – and is also more accurate when monitoring large samples. It can not only determine where and whether water is infiltrating concrete, but how fast it is moving, how much water there is, and how existing cracks or damage are influencing the movement of the water. Previous technologies relied on X-rays or neutron radiation, but both have significant limitations.

North Carolina State University

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Germany: Lightweight rotor blades made from plastic foams Offshore wind turbines are becoming ever larger, and the transportation, installation, disassembly and disposal of their gigantic rotor blades present challenges. Researchers have developed highly durable thermoplastic foams and composites that make the blades lighter and recyclable. The new materials are also useful for the automotive, aviation and shipping sectors.

These theremoplastics are meltable plastics that can be processed efficiently in automated production facilities. For the outer shell of the rotor blade and segments of the inner supporting structure, sandwich materials made from thermoplastic foams and fibrereinforced plastics are used. These meltable plastic foams are temperature-stable and therefore suitable as insulation material in areas close to the engine. They can permanently withstand higher temperatures than, eg. expanded polystyrene foam.

Fraunhofer

USA: New material improves de-icing Researchers have discovered a ‘smart’ material that can be applied to any surface to repel ice and outperforms all others currently in use. One side of the surface of the material known as a magnetic slippery surface (MAGSS) is coated with a magnetic material, while a thin layer of magnetic fluid - a mixture of fluid and iron oxide nanoparticles - is deposited on the other side. When a droplet of water hits the surface, the magnetic fluid acts as a barrier, stopping the droplet from reaching the solid surface. The ice basically slides off the surface. Among the advantages of the new material is that it has a far lower freezing threshold than the best icephobic technology currently available.

University of Houston.

Tech News

USA: Lowering the heat for new materials

Israel: “World’s first” direct 3D metal jetting system

A new technology called cold sintering process (CSP), enables the combination of incompatible materials, (ie ceramics and plastics), into new compounds, and to lower the energy cost of many types of manufacturing. Ceramics were traditionally made by energyintensive heating to high temperatures, but CSP is a low temperature process (room temperature up to 200deg.C). “We are also densifying some materials to over 95% of their theoretical density in 15 minutes” said Prof. Clive Randall. “We can now make a ceramic faster than you can bake a pizza, and at lower temperatures”. The key is knowing the exact combination of moisture, pressure, heat and time required to capture the reaction rates so the material fully crystallizes and gets to very high density.

Developed by Israeli firm Xjet, it claims its pioneering NanoParticle Jetting technology

Penn State Materials Research Institute.

produces high quality metal parts which feature unprecedented levels of details, surface finish and accuracy, with no compromise on speed or build-time. The technology uses ink jetting to produce complex metal parts from a suspension of nanoscale particles. It uses solid metal nanoparticles suspended in liquid “ink” in sealed cartridges. Ultra-fine layers of droplets of this ink are deposited and extremely high temperatures cause the liquid ‘jacket’ around the metal nanoparticles to evaporate. After this a sintering process is carried out to fuse the metal particles. Whilst other techniques rely on uniform metallic particles, the particles used in the jet process are of random shapes and sizes. This produces properly dense parts with no porous attributes, resulting in superior quality metal.

XJET & The Engineer

Australia: Revolutionising water-proofing

UK: Non-toxic solvent for solar cells

Scientists have developed a new spray-on nanoparticle material (superhydrophobic) with a remarkable ability to repel water. The new protective coating could eventually be used to waterproof mobile phones, prevent ice-formation on aeroplanes or protect boat hulls from corroding. The coating is transparent and extremely resistant to UV radiation. The key innovation is that this transparent coating is able to stabilise very fragile nanomaterials, resulting in ultra-durable nanotextures with numerous real-world applications. The team developed two ways of creating the material, both of which are cheaper and easier than current manufacturing processes. Many functional coatings today are very weak, but these principles could be applied to make robust coatings that are, for example, anticorrosive, self-cleaning or oil-repellent.

Australian National University

Scientists have developed a solvent system with reduced toxicity that can be used in the manufacture of perovskite solar cells, clearing one of the barriers to the commercialisation of a technology that promises to revolutionise the solar industry. By combining methylamine and acetonitrile, researchers have developed a clean solvent with a low boiling point and low viscosity that quickly crystallises perovskite films at room temperature and could be used to help coat large solar panels with the material. At the moment, there are three main solvents used in the manufacture of perovskite solar cells, and they are all toxic. This is the first clean, low-boilingpoint, low-viscosity solvent for this purpose. It is cheap and can be easily processed. Reducing the toxicity of the solvent has not led to a reduction in the efficiency of the material in harnessing solar energy.

University of Oxford

Australia: Australian innovation in radio telescope The world’s largest filled single-dish radio telescope was recently launched, and relies on a piece of Western Australian innovation.

The telescope, known as FAST, uses a data system developed at the International Centre for Radio Astronomy (ICRAR) in Perth and the European Southern Observatory to manage the huge amounts of data it generates. The software is called the Next Generation Archive System (NGAS). The system will help to collect, transport and store about three petabytes of information a year from the telescope. “For us it’s quite exciting to install NGAS on yet another telescope because the system is now being used all around the world” said Prof Andreas Wicenec who heads the program.

University of Western Australia

“It looks like a Tesla, but the automated driving functions are ours … under the covers it’s all new” Bosch Australia President Gavin Smith, explaining the first self-driving car developed in Australia and unveiled in October.

Bosch developed the vehicle at its Australian plant in a joint venture with the Victorian Government, which has invested $1.2m in the project. Built over nine months by 45 people, it uses the shell of a Tesla with Bosch components. The manufacturers claim the car is 10 years ahead of other selfdriving vehicles and incorporates 60 additional components.

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product news

Compact cleaning table requires no electrical power supply

Dimac Tooling has introduced a new Reven compact cleaning table, the ‘T Series’, to its product range.

Germany-based Reven was founded in 1905.

From as early as the company’s foundation phase, it took up the construction of extraction apparatus and systems for production facilities and workshops. Reven has now been specialising in industrial air cleaning for decades and the company’s knowledge in the field of air cleaning has grown continuously. This expertise is reflected in numerous internationally protected patents, design protection rights and unique technologies.

“The compact ‘T Series’ is particularly versatile due to the fact that it does not require any electric power supply as the cleaning is performed by compressed air, hence making it ideal for the cleaning and inspection work of CNC parts,” says Dimac Managing Director Paul Fowler. “The key benefit is that when parts from the CNC are being cleaned by the air blast, the residue coolant and chips from the workpiece are captured, with coolant recovered, therefore keeping the work area clean from coolant and chips.”

The unit features Reven’s patented high-performance X-Cyclone separating system which is integrated into the table. X-Cyclone technology, now into its fifth generation of this unique technology,

was developed for the separation of air-borne substances including fluid and fine dusts. This latest version is characterised by new arrow geometry which provides a 20% increase in separating efficiency.

Crucially, the system is entirely mechanical without any auxiliary energy required, and contains no disposable products or filters that need to be replaced. It is a sustainable aircleaning concept thanks to the use of cleanable separators. As a result the operating and maintenance costs are considerably lower than with conventional air cleaners.

Four different-sized ‘T Series’ models are available and a number of accessories are also offered including an activated carbon filter module suitable for fitting to the air outlet, a filter mat at the air outlet for post filtering and noise reduction and a table extension with washing facility and basin. Designed, constructed and manufactured in Germany, the unit features a stainless steel enclosure that is 100% rustproof, providing a considerably longer service life. A lifetime guarantee is offered on the X-Cyclone basic separator element and on the corrosion resistance of the enclosure. www.dimac.com.au

NCCS unveils SolidWorks 2017 with inno3D event

As part of its commitment to stay on the cutting edge of 3D technology and the SolidWorks community, NCCS hosted its annual inno3D event on 5 October, at the Merrimu Reception Centre in Chadstone, Victoria. and Marverick Chung unveiled SolidWorks 2017 and gave a snapshot of its future direction. These new SolidWorks 2017 features increased core power and performance, along with new capabilities for emerging technologies.

The event provided a showcase where engineers, designers and leaders could come and network, and the opportunity to gain a sneak peek at SolidWorks 2017.

Discussing the event, NCCS’ Director Stalin D’Souza said: “It is about being a company which has its customers’ best interests at heart. We also wanted to give back to the community, network and provide this opportunity.”

Featured at the event were seven major exhibitors: Isuzu Engines, Hi-Tech Metrology, Versatile Technology, Prytec Solutions, Applied Machinery, Peter Norman Personnel, and 333D. There were also presentations by various members of the 3D community. Products on display covered the spectrum from 3D scanning to 3D printing.

As part of the event, Alex Kok, Territory Technical Manager at SolidWorks, and NCCS Application Engineers Andrew Kim

AMT Dec 2016/Jan 2017

“It has never been easier to design and create with SolidWorks,” said D’Souza.

“The design and development solution chosen by more than 3.1m users worldwide.”

The event was a success for all who attended. Plans are already underway for 2017’s event.

“This was a chance to let the guests see where our industry is going, and the results are eye-opening,” said D’Souza. “Our biggest satisfaction was to see people coming together and sharing knowledge, allowing us all to grow together.” www.nccs.com.au

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038

product news

Kaeser blowers boost efficiency

Kaeser Compressors’s energy-saving screw blowers from for the low-pressure range are now available in three sizes, designed to provide a dependable supply of quality compressed air that is also compatible with ‘Industry 4.0’.

Featuring an integrated Sigma 2 Controller, Kaeser’s DBS, EBS and FBS series screw blowers prove that the tried-and-trusted technology already powering Kaeser’s compressor ranges to deliver significant energy savings can also be successfully applied to the low-pressure range. The new Kaeser screw blowers are up to 35% more efficient than conventional rotary blowers, yet they also outclass other comparable screw and turbo blowers.

The rotors are uncoated so users can be assured that efficiency continues even after years of use. The data provided for the effective total energy consumption and usable flow capacity correspond precisely to the machines’ actual performance (as per the conservative tolerances provided for by Standard ISO 1217; measurements validated by TÜV-Süd).

For optimal performance, the integrated Sigma Control 2 controller provides continuous, comprehensive monitoring, and allows straightforward connection of each machine to a communications network. ‘Traffic light’ LED indicators show operational status at a glance. Along with plain text display, 30 selectable languages and soft-touch keys with icons, the Sigma Control 2 offers fully automated monitoring and control.

Where multiple blowers are being used, additional optimisation can be achieved by incorporating the Sigma Air Manager 4.0 (SAM 4.0) master controller. SAM 4.0 delivers more than just optimised blower air system efficiency. Thanks to its high level of data integration and multiple interface options, it can be easily integrated into advanced production, building and energy management systems, as well as Industry 4.0 environments.

The new screw blowers feature an internal cooling system that makes the energy-intensive use of oil pumps and coolers superfluous. Furthermore, they feature a highly effective sealing concept that ensures long-term seal integrity, without the need for vacuum pumps.

The durability and reliability of the machines is also enhanced as a result of eliminating the need for auxiliary equipment and circulating oil lubrication. Cooling and process air are drawn in separately from outside the machine enclosure, which provides greater usable air mass flow for the same power consumption, and ensures optimum cooling and efficiency.

All three sizes of screw blowers are complete turnkey machines.

Installation is therefore a breeze presenting a truly ‘plug-andplay’ proposition and significantly reducing the work and costs required for planning, installation, certification, documentation and commissioning. Delivered as user-friendly, turnkey systems, Kaeser screw blowers simply need to be installed in position, and connected to the air distribution network and the electrical supply.

A clever component layout further allows the units to be installed directly next to a wall or side by side, making them ideal where space is at a premium. The DBS, EBS and FBS series screw blowers from Kaeser deliver flow rates from 6 to 67 cubic metres/ min with a pressure differential up to 1.1 bar, drive powers range from 22 to 110 kW. www.kaeser.com.au

Walter goes for Gold

Following in the wake of its Tigertec and Tigertec Silver coatings, Walter has now announced another technological advance with Tigertec Gold.

Walter is one of the world’s first companies to present a new technology platform: Tigertec Gold with the WKP35G milling grade. Compared with the CVD aluminium oxidecoated grades currently in use, the new Tigertec Gold with a titanium aluminium nitride (TiAlN) coating once again boasts significantly improved properties – resulting in longer tool life, increased productivity and greater process reliability. This is partially due to the innovative, special “ultra low” coating process (ULP-CVD) that Walter has used to establish tomorrow’s technology today.

The new TiAlN coating from Walter is their response to growing demands. The Walter developers have been using Tigertec Gold for some time now in special applications – and to great effect. They recorded markedly improved properties compared with other coatings: Considerably higher wear resistance on the flank faces, reduced formation of hairline cracks and greater resistance to plastic deformation. Numerous practical tests on steel and cast iron materials demonstrated considerably longer tool life – often by up to 200%. In addition, the gold-coloured top layer also facilitates wear detection. www.walter-tools.com

AMT Dec 2016/Jan 2017

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product news

Hypertherm introduces CoroPlus brings new mild steel Centricut connectivity to manufacturing plants consumables Hypertherm’s Centricut brand is shipping new Cutting tool and tooling systems specialist Sandvik Coromant has unveiled its CoroPlus suite of Industrial Internet of Things (IIOT) solutions aimed at helping manufacturers prepare for Industry 4.0.

The concept is designed specifically to improve the control of productivity and costs through a combination of connected machining and access to manufacturing data and expert knowledge. CoroPlus is the umbrella name for a new platform of connected tools and software, essentially comprising technologies that can send and/or receive data. The concept makes it possible to reduce data waste and improve manufacturing processes, from pre- to post-machining, through the use of connected technology and machining knowledge from Sandvik Coromant.

“Users not only get access to Sandvik Coromant product and application data through connected software and hardware, but with sensor-equipped tools they can adjust, control and monitor machining performance in real time,” says Göran Näslund, Head of Digital Machining. “The entire machine shop can be controlled via accurate on-site data dashboards, through the cloud and via integration with the user’s software and machine environment.

CoroPlus connects into existing software environments through open APIs, offering two-way connectivity and accurate data quality.”

The principal benefit for production managers is that CoroPlus makes it possible to optimise manufacturing through better understanding and insight into what’s happening in the workshops and machining environment, on either a micro or macro level.

From a CAM programmer’s perspective, connection with accurate tool and application data means that recommendations can be adapted to specific tasks. There are also advantages for operators as machining processes can be monitored remotely. Furthermore, specific sensor-equipped tools can be controlled to ensure that breakages are avoided and performance is secured, with data intelligence collected live throughout the machining process.

The offer currently comprises dashboard solutions, software solutions in CoroPlus ToolGuide and Adveon Tool Library, as well as Silent Tools+ and CoroBore+ cutting tools and Promos 3+ machine monitoring IoT system.

“With CoroPlus we are partnering with machining tool builders, cloud suppliers and network companies,” explains Näslund. “In this way we can help users capitalise on new technology developments. Our role is to increase productivity and flexibility through value-creating technological advancements in digital machining.”

Ultimately, CoroPlus makes it possible for manufacturers to take the next step in industrial evolution by making use of new cyber-physical systems – meeting industry’s needs now and moving forward. www.sandvik.coromant.com

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consumables designed for use with all Kjellberg PerCut 221M and PerCut 451M torches found on Kjellberg HiFocus neo plasma cutting systems.

The new Centricut brand consumables for mild steel cutting deliver the same benefits found when using Kjellberg neo consumables, at a lower cost. In addition, the Centricut brand consumables are designed with keyless nozzles for use in all Kjellberg torch models available today. Testing by Hypertherm confirms consumable life, cut speed, and cut quality are all comparable or better when using the Centricut brand. In addition, the Centricut brand consumables offer process repeatability.

“Hypertherm’s engineering and manufacturing excellence ensures users get high quality consumables that provide consistent, reliable performance of their cutting system,” explains Cynthia von Recklinghausen, Product Manager for Hypertherm’s Centricut brand. “At the same time, customers can lower their overall cost of cutting since Centricut brand consumables cost less.”

Centricut products are designed with critical-to-function tolerances and are precision-manufactured by advanced machinists to deliver the best quality product every time. Businesses interested in a free trial of any Centricut brand product or a technical consultation about improving their cutting process can contact Hypertherm or their authorised Hypertherm distributor. www.hypertherm.com

Awards honour for ECO Idling Stop Okuma’s next-generation energy-saving system, ECO suite, has won the MM Award 2016 (Handling/ Automation Category).

The MM-Awards are given by Maschinen Markt (MM), a highlyrespected manufacturing industry journal centred in Germany, to outstanding and innovative products and new technologies in various fields. This is the fifth time Okuma has won this award. With ECO Idling Stop, the machine itself determines whether cooling is necessary and stops the idling of coolers while maintaining stable accuracies. The energy consumed during non-cutting times is greatly reduced with the precise stopping of coolers. The ECO suite system achieves machine tool energy savings with four applications, including ECO Idling Stop. www.okumaaustralia.com.au

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product news

Faro releases VantageE highperformance laser tracker

Faro has launched a new addition to its Vantage Laser Tracker product line. The new VantageE includes well-proven features and capabilities such as high-speed dynamic measurement, and is affordably priced for customers who demand high performance while working with short-to-medium range applications.

The Faro VantageE Laser Tracker is ideally suited for customers who do not require the extended measurement range that is provided by the premium Vantage solution but still demand the trusted and robust features the Vantage platform provides. This release provides customers with increased flexibility in terms of capability and pricing, dependent on their applicationspecific demands.

The new VantageE Laser Tracker has a range of up to 25m through Faro’s patented, fifth-generation TruADM (Absolute Distance Meter) technology, which enables fully-dynamic measurement capabilities.

Vantage Trackers are able to continuously scan and take measurements while a spherical optical probe is tracked across the surface of the part, object or assembly. If the laser beam is interrupted at any time while the probe is being moved, the user can simply and instantly reacquire the beam and continue measuring.

The VantageE provides full support for Faro’s patented Super 6DoF (Degrees of Freedom) TrackArm solution, which enables a Vantage Tracker and one or more Faro ScanArms to work together to create an integrated 3D measurement system. Super 6DoF completely eliminates line-of sight challenges and significantly expands measurement range while maintaining superior accuracy.

“A number of our factory metrology customers have expressed the need for a more affordable, but feature-rich tracker that would meet their applications for short-to-mid distance measurement,” stated Joe Arezone, Chief Commercial Officer of Faro. “In developing the VantageE, we quickly realized that customers would still need the accuracy of our longerdistance tracker along with the robust features that make the Faro Vantage Tracker solution ideally suited for solving real-world, everyday measurement challenges. Additionally, the VantageE is value-priced at approximately 30% less than the premium Vantage while offering many of the same features and similar accuracy.”

The Faro VantageE Laser Tracker offers a cost-effective solution for applications such as quality inspection, tool-building, alignment, and reverse engineering. In contrast to using traditional measurement solutions, operators are able to complete complex 3D measurement jobs much faster, reduce downtime and scrap, and most importantly, get accurate, consistent and reportable measurement data. www.faro.com

Adept enhanced by Sisma’s fiveaxis laser welding mound repair

Auckland-based company Adept has enhanced its capabilities with the latest Sisma SWA 150 five-axis precision laser welding system supplied by Industrial Laser.

Adept has been at the forefront of plastic processing technology, and new product development in New Zealand for over 40 years, working with many large brands at its state-of-the-art tool design, manufacture and repair facility. Installation and training of the Sisma welding system was completed within three days and went like clockwork according to Jason Yalden, Tooling manager at Adept.

“Laser welding injection moulds accurately and easily has obvious flowthrough of lower costs and speed of repair” says Yalden. “Extremely fine work can be undertaken efficiently requiring less time machining post welding. In addition, we use the Improbond wire, which allows precision laser welding of harder or softer filler wire on to the mould. This allows the possibility of better tool life in high wear areas.”

Sisma has appointed Industrial Laser as its Australasian partner.

Established in 1961, Sisma is a leading supplier of high-quality

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laser systems for 3D printing in metals, marking and engraving, moulds repair, and cutting and welding, with a product range that can be applied across a vast range of industries including medical, dental, automotive, aerospace, manufacturing, tool & die casting, and fashion & jewellery.

Jason Yalden, Tooling Manager at Adept.

Its additive manufacturing machines are the product of a joint venture between Trumpf and Sisma. Based in Schio, Italy, Sisma’s new purpose-built 1,800 sqm facility is used for R&D, laboratories and production of its Mysint metal 3D printing system systems.

Its new Mysint 300 system 300 boasts a 300mm diameter by 400mm high build area, with an emphasis on usability, quality and repeatability at a competitive price. Industrial Laser is also the distributor of Improbond wire. www.adept.co.nz

www.industriallaser.com.au

Creating the world’s first 3D printed metal bike frame

Unlock the potential of additive manufacturing The bike frame has been additively manufactured from titanium alloy powder using an AM250 laser melting system. This project highlights the benefits of Renishaw’s technology: • Rapid design iterations - shorter development times • Weight reduction - use material only where required • No investment in tooling • Complex, thin walled, and internal features • Choice of high performance alloys What can Renishaw do for your products?

For more information visit www.renishaw.com/bike

Renishaw Oceania Pty Ltd Unit 4, 6 – 7 Gilda Court, Mulgrave, VIC 3170 Australia T +61 3 9521 0922 F +61 3 9521 0932 E australia@renishaw.com

www.renishaw.com

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Agriculture, Food & Beverage

Innovative Australian food and agribusinesses are working together with product designers and local manufacturers to meet growing national and global demand for their products and expertise. By Carole Goldsmith.

Funded by the Federal Department of Industry, Innovation and Science, Food Innovation Australia Ltd (FIAL) was set up just over three years ago to encourage commercially driven collaboration and innovation in the Australian food and agribusiness industry. FIAL operates across the entire food and agribusiness value chain, from growers, raw material producers and manufacturers, to packaging, sales, marketing and retail providers, through to final users of the sector’s output.

FIAL works with major food manufacturers, universities, scientific research organisations, supermarket chains and industry groups across Australia. There are around 180,000 food and agribusinesses nationally, and they can all use FIAL’s services.

“We are currently working with Data 61, to develop a searchable directory for the sector,” says FIAL’s Managing Director Dr Mirjana Prica.” A vision for the industry has also been developed involving industry stakeholders from across Australia over the past year. This is due to be released in October.”

FIAL offers a range of opportunities for the industry, among which are: knowledge of technologies and markets, skills training, grants for innovation projects involving both small and large businesses, trade missions, trade shows and other export market activities.

FIAL is co-located at CSIRO, with its headquarters in Melbourne and a satellite office in Sydney.

“Australia is in a really exciting position to take advantage of the growing middle class in Asia, as they demand more nutritious and healthy foods,” adds Dr Prica. “We have all the ingredients to meet their needs and capture an increased share of this growing market.”

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Mirjana Prica, Managing Director of Food Innovation Australia Ltd.

Agriculture, Food & Beverage

Evolve and Flow Hive – teaming up for global success

The FlowHive.

One of the greatest manufacturing innovation success stories of the year has been the development and global growth of Flow Hive. Byron Bay father-and-son team Stuart and Cedar Anderson secured funding for their invention, an innovative bee hive system that can deliver honey directly on tap, via the crowdsourcing website Indiegogo.

Brisbane-based company Evolve Group has been working with the inventors for the past year to get their product to the global market.

Evolve Group has two key business units: its product design and development division Evolve NPD, and its manufacturing arm Marco. The Group’s Managing Director and Founder Ty Hermans recalls some of the hurdles encountered as the project developed.

“In the first 60 days of the Flow Hive’s Indiegogo initial fundraising, mid last year, the project raised $US12.1m,” he recalls. “However one of the greatest problems with crowd-funding is the realisation and fulfilment delivery to the backers that support the idea. We have been working through the crowd-funding program to ensure the backers supporting the realisation of Flow Hive production receive their order in full and on time.”

One of the biggest problems was one of dealing with the unexpected success of the crowd-funding campaign. Throughout the campaign, the inventors were receiving thousands of Flow Hive orders. However, at the time, they had no facilities to manufacture them.

“We approached Cedar and Stuart and they came up to Brisbane to see our facilities, where it was made apparent that we could complete their requirements successfully,” says Hermans. “We have since been working with them on the Flow Hive product design, development, manufacturing, commercialisation and distribution nationally and globally. So far we have manufactured over 22m plastic components making up over 45,000 complete bee hives, and distributing them to 128 countries globally from our Brisbane facility. In turn we have employed an extra 50 people to cope with the increasing global demand which has raised our employee numbers to just over 150.”

Continued next page

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Flow Hive inventors Cedar (left) and Stuart Anderson at the Brisbane factory.

Flow Hive and Evolve Group at Good Design Awards, including Ty Hermans, Managing Director and Founder of Evolve Group (far right).

Continued from previous page

The Flow Hive won this year’s Good Design Australia’s Award. At the Awards ceremony, Hermans said: “Winning this award shines a spotlight on what great design can do for Australia. There is little future for manufacturing in Australia without great design. Also there is little value in designing products that go straight to China to be manufactured.

“By designing products that can be manufactured locally in Australia, we’re creating jobs that change the lives of the people we employ. To us that’s a winning formula that Australian design and manufacturing should be focusing on more.”

Smo-King Ovens – Commercial food smoking ovens Smo-King Ovens Pty Limited has been designing and manufacturing commercial ovens for smoking food in Australia for 18 years. The company has almost 2,000 of its ovens installed in a variety of food

processing businesses across this country and in New Zealand and Asia.

Speaking from the company’s head office and plant in Silverwater, NSW, Smo-King Founder and Managing Director John Hodgkinson says: “Our ovens, which are designed and developed by us, are simply operated using a microprocessor control system. They are fan-forced, have electrical elements for heating the oven and igniting the genuine wood chips to generate smoke. This gives the food that smoky taste that our customers love.

As well as providing a profitable business for Smo-King itself, it also creates work for local suppliers. Local fabrication business Interfab makes the stainless steel bodies for the ovens, while the electronic control system is manufactured by Sydney firm All Systems Electronics. Smo-King then assembles the ovens at its plant in Silverwater. The smaller ones weigh around 200kg with the largest coming in at about 500kg.

Hodgkinson advises: “Smo-King employs four people, with two in the factory working on technical issues, assembling the ovens and customer support. Vicki handles admin, reception and spare parts, and I handle sales and marketing as well as customer liaison.”

The ovens are used by retail butchers for processing meats and by fish processors for hot and cold smoking. Restaurants and specialty food processors use the ovens for smoking and cooking meat. The company also distributes a range of European and USA food processing equipment across Australia.

Hodgkinson explains that the advantage to retail butchers of having one of the SmoKing ovens is that they can make a range of value-added products.

“As an example, a Mansfield butcher in country Victoria who owns one of our ovens brings in a chef regularly, to make a wide range of products such as pies, pasties, pasta as well as processing traditional small goods such as ham, bacon and sausages.”

Most of the oven sales are in Australia and New Zealand where the demand is high, with sales also to the Grand Hyatt in Hong Kong and to food processing businesses in Fiji, Malaysia, Vietnam, Thailand and The Philippines.

“The American style BBQ has recently become popular in this country and restaurants are buying more of our smoke ovens,” adds Hodgkinson. “This all started with Justin Hemmes, owner and CEO of the Merivale Group, which started as a fashion house, and it now owns a group of restaurants and other hospitality venues across Sydney.

Smo-King Ovens

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“Hemmes was opening a new restaurant at Manly Wharf and his chefs searched in the USA for a suitable smoking oven for BBQ meat. When they returned to Australia and saw our ovens, it was exactly what they had been looking for.

Agriculture, Food & Beverage A Silvan vineyard sprayer at Goaty Hill, Tasmania.

“We have now sold them ovens for use in three of their Sydney restaurants: Newport Arms, Ivy, and Papi Chulo on Manly wharf,” Hodgkinson adds proudly. “They have been very supportive about our ovens and this is helping us gain more sales in to the restaurant industry.”

fruit and vegetables from Queensland and saw some agricultural machinery there, so brought them down to Melbourne. He set up a manufacturing shop in South Melbourne, in inner Melbourne and named the business Silvan after the town he was living in.”

Silvan – ‘Big red tank’ sprayers

Tricarico adds that he was working in marketing at a large irrigation company, before he took over the reins of Silvan, three years ago.

Silvan Australia’s, ‘big red tanks’ are very well known in this country’s agricultural landscape. A leader in the design of horticultural sprayers, Silvan has evolved into one of the largest Australasian manufacturers of world-class crop protection sprayers and related machinery.

The company has developed specialised equipment for a wide range of applications including vegetables, grapes, apples, pears, citrus, bananas, olives, sugar cane and turf. Silvan also imports a range of farm equipment, which is sold alongside its sprayers at its distributors Australia-wide.

Founded 54 years ago by Michael Tricarico, Silvan has been headquartered at its current site in Dandenong South, in Melbourne’s east, for the past 10 years.

His son, Michael J Tricarico, is now Silvan’s CEO, but as he explains, his father still plays a hands-on role.

“Dad is still active in the business and he comes in once a week to offer advice and say hello to everyone here,” he says. “Our business employs around 100 people across Australia and New Zealand (A&NZ), many of whom are long-term employees.

“Before he started Silvan, Dad was a fruit and vegetable merchant at Footscray Market in Melbourne’s west,” explains Tricarico. “His family moved to Silvan in Victoria’s Yarra Ranges. Dad was buying

“There are not too many Australian country towns that have not seen one of our big red tanks. Silvan has always been in the forefront of introducing spraying technology into Australia.”

All of Silvan’s spraying equipment are designed in-house by the company’s R&D team. The lead engineer has been with the business for 25 years and it was his first job out of university. The red tanks that contain the agricultural sprays were originally manufactured in fibreglass at Silvan’s plant, though this process has now been outsourced to a nearby plastics manufacturer. Some of the spraying parts are imported globally, with the bulk from Italy, the leading country for spraying components.

“We manufacture the parts that we can in Australia and assemble the tanks with attached spraying equipment at our factory here,” says Tricario. “Our 3D printing is outsourced to a local business.

As an example of our innovation in design and technology, Leigh our lead engineer recently designed our new JetPro spray gun in which the gun sprays in the direction of the arm, making it ergonomic. And we are selling it world-wide.”

Silvan’s sprayers are currently exported to New Zealand, Japan, Vietnam, Fiji, Thailand, The Philippines and several other countries. Tricarico explains about one Japanese customer: “About 15 years ago they came to our plant to sell us some of their machinery. They liked our Linkage Sprayers and have been purchasing the same model for 15 years. We also have a long relationship with Treasury Wine Estates, supplying their vineyards in Australia and New Zealand with our viticulture sprayers.”

In Silvan’s factory, employees are busy connecting the sprayer parts to one of the elevated red tanks. Wheelbarrows are assembled in Silvan’s warehouses in Brisbane, Perth, Sydney and in Dandenong, bound for Bunning’s retail sales. Forklifts dart past, and to one side of the factory a Silvan Turbomiser sprayer is assembled and made ready for its journey to another farm.

Tricarico says he regularly visits the dealers and customers – he was recently at Goaty Hill Wines in Tasmania’s Tamar Valley: “They bought a vineyard sprayer and I visited during the initial sprayer setup.”

Speaking about Silvan’s future plans, Tricarico advises: “It’s business as usual and we plan to grow the business domestically, introducing new developments in spraying techniques. The agricultural industry is growing upwards, delivering an increased demand for our equipment.” www.fial.com.au www.honeyflow.com.au www.evolvegrp.com www.marcoengineering.com.au www.smo-kingovens.com.au www.silvan.com.au

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Agriculture, Food & Beverage

Food, agriculture and robots: Next-gen solutions as we head towards 2030 Research projects under the CSIRO’s Future Science Platforms are paving the way for new breakthroughs across agriculture and food production and among manufacturers supplying the sector. By Danielle Kennedy.

CSIRO’s research is broad and its research capabilities traverse many scientific and engineering disciplines as it seeks to be a trusted adviser to Australian industry. A strong focus of the CSIRO strategy is to aid the transition of Australian businesses towards more advanced, sustainable and profitable practices – whether that be in agriculture, mining, energy or manufacturing.

The recent announcement of CSIRO’s Future Science Platforms (FSPs), an investment in breakthrough research growing to $52m per year over five years, demonstrates the organisation’s commitment to undertaking fundamental science in areas that will be critical to the opportunities and challenges we face in the future. One Future Science Platform is Active Integrated Matter (AIM).

The AIM FSP, led by CSIRO’s Dr Danielle Kennedy, is looking towards 2030 with a focus on new discoveries that occur when you combine what are core research strengths for CSIRO: materials, processing, sensing, robotics, autonomous science and big data.

According to a number of future forecasts, there will be dramatic and wide-ranging changes in the world by 2030. Personalised food and therapeutics, increased regularity of extreme weather events, and humanfree autonomous manufacturing and maintenance environments known as dark factories are just some examples of what we are to expect. AIM’s goal is to provide Australian industry with the tools needed to capitalise on these predicted changes and ensure preparedness for future population, climate and environmental scenarios.

Within AIM there are several focus areas called test-beds: Eliminating Food Loss; Morphing Equipment; Autonomous Science for Physical Construction; and Smart OnFarm Manufacturing.

Smart On-Farm Manufacturing The Smart On-Farm Manufacturing testbed is set to place Australia ahead of the forecast disruption in current agricultural supply and value chains. CSIRO is investigating the introduction of precision bespoke chemical manufacture, delivered by automated mechanisms and supported by environmental data.

Take herbicides, for example. Currently, herbicides are applied to fields at 1,000 to 10,000 times the optimal dose, posing

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waste and cost challenges for farmers.

These issues could be addressed through the production of “customised” formulations – on the farm, as needed, and to the precise formulation as required by crops at any particular time. Moreover, these tailored formulations could be produced and delivered with a granularity to the resolution of centimetres.

This dramatic change in manufacture and delivery of agricultural products needs to be informed and enabled through the development of a range of sensors detecting variants such as temperature, rain, humidity, water hardness and chemical composition.

Such sensors would be mounted on drones or small robots for crop growth monitoring. The collected data would inform an automated system that could then recommend and distribute fertiliser at an appropriate level while monitoring run off to optimise future applications.

A smart on-farm agricultural system would enable the production of pesticide, herbicide and/or controlled-release nutrients at the farm by shifting precision chemical manufacture and formulation to the farm gate or centralised agri-hubs.

Morphing Equipment The world is experiencing a Cambrianlike explosion in robotics. The successes of robots in specific applications are underpinned by breakthroughs in affordable computation, advanced materials and manufacturing processes as

well as the availability of high-bandwidth communication. AIM’s Morphing Machines test-bed is pushing the boundaries further by developing robots that can adapt their shape and properties to suit environmental and task requirements.

Imagine a robot that is deployed by a first responder in a disaster area after a building collapse. A morphing robot would be able to change its body size and shape to squeeze through tight spaces in rubble to search for survivors trapped underneath and provide vital resources like glucose and water for sustenance during the rescue process. Or imagine the dangerous task of confined space inspection of hazardous environments like fuel tanks, pipelines or sewage systems. A morphing robot would be able to adapt its structure to effortlessly navigate these complex environments, keeping infrastructure inspectors and maintenance workers out of harm’s way.

The ability to change a robot’s structure and properties on demand has the potential not only to significantly improve the efficiency of current industrial inspection processes, like for example in confined space inspections, but also to develop new tools for rapid search-and-rescue disaster response and natural habitat monitoring.

Scientists across CSIRO are working together under the AIM umbrella to develop novel materials and processes that enable design and deployment of the next generation of flexible, lightweight morphing field robots.

Agriculture, Food & Beverage

All images: Active Integrated Matter, or AIM, is part of a larger Future Science Platform initiative and an important element of CSIRO’s Strategy 2020. Credit: CSIRO

Eliminating Food Loss Approximately 795m people around the world are currently undernourished. By 2050 forecasts predict 9bn people will need to be fed in an environmentally and nutritionally sustainable way. Food and nutrition security poses both a major global challenge and an economic opportunity. Roughly one third of the food we produce is lost in the supply chain between production and the consumer. This food loss is contributing to food insecurity and negative environmental impacts, with limited strategies existing for the recovery and reuse of food loss for production of value-added products.

For manufacturers there are many opportunities to increase the efficiency of food processing and reduce food loss along the value chain, from production to consumption, while maintaining nutritious food products with high consumer appeal.

Over previous decades the focus has been on efficiencies in production and manufacturing processes, more efficient supply chains and fresh produce storage methodologies.

CSIRO proposes that the next step in food production efficiency is food loss avoidance, by utilising the edible portion of lost or wasted produce both on the farm and in the supply chain before it reaches the consumer. Reducing loss could be using the offcuts of vegetable crops. It could be developing new methods for processing non-saleable produce or catching produce at peak nutrition. Addressing food loss offers new prospects for food production and nutraceutical markets with potential economic, environmental and social gains.

The goal of AIM’s Eliminating Food Loss test-bed is that producers and manufacturers will be able to make informed decisions on the suitability of lost food to reenter the food chain. The focus will be on producing food ingredients, supplements and food products that are safe, nutritious

and sustainable. Mapping where food is lost along various supply chains in Australia will be an important prerequisite for intelligent decision making. This will be coupled with advanced sensing technologies, which enable decisions to be made on the fitnessfor-purpose applications of food loss and waste. The further development of efficient processing and preservation technologies will allow the stabilisation and conversion of underutilised edible biomass.

Autonomous Science for Physical Construction As the rise of the machines across industry continues unabated, the limitations of those machines are becoming increasingly exposed. Hardware issues can include component breakage, maintenance, energy supply, and physical limitations such as servo angular ranges and torque limitations.

On the software side, control algorithms can lack adaptivity and fail to respond effectively to dynamic scenarios.

Combined, these hardware and software factors shackle the potential of robotics in industry, and limit the number of feasible use cases by requiring persistent human intervention. AIM is solving some of these problems by pushing the limits of intelligence algorithms and construction techniques. This work seeks to close the loop on human intervention.

AIM’s Autonomous Science for Physical Construction test-bed will focus on ways to improve the construction of new robotic hardware without human involvement. To create new hardware, the team is applying advanced machine learning techniques to automatically generate fit-for-function robot hardware, which can then be tailored to various needs: capability, cost reduction, and long lifetime. Because components are created specifically for a given operating environment, they can outperform off-theshelf solutions in their specific niche. Also being investigated is the use of flexible

manufacturing techniques, allowing capable, bespoke robots to be created in one shot.

The team is concurrently developing intelligence algorithms that will allow robotic systems to understand changes in their environment, and then respond and adapt without the need for human intervention.

This means that robotic systems can observe parts of their environment, and test hypotheses based on these observations.

They can then use these results to improve their own performance, and also share findings amongst themselves in a form of whole-process optimisation. The algorithms will also allow robots to adapt to hardware degradation.

By endowing robots with intelligence, and enhancing their capabilities, the team aims to increase the pervasiveness of robotics in industry and deploy them into challenging areas to meet the demands of Industry 4.0 and beyond.

AIM represents an opportunity to influence the modernisation of the materials, manufacturing, processing, maintenance and environmental management industries through the broad adoption of cost-saving autonomous and robotics technologies and advanced materials processes – all underpinned by big data and intelligent algorithms. Scientists from across CSIRO’s eight multidiscipline business units are working together under the Active Integrated Matter Future Science Platform to undertake the fundamental research required. The AIM team is looking to develop partnerships between academia, research, industry and business in a variety of flexible ways, including through research collaboration, researcher placements, consultancy services and commercialisation of intellectual property (IP).

Danielle Kennedy is the Director of CSIRO’s Active Integrated Matter. www.csiro.au

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Agriculture, Food & Beverage

Regional agritech company packing a big export punch

Hidden away at the back of a business park on the outskirts of Toowoomba, Queensland, is a small company packing a big punch in the global agricultural technology market.

From its Toowoomba headquarters, Farmscan Ag designs and manufactures precision agriculture systems and devices that are now helping farmers in all corners of the globe to produce food more efficiently. The company’s self-designed and developed technology includes GPS guidance and auto-steering systems for farm machinery, variable rate controls and monitors for spraying, seeding, spreading and land leveling applications, and digital mapping and record keeping. Farmscan Ag has also pioneered the development of GPS guidance systems now being used in remote Western Australia to allow pinpointed delivery of wild animal baits to precise locations from aircraft.

Precision agriculture is all about harnessing technology to help farmers produce more with less, and avoiding wastage of fuel, seed, fertiliser or spray by reducing tractor/ spray-rig/aircraft run overlaps. Australia is a recognised world leader in the development of precision agriculture technology, a status achieved largely through necessity: with no protection from trade barriers or subsidies, and large areas to farm and relatively few labour resources with which to farm them, Australian farmers have had to embrace technology in order to remain efficient and competitive against more protected farming competitors.

It is “pretty amazing” technology, as John Chalmers, one of Farmscan Ag’s three directors and owners, explains: “Think of a 400 horsepower tractor with wheels this high (reaching above his head) and two wheels either side this wide (hands outstretched), we can steer that within about 2-3cm of line at 12kph.

“One of the reasons we are in Brazil is that they’re doing sprayers, and they’re travelling at 30km an hour, with a 48 metre boom, all operated with no hands, and across contour banks. It even astounds us, it is amazing that you can have a system that is able to react that fast, no human can do it, it is physically impossible for a human to do that.”

Export expansion Farmscan Ag began exporting in order to overcome the seasonal nature of its Australian-based business. About 50% of its income was being generated in just three months of every year, a difficult scenario to manage from a staff, stocking and cashflow perspective. So the directors took

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Farmscan Ag Directors Jason Stone (left) and John Chalmers during a visit by LNP candidate for Maranoa David Littleproud and Minister For Regional Development and Regional Communications Fiona Nash.

the approach that with two hemispheres on Earth, it made sense to service farmer needs in a different hemisphere while their own was in a seasonal lull.

Farmscan Ag now draws 40% of its revenue from exports, with products sold to 15 countries including the UK Belgium, Spain, Italy, Germany, Ukraine, Brazil, Canada, New Zealand, South Africa and China.

The company has recently opened its own office in the UK to service its growing list of Northern Hemisphere clients.

Farmscan Ag is also the only Australian company to display at Agritechnica in Germany, the world’s biggest international exhibition for agricultural machinery and equipment, attended each November by more than 500,000 people. While there used to be several more, Farmscan Ag is now the only wholly Australian-owned company designing and developing comprehensive precision agriculture technology.

How can a relatively small company with only 15 staff compete so effectively on the global stage against big multi-national competitors?

What might be perceived as a weakness – its relatively small size as a company – is in fact a key strength. Being small and agile means Farmscan Ag can respond quickly to customer requests for specifically tailored products or applications, and also to changing technology. Where much larger, multi-layered corporates may take years to convert a new idea into a commercially available product, and one that could even be obsolete by the time it is delivered to market, Farmscan Ag is able to react very quickly. Its smaller size means it can also cater to smaller customers and batch sizes than bigger companies are often interested in, or able, to service.

“That is what being agile is about, we can make things happen for small to mid-range

groups fairly quickly,” says Chalmers.

Another point of difference is that the equipment created by Farmscan Ag typically enables farmers to perform many applications with a single, integrated package.

Supporting innovation In May, Farmscan Ag’s Toowoomba headquarters was visited by the Minister for Regional Development and Regional Communications, Fiona Nash, and LNP candidate for the Federal Seat of Maranoa David Littleproud. The Farmscan Ag directors said it was satisfying to see the Federal Government putting money into encouraging innovation in Australia, but they urged greater support for building export markets for tertiary exports like theirs. New free-trade agreements were fantastic, but they focused on exporting primary produce to foreign countries.

Farmscan Ag is effectively manufacturing and exporting tertiary farm technologies, and said more Government support would go a long way towards expanding these export market opportunities, in which Australia is a world leader.

Australia does not, for example, have a branded country-presence at the massive Agritechnica machinery expo held in Germany every year, as many other exporting countries do.

“If you can get equipment manufacturers together and they can get an Australian stand, we think the investment would pay for itself,” says Farmscan Ag director and R&D manager Jason Stone.

Another challenge for the business at present is the lack of access to broadband in their southern Toowoomba location.

They are currently relying on two ADSL lines because one is not adequate, and are in the process of spending $12,000 to establish a radio link with a nearby location

Agriculture, Food & Beverage David Littleproud and Fiona Nash inspect Farmscan Ag’s suite of ag tech products with director Jason Stone.

in order to access faster and more reliable internet services.

Minister Nash said the scheduled roll-out of NBN broadband was underway, with the entire project due to be completed by 2020. A search of Farmscan Ag’s suburb on the NBN’s scheduled rollout map online suggests groundworks for fixed-line broadband connections in the area are underway, but the site offers no timeframe as to when access is likely.

According to Stone, the Federal Government’s investment in improved wireless and satellite coverage for rural areas would be beneficial to users of Farmscan Ag’s technology, by allowing them to automatically synchronise data from their farming equipment with their

office and their agronomist, which in turn will help them to make more informed decisions. The expansion of 3G mobile coverage throughout farming areas in recent years has also streamlined the process of maintaining and repairing technology in the paddock.

“One of the most fantastic things we have been able to do in the last few years with enhanced 3G coverage is that we can log in (directly to a farmer’s Farmscan Ag unit) and provide support,” says Stone. “So you are not on the phone trying to fault find, we can log in, and where properties don’t have 3G but with better internet they can drive the tractor up to the homestead and connect with wifi. The broader the coverage gets, the better that will be.”

Farmscan Ag Director Jason Stone with some of his company’s products.

In 2015 Farmscan Ag was a winner in the Queensland Premier’s Export Awards (in the Environmental Solutions category) and was a finalist in the 2015 national export awards.

In the early 1990s, Stone was a member of the University of Southern Queensland research team that pioneered on-farm robotics and fully automated equipment for agriculture. He was also a member of the USQ’s School of Engineering research team that in 1993 developed the world’s first commercial vision guidance system, which allowed a tractor to be automatically steered using a camera.

Reprinted courtesy of Beef Central.

www.beefcentral.com www.farmscanag.com

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Enmin Vibratory Equipment – Materials handling for food processing Based in Boronia, Melbourne, Enmin Vibratory Equipment has been designing, manufacturing and installing world-class vibratory equipment in Australia for close to 40 years. The company’s expertise has assisted most of the leading food processors to find elegant solutions to their materials handling requirements, either as Enmin’s direct customers or by helping OEM equipment manufacturers to incorporate Enmin vibratory modules into larger food-processing systems.

Alignment

Most people have little to no understanding of how vibration can be used in product handling. However, this technology has been successfully used in many materials handling applications for years and can be of great benefit when it comes to costefficient materials handling and packaging processes.

Vibratory equipment can be applied in a wide range of processes:

Many products need to be aligned for further processing or for packaging, such as hotdogs, carrots or fish. Some just need to be in parallel lanes, some need to be presented head first, some need to be right-side-up, and some need all of the above. A cascading vibratory feeder, with attachments to suit the product, handles this task with ease.

Moving product from A to B

Blending ingredients in-line

In most production processes there are requirements to move ingredients, parts or finished product from one point to another.

Automation is critical to productivity and a vibratory feeder provides the ideal solution.

It offers a range of significant advantages over a conveyor, including:

Using a combination of vibratory hopper feeders with metering controls, ingredients can be added in correct proportions and blended while being conveyed to the next processing step.

• It is easy to install.

• It is hard-wearing.

• It is highly compatible with hygienic environments.

• It is easy to clean.

• There is no carry-back on the belt return.

• There is no contamination of product.

• It can move horizontally or vertically.

• It requires little maintenance.

Screening While the product is moving from A to B on the vibratory feeder, why not add a screening function? A scalper/fines screening module can perform various functions without retarding the full flow of product: it can remove unwanted product or contaminants such as clumps from cereal, oversized or joined biscuits, or stalks from sultanas; or it can extract fines such as cereal dust or product crumbs

Sizing It’s not a big jump from a scalper/fines screen to using a vibratory system for more

exacting selection of product size. A wide range of screen types and apertures are suitable for use with a vibratory feeder, though a degree of expertise is needed to select the right combination for the application.

Stockpiling and progressive release Adding a hopper and loading it up in one go, means a vibratory feeder can be ready for hours of production, eliminating repeated manual de-bagging, and freeing up that operator for other duties.

Automated control of the vibratory feeder will progressively release the product as required by the production process.

Sorting Many natural products (nuts, berries, etc) are more valuable when packs contain the same sized product. Sorting product into size groups is therefore an important valueadding step for many food processors.

Variations in bulk density can be used to sort product into two or more streams.

Metered flow A vibratory feeder is also ideal for applications that require a metered flow of product. At the design stage, tray dimensions and amplitude of vibration can be optimised to deliver calibrated product flow. Furthermore, the vibratory drive can be pulsed or switched from external sensors to regulate the flow of product for when it is needed.

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Compaction Vertical bag filling in many cases can result in a pear-shaped bag evolving, which makes subsequent packaging into cartons or onto pallets more difficult. Bagged products that are to be palletised must stack firmly if they are to be transported safely, without the stack collapsing and causing ruptured bags, product loss and danger to people working in the area. To overcome this problem the Enmin Bag Flattener automatically shapes the filled bag using the company’s unique Controlled Vibration and pressure action.

Spreading Some production processes require the product to be presented in a uniformly thin layer. Using a vibratory feeder to evenly distribute product going into a conveyor-fed drying oven optimises drying performance and product quality, while reducing the high energy costs of the drying process.

Sprinkling An automated vibratory feeder has proven to be the ideal mechanism for sprinkling icing sugar on cakes or chocolate flakes on cheesecake. www.enmin.com.au

Agriculture, Food & Beverage

Lasers meet agribusiness head on

Enhancing Australia’s prosperity in agribusiness with technology and innovation is just another challenge lasers systems are up for.

Dutch company PerfoTec has devised a system that combines laser technology, sensory technology and a visual inspection system to deliver a unique form of packaging with the express purpose of extending quality and taste of fresh-picked fruit and vegetables. The benefits of extending the life of fresh produce impacts supermarket returns, reduces food waste and provides greater consumer satisfaction.

Provenance of food is important to consumers and with Australia’s reputation as a clean, safe environment for producing premium fresh fruit and vegetables, the PerfoTec laser system offers great export potential, particularly to the fast growing markets of the Middle East and China, where demand is fuelled by greater affordability and a growing awareness of the health benefits of fresh produce. Laser technology can now provide exporters the opportunity of retaining the quality of their products.

The process is called Equilibrium Modified Atmosphere Packaging (EMAP). It entails making micro-perforations in the packaging film that ‘match’ the respiration rate of the produce inside, enabling a longer life, even as much as 100% on previous storage times. So how does it work?

Firstly, fresh produce respires. Respiration is a complicated sequence of chemical reactions involving the conversion of starches to sugars and from there into energy. Respiration rates vary from product to product, season to season and thereby country to country! EMAP is a way of controlling respiration rates that cause the deterioration of taste and flavour.

When a product such as a strawberry, grape or banana arrives at the packing location, the first step is to place it in a Respiration Meter. This standalone device measures the product’s oxygen consumption and carbon dioxide production. Using an online measuring service, this data is used to calculate the desired size and number of holes required in the packing film. This information is uploaded to the computer-managed laser system, usually integrated into the packaging system by either vertical or horizontal mounting.

The third step is the laser perforation process. As the film passes the laser system, perforation occurs, resulting in a wrapped, sealed product with a controlled atmosphere as it comes off the packaging line. Holes as small as 55-60 microns in diameter can be made, with the size and quantity of perforation unique to each variety of produce.

The integrated vision system.

A PerfoTec integrated into a packing system of berry punnets.

The fourth step which occurs sees each perforation inspected by an integrated camera, analysing the diameter and shape. The vision system exercises quality control as it checks the oxygen transmission rate of each pack. The PerfoTec is the only laser in the world with the ability to adjust micro-perforation with relation to film thickness using this patented closedloop feedback camera system.

The respiraton meter determines laser perforations.

PerfoTec lasers are already used extensively in Europe. Trials by UK retailer Marks & Spencer (M&S) found that laser-perforated packaging of berries in particular, not only extended shelf life, but increased sales and customer satisfaction while reducing food wastage. This led to M&S specifying EMAP as a condition for supply of fresh produce to its international chain of stores.

In 2015 a survey by Euromonitor recommended EMAP as a major benefit to Australian growers. Extending the life of fresh produce has real advantages not just for local markets, but offers exceptional advantages for export. Australia is challenged by distance, but the recent rise in the quantity of exports of fresh produce can only be enhanced by adopting laser technology to retain the taste and quality of our already-prized fresh produce. www.perfotec.com

www.raymax.com.au

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Safe bulk handling of biscuits

When an iconic Australian food company needed a new method of reliable, continuous supply of snack biscuits to its high-speed weighers and feeders for packaging, it sought the assistance of two Australian manufacturing companies who are leaders in their fields.

Victoria-based Kiel Industries collaborated with Pro Ali Design in Sydney on the project to design and build a new production line for the snack biscuit manufacturer. The project demonstrated the expertise and skill of the two companies.

The ‘lift and tilt’ mechanism from Pro Ali Design that empties the Kiel Industries bins onto the production line.

From a modest beginning as a small, family-owned and operated company, Kiel has grown into a prominent leader in the rotational moulding industry. Founded in 1989 by the Kiel family, the company now supplies the largest range of plastic pallets in the Southern Hemisphere and dominates materials handling with innovative designs for pallets, bins, and ancillary products.

Kiel utilises some of the most technically advanced moulding equipment in the world, and over time, its custom moulding division has grown to be a prominent participant in the industry.

Its equipment was specifically selected so the company can offer economical short production runs, together with competitive pricing on high-volume production.

Pro Ali Design’s dedication to quality, design and service, coupled with continuous improvement and technological innovation, has made it one of the most reputable and respected providers of conveying solutions for many of Australasia’s leading food manufacturers.

A major requirement of the biscuit packaging line was to replace the existing bins and handling system with a line that used a cleaner, more versatile bin. According to Kiel’s Managing Director, Colin Kiel: “For the production line, ‘cleaner’ meant the bins had to empty completely with no residual biscuits being trapped by corners or edges.”

The biscuit production process involves several basic steps. Pastry is made and spread before the topping is added and then cut to shape and baked. Once through the ovens, the snack biscuits are placed into the Kiel-designed plastic storage and transport bins in large plastic bags. When the biscuits are ready for packing, the bins are moved and the biscuits decanted to portion pack sizes of 25g and 70g. Portion packs are retained in the Kiel bins until emptying is required to create multipacks on the packaging line. The portion packs are then boxed, ready to be sent out to supermarkets.

The customer requirements were for 650-litre, food-grade polyethylene bins that were standard pallet-sized with smooth walls, and easy to clean. The bins also needed the capability to be safely stacked up to eight high.

The biscuit manufacturer ensures the freshness of its product by insisting on a 14-day turnaround between baking and packaging.

During this two-week period, approximately 1,000 bins of snack biscuits are produced. To meet this demand and ensure there were always sufficient bins, Kiel manufactured 1,500 bins in total. Kiel tendered for the project but was only given four months to produce the minimum number of 800 bins.

“This was a little tight because during our normal operational shifts, one mould can only produce 100 bins per month,” Kiel recalls. “We had to maximise the efficiency and utilisation of the production line to make best use of the machines.”

Once the design of the bin had been confirmed, prototypes were sent to Pro Ali Design in Sydney for development of the automated tipping machinery that was to be part of the new production line.

“It was interesting for a change for us to develop a bin and have the handling equipment built for it,” says Kiel. “Usually, a company designs and builds a processing plant and then asks us to give them a bin that fits their system.”

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Pro Ali was selected because it specialises in the design and construction of state-of-the-art stainless steel conveying systems for the food industry, including customised package and box handling conveyor lines. In addition, all the company’s equipment is manufactured to meet the appropriate Australian Standards, as well as AQIS, MAF or FDA ‘clean design’ specifications.

According to Jon Ball, Pro Ali’s Business Development Manager, his company received a very specific brief for the new production line. The main requirement was to improve efficiencies and remove the need to manually load biscuits from different-shaped bins. The cubic-metre bins developed by Kiel had to be robust to withstand being picked up and moved around in areas where multiple forklifts were operating, so the Pro Ali design incorporated a heavy-duty bin tipper.

“We were working with very fragile product in both the contents and the packaging,” says Ball. “The consumer packs are highly decorated so cannot be scuffed during transport along the line.”

The packaging line includes elevated and radius conveyors, so Ball had to ensure there were minimal junctions, bends, lips and edges in the line on which packets of biscuits could be caught. The feeder hoppers all include a laser level, which sends an alert when the biscuit level is low and requests another bin be decanted into the packaging line. The line has four units operating on a continual basis to ensure that it is conveying a regular, constant stream of product.

The processing line design incorporates a number of safety features to protect workers, including light curtain safety lock-outs.

“Safety was paramount and our design had to reflect this,” Ball adds.

“When the beam of one of the light curtains is broken, the system shuts down and must be manually reset to start the process again.”

Agriculture, Food & Beverage Left: A cleaner, more versatile Kiel Industries bin being emptied onto a biscuit packaging line.

Right: Some of the 1500 650-litre bins manufactured by Kiel Industries for a biscuit manufacturer.

“We had to remove a wall and then unbolt, raise and reconnect a number of conveyors,” Ball explains.

One feature of the project was that the new production line was to be built on a blank floor area dedicated to the bin tippers and conveyor system; not around or over existing machinery as is often the case.

“This allowed us to have a lot of straight runs to ensure nothing gets stranded high up on an elevated section,” says Ball. “In the past, it was possible to get the contents of different packs mixed because some got caught at a junction and dislodged on a later run.”

While the area for the new line was a clear, open expanse, gaining access to it was not a simple matter.

Pro Ali was given approximately six weeks to design and build the bin handler and conveyor system. According to Ball, more time was spent during the design phase because the biscuit manufacturer requested numerous reviews before signing off on the system. A mock-up of the production line handling system was assembled at Pro Ali’s manufacturing base in suburban Sydney after prototypes of the Kiel bins were delivered. Factory acceptance tests were conducted to demonstrate the whole operation to the customer.

After a few tweaks of the design, Pro Ali built and delivered the three other handling units.

“While this project was challenging, we haven’t been thrown a task yet that we weren’t able to deal with,” concludes Ball. www.kielindustries.com.au www.proali.com.au

FDM produces ‘impossible’ part for food packaging business

Based in Elgin, Illinois, M-Tek is a leading manufacturer of modified atmosphere packaging systems used for fresh poultry, meats, seafood, cheese and produce. These systems remove oxygen from the package and replace it with nitrogen or carbon dioxide to inhibit the growth of bacteria, reduce the risk of contamination, and improve shelf life.

The process is built around a groove-shaped probe that is inserted into packages to remove the interior gas and replace it with inert gas. However, the plastic packaging is often drawn into the interior of the groove, which chokes off the probe and increases the time required to complete the exchange process. This is a condition referred to as “valve-off”.

M-Tek engineers solved this problem by including an internal void in the probe’s design, but conventional CNC machining methods could not maintain the required tight manufacturing tolerances required for such a long, thin part.

Solving the impossible M-Tek originally purchased a Fortus 3D Production System from Stratasys to build conceptual models and functional prototypes of machine components and assemblies with fused deposition modelling (FDM) technology. However, M-Tek’s engineers discovered that FDM is also terrific for creating parts with intricate design features that are not possible with conventional CNC milling methods. With FDM, engineers were able to design a new probe that eliminated the valve-off problem.

M-Tek now uses probes made from polycarbonate that are created in-house on its Stratasys 3D printer. The redesigned probes make it possible to draw the vacuum and inject inert gas into the package in 20% less time than was required by M-Tek’s previous design, or by competitors’ current designs.

Not only does the 3D-printed tool eliminate the valve-off problem, but it can be produced in one day rather than the four days required

A redesigned gas probe on the Corr-vac Mark III modified atmosphere packaging system.

A production Corr-vac Mark III packaging system with FDM components.

previously – a 75% reduction in time, as well as a 56% reduction in cost. What’s more, since injection time was the limiting factor on the cycle time of the packaging process, M-Tek’s 3D printed probe has increased throughput by 20%.

“It would have been impossible to machine an internal cavity in a part this long and narrow,” says Norm Buggele, Executive VicePresident and Chief Operating Officer for M-Tek. “With the Fortus 3D Printer it’s perfect every time.”

Stratasys FDM technology production systems are available in Australia through Objective3D. www.objective3d.com.au

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South Australian innovators tap global agri-markets

Machines to increase the efficiency of planting crops, opening oysters and manufacturing ancient superfoods are helping South Australian companies meet demand from global markets.

A tillage system developed in the mid-north of South Australia is helping to boost the productivity of cover crop planting. The Kelly Engineering system combines a diamond-shaped tiller with an air seeder to allow the entire sowing process to be completed in one pass.

The patented Diamond Harrow tillage machine, fitted with a Cover Crop Seeder, began testing in the US last month and is expected to be commercially available next year. The launch is a calculated response to the rise of planting of cover crops in the United States as farmers look to increase crop yields while reducing their reliance on pesticides and nitrogen fertilisers.

The Diamond Harrow is made from Australian RHS steel, which is laser cut in Adelaide using a CNC-controlled machine enabling very specific profiles to be cut on the end sections. Plates are also laser or plasma cut for accuracy before components are MIG-welded.

Cover crops are increasingly becoming an accepted technique to improving soil health and crop yield. The North Central Sustainable Agriculture Research and Education (SARE) program and the Conservation Technology Information Center (CTIC) in the US estimate there was an almost 40% increase in the number of farmers planting cover crops from 2012 to 2013.

SARE has set a target of 20m acres of cover crops in the US by 2020. Some of the most common types of cover crops in the US include rye, wheat, barley, field pea, canola and mustard.

Kelly says the new Diamond Harrow would not only save time, but its precision seeding would lead to more accurate germination and deliver higher crop yields in all types of weather. He says the machines can also help farmers save on additional maintenance costs.

More than two-thirds of Kelly Engineering’s business is in the US, where it has generated more than $50m in sales. The family-owned business, based at Booleroo Centre in South Australia, also exports to Canada, Germany and the UK and is gearing up to grow its business in Africa.

Freekeh frontrunner At the other end of the grain cycle, a company about 60km north of Adelaide has modernised an ancient technique to become the world’s biggest manufacturer of freekeh. Regarded as a “superfood”, freekeh is made via a process of heating immature green grain to halt its maturation without cooking it. It was first developed in the Middle East in about 2300BC.

The diamond shape of the harrow includes a perimeter set of chains that allows the machine to pass the soil to the left and right.

This way there is no ridging or clumping through the paddock. The four chains allow the machine to prepare the seedbed in rough fields. The Cover Crop Seeder is integrated into the machine, which is towed by tractor. Each chain is fitted with a crop-specific row of metal discs that rotate and penetrate the soil. The design also allows the machine to work the soil, attack crop residue and manage weeds.

It takes 4-5 days to manufacture a harrow, which sells for $85K-$90k.

Kelly Engineering Managing Director Shane Kelly says the company’s focus was to build highly efficient products, which were also affordable. He believes the addition of the Cover Crop Seeder to the Diamond Harrow successfully achieved this.

“There are government incentives for farmers in the US to get involved with a cover crop program for environmental benefits, whether it be nutrient recycling, erosion control, soil improvements or water runoff,” says Kelly. “In the US, as here in Australia, there is recognition that maintaining live plants year round helps soil health and productivity.

“Farming on a global basis should be sustainable and we know that soil degradation, weeds and water-use efficiency are things affecting agriculture – we know that the tillage tools we provide can help address all of those issues.”

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Greenwheat Freekeh has been producing the superfood commercially in South Australia since 1997 and was awarded two gold medals at this year’s inaugural Australian Food Awards.

However, it is the processing technique invented by Greenwheat Freekeh’s Managing Director Tony Lutfi that has allowed its production to grow to more than 500 tonnes a year.

The company plans to expand production at its plant north of Adelaide to 3000 tonnes a year by 2018. It exports to 17 countries including the US, Canada, UK, Netherlands, Spain, South Africa and Brazil and has begun shipping product to Japan and South Korea this year.

Lutfi first tasted the grain in the Middle East nation of Jordan in 1994.

“It’s a product that’s been around for 4300 years and processed by very primitive means,” he says. “I started examining the process and experimenting in 1995, then in 1996 developed the process

Agriculture, Food & Beverage Federal Senator Anne Ruston and Bob Simmonds (centre) discuss the new oyster innovation with Seafood CRC CEO Dr Len Stephens.

and in 1997 built the company in Adelaide and started exporting it to the rest of the world.”

As well as expanding production in South Australia, Lutfi says the company is looking to license its technology in a joint venture arrangement, particularly in the Northern Hemisphere so that the seasonal production could continue year round. Demand from the US soared in 2011 after television host Oprah Winfrey nominated freekeh as “one of four exotic grains that can improve health”.

Freekeh is cooked and served in a similar fashion to rice and can also be used in salads, breakfast cereals, soups, breads and cakes.

Lutfi says demand for his freekeh products continued to grow globally and in Australia.

“In 2011 the Australian market accounted for less than 1% of our sales,” he says. “In 2015 it accounted for 50% of sales.

“I could sell our entire product to export up front but we are holding stock back for the Australian market. There are so many companies from all over the world writing to us … it’s a genie out of a bottle and we are the main supplier.”

Easy-access oysters Meanwhile, an Adelaide company is engaged in developing massproduction machinery for a new method to make oysters easier to open. Devised by Simmonds Seafood Marketing Agencies, the new method involves shaving the lip of the oyster to create a small opening where a knife can later be inserted to greatly simplify the shucking process. The opening is immediately sealed with wax to keep the juices in and the oyster alive.

Inventor and oyster marketer Bob Simmonds says the wax coating also provided branding opportunities because it allows stickers to be applied that provide information about providence and packing dates.

Simmonds explains that the ability to keep oysters alive while making them easier to open gave them a much greater shelf life compared with the typical pre-shucked product.

“Most oysters are opened, half-shelled and then sent to restaurants and hotels,” he says. “You only get three or four days life out of the product whereas with the new process you probably get 10 to 12 days life out of the product, which is a huge benefit.”

Trading in Adelaide as Oyster Bob, Simmonds sells 18m to 20m oysters a year on behalf of South Australian oyster farmers, who produce about a third of Australia’s harvest. He has entered a partnership with the Fisheries Research and Development

Corporation (FRDC), which now owns the worldwide patents for the procedure, and is working to develop machines to streamline the process.

“The product itself performs. It’s now about getting the numbers up,” Simmonds says. “We’re looking at robotics and laser technology.”

Simmonds says the easy-open oysters would be ideal for the Asian market because of its appetite for live seafood products. Australia exports more than $1bn of seafood a year to Asia, driven by strong demand for rock lobster, tuna and abalone.

“All the oysters that are sent out of Australia have been whole live and they are opened overseas but it’s a very laborious task,” Simmonds says. “If we can take that part of it out of the equation and have an oyster ready to eat, that’s going to appeal to a whole lot of areas – especially China and Asia where they like live product.

“It can be opened live at the table and people can see the branding and have a discretionary taste of it just like they do with a bottle of wine.”

In 2013-14, Australia produced 11,402 tonnes of oysters with a value of about $90m. Simmonds and the FRDC have secured grants to develop three machines to realise commercialisation.

Oysters processed using the new method could be on the shelves in about a year.

Simmonds says as well as having great potential for export, the new method also was ideal for the retail market. He says cooking shows on television had created an appetite for freshness among home cooks and made people more adventurous when it came to news ways of serving food.

“Now at retail level we can put them in a dozen pack and people can take them home and open them themselves easily at a dinner party or whatever it may be,” Simmonds says. “It’s also the novelty factor of doing something a bit different too. Having it live at the table and branded are the essential ingredient to me.”

Simmonds says the machines could be potentially sold commercially to other oyster processors once the process was perfected.

“The FRDC and I both believe this is one of the best things to happen to the oyster industry as far as marketing is concerned for a long, long time,” he says. “I don’t say it’s ever going to replace the current method but it’s just another string to the bow.” www.kellyengineering.com.au www.greenwheatfreekeh.com.au www.oysterbob.com.au

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one-on-one

Jens Goennemann is the Managing Director of the Advanced Manufacturing Growth Centre, founded as part of the Federal Government’s Industry Innovation and Competitiveness Agenda.

AMT: Let’s start with your professional background and how you came to your role with the Advanced Manufacturing Growth Centre?

Jens Goennemann: For the past 20 years I have been working for Airbus, eight of them based here in Australia responsible for the Australian and New Zealand operations.

When it was more than time to go back to Europe, it became a family decision to give it a miss – Australia had become my home. So, it came that I joined the Advanced Manufacturing Growth Centre earlier this year, and as anticipated it is a very interesting and promising opportunity.

Manufacturing in Australia isn’t what the public perceives it to be, and I felt that we could do something quite extraordinary if we started to believe more in our potential – especially from what I have seen coming from previous experience at Airbus by working closely with innovative Australian manufacturers.

AMT: And what is the Advanced Manufacturing Growth Centre? Why was it established, and what are its objectives?

JG: The Advanced Manufacturing Growth Centre was established in 2015 as part of the Industry Innovation and Competitiveness Agenda. There were five original Growth Centres formed at that time (Advanced Manufacturing, Food & Agriculture, Medical Technologies, Mining, Technologies & Equipment, and Oil & Gas), with the sixth Centre (CyberSecurity) announced earlier this year. The overall idea is to focus on our unique strengths and by doing what we are already good at as a country rather than attempting to do everything making very little impact.

The Advanced Manufacturing Growth Centre was formed to raise the competitiveness of our Australian manufacturing sector to a global level. While we had a good idea of what that could look like, we decided

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to conduct solid round consultations with industry and research institutions as well as in-depth analysis to gain clarity on our objectives and what it would take to realise our goals.

What we found confirmed that connecting into global supply chains has to be our sector’s first priority. Second, we need to improve our professional skills both at the management level and to utilise more highskill workers across the entire manufacturing process to seize opportunities. Third, we need better co-ordination and partnerships between industry – and this means between one manufacturing firm and another – and between industry and researchers, with the goal of tangible commercial outcomes. Last but not least, we could all benefit from more institutional alignment and stability by giving any plan sufficient time to deliver before changing the goal posts.

AMT: What can you tell us about your new Sector Competitiveness Plan?

JG: I can tell you that it will be published before the end of this year. We’re excited to get our Sector Competitiveness Plan into the hands of Australian manufacturers to share with them, and the wider public, that our sector is full of potential. The frequent suggestion that the manufacturing sector is in decline is not supported by the facts, especially when all those jobs which exist because of manufacturing are currently not taken into account.

What our Sector Competitiveness Plan provides is a razor sharp and data-based look at what makes us more successful, and we show pathways that manufacturers can take in order to lift their competitiveness. I think many readers will be surprised as well as heartened to know that we can definitely hold our own internationally. What we need to do is to agree that competition is not within, but beyond our borders, and we can win the global game when we focus on

where we can add the most value, where we are at our best.

Moreover, our Sector Competitiveness Plan is an iterative process with updates coming out on a regular basis. We listen, learn and help put into action what promises to make our sector more successful.

AMT: With Australian manufacturing undergoing a period of transition, what are the major challenges and opportunities?

JG: Manufacturing is always under pressure as technology continues to push the frontiers. But this is the case for all sectors across our economy, not manufacturing alone. We know of companies in the automotive sector who saw the writing on the wall over 15 years ago and who have successfully reinvented themselves.

What we are witnessing is the persistent advancement of how manufacturing continues to change. Why this has been particularly hard in some cases here in Australia is that we have not sufficiently prepared ourselves to see around the corner as we could have. Instead we’ve stuck to ways of production that were neither helping employees gain the essential skills to keep up nor shaping our sector to stay ahead or at least in touch with global trends.

It’s rare for Australia to be cost-competitive, unless we are prepared to say farewell to our lifestyle. Our future depends upon competing on value, be it in technology leadership or service offerings – or in a combination of both.

This is why I find our Sector Competitiveness Plan to be an inspiring read. It plots a course for this massive ship called Australian manufacturing, and I believe we have the fact-based analysis and actions instead of the myth-fuelled publicity to help get us on the right course

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AMT: Where do you see the sector in the next 10 or 20 years?

JG: Globally competitive – not in everything, but in relevant niches – because we target and co-ordinate our institutional decisions, instruments and investments. Collectively, we will be more informed about what the challenges and the opportunities are – as a sector and as a nation. Manufacturing will be appreciated as the sector where complex things are being realised and the sector which enabled Australia to sensibly participate in ‘moon-shot’ opportunities such as the Future Submarine building program. Only a healthy, vibrant and ever advancing manufacturing sector can pull this off.

AMT: What might an ordinary working day entail for you at Advanced Manufacturing Growth Centre?

JG: Thankfully, and like for most executives, there isn’t really an ordinary day. There are major themes though that drive our schedule: My core role for the moment is making sure our sector knows who the Advanced Manufacturing Growth Centre is, what we do and why it matters. The foundation for this is our profound analysis, such as through the Sector Competitiveness Plan, because without data and facts, it’s like trying to nail a pudding against the wall!

We are a team with big ambitions and I believe we have the right trajectory and government commitment in place to make Australian manufacturing successful over the long term. Equally, I’m keen to connect with your readers in the near future and find out how our ambitions resonate best with theirs.

Let me finish by saying that manufacturing now and in the future is a most exciting affair. Let us be self-aware and more confident about it and tell our children as well. Their future is certainly not built on the fate of unstable commodity prices and everincreasing property values alone. www.amgc.org.au

AMT Dec 2016/Jan 2017

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Forming & Fabrication

‘Englishman’ boosts productivity for Auckland Sheet Metals

Gary Wight of Auckland Sheet Metals makes no bones about it: the purchase of a new Swift-Cut plasma cutting table from Machinery House has increased business efficiencies by 30%. In fact, Wight wonders what they ever did without the machine affectionately known in the workshop the ‘Englishman’.

“It doesn’t get sick, never stops working and every cut is a classy finish,” says Wight.

The company has been at its current premises for close to 10 years, with most of that in partnership. However, according to Wight the real business evolution has occurred in the past two years when he “went it alone”, with the dissolving of a partnership that had two owners wanting to pull the business in different directions.

“It meant I could invest in machinery,” he says. “The last two years we’ve been Auckland Sheet Metals – in sole charge – and I’ve bought new presses, welders, the plasma, vehicles that have made life easier. And the result has been more progress in the last little bit than the whole time of being in business prior to that.”

Indeed, since the change the company has been struggling to keep up with demand.

“I’ve made it a focus to buy machinery that keeps the work going while we aren’t.”

The ‘Englishman’ (the nickname derived from its country of origin) does exactly that. Wight explains that the plasma machine can be cutting and making parts while his workshop engineers crack on with the welding.

“It’s actually given us more man power,” he says. “To make those parts the old-fashioned way, with less accuracy, would take hours longer and this machine never stops.”

Wight adds that the machine was only just installed before the EMEX 2016 exhibition, held in Auckland in May. Nonetheless, despite it being early days he estimates that the Swift-Cut improves the jobs they are using it for by as much as 30%.

“I wouldn’t be without it now,” he says, explaining that before to the installation they would have to outsource work, and also rely on other businesses being efficient and delivering to timeframes. “We can continually change things, tweak things, make things better, and if there are ever any problems we just pick up the phone to Machinery House. It’s allowed us in great part to control our own destiny.

“We actually end up making a little bit more money on the side because you become almost a merchant of materials, putting markup on the material we are buying in as well as making money on cutting the product. The local businesses that use our services have responded so well... the new plasma has such a clean finish, we’ve got people asking us for more laser cut plates, thinking we are laser cutting it.”

Business has grown through word of mouth, and the quality of the jobs that the company undertakes has meant that Auckland Sheet Metals doesn’t even need a website. The team already has enough on their plate. Ten staff do a large range of work: stainless steel to structural steel at former All Black John Kirwan’s house.

Structural steel is a growth area for the business, thanks to legislation with regard to steel in housing and earthquake regulations.

AMT Dec 2016/Jan 2017

The Swift-Cut plasma cutting table at Auckland Sheet Metals.

The company’s premises house a four-metre guillotine (up to 8mm thick), a 135-ton, 4m press brake (also purchased from Machinery House), bandsaws, Mig and Tig welders, rollers and all the general equipment you’d expect of a good engineering workshop. However, the plasma cutter has quickly taken pride of place.

“For our size business it’s a perfect fit,” says Wight. “It’s not top of the market in terms of price and/or function, but it’s pretty bloody good and also easy for the staff to handle.”

Another staff member is kept busy fulltime draughting and quoting jobs so “we have a bit of a one-stop shop when it comes to that and our customers are dealing with one person through the process”.

“Most of the guys are trained and qualified sheet metal workers, which is pretty hard to say nowadays and that’s a feather in our cap,” says Wight.

Gary Wight of Auckland Sheet Metals.

Wight loves the engineering industry, having started work with Morris Sheet Metals in Onehunga as a 15-year-old sweeping the floor. Today, armed with the Englishman and a highly efficient staff and workshop, Auckland’s current housing crisis will do nothing but add to an increasing workload that already has him eyeing larger premises. Whether it be residential, commercial, maintenance, structural or repairs, with Auckland Sheet Metals, Wight, his team and the Englishman are a cut above the rest. www.machineryhouse.com.au

AMT Dec 2016/Jan 2017

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Forming & Fabrication

The fastest coil handing and cutting system Cutting a range of coils to width and length is often cumbersome and time-consuming. Damage to coils, slow cycle times, inaccurate inventory management and operator safety are just a few problems faced.

The Krasser Centurio provides a complete solution for thin sheet applications, optimally combining both protective storage of coils and the precise and logistically efficient cutting of coiled sheet.

Once the coil is loaded into the storage system, all movements of the material occur automatically without any physical labour. Storage and transport damage to material and edges is minimised. The automatic adjustment of slitting knives with patented blade gap adjustment ensures precise strip widths and guarantees the best cut quality.

Coil loading and slitting processes run simultaneously while guarded by a safety fence. To change a coil from the furthest coil storage position takes only two minutes; this process includes straightening and weighing the coil. According to Sheet Metal Machinery, these features and benefits make the Centurio the safest and the fastest coil processing and slitting system worldwide.

Extendibility is absolutely the biggest advantage of the Centurio coil processing system. Depending on requirement and budget, Sheet Metal Machinery is able to offer single or multi-row setups, up to five lines side by side. The flexibility in length and number of stations is nearly unlimited. Coils are weighted automatically and after every move in the storage, the weight is saved again in the system. Order and reorder can be coordinated perfectly as you always know how much of your coil is left. You can load new coils into the storage system whilst the machine cuts your orders. This saves you even more time and is one of the biggest advantages of the system.

Speed is key F&M Fabricators in Brisbane makes commercial roofing and rainwater products and works with steel, aluminium, zinc and copper. The company serves a large portion of south-east Queensland and part of New South Wales. At F&M, speed is key.

The custom sheet metal fabricators market their fast turnaround time and advanced technology at every opportunity.

“We promise a lot of light gauge sheet metal jobs on delivery in 12 hours so it’s fairly high pressure,” said Marty Vosper, Supervisor at F&M. According to Vosper, the Centurio was like an answer to a prayer. The machine went into F&M’s production line, with eight knives on the slitter and an eight-station coiling system. It replaced two aging slitters manufactured in Australia that could only

AMT Dec 2016/Jan 2017

take one-ton coils, whereas the Centurio can handle coils that are five tons. Vosper believes that the difference has been like night and day.

“We used to have to manually change the knives and manually change the coils,” he says. “With the Centurio, we put on a four-ton coil on Monday. On Tuesday, we’d stripped it down to nothing on this onecolor job. Plus, we were doing several other smaller jobs in other colours, so there were a number of coil changes in there to meet deadlines.

“All together, there was about eight tons of work produced over less than two days. It’s really unbelievable. The output of work now for us is triple what we were doing before, easy.”

Vosper said the Centurio primarily feeds to three 8m long Folders, and its speed assures that there is rarely any downtime waiting for material. Compared with the machines and workflow that it replaced, Vosper says: “It’s about 10 x faster and the operator doesn’t have to do any real physical work. The machine does it all.”

Moreover, it has helped F&M live up to its marketing promise.

“It has made us extremely competitive,” Vosper says. “No one can get custom product out as fast as us.” www.sheetmetalmachinery.com www.fmfabricators.com.au

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Material Removal

Water supplier goes with the flow – to Harrison’s Alpha lathes

The never-ending 24/7 demand for reliable water supplies was a contributor to the choice of a new Harrison Alpha lathe for the workshops of Goldenfields Water County Council in Temora, about 400km south of Sydney in the heart of the NSW grain-growing area.

Goldenfields recently moved into its new purpose-built workshop, where it has installed a mixture of existing and newly acquired equipment needed to build and maintain a huge network of reservoirs and pipelines that deliver water to customers throughout the region.

Goldenfields Mechanical Co-ordinator Shane Baldry identified the need for a combination manual/CNC lathe. He worked together with the management team at Temora, along with engineers from 600 Machine Tools, to identify the right machine configuration to deal with the current and projected workload of the workshop.

milling, and much more,” said Cliff Purser, Asia-Pacific Managing Director of 600 Machine Tools. “What this remarkable combination CNC lathe gives workshops in Australia is the ability to perform secondary operations that usually require machining centres or expensive slant bed CNC turning centres.

An example of work on the Harrison Alpha XC, showing (from left to right) scalloping around a PCD, engraving showing bidirectional C axis movement, keyways on end shaft.

“We had several long-serving machines in our former workshop,” said Baldry. “And the construction of a new purpose-built facility was an appropriate time to evaluate what we were going to need in the future.”

In addition to Baldry, there are three fitters and three apprentices, all needing to use a lathe at various times. This makes flexibility absolutely essential, and the new machine needed to switch quickly from being a centre-lathe to full CNC. “After studying the options, it was decided that the Harrison Alpha 1550XS would meet our requirements,” said Baldry.

Adding the c-axis, milling and drilling to the Harrison Alpha range dramatically reduces the need for secondary operations. It genuinely increases productivity and slashes cost-percomponent – especially on prototypes, oneoffs, and small batches. The control unit on the machine is the renowned Fanuc 0iTD system.

Purser explained: “As engineers will recognise, Harrison has its own Alpha programming system that is unique, and acclaimed by users worldwide. This is in addition to the Fanuc Manual Guide system that is fully Shane Baldry and Jack Fuller at the conversational for the end-user, using pictorial Goldenfields installation. guides along with the full G-Code CNC system – not forgetting manual operation – giving Alpha operators unrivalled programming options.

The globally-successful Alpha 1550XS has a swing-over bed of 554mm, a 15kW motor, spindle speeds up to 2,000rpm, and a spindle bore of 104mm. The spindle nose is a D1-11 Camlock. The precision-engineered CNC combination lathe range is designed for fast, high-quality repeatability, accuracy and surface finish to exacting toolroom accuracy standards (DIN 8605).

Steve Drummond, Sydney-based Sales Manager at 600 Machine Tools, said: “The machine we have configured and supplied is a big lathe, with three metres between centres. However, despite the generous machining capacity and size of the Alpha, the latest Fanuc OiTD control ensures that operators can approach this machine with confidence, due to its ease of use and simplicity of operation.”

With regard to manual operation, he added: “Even if you haven’t used a lathe since your schooldays, you could walk up to an Alpha XS now and start cutting metal.”

Heavyweight performance A member of the UK-based 600 Group, one of the biggest lathe manufacturers in Europe, 600 Machine Tools offers the full range of Alpha models from Harrison, along with the award-winning range from Colchester. The all-new Harrison Alpha XC combination CNC lathe, the breakthrough machine that caused such a stir at the MACH 2016, is now available in Australia. Making its debut at the NEC in Birmingham, this range now incorporates driven tooling and full c-axis interpolation. This feature, a significant addition to the simple-to-operate CNC lathe, now allows operators to carry out secondary operations at the machine in one set-up.

“The new XC can conduct off-centre drilling and boring, hexagonal

AMT Dec 2016/Jan 2017

He added: “The turret has eight stations, and all positions can be driven at up to 5,000rpm on some models. The VDI tooling set-up is based on the size of the machine and has either a 20 or 40 VDI configuration.”

“Simply put, the new Harrison Alpha XC is the simplest CNC lathe to operate in the world.”

The company also offers a larger capacity model – the Alpha 1550 XC – now available with a swing-over bed up to 550mm and centre distances up to 3,000mm. This powerful CNC lathe can be configured for milling, too, thereby eliminating any need to lift large and heavy workpieces to other machines for secondary operations.

This is true of other machines in the Alpha range, which includes the 1660XS and 1760XS with beds of up to 4m, and the massive 2800XS with beds of up to 6m. The 1660XS is fitted with a high powered 18.5 kW motor, swing over bed of 660mm, and 105mm spindle bores, bringing true heavyweight turning performance to Alpha users.

These big machines have a one-direction indexing c-axis with a 0.1-degree of accuracy. They manage with ease such commonplace secondary operations as drilling holes in the flange of a 6m-long workpiece, such as a prop-shaft.

Purser said: “Now that the XC models in the Alpha range come with full c-axis, as found on many slant-bed CNC machines, workshops throughout Australia can increase throughput and achieve significantly higher productivity, while maintaining high levels of accuracy and repeatability.

“Research shows that there are very few flatbed machines in the marketplace with a fully functioning c-axis, and the new capability of the XC range comes at a keen price that really does represent excellent value for money.” www.600machinery.com.au

Performance and economy in one CoroMillÂŽ 745 is a brand new multi-edge face milling concept for steel and cast iron. Double-sided, but with uniquely tilted inserts for a positive cutting action, it leaves you with 14 true cutting edges for superior cost-efficiency. The innovative design offers benefits such as excellent chip formation, low power consumption and a smooth sound, at a reduced cost per component.

CoroMillÂŽ 745. Made for Milling.

sandvik.coromant.com/madeformilling

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Cutting Tools

Production stuck in the groove?

The increasing complexity of parts is driving an ever-rising demand for more efficient means of machining grooves. In short, more complex parts mean more grooves and the need for more intricate grooving operations to be undertaken.

As every industry and each material has its own unique characteristic grooving tool requirements, a wide range of diverse grooving solutions is needed to accommodate varied markets and material needs. Iscar’s standard range spans from widths of 0.5mm up to 51mm, internal bore diameters from 2mm and up, economic pressed inserts or precision-ground inserts, and a wide range of chip breakers and carbide grades.

Iscar’s grooving tools have a flexible design that allows the tools to perform side turning in both right and left-hand directions, enabling a more efficient machining process. This original Iscar innovation has become a world standard referred to as ‘Groove-Turn’. Iscar’s many years of experience in providing first-class grooving solutions has enabled an extensive standard range of highly efficient grooving tools to be launched, and for Iscar to now be recognised as a global market leader in this area.

Drawing on the company’s detailed knowledge of the subject and its indepth understanding of both conventional and exotic materials, Iscar’s prolific R&D department has developed the most comprehensive range of advanced GrooveTurn tools.

cutting the deepest of grooves. In addition to substantially extended tool life, efficient coolant delivery increases productivity and results in improved surface finish.

• A robust, rigid clamping system engineered to withstand heavy loads associated with heavy duty grooving environments.

• Convenient and reliable indexing.

Heavy industry Iscar boasts two high-quality product families that are designed specifically for heavy duty grooving and groove-turn applications, Sumo Grip and Dove-IQ-Grip, with a range of 8-20mm. Both families share the main advantageous properties that are essential for high performance in this type of harsh application: • The absence of an upper jaw across each range, enabling unobstructed chip flow.

• The effective delivery of a direct coolant supply to ensure the tools’ cutting edges remain effective, even while

Iscar understands that one size does not always fit all. Mindful that each industry has its own specific needs and complications, the staff of Iscar’s R&D department has worked closely with leading companies in all of the world’s main industrial sectors to ensure the delivery of highly efficient, industry specific grooving tools.

Bearings industry The vital components produced by the bearings industry perform a critical role across an extensive and diverse range of applications, from machine tools to wind turbines. Consequently, the technical staff at Iscar are familiar with the unique grooving requirements of the industry. The solutions provided by Iscar accommodate the industry’s demanding precision and surface finish needs, in conjunction with boosting productivity.

Iscar continues to work closely with leading bearing manufactures to provide unique and innovative cost saving solutions such as profiling solutions based on V-lock inserts, and unique multi-corner solutions.

Swiss-Type machines and small lathe applications Mindful of the precision requirements of Swiss-Type machines and small lathe applications, Iscar is continuously increasing its offering in this fast-growing market segment: Based on the new SwissCut Innoval inserts, it continues to add grooving inserts with effective pressed chip-formers.

Iscar’s standard grooving tools have been upgraded by the application of an innovative side clamping mechanism, which is much more user friendly when used on Swisstype machines.

Iscar’s Picco line for mini-internal grooving inserts enables the performance of grooves from a bore diameter of 2mm.

Aerospace Over recent years, the effective reduction of global air travel costs has enabled everincreasing numbers of passengers to fly.

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Cutting Tools

targetted audience 8000+ contacts

impact 20.02% average open rates

outcome This passenger increase has been made possible by the unremitting reductions in the cost of manufacturing aircraft. The ongoing ‘cost-down’ pressure means that aircraft and engine manufacturers continue to demand that subcontractors produce the same high-quality components at everreduced prices.

The challenge of delivering cost-per-part reductions each year while maintaining profitability has encouraged subcontractors to search for more efficient tooling solutions that will release the latent productivity potential of their expensive machine tools. Increasing numbers of aerospace manufacturers are turning to Iscar to enable the required efficiencies and ‘cost-down’ savings to be achieved.

In addition to several other aerospace related sectors, Iscar has long and extensive experience in providing efficient machining solutions for jet engine parts that are made from titanium and a range of heat resistance alloys. In recent years Iscar vastly extended its standard products offerings that are aimed at the aerospace industry’s challenging grooving applications. To enable ever more efficiencies to be gained within the areas of aerospace grooving applications, Iscar provides: • A huge range of modular adapters with JetCut pin-pointed coolant directed precisely to the cutting edge. The entire range can be used with high pressure coolant up to 340 bar.

Automotive Iscar’s groove-turn products are extensively used in the car industry. The main automotive applications that employ these products are gearbox components, synchronising rings, shafts, pulleys, brake systems, turbo chargers and others.

These applications run 24-seven and almost totally unmanned. Therefore chips must be smaller and controlled to enable smooth operation of the machines. Iscar’s GIMN inserts are especially effective in these cases. In most cases, following heat treatment, a finishing operation is also needed. Iscar’s GITM line of CBN tipped grooving inserts provide excellent performance in these hard operations of 50-68 Hrc. Wheel alloys are made of aluminium with magnesium and silicon additives that provide far superior mechanical properties when compared to pure aluminium.

Aluminium wheels have higher strength and are lighter compared with steel wheels, consequently saving energy. As a leading tooling supplier to the global automotive sector, Iscar now provides a range of leading solutions for the efficient machining of aluminium wheels. These include unique inserts with a front stopper for extra stability, and a new quick change system dedicated to the machining of aluminium wheels. www.iscar.com.au

4.89%

average click thrus

results statistical reporting submitted

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

www.amtil.com.au

AMTIL1305

• The effective delivery of coolant to the cutting edge extends tool life and enables doubling the cutting speeds.

• New IC806 & IC804 grades dedicated and optimized for the effective machining of Titanium and heat resistance alloys.

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068

Cutting Tools

A tale of two cutting tools – Rotary vs. Indexable

Modern cutting tools comprise two distinct categories: rotary tools and indexable tools. Fabio Sala and Lukas Pavlis of global manufacturer Dormer Pramet explain the differences between the two types.

In the early industrial days of cutting tool development, metalworking was very limited. It remained a slow task until the nineteenth century when the industrial age brought the availability of machine power via the steam engine and, later, electricity. Machine tools developed considerably in response, and with the introduction of high speed steel (HSS) in the twentieth century, the modern metal cutting era began.

Today, there are two types of cutting tools, rotary and indexable.

Rotary, also known as solid round tools, forms one entire piece made up of the cutting edge and shank. It is typically associated with drilling, threading and milling applications. Indexable tools are predominantly made of inserts or tips, where the cutting edge is a replaceable shaped piece that is welded or clamped on to a tool body. These are generally used for turning, milling and hole-making operations.

Fabio Sala is Dormer Pramet’s Product Manager for round tools, while Lukas Pavlis is the company’s product manager for indexables. They discuss the key elements that make up the differences between the two types of cutting tools, including the material, performance and versatility.

A Dormer milling cutter.

Material – indexable At the beginning of the twentieth century, cutting tool material was sometimes only slightly harder than the material being cut.

Therefore tool life was poor and cutting speeds had to be kept very low. As cutting tool materials developed, they allowed for increased machining parameters and the ability to withstand higher temperatures while maintaining hardness. The harder the tool substrate, the more wear-resistant the cutting tool, resulting in longer tool life.

The compromise here is that harder tool substrates are more brittle and more likely to fracture or break under adverse operating conditions. Softer tool substrates mean the tool will be tougher, allowing successful machining even under adverse conditions.

Although, tougher substrates are less likely to fracture or break, they operate at lower performance parameters and so tool life is not as long.

An ideal cutting tool material should resist flank and point wear, as well as deformation, be tough to resist breakage, does not chemically interact with the workpiece material, resist oxidation and diffusion and have good resistance to sudden thermal changes.

Inserts are made from tungsten carbide, which is the most commonly used material for indexables. Other available material used for inserts includes cermet (CT), ceramics (CC), cubic boron nitride (CBN) or polycrystalline diamond (PCD).

CT has good flank and crater wear resistance and is not prone to built-up-edge. Because of this, the cutting edge maintains its sharpness over a longer time. CC has a wide application area in cutting hard materials (45-55 HRc) and has high resistance to abrasive and thermal conditions. CBN is an excellent cutting tool material and offers extremely hard high thermal resistance. CBN is utilised in materials such as hardened steels and cast iron.

PCD exists in two types (natural diamond or industrial diamond) and is utilised for non-ferrous materials, such as high silicon aluminium due to its high resistance to wear. As PCD is extremely hard and brittle, it is not a good choice for high hardness or impact applications.

AMT Dec 2016/Jan 2017

Material – rotary Round tools are traditionally made from high speed steel (HSS), high speed cobalt (HSCo or HSS-E) or solid carbide. Carbon, chromium, tungsten, molybdenum, vanadium and cobalt all make up the main alloy elements used within high speed steel cutting tools.

HSS is a medium alloy that has good machinability and performance. It offers toughness and is a cost-effective option for a wide variety of large scale drilling and threading applications in multiple materials. However, it is not very wear-resistant and so not suited to demanding, difficult conditions.

Cobalt high speed steel offers a good combination of toughness and hardness, providing good machinability and wear resistance.

This makes the material suitable for drills, taps, milling cutters and reamers. Solid carbide is the most widely used and wear resistant cutting tool material today and is suitable for both round tool and indexable applications.

Performance & versatility – indexable From a cost perspective, indexable inserts and tool holders represent a significant investment. However, they have the potential to last for longer periods of time. Also, when a replacement is needed, this is more time and cost efficient because of the need to only rotate or change the insert.

To support the long-term investment of indexable inserts, they are also interchangeable and versatile. Machinists have the ability to keep the cutter (or tool holder) in place while easily switching the inserts with varying alternative grades more suited to machining different work-piece materials.

Indexable cutting tools offer greater versatility in terms of performance than rotary tools, providing stable results even in adverse conditions and are able to perform multiple operations. For example, the operational versatility for milling inserts includes plunging, helical interpolation, profiling and enlarging a hole. Indexable cutting tools can also offer much larger diameter capability than round tools.

Cutting Tools Performance & versatility – rotary Although round tools generally involve a large initial investment compared to inserts, this investment can be spread over the long term, with the added possibility of regrinding. This is not an option with inserts. The geometry, substrate and coating of a round tool determine performance. Application-specific tools have the potential to produce greater accuracy than general purpose tools.

Also, the overall design allows the machine operator to achieve much smaller diameters.

The four-facet Split Point geometry, for example, used on rotary drills, was originally developed for deep oil holes in automotive crankshafts. Today, it is used on many drill designs for a wide variety of hard and soft materials. It can be applied to a variety of drill point angles, the most common being 135 degrees. This highlights the evolution of round tools where key features, developed for specialist and unique applications have, in time, expanded for use in a wide number of applications and materials.

A key benefit of the split point is easier and more precise selfcentring and to prevent the tool from “walking” before penetrating the work-piece. The web thinning or split point greatly reduces thrust and Dormer Pramet adds a positive rake cutting edge has an extensive assortment of that extends to the centre of the drill.

In many materials, the point will also act as a chip breaker to produce small chips, which can be ejected more efficiently through the flutes.

This is a distinct advantage in most applications, but especially when portable drilling or in a drill press where bushings cannot be used.

round tools and indexables available.

The Dormer brand of round tools provides options for milling, drilling and threading.

Summary Both round tools and indexable tools have their own distinct advantages based on material, operation and user requirements.

Each one continues to see ongoing developments and improvements, including new geometries, coatings, substrates and manufacturing processes, such as edge preparations, surface finishing and other treatments.

As cutting tools, they present a collective offer to end-users by providing an overlap in diameters and applications, so that tooling engineers can assess and advise where and when it is appropriate to apply each. Dormer Pramet has a range of support services, including printed publications, an E-shop and product selector tool, as well as face-to-face advice, to help make choosing the right cutting tool simple. www.dormerpramet.com

Big on… CHOICE, QUALITY & VALUE Dealing with 600MachineTools means you aren't limited to a single brand, style or build of the machine tool you are looking for. We are focussed on meeting your needs, so have assembled the best selection of quality brands that meet the requirements of today's fast paced industrial economy.

From CNC machining centres and lathes, mills, bandsaws, drilling machines, chucks and lasers we also have the experience and credibility to assist you in selection and support over the lifetime of your purchase!

Contact us today for a NO OBLIGATION assessment of your requirements.

SYDNEY BRISBANE Phone: 02 9674 4738 Phone: 07 3277 4844 Email: machines@600machinery.com.au Email: qldbch@600machinery.com.au Website: www.600machinery.com.au

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Cutting Tools

Advanced software and tools for rough milling

Manufacturers never stop seeking ways to increase the speed, quality and cost-efficiency of their machining operations. To fill that demand, suppliers of machine tools, CAM software and tooling must continually develop new products and application strategies. By Teun van Asten, Engineer Marketing Services Solid Milling, Seco Tools.

Combined products and strategies address specific machining situations to provide the highest productivity. Current progress in rough milling operations, for instance, clearly illustrates the benefits of applying advanced metalworking technologies in an integrated way.

Elements of the process The machine tool is the foundation of the milling process. To rough mill effectively, a machine must possess enough rigidity to resist cutting forces, as well as the capability to accelerate and decelerate axes at rates that maximise metal removal and minimise wasted time between cutting passes.

Also, a powerful spindle facilitates high cutting speeds and aggressive application parameters. And finally, a machine’s CNC system must have computing power to sufficiently look ahead and meet rapidly changing demands for machining power and movement of linear and rotary axes.

CAM software determines what those demands will be. In generating milling toolpaths, software developers must consider milling processes ranging from simple to complex. A fundamental milling operation is side milling, in which an end mill engages a workpiece with the side of the tool at certain axial (ap) and radial (ae) depths of cut. A simple side milling operation involves minimal change in the tool’s radial engagement, or arc of contact, during each pass. Consequently, an operator can adjust the arc of contact to take full advantage of productive end mill design features, including multiple flutes and thick reinforced cores. Increasing the number of flutes permits higher feed rates and strong tool cores resist heavy machining loads.

Slot milling, however, poses a different situation. In slot milling, the full diameter of the end mill is engaged in the cut, creating a 180-degree arc of contact. The load on the cutter is much greater than that generated in side milling, and chips are more difficult to clear, which means they may be recut and eventually jam the cutter and break it.

Milling workpiece materials with poor thermal conductivity such as stainless steel, titanium and nickel-base alloys exaggerate the problem, concentrating heat in the cutting tool and accelerating tool failure.

As a result, it may be impossible to utilise the tool’s full axial depth of cut capability.

AMT Dec 2016/Jan 2017

Completing a part will require multiple steps at increasing axial depths that will lengthen the machining time. Slot milling typically also requires the use of reduced cutting speeds and feed rates, further diminishing productivity.

milling a concave feature, the tool’s arc of contact grows, increasing loads on it and the machine tool. The converse is true when milling a convex feature; arc of contact decreases and cutting efficiency suffers.

Advanced CAM software facilitates producing slots by enabling users to carry out complex cutting strategies such as trochoidal cutting. In a trochoidal toolpath, the software guides a tool of a smaller diameter than the desired slot in repeated circular movements in the X and Y axes.

Radial engagement of the tool is less than half its diameter, and the circular toolpath effectively changes slot milling into side milling. The tool’s arc of contact is greatly reduced, thus enabling the use of multi-flute end mills and longer axial lengths of cut to increase metal removal rates and reduce cycle times.

Software suppliers have developed and refined toolpath algorithms that control tool engagement in real time, enabling highly productive and reliable roughing of both simple and complex contours. These toolpaths typically combine large axial depths of cut (ap) with small radial depths of cut (ae), high feeds per tooth (fz) and high cutting speeds (vc) that significantly shorten cutting times and increase metal removal rates. In addition to providing greater productivity, these advanced roughing strategies feature smooth cutting paths without rapid changes in direction or cutting parameters, thus reducing the load on the tool to greatly improve tool life.

Between the extremes of simple side milling and full-engagement slotting are milling operations that involve machining of varying concave and convex contours.

These situations are increasingly common as end-user part requirements become more complex, magnifying the need to efficiently cope with changing contours as well. The key issue is control of the tool’s arc of contact with the workpiece. When

The latest software strategies for rough milling toolpaths take two basic approaches.

One approach applies the tool at a constant feed rate and arc of contact when milling a concave or convex part feature and varies the step over between passes to achieve maximum metal removal rates. The second approach maintains a constant step over but varies the feed rate and the tool’s arc of contact, with the intent of maintaining

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Cutting Tools

constant chip thickness. In the second approach, the tool’s arc of contact can be as large as 80 degrees or even 140 degrees, depending on the brand of software in use.

Tools for advanced roughing The differences in the two roughing approaches dictate application of different tool designs. In many cases, the first approach permits the use of cutting tools with multiple flutes and double/reinforced cores where desired. And, users can employ high ratios of axial to radial depth of cut.

The second approach can potentially remove metal at a greater rate, but cutting tools must be able to evacuate greater volumes of chips. Tools engineered for use with the second approach typically feature fewer flutes and have open core designs that promote chip flow or are applied with defined flute cavity shapes (high performance tooling).

In general, tools designed for large depths and widths of cut and heavy loads will be effective in either approach. In the second approach, however, multi-flute tools and tools with reinforced core designs will face chip control problems when encountering large arcs of contact given large axial depths. Usable ratios of axial depth of cut to radial depth of cut are more limited.

In some applications, adding certain tool geometry features will enhance tool performance. For example, Seco added chip splitters to the cutting edges of its Jabro JS554-3C end mills. These chip splitters are a series of small notches or grooves on the flutes spaced at a distance of one times the tool diameter.

Regardless of the axial depth of cut, the chip splitters break the chips before they become long enough to interfere with smooth evacuation flow. As a result, the end mills can operate at axial depths of cut up to 3.5 or four times tool diameter. Applied with advanced roughing CAM software programs, these tools can reduce cycle times with 60% to 70% as compared with traditional methods. This cycle time saving is due to both higher metal removal rates as well as more efficient toolpath cycles.

In tools designed for use in the second advanced roughing approach – which employs varying arcs of contact and feed

rates – different geometry details are required for top performance. The tools must allow adequate room for chips to form and evacuate. An example is Seco’s Jabro JS554-2C end mill, which features a core that tapers from front to back – a design that provides more space in the flute cavities for chip flow. Tapering the core does somewhat reduce tool strength, and as a result the tools are not suited for full-diameter slotting. While on the other hand, the end mills feature modified tips that increase performance applying helical interpolation ramping. This selection of tools, for instance, can rough mill at up to 2.5 times tool diameter.

Advanced roughing software, used with tools engineered to maximise its benefits, boosts stock removal per each milling pass and results in faster cycle times. A case in point is a mould/die application that involved machining of an aluminium motorcycle engine cover. A manufacturer sought to reduce the 15-hour cycle time of the operation when it was performed with a high-feed roughing approach alone.

article. By combining shallow depths of cut with high feeds per tooth, high-feed milling methods direct cutting forces axially into the machine spindle to help stabilise the machining process.

Different application strategies suit other manufacturing situations. In some cases, high-speed machining, which focuses on light passes at high spindle speeds and feed rates, or high performance machining that employs conventional feeds and speeds in combination with very high axial and radial depths of cut, will be the best choice.

In all examples, combining advanced milling strategies and software with tools engineered for maximum performance at those parameters will produce optimum results in terms of metal removal rates, tool life and cost efficiency. www.secotools.com

To improve the process, a Seco Jabro JS554-3C cutter was applied using advanced roughing software that maintained a steady arc of contact by varying step over. The method permitted the bulk of the roughing to be accomplished in a little over 2.5 hours. Sufficient material was removed so that a following high-feed roughing operation required only four hours to complete. Overall, roughing time was reduced by 55%.

Conclusion As in any machining operation, specific tools and strategies should be applied with all aspects of the manufacturing situation in mind. For example, when tool cutting length exceeds four times tool diameter or when tools are applied with long overhangs or on unstable machines or workpieces, high-feed milling is possibly a better alternative to the advanced roughing approaches described in this

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How effective professional development builds great companies

According to one of the many books about the Japanese car-making giant, a common expression heard around Toyota is “We do not just build cars, we build people”. It sounds nice, but what does it practically mean? By Tim McLean of TXM Lean Solutions.

I had the good fortune to start my career in a major global corporation. In my case, it wasn’t Toyota, but the German chemical giant Hoechst AG. When I look around the TXM team, I see successful professionals who all started their careers with leading global companies such as Boeing, Ford, Autoliv, Toyota and GM. So what is it that makes the really great companies so successful?

What enables them to grow and grow? The answer, of course, is their people.

A few years ago I saw a speech by John P Duddy, the President of Boeing Aerostructures Australia. One statement he made particularly caught my attention. He was coming to the end of his tenure in Australia, but stated that this change would not affect the business as his replacement would be “another Boeing person”.

What he meant (or what I took him to mean) is that his replacement would be someone who had been developed through the Boeing system, who was steeped in the Boeing values and aligned with the Boeing vision and strategy. Of course the new person would bring their own personal style, strengths and weaknesses, but they would still manage the business in a “Boeing way”.

Often I see companies pulled from one direction to another as external appointment after external appointment gets recruited to key roles and then moved on to be replaced by another external appointment.

So how are companies like Boeing and Toyota able to find leaders who can lead the various parts of their business in a consistent way?

The answer is that these companies consciously work to develop leaders at all levels of their business. They pride themselves on offering a career path for employees from graduation to the C-suite.

whom I recognised leadership potential and provided with development and educational opportunities. This started him on a 20-year path to senior operational leadership.

• Projects are an opportunity to develop people. When I reflect on my time at Hoechst, the business trusted me with key projects from very early in my career. Initially this was assigning me to a Total Quality Management team that fired my lifelong interest in Lean and Continuous Improvement.

As I successfully took on and completed projects, I was then trusted with larger and more challenging project opportunities.

It was never sink or swim though. Even though I was leading projects, there was always an experienced mentor I could call on for support if things got difficult.

So what are the elements of good professional development?

Drawing on my own experience and the experiences of the talented people around me at TXM, the following are the key elements of a successful professional development program that will provide the leaders your business will need for the future: • Assessment of individual talent. “One size fits all” is definitely not the basis of a successful professional development program for leaders. Many companies offer standardised graduate programs, but the reality is that this can be highly frustrating for your most talented individuals.

They will be looking to do real work and make a real difference straight away rather than spending a year or two rotating around departments to “find their feet”. Therefore, you need to understand the strengths, weaknesses, talents and personal goals of the individuals you have and tailor their individual development accordingly.

• Mentors are important. Throughout my career, key individuals (usually but not always my manager) provided me personal mentoring and coaching. This extended beyond technical skills to coaching me how to improve my listening skills, deal effectively with difficult individuals, and cope with stress. In highly successful companies the task of developing future leaders is seen as the most important work of existing leaders. It is also perhaps the most satisfying part of leadership. The LinkedIn recommendation I am personally proudest of is from a former process operator in

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When you have a big project such as a capital project, new IT system, your Lean project, a business restructuring or an acquisition, don’t just go to the “usual suspects”. Look at your management talent pool and ask: who is ready to lead this? Who will really benefit from this opportunity? Make sure that the “old hands” are around to support the person you appoint. This process also can provide a double development opportunity as you “backfill” roles temporarily vacated with other high-potential leaders. If you just give these projects to the usual experienced “trouble-shooters” you potentially will waste the best development opportunities you have.

• Support the people you promote. Another very common mistake I see made is how companies ruin the careers of their best people by promoting them and not supporting them. This can be compounded by egotistical individuals who refuse the support offered. At every step in my career with Hoechst there was support and guidance offered to help me on the way. I remember my first, highly unsuccessful encounter with the Union Shop Steward. I was forced to back down on disciplining an individual who thoroughly deserved the disciplinary warning I had given. Rather than being performance-counselled, I was able to sit down with one of my much more experienced peers, talk through the issue, agree how it could have been handled better and plan how to manage it next time.

When you promote someone, you have a personal investment in their success; therefore as a leader you must do everything you can to ensure that success. “Sink or Swim” too often leads to the costly loss of good talent, and that is neither good for you, the business or the individual involved.

Business managament • Education must be targeted. I frequently come across companies who identify weakness in their management or front-line leadership ranks. The solution? Put everyone on a management training course.

Some level of generic skills training is useful. For example, you want to ensure that your management all receive the same message about safety, corruption or appropriate behaviour towards employees. However, education around leadership and career development must be targeted to the individual.

Education that is targeted to the individual’s particular needs and interests will often be seen as a reward, whereas forcing everyone to go on the same course will often be seen as a chore and can actually be resented. I have found that for middle and senior leaders, one-on-one coaching with an experienced coach or consultant can be far more effective than a leadership training course. This is because it allows coaching in action around the actual strengths and weaknesses of the individual.

• Line leaders have the primary responsibility for the professional development of their people. Many big companies now have Talent Development functions dedicated to the identification and development of high-potential staff.

However, the role of these functions is intended to be crossdepartmental and operate across geographies. They do not replace the need for every leader at every level in every function to see developing their people as one of their most important jobs. The best “executive coaches” I ever had were also my best bosses. Every leader in your business should be assessed on how well they develop their team as well as their direct contribution to business performance.

• Professional development is never 100% successful.

A reason that many companies give for failing to actively develop their talented people is that “they will just leave”.

Others will point to examples of people who “failed”. The reality is that a level of natural attrition is inevitable in any organisation and some of the people you invest in will leave and take all those skills elsewhere. That can be very frustrating. However, the problem with not developing people is that you almost guarantee that your best talent will leave, and you will be left with the people who don’t want to be developed and probably have little or no potential as future leaders. Therefore, invest in development and accept that a proportion of people will leave.

However also expect that more and more of your best staff will see the development pathway you offer and look to emulate those who have grown their careers within your business.

The bottom line Every time your business expands, opens a new site or acquires a new business, you need to ensure that the things that made your business great at the start – your unique culture and competitive advantages – get transferred in to these new operations. The way to do this is to appoint leaders steeped in your culture and way of doing things to run these new operations. This kind of leader must be developed from within. The more you grow the more leaders you will need. Therefore, you must have a means of developing these leaders. This means that effective professional development is a prerequisite for the profitable growth of your business.

Tim McLean is the Managing Director of Lean consultants TXM Lean Solutions. With a 30-year manufacturing career, he is the author of ‘Grow Your Factory, Grow Your Profits: Lean for Small and Medium-Sized Manufacturing Enterprises’, published in 2014

by US publisher Productivity Press. His new book ‘On Time, In Full: Achieving Perfect Delivery with Lean Thinking in Purchasing, Supply Chain and Production Planning’ is due for release in April 2017. www.txm.com.au

Focusing on opportunities

The Smithfield-Wetherill Park Industrial Estate in Sydney’s West has long been renowned as the biggest engineering and manufacturing precinct in the Southern Hemisphere, housing more than 1,000 companies with over 20,000 employees.

Based inside the estate is a unique not-for-profit organisation focused on stimulating business growth and employment opportunities. The Cumberland Business Chamber was created 29 years ago by local business owners, and like other chambers across the city, as it grew it absorbed people from all walks of life. The big change came in 2014 when the Chamber decided to focus solely on the industrial sector.

“The engineering and manufacturing markets have been shrinking and they receive little direction or confidence from what goes on in Government, despite their rhetoric,” said President Craig Hingston. “To remain competitive there is a need to embrace technological change and to diversify and consider foreign markets, and whist many companies want to grow, they don’t know how to transition. With so many industrial employers right at our doorstep we decided we would just focus on one area.

Two years later we’re seeing the fruit of our decision.”

Based on research and surveying of local companies, the Chamber developed a foundation of Four Pillars: Leadership, Knowledge, Connections and Inspiration.

“We represent the business community to Councils and Government on a wide range of issues from illegal dumping of asbestos to the lack of adequate infrastructure for road transport and the future need for road and rail links to connect the region with Western Sydney Airport,” says Hingston.

“We run workshops and evening networking events where we present practical information that our members can immediately apply to their businesses. For example, we have looked at emerging technology and its impact on manufacturing, understanding the real meaning of innovation, 3D printing, product development and commercialising ideas, staying competitive in a changing world, optimising warehouse space, disruptive technology, and the ATO’s R&D grant.”

Cumberland Business Chamber has announced collaboration projects with industry (RoadFreight NSW), education (TAFE), mentoring of young people entering the workforce (Holroyd Rotary), and research into sustainability in production (Macquarie University).

“We’re very much feet on the ground,” Hingston adds. “We constantly talk to local industry to see how they are going and we attend manufacturing forums and conferences to get the big picture. The Chamber has created a positive, informal environment where like-minded industrial business leaders motivate and encourage each other. This is just as important as gaining new knowledge. It is always encouraging to see them form their own relationships and go off to do business together.” www.cbchamber.com.au

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Annualised salary arrangements and compliance with modern awards Does paying an employee an annualised salary satisfy the employer’s obligations under a modern award?

By Jeremy Cousins.

It is common for employers to pay their employees an annualised salary on the assumption that doing so will satisfy the employer’s obligations under any applicable modern award. A recent decision of the Western Australian Industrial Relations Commission (WAIRC) casts doubt over this approach, particularly for administrative or clerical employees covered by the Clerks - Private Sector Award 2010 (Clerks Award) who are not provided with a properly tailored employment contract.

Employers paying their administrative or clerical employees pursuant to an annualised salary arrangement should consider reviewing the terms of their employees’ contracts of employment in order to remove, or reduce, the risk of back-pay claims and to avoid potential civil penalties under the Fair Work Act 2009.

The issue The Clerks Award states that an employer may pay an employee an annual salary in satisfaction of any or all of the following entitlements under the award: (a) minimum wages; (b) allowances; (c) overtime and penalty rates; and (d) annual leave loading. The actual salary paid must be no less than the employee would be entitled to if they were paid effectively on an hour-by-hour basis under the award. The award also states that the employer must “advise the employee in writing of the annual salary that is payable and which of the provisions of [the] award will be satisfied by payment of the annual salary” [at clause 17.2].

In the recent decision of Stewart v Next Residential Pty Ltd [2016] WAIRC 00756 (Stewart case) the WAIRC was required to consider whether an employer could rely on the payment of a $78,000 annual salary to an employee covered by the Clerks Award to discharge its obligation under the award to pay overtime to the employee (for working through her lunch break and at other times). The annual salary was considerably higher than the minimum rates of pay under the award for working standard hours. The employer had failed to provide the employee with a contract of employment which notified the employee about which provisions of the Clerks Award were said to be satisfied by the annualised salary (in breach of clause 17.2 of the Clerks Award). The employee claimed $28,894 in overtime pay, in excess of the $78,000 annual salary already paid to her.

The employee’s contract of employment referred to an annualised salary and stated that” “Your salary is inclusive of any award provisions/entitlements that may be payable under an award”.

However, the contract did not refer to clause 17 of the Clerks Award, as was necessary in this case because of the type of work performed by the employee.

The WAIRC was required to determine a preliminary issue of whether or not the employee’s contract of employment excluded the employee’s claim to overtime.

The outcome The WAIRC found that the employee’s contract of employment did not prevent her from pursuing her claim to overtime pay. This was because the contract did not clearly indicate that the employee’s annual salary included the entitlements she sought to recover.

The WAIRC said: “For administrative ease, it is common for employers to pay an ‘all-inclusive rate’ which is intended to compensate the employee for all award entitlements in relation to their work, which may include minimum wages, overtime penalty rates and leave loading. It is imperative that such intention be clearly

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articulated in the employment contract because an employer will be unable to meet its award obligations by offsetting award obligations against over-award payments, unless there is specific agreement with the employee about what the over award payments are compensating the employee for.

“The need for specificity is recognised by cl 17(1)(b) of the Award which requires the identification of the specific provisions of the award that will be satisfied by the payment of the annual salary. If a payment is made to satisfy a particular award obligation such as ordinary hours of work, then the excess cannot be set off against a different award obligation such as overtime unless the contract of employment clearly indicates that the excess is paid to satisfy any entitlement to overtime. The requirement for specificity is aimed at removing any doubt about what the annualised payment is for.”

The WAIRC noted that the employee’s contract of employment “lacked the type of specificity” required by the award. The WAIRC’s decision confirmed that the employee could pursue her underpayment claim.

The impact Employers should review their relevant modern awards and contracts of employment used in connection with annualised salary arrangements. However, while many employers are likely to have some employees covered by the Clerks Award and therefore could be affected by the Stewart case, not all awards contain the same requirement to notify employees about award entitlements which the employer seeks to satisfy by payment of an annualised salary.

The Clerks Award is very specific in this regard.

Furthermore, the WAIRC’s decision in the Stewart case is not binding on other courts and it may ultimately be found to contradict earlier case authority to the extent that it indicates an employer may not be able to set-off the annual salary against other award entitlements.

An employer will commit a breach of the notification requirements in clause 17.2 of the Clerks Award where the required information is not provided to a relevant employee. This could lead to civil penalties being imposed. However, it may ultimately be found that where an employer fails to comply with the notification requirements, the employer is still able to apply the annualised salary to set-off any entitlements under the award to overtime and penalties etc. where the annual salary is in excess of the basic award rates of pay and intended to be in satisfaction of all entitlements, even where this is not specifically expressed. However, this would be a risky and uncertain approach given recent cases. Employers should simply ensure that their employment contracts comply with the Clerks Award and are properly effective to discharge the relevant award obligations.

When checking and updating contracts of employment, it is important that employers ensure the relevant modern awards are properly identified and any annualised salary clauses are taken into account, and where necessary, referred to in (but not incorporated into) the contract.

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

Business managament

Efic app helps Australian SMEs on their export journey

Efic and the Export Council of Australia (ECA) have joined forces to launch a first-of-its-kind export-focused app.

The Export Essentials app has been designed with new and growing exporters in mind, with a focus on small and medium businesses.

“Both Efic and the ECA are focused on helping Australian SMEs achieve export success,” says Andrew Watson, Executive Director, Export Finance at Efic. “With that in mind, we developed an app with need-to-know information at their fingertips. Export Essentials will help Australian businesses take the right steps on their export journey.”

The application is filling the export information gap for Australian SMEs, providing key details often overlooked by businesses when planning to export. From checklists and calculators, to understanding how to manage currency risk, Export Essentials will continue to be updated on a regular basis to provide businesses with the help they need to develop export strategies and opportunities.

“Exporting can be a complicated business, especially when you’re new to the process or entering a new export market,” says Watson.

“The Export Essentials app is designed to empower new and less experienced SME exporters with the tools and information they need to achieve their export goals.

“We encourage new exporters to seek professional advice when starting their export journey. It’s important to understand the steps and risks, and critical to get help from the experts – the likes of Austrade, ECA, and legal and accounting professionals.”

Former Federal Minister for Small Business Bruce Bilson says the evolution from an Australian SME to an exporting SME can be daunting: “There are so many questions that a SME needs to ask itself when planning to export, or enter a new export market. Export Essentials is a resource that provides useful, practical and actionable information and supports SMEs to get their ambitions underway. There is nothing else like it.”

To download the free Export Essentials app, visit the Apple or Android app store and search for ‘Export Essentials’. www.efic.gov.au

Running payroll in-house – do the costs warrant outsourcing?

Does your business have an accurate insight into the true cost of running payroll in-house? By Rashesh Parikh.

Many companies fail to adequately prepare for the burden of payroll and HR expenses due to an unrealistic underestimate of the actual costs. Payroll, in general, is considered a fixed cost to a business and easily forgotten. While the most obvious payroll expenses, such as processing staff and their salaries as well as technology acquisition, are identified, the hidden and indirect costs can make up a significant portion of the total operating expenditure. This is enhanced further if you had multi-country operations requiring local regional expertise.

When considering the true cost of payroll within your organisation, you need to be aware of all possible expenses your business could face. Below are six examples of costs that are typically forgotten or could come as a surprise: 1. Indirect labour costs. Cost of labour for employees not directly related to payroll, but support the payroll function through collecting, approving and preparing payroll data e.g. manual rostering and timesheets.

2. Audits and internal controls. A required expense to ensure payroll function remains compliant with local legislation.

3. Multi-country jurisdictions. If your company operates across different countries within the APAC region, you will find certain jurisdictions are required to pay for tax and insurance lodgements.

4. Integration costs. Costs related to integration of different systems that require manual intervention or technological integration, resulting in additional costs.

5. Technology costs. A lapse in technology and software upgrades could incur additional unintentional costs – through inefficiencies and potential penalties for non-compliance.

6. Business continuity and disaster recovery. Have you allowed for the costs of a service interruption to your payroll system, or built in corporate-class business continuity and disaster recovery?

When your business does a true and fair analysis of in-house payroll costs, it provides you with a framework for comparison. The choice would be to either absorb these costs or to find ways these can be reduced through consolidation of technology or finding a payroll outsourcing partner who can assist with reducing head-count costs and multi-country compliance risks.

For an important function like payroll, there are other factors to be considered apart from costs. However one thing is for sure – you are unlikely to explore efficient ways to manage costs unless you have a true measure of these costs.

Rashesh (Raj) Parikh is a Payroll Regional Sales Specialist at Ascender HCM. Ascender specialises in payroll solutions in ANZ/APAC and currently pays more than one million employees through its systems. www.ascenderhcm.com

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No man is an island – How building an omni-channel experience boosts customer experience

Manufacturing in Australia is poised for its own digital evolution – and it’s a business imperative to get on the front foot now. Stuart O’Neill, Head of Business at SAP Hybris Australia and New Zealand, explains why the industry can no longer afford to lag behind in building omni-channel experiences and how learnings from abroad can inform the local market.

Australia is an island nation and it informs the way we see ourselves: remote, parochial and protected from global changes that threaten the status quo. However, in a digitally connected world, we are no longer sheltered from economic market forces. While digital disruption is nothing new, until now manufacturing has been relatively untouched by its presence. But as B2C experiences groom customers to expect ease of use and seamless transactions, B2B organisations can no longer afford to trail their retail counterparts in the experience stakes.

This will be a huge change for the industry. Luckily for Australia, we have an opportunity other markets are seldom afforded. We have a window into the industry of tomorrow, leaning on the experiences of the US and Europe. In the US, digital effectively disrupted the entire market dynamic of the manufacturing and B2B space. Businesses that had dominated the landscape for 30 or 40 years no longer exist and new players who had a digital strategy from inception have been able to embed themselves. Fast, smart movers who saw the tide turning adapted and pivoted to the change, weathering the transition.

The key outtake is that manufacturing businesses need to be cognisant of this move to the consumer and seize the opportunity rather than bracing against change – or worse, ignoring it. In addition to their traditional reseller links, there is a huge aftermarket consumer base that needs to be viewed as part of an omni-channel business instead of a separate, or lesser silo. A Forrester study commissioned by SAP Hybris, Building the B2B Omni-Channel Commerce Platform of the Future, found that more than half of global B2B buyers plan to make 50% of their purchases online in three years. Importantly for manufacturers, these buyers expect that experience to match retail offerings. This means building easyto-use shopping experiences with real-time service and response, intuitive options for recurring orders and online accounts to allow customers to view their order history and status.

The digital age has also meant the barriers to entry for competitor organisations are long gone. Businesses like Amazon can be hugely competitive without traditionally cost-prohibitive expenses such as warehouses and thousands of regionally-based staff. A website and a supply chain is all that is needed to produce a commercially competitive business.

Unfortunately, our experience is the vast majority of manufacturing businesses in Australia are ill-prepared for the scale of change at their doorsteps.

For some, fears of channel conflict and impacts on reseller agreements are the reason they’re reticent to change; a problem addressed in overseas markets with private portals for reseller partners. But many more still believe in the mythology of Australia as an island, and fail to see the imperative to move quickly and adapt their businesses.

Even when they do, they often find themselves confronted with a technical challenge. PwC’s 18th Annual Global CEO Survey found that 58% of CEOs expressed anxiety about keeping pace with technology change. Businesses that don’t fully comprehend the scale of the transformation believe placing a directory or product

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information on a website is enough to count as a digital strategy. Even fewer businesses have a full-scale omni-channel strategy that places customer experiences at the centre of their business.

A customer experience strategy needs the ability to share data and analytics between department channels, countries and locations, meaning for most manufacturers there is a process gap to address. Legacy systems, built along a linear supply chain, need to be updated to give rise to personalised strategies.

So how can manufacturers at the start of the journey get moving?

If the first step is to get online, then the second step is to invest in the process. While cheaper options can be tempting when it comes to building that initial digital footprint, it’s important businesses invest for priorities in the mid-term and not just tomorrow. Instead, knowing from the outset that building an intuitive, customer-centric website is going to be a sunken cost in the short term can help a business justify the expense, and build a robust system that will last.

It’s also important to ensure any digital footprint is easy for stakeholders to navigate and the basics are set up properly. The system needs to be intuitive and simplistic to use with functions including search capabilities, mobile-optimisation, several payment options and ‘search and trace’ for products purchased. There should be the ability to capture customer data and analytics across the chain to ensure when buyers browse online, in store or on social media, and that a single customer view is maintained.

Further, building a 360-degree perspective of each customer helps businesses intelligently up-sell and cross-sell.

It is big process, often taking more than 18 months from beginning to end. But having an integrated software platform allowing transaction data to follow seamlessly between commerce, customer relationship management, enterprise resource planning and manufacturing applications is a necessity for modern business. It is also important to bring employees along on the journey of transformation through upskilling, additional digital hires, and engaging staff. While the systems underpinning customer experience are important, technology is only as good as the people using it.

The results can be staggering for businesses that get it right. SAP Hybris client Rheem implemented a cloud-for-customer system in 2015 despite its core business being manufacturing and sales, after recognising it had become a first point of customer contact for the products it built. This resulted in an average of 10-15% saving in call times and improved customer satisfaction.

Manufacturing is embarking on a new era with the customer at its core and the options are to either sell out, move out or move up.

For adaptive businesses it creates a huge opportunity; one of not just survival, but growth too. www.hybris.com

Business managament

Unearthing the hidden costs of offshore manufacturing

Offshore manufacturing has become a popular strategy for many Australian operators but hidden costs can make for an expensive move, warns commercial law firm Cowell Clarke.

“Many local manufacturers have taken advantage of cheaper overseas production costs in the hunt for greater efficiencies and profits,” says Brett Cowell, Chairman of Partners at Cowell Clarke.

“While the practice has become commonplace, that doesn’t mean it’s simple. Done right, it can be a very astute move and help open up new sales networks into global markets. However, offshore manufacturing is not the silver bullet for every Australian operator under cost pressure.”

Through its membership of ALFA International, the global legal network Cowell Clarke utilises its local relationships worldwide to support Australian businesses transacting and operating in foreign countries. Cowell said for some companies, cheaper base production costs in offshore manufacturing may be offset by a number of unexpected expenses.

“Difficulties in communication, blow-outs in set up costs, additional ‘political’ or administrative requirements and large minimum quantity demands can add significantly to the cost of offshore production,” adds Cowell. “Offshore manufacturing can also expose the company to greater intellectual property (IP) theft risk and quality control inconsistencies. In some cases, when you crunch the numbers, the company may have been better off remaining on home soil.”

Based on experiences of its clients, Cowell Clarke has produced a list of the top ten behaviours of successful offshore manufacturers.

1. Shop around “Establish a relationship with an offshore manufacturer using a similar process, but a higher level of caution, as you would use to build a relationship with any local supplier,” Cowell advises. “It pays to research the right partner that will deliver to your requirements, support your goals and protect your business interests. Don’t just default to the first manufacturer that shows interest or the manufacturer someone you met in the pub said was good.”

2. Seek out inbuilt expertise and experience “If your offshore partner manufactures products similar to your own, it will already have a level of in-built expertise and experience, implying fewer growing pains in adapting to your manufacturing requirements. The downside risk may be that they are better able to knock off your IP so protect your IP as best you can.”

3. Retain tight quality checks.

“You will have your own expectations and specifications for your product outcomes; the finish, the workmanship, the precision.

Hands-on checking of samples and products made by the manufacturer is important in determining if the quality meets your standards. In general, the greater level of control and interaction you need, the higher the cost is likely to be.”

4. Social proof “Speak with other customers who use this manufacturer to find out what it’s like to work with them. Read as many reviews and recommendations as you can. Who else do they work with that gives you confidence in using them too? The manufacturer won’t give you the contact details for a customer that had problems so you may need to do your due diligence.”

5. Protect your design and ideas “Think about how you should protect IP before you enter the relationship or even before you start talking. Confidentiality agreements are essential but bear in mind you need to find out about a breach before you can enforce the terms. You may also need to deal with a legal system that is not as helpful to your cause as you would like. Patent, design and trademark registration is important, as is consideration over how you will protect any trade secrets. In any manufacturing contract, make sure that these are protected, as well as any IP developed as a result of working together.”

6. Be aware of pricing inclusions and exclusions “Be across production of samples, including the cost, before proceeding with full run production. The cost implications of additional product refinements and minimum run quantities can erode margins. Look beyond manufacturing costs towards inmarket delivery. It’s obvious but the cost of getting your product to market can be significant.”

7. Keep in close communication “You’ll need to work closely with your manufacturer for new stock orders, lead times, product quality issues and delivery. A comfortable two-way communication channel that is responsive and timely is vital.”

8. Understand cost of time “Production lead times can make or break a business or product launch, impacting cash flows, customer relationships and reputation and giving competitors an edge. Be clear on best case and worst case scenarios and plan your marketing and management around this.”

9. Contract the right business “Make sure that you are entering a contract with a proper foreign entity and you have measures in place to protect your interests. ‘Off the shelf’ or ‘Off the Internet’ contracts are rarely the right choice.

You want a contract that properly addresses the terms important for making the relationship work well.”

10. Be prepared for problems.

“Whether working across borders or within your domestic environment, product liability and warranty needs to be addressed in your contract and via insurance policies. Indemnity provisions are common, so consult with an experienced lawyer to ensure that you get this right. Also think about how you will address potential contract infringement, where will a dispute be decided and whose law and language will apply. People often think these terms are just the agreement boilerplate clauses but they can have a major tactical impact in the Brett Cowell, event of a dispute.” www.cowellclarke.com.au

Chairman of Partners at Cowell Clarke.

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Company Focus

Romar Engineering – Prospering through partnership

Having transitioned successfully from automotive tooling into medical devices, Romar Engineering has shown its ability to diversify over the years. Its latest venture sees it partnering with CSIRO in the brave new world of additive manufacturing. By William Poole.

Romar was founded in 1968 by Robert Wilson, the company’s name a combination of his own name and his wife Marion. Robert began operations out of his own garage, before moving to a facility in Sefton in Sydney’s western suburbs. After a few years, Robert’s son Neil Wilson joined the company, and today he remains Romar’s Managing Director and owner, with Mathew Farag coming on board as CEO around three years ago.

In the early days, the company’s business was based around providing tooling for the car manufacturing industry, but around 15 years ago it began to diversify into medical devices, initially producing silicone masks for Resmed. Today Romar is predominantly engaged in the medical sector, though it also works in several other hightech industries, such as aerospace, lighting and electronics. While it still operates from the same facility in Sefton, it has spread to four other sites on the same street as well as a micromoulding facility in Singapore, with around 40 members of staff.

“We’re now what I call a manufacturing solutions provider,” says Farag. “We’ll do the whole gamut, from tooling and design, to the actual manufacturing of the individual components, (and sourcing of things we don’t do here such as PCBs), to assembly of products, and the final packaging, whether it be ready for sterilisation or for general sale.”

The early shift out of automotive seems like an astute bit of business now given the subsequent fate of the car industry, but the move into medical wasn’t all plain sailing. US pharmaceutical giant Eli Lilly was a major customer until around two years ago, when the product Romar was involved in was withdrawn from the US market, taking away a big chunk of the company’s revenue.

“In the last two years we’ve been trying to replace that business, and we’re coming close now to realising that,” says Farag. “We spent about $2m in R&D last financial year, and that was essentially to replace that Lilly business with new business. And it’s starting to kick over, we’re turning it back around.”

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Another challenge arising from the move into medical was the higher demands set by the client. Farag explains that, while automotive customers knew exactly what they wanted and could dictate clear specifications, in the medical sector there are higher expectations for suppliers to contribute expertise and help devise solutions.

“That’s where I think we have an advantage over other suppliers,” he adds. “We not only do manufacturing and assembly, but we do the tooling internally, which gives us a lot of control over how we manufacture the parts. From the very beginning of the concept stage, we know how we’re going to make the tool to meet the medical requirements down the track. It makes a pretty big difference with the product at the end of the day.”

Romar’s success in being able to make this transition is attributable in part to the company’s emphasis on R&D and retaining skilled staff.

“I think personally manufacturing in Australia is heading this way,” says Farag. “We have more engineers on staff than actual production workers, and R&D to keep them occupied, that’s what’s creating our future business. We had about 60 staff when we were manufacturing for Lilly, and that represented about 70% of our business at the time.

When that disappeared we didn’t lose 70% of our staff, we only lost 10-20 staff, predominantly casuals. The rest were all engineers who stayed on so that we can continue development of the work and products that we’d started to get those across the line.

Today the company’s customer base includes a number of innovative medical companies. It’s working with Melbourne-based Planet Innovation, the designers of an IVF product for Genea. It’s engaged in R&D work for Vaxxas, who invented a patch for vaccination and vaccine delivery solutions, and supplies parts for global medical devices manufacturer Cook Medical.

This client base also shows the scope of what Romar can offer as a supplier. With Cook for example, the company only manufacturers a single part, a silicon bung used in a much larger assembly (albeit manufactured to the most exacting quality and cleanliness

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criteria). For the Genea product, on the other hand, Romar’s input encompasses more than just individual components, but an entire, end-to-end process covering manufacture and assembly, quality checking and packaging for sterilisation, right through to final packaging.

“Customers in medical, particularly inventors or innovators, they say ‘I’ve got this invention but I don’t know how to make it. We’ve got the designs for it, we’ve been to industrial designers and they’ve done all the drawings and everything is there. We know what has to be made, but we don’t know how to make it and how to assemble it.’ This is why I say we’re a manufacturing solutions provider. We can provide them with that information.”

Adding capabilities Announced in September, Romar’s newest venture is a partnership with Lab 22, the CSIRO’s additive manufacturing centre. The collaboration is built around Romar’s recent acquisition of a LASTERTEC 65 3D from DMG MORI. The first of its kind to be installed in Australia, the LASTERTEC is a hybrid machine that incorporates additive laser deposition welding into a fully-equipped five-axis milling machine.

“Essentially, you can do your additive manufacturing, print your metal, and also machine it,” says Farag. “And it’s so much faster.

Additive printing from a bed is wasteful and takes a long time, whereas this is 3D printing via cladding methodology.

“The vision for CSIRO was that having a machine that can actually build and machine at the same time creates a lot of opportunity for people wanting that capability. It would be very difficult for CSIRO to put that in their own house because they don’t have the skills of the tool-maker, so they said ‘Let’s partner with Romar, we can work with them’. So that’s the base, but the future is: ‘Can we also get it to do titanium 3D printing?’”

That question represents the other dimension to the CSIRO partnership. At the moment the LASTERTEC works with nonreactive metals such as stainless steels, but not with reactive metals such as titanium, because of exposure to the environment.

“So this partnership with the CSIRO is partly to develop this machine to be able to print titanium parts in this format,” explains Farag.

“Because it adds capability that nobody else has. Many people at the moment can print titanium – not a problem. But you can’t machine it on the same platform. This will allow us to do that.”

To expedite the collaboration, the partnership will see Romar establish a desk for CSIRO at its premises, with similar facilities made available to Romar at CSIRO’s sites in Lindfield and Clayton.

For Romar, one of the intended benefits of the partnership will be the opportunity to gain new customers. According to Farag, this openness to collaboration for mutual advantage is all down to Neil Wilson.

“Neil’s vision has always been, particularly in Australia, we have to collaborate, not only with research organisations but with other business partners. There’s no point fighting each other if we can work together. We do that with a few companies, such as Minifab in Melbourne. They have an expertise we don’t have, we believe we have an expertise they possibly don’t, so let’s work together to get things across the line rather than try to work separately. There’s so much work out there globally, more than enough for everyone in Australia. We can’t get it on our own, let’s get it together!”

Managing uncertainty One challenge Romar continually faces is simply choosing which projects to commit to. A sector like medical is characterised by constant, cutting-edge innovation, and with it a high degree of uncertainty. This is compounded by the long development times and multiple regulatory hurdles that any new medical product entails.

“We have a lot of customers that are coming to us with an idea, but we don’t know how successful their idea will be,” says Farag.

“Everyone has always got the greatest invention ever, right? It’s being able to identify the right customer, and also attracting the right customer to us. That’s going to be a big challenge for us.”

A further difficulty lies in simply persuading the big global players to venture outside their usual networks and consider a company like Romar.

“The US in particular, where a lot of this stuff is sold, they don’t always look outside of their own home ground. And when they do, they usually look at China. It’s getting them to look a bit south of China, and have a look here! We’ve done that with a couple of companies. We have to keep attracting those types.”

Nonetheless, Romar is moving forward with some exciting, ambitious plans for the future.

“We’re working on a couple of research projects, but the next big plan is to consolidate our facilities, bring them into one site. We’ve got five different industrial units on this street, so bringing that all into one and expanding that. We’ve invested a lot of time and money into the Vaxxas project, and if and when that product does take off – we’re talking 2020 or 2022 – it will require significant investment in people and plant. Timing our next step for that is a big project.”

Above all, Farag is optimistic about the current outlook for manufacturing and the prospects and opportunities for Romar.

“I’ve only been in this area for around three years, and compared to back then, I feel a buzz that I haven’t felt before. There’s a lot of activity. People want to create new things. I think at the moment there’s a lot of positive sentiment, particularly in the medical space, about what can happen and who can do it. People seem excited about the future.” www.romareng.com.au

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Robotics & Automation

EU takes pole position in global automation race

By 2019, more than 1.4m new industrial robots will be installed in factories around the world – according to the 2016 World Robotics Report from the International Federation of Robotics (IFR).

In the race for automation in manufacturing, the European Union (EU) is currently one of the global frontrunners: 65% of countries with an above-average number of industrial robots per 10,000 employees are located in the EU. The strongest growth drivers for the robotics industry are found in China; in 2019 some 40% of the worldwide market volume of industrial robots will be sold there alone.

“Automation is a central competitive factor for traditional manufacturing groups, but is also becoming increasingly important for small and medium-sized enterprises around the world”, says Joe Gemma, President of the IFR.

The industrial robots boom 2019 The number of industrial robots deployed worldwide will increase to around 2.6m units by 2019. That’s about one million units more than in the record-breaking year of 2015.

Broken down according to sectors, around 70% of industrial robots are currently at work in the automotive, electrical/electronics and metal and machinery industry segments. In 2015, the strongest growth in the number of operational units was registered in the electronics industry, which boasted a rise of 18%. The metal industry posted an increase of 16%, with the automotive sector growing by 10%.

robot density in the big Western European economies is still currently ahead of upand-coming China. The largest gap in this respect is with Germany (301 vs. 49 units), the smallest being with the UK (71 vs. 49 units).

The strongest growth figures in Europe are being posted by the Central and Eastern European states – the rise in sales was about 25% in 2015 with a similar growth rate forecast for 2016 (29%). The positive trends are expected to continue: the average growth will remain steady at around 14% per year for the 2017-2019 period.

The biggest climbers in sales of industrial robots are the Czech Republic and Poland.

Between 2010 and 2015 the number of new robot installations climbed in the Czech Republic by 40% (compound annual growth rate) and in Poland by 26% (CAGR).

With its ‘Made in China 2025’ national tenyear plan, China is aiming to become one of the top technological industrial nations within just a few years. However, in order to achieve Beijing’s target of a robot density of 150 units by 2020, some 600,000 to 650,000 new industrial robots will have to be installed throughout China. By comparison, around 254,000 units were sold in the global market during 2015. Nevertheless, today China is already a leading sales market. At around 68,600 units sold, the statistics for 2015 were 20% above the previous year’s figures, thereby exceeding the volume of sales for all European markets combined (50,100 units). Total sales will increase by 30% in 2016 and between 2016 and 2019 by 20% on average to more than 400,000 units in 2019. This will be 40% of the total sales in 2019.

In a worldwide comparison, the EU member states as a whole are particularly far advanced regarding automation. This is evident from the robot density existing in the automotive industry, for example.

Half of the top ten nations with the most industrial robots per 10,000 employees belong to the EU. The highly developed nature of automation in Europe is also clear from looking at the manufacturing industry.

Of the 22 countries with an above-average robot density, 14 are located in the EU. The

South Korea and Japan come in second and third place as the world’s largest sales markets for industrial robots. The number of units sold in 2015 grew by 55% in South Korea, and by 20% in Japan. Together with Singapore, these two countries lead the rankings of the global automated economies for robot density in manufacturing. With a stable economic situation, it may be expected that both South Korea and Japan will see average annual growth of 5% in sales of robots from 2016 to 2019.

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The US is currently the fourth-largest single market for industrial robots in the world. Within the North American Free Trade Agreement (NAFTA) area (the US, Canada and Mexico), the total number of newly installed industrial robots rose by 17% to a new record of some 36,000 units (2015). The leader of the pack was the US, accounting for three-quarters of all units sold. 5% growth was recorded. With a comparatively much smaller amount of units, the demand in Canada increased by 49% (5,466 units), while that in Mexico grew by 119% (3,474 units). With a stable economic situation, it may be expected that North America will see average annual growth of 5% to 10% in sales of robots from 2016 to 2019.

The USA plays a leading role when it comes to automation in the automotive industry. US car makers are ranked third in robot density, behind Japan and South Korea. The US automotive industry has performed well over the last six years.

2015 proved to be the most successful year since 2005. Major manufacturers from the US, Europe and Asia embarked on restructuring programmes resulting in the installation of some 80,000 industrial robots between 2010 and 2015. This is the largest investment worldwide, second only to China at around 90,000 units. This commitment is reflected in the increasing number of new jobs: The number of people employed in the automotive sector grew by around 230,000 between 2010 and 2015.

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Robotics & Automation Robots and jobs The enormous automation programmes with robots had a positive effect on employment not only in the US. In the German automotive sector, the number of employees likewise increased parallel to the growth of robotic automation: The increase between 2010 and 2015 averaged 2.5% – the operational stock of industrial robots showed a parallel increase averaging 3% per year. The positive effect of automation on the number of jobs is confirmed by a study recently published by the ZEW in partnership with the University of Utrecht. In essence, reduced production costs result in better market prices. The increasing demand then triggers more jobs.

By the end of 2016, the number of newly installed industrial robots will have increased by 14% to 290,000 units during the year. For 2017 to 2019, continued growth averaging at least 13% per year is forecasted (CAGR). Robotics manufacturers have made preparations for these kinds of growth prospects. To this end, production capacities have been increased, and the majority of European manufacturers are operating new locations in the large sales markets of China and the USA. As far as technological trends are concerned, companies will, in the future, be concentrating on the collaboration of human and machine, simplified applications, and light-weight robots. Added to this are

the two-armed robots, mobile solutions and the integration of robots into existing environments. There will be an increased focus on modular robots and robotic systems, which can be marketed at extremely attractive prices.

The demand among customers for industrial robots will likewise be driven by a whole assortment of factors. This includes the handling of new materials, energy efficiency, better developed automation concepts, enabling the real-world factory and the virtual world to be interlinked with one another, as per the definition of Industry 4.0 and the Industrial Internet of Things. www.ifr.org

Bosch Australia demonstrates automated vehicle

Bosch Australia demonstrated and road tested its all-Australian-engineered automated vehicle at the Intelligent Transport Systems (ITS) World Congress in Melbourne in October.

The ITS World Congress brought together the world’s leading transportation policymakers, technology, business and research professionals with the goal of exhibiting and discussing solutions that promote greater levels of safety, efficiency, reliability, sustainability and connectivity to transportation systems worldwide. Bosch’s vehicle drove on a closed Albert Park circuit during the ITS World Congress Media Day and continued to be demonstrated throughout the remainder of the Congress.

Bosch built the highly automated driving (HAD) vehicle at its Clayton headquarters.

The vehicle is able to communicate with other vehicles to automatically act on behalf of the driver based on projected dangers such as road-works, sudden changes in traffic conditions and unexpected obstacles. Motorcyclists are vulnerable road users, and connectivity between vehicle and motorcycle was demonstrated between the Bosch vehicle and a Ducati motorcycle at Albert Park. In addition, the vehicle includes advanced human machine interface (HMI) technology that can adjust vehicle settings and monitor for driver distractions.

The Victorian Government has invested $1.2m in Bosch Australia’s automated driving program through the Transport Accident Commmision (TAC). Bosch Australia President, Gavin Smith believes the advancement of highly automated driving will help reduce the road toll and bring a myriad of other benefits.

“More than 90% of all crashes are caused by human error,” said Smith. “By increasing automation in vehicles, we can have a

profound impact. Trials of the vehicle will be used to inform the development of regulations and infrastructure to enable similar self-driving cars to operate on Australian roads when they become commercially available in the future.

“Projects such as these are not just vital for the advancement of road safety but also for the further development of technical expertise and capability of Bosch Australia engineers. More than 45 Bosch Australia engineers worked on the car in the last year and we are extremely proud of what they have achieved.”

Smith believes the future of mobility will include a progressive increase in automation. Beginning in 2017, cars will be equipped with systems such as “integrated highway assist”, which allows a car to travel at speed on the highway, while remaining

in its lane. In 2018, this will be augmented with a “highway assist” system that allows the car to change lanes by itself. Both systems still require a human driver to monitor the road.

By 2020, cars will be equipped with a “highway pilot” that can essentially take over all driving tasks, although a human may need to intervene sometimes. By 2025, an “auto pilot” system that can drive a car from point A to point B without any human involvement and thus any possibility of human error.

“Although we cannot say precisely when the tipping point for highly automated driving will be, we are certain the future of mobility will be connected, electrified and automated,” said Smith. www.bosch.com

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Robotics & Automation

Robot refurbishment keeps tea and coffee flowing

A fast, proactive and cost-effective response from ABB helped Dutch coffee and tea company Jacobs Douwe Egberts avoid disaster.

The European roasting factory of Jacobs Douwe Egberts sits in the Dutch village of Joure, located close to the ‘Eleven Cities’ key trade route. Since its founding in 1753, the company has grown to more than €5bn in annual revenues, and exports coffee and tea to over 100 countries, including brands such as Douwe Egberts, Gevalia, Jacobs, Kenco, L’OR, Moccona, Pilao, Senseo and Tassimo.

The Joure plant has two hardworking ABB IRB640 palletising robots: a 1999 installation involved in tea production; and another from 2003 in the coffee department. The robot in the coffee section was covered by a service agreement, while the robot in the tea section was not. One of the gearboxes of the IRB640 robot in the tea section had been backlashing, which in the past had led to a long unscheduled stop.

To prevent this happening in the future, ABB contacted Jacobs Douwe Egberts and offered a premium refurbished IRB640 robot to resolve the issue in the tea-producing section. However, the offer was turned down as the customer was considering replacing the two ABB units with a competitor’s robots.

While the customer was evaluating other options, the issue had escalated with the IRB640 robot, which was now running at 50% production speed, jeopardising the entire tea production line. ABB was now asked to resolve the issue, even though the robot was without a service agreement.

“Given the history and the acute situation, I decided to visit the plant,” said Tijn van Pelt, Service Sales Specialist at ABB Netherlands.

“On-site repair of the IRB640 was not an option as it would have meant a longer production stop. Instead the customer decided to purchase a premium refurbished IRB640, for a fast, cost-effective solution. Then just before delivery, the original IRB640 robot stopped completely, after which the customer asked for an even faster delivery.”

ABB’s Repair and Reconditioning Centre in Ostrava, Czech Republic, was able to cut delivery time by almost a week. ABB performed the IRB640 exchange in one day without any delay to meet the stringent customer demands.

“Jacobs Douwe Egberts was very satisfied with ABB’s performance and ordered a 24/7 service agreement for the IRB640 robot in the tea department, including recommended spare parts, plus another premium refurbished IRB640 robot for the coffee section,” said van Pelt. “The next step will be an IRC5 controller upgrade of their S4C controller in the tea section, followed by an upgrade of the S4C+ controller in the coffee section.”

Thanks to ABB’s proactive solution, coffee and tea production at Jacobs Douwe Egberts will continue unhindered for years to come.

“ABB has carefully guided our refurbishment process from beginning to end,” says Stef Jonkman, Head of Maintenance at Jacobs Douwe Egberts. “They are great to do business with and in them we see a partner who understands our needs and acts in a proactive way.” www.jacobsdouweegberts.com www.abb.com/au

ANCA RoboTeach – A step-change in the robot teaching process ANCA’s new RoboTeach solution enables greater efficiency and accuracy when setting up robot automation on its range of CNC grinding machines.

RoboTeach simplifies the complex process of teaching a robot, enabling customers to increase production output and maximise productivity on ANCA’S MX and TX machines. By automating the teaching of the RoboMate Fanuc 200iD robot, the product significantly decreases downtime achieving greater productivity and reducing the need for specialised operator skills.

“Until now, teaching of the Fanuc Robot (200iD) on RoboMate could be labour-intensive and require a unique set of operator skills,” says Simon Richardson, ANCA MX Machine Platform Product Manager. “Furthermore, accuracy could vary depending on the user conducting the teaching. To solve this problem, ANCA has released RoboTeach, a product that automates the teaching

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of the RoboMate Fanuc 200iD robots on our MX and TX machine platforms.”

RoboTeach is a machine-run program that uses the high accuracy of the grinding machine to measure the robot position and automatically teach and calibrate it. The robot position is taught using an electrical contact touch probe held in the robot gripper and a mandrel that locates the position of the machine collet adaptor and tool storage pallets.

A series of instructions on the operator screen guide the user on how to teach the Fanuc robot using ANCA Loadermate software.

Easy-to-follow instructions ensure the operator can quickly and easily teach the Robot positions and coordinates. www.anca.com

Bosch Australia Manufacturing Solutions Your partner in automation and robotics

APAS assistant collaborative robot

The APAS assistant is a versatile automatic production assistant. As an intelligent and intrinsically safe robot system, the APAS assistant allows direct collaboration with people without expensive additional shielding. This is made possible by the unique sensor skin, which covers the robot arm of the APAS assistant and which reacts, as soon as somebody approaches.

With a breadth of industries and products that extend from the automotive industry, to medical, pharmaceutical, healthcare, food, energy, power tools, household appliances and whitegoods. With a strong history in supplying equipment to the automotive supply chain, Bosch Manufacturing Solutions now delivers into a diverse range of Industries.

Automation

Assembly Line, Assembly Equipment, Material Handling, Axis /Robotics & Jigs & Fixtures

Test & Measurement

Product Test Systems, Communication Interfaces, Data Analysis & Data Acquisition

Process Technology

Dispensing Systems, Riveting, Tightening Systems & Vision Systems

Engineering Services

Feasibility studies, Lean equipment design, Project Management, System Integrators

The standardized production assistants APAS assistant, APAS inspector and APAS flexpress, as a stand-alone solution or in a manufacturing island, are designed for: ad-hoc small series production, semi-automation, pilot production for safeguarding a process, agile engineering with early interim results and quality tests.

To find out more contact John Croft (61) (0) 434 185 329 M (03)9541 5086 T john.croft@au.bosch.com E bosch-manufacturingsolutions.com.au W

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Robotics & Automation

Auckland-based manufacturer automates processes

The significant labour costs and geographic isolation of the New Zealand manufacturing industry has meant that in order to compete with international players, local manufacturers must look to innovate with new technologies and automate their production processes.

To compete with global manufacturing hubs, leading Aucklandbased injection moulding company, TCI New Zealand (TCI) were looking for an automated solution that would offer a more costeffective means of producing its customers’ products. TCI found the solution in Universal Robots (UR) - a global developer and manufacturer of six-axis industrial robots. TCI has now deployed two of Universal’s industrial robotic arms: the UR3 and UR5, to perform labelling and assembly tasks for the company’s EasiYo Yoghurt Maker line, as well as its storage bins.

With a UR robot assisting, several key processes in the manufacture of these products have been automated, relieving employees of repetitive assembly processes and ensuring smooth production flow. The UR3 was the first machine implemented by TCI, with the costs of the robot recouped six months after it was first purchased.

Satisfied with this return on investment, TCI then decided to purchase the UR5, with the payback period expected to be under 12 months.

Finding a solution TCI is one of the largest privately-owned plastic injection moulding companies in New Zealand, based in Avondale, Auckland. For more than 20 years, TCI has manufactured a vast array of products, including building products, components used in instrumentation,

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navigation, rescue and communications, as well as a range of retail products including homewares, garden products and outdoor furniture for companies across New Zealand and the rest of the world.

“Previously we were paying two employees to work in 12 hour shifts to ensure around-the-clock production of our EasiYo Yoghurt Maker,” said Quintin Fowler, Manager Director at TCI. “If one employee didn’t turn up for work it meant the entire production line would be halted. This wasn’t really financially sustainable for us so we were looking for an automated solution that would guarantee quality assurance and help us to reduce costs.”

During its search for an automation solution, TCI came across UR’s technology at a trade show and made contact via Design Energy, its New Zealand distributor.

“We developed the layout for the production cell and designed and built an appropriate gripper unit for each of the applications,” said Mike Shatford, Managing Director at Design Energy. “TCI then manufactured the machine frames and mounted the various operating units in the relativities we had laid out. Once the machines were completed our technician spent time at TCI writing the robot programs and getting each cell operating to the customers’ requirements.”

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Robotics & Automation “Design Energy were fantastic,” said Fowler. “We were initially considering an off-the-shelf robot from overseas, but I’m glad we were able to find a customisable solution.”

Robots in action The UR3 is a compact table-top robot that weighs just 11kg and is capable of handling payloads up to 3kg. The robot has a reach radius of up to 500mm and features 360-degree rotation on all wrist joints and infinite rotation on the end joint. It is ideal for manufacturers such as TCI that have limited factory floor space and a number of intricate processes.

TCI uses the UR3 to help label and place rubber feet on its EasiYo Yoghurt Makers. After a product is moulded, the UR3 aligns and passes the product though a label printer, then it adheres the label to the base of the product. The UR3 then inverts and places the product onto a mandrel, then picks up rubber feet from a bowl feeder and places them on the base of the product.

A pneumatic press is then activated, which presses the feet firmly on the product. The UR3 picks up the finished assembly and places it on a conveyer belt for delivery to the next process. The UR3’s controller provides control for all ancillary equipment including the label printer, bowl feeder, pneumatic press and conveyor.

The success of UR3 gave TCI the confidence to implement a UR5 robot to help assemble several different sizes of storage bins, from 40L up to 112L. The UR5 helps manufacturers automate repetitive and dangerous tasks with payloads up to 5kg and a reach radius of up to 850mm. The UR5 is suitable for collaborative processes such as picking, placing and testing.

“We use the UR5 to put wheels on storage bins and we programmed the robots to be able to place wheels on multiple sized storage bins,” said Fowler. “The robots are so easy-to-program that we can quickly change from one size to the next by pressing just a few buttons.”

Flexible, easy to program and safe to use “Both the UR3 and UR5 went beyond our expectations in what we were looking for in a robot,” Fowler noted. “These robots have the ability to perform the tasks that we need without being overly expensive or difficult to program. They also offered a quick return on our investment.

“UR’s robots can easily move around and fold over on themselves in very tight spaces. The robot can also operate safely alongside

our staff without the need for guarding.”

All UR robots can be completely reprogrammed and deployed for other tasks in a matter of minutes. A graphical user interface with a teach function enables an operator to simply grab the robot arm and show it how a movement should be performed. The userfriendly interface then allows staff to drag and drop the routines to do their programming.

“The UR3 and UR5 are very flexible robots. They are very easy to reprogram, which is why we use the UR5 to help assemble all of our storage bins. The robot can be reset to perform different jobs depending on the size of the bin,” said Fowler.

In contrast to traditional industrial robots in the market, UR’s small and lightweight robotic arms are able to work safely alongside staff (subject to prior risk assessment). The robots’ state-of-the-art force limit safety feature automatically stops the robot from operating when its movement is obstructed. The robot will not exert a force greater than the limit specified in the adjustable safety settings.

“One thing I loved about UR was that we didn’t have to worry about guarding,” said Fowler. “Whereas a lot of the other robots in the market guarding was an issue because you’d have to use safety barriers for all the machines which just complicates the situation.”

The pay-off According to TCI, the company has been able to significantly reduce expenditure by using robots at a time when labour costs can be 10 to 20 times higher that of other overseas markets.

“We paid off the UR3 within six months, which means we can reinvest in further product development and innovation,” said Fowler. “We also saved around 75% on yearly product assembly labour costs for the UR3 and UR5.”

When asked what appealed to him the most about the UR3 and UR5 robots, Fowler pointed to their simple programming and consistency.

“The robots are easy to set up and reprogramming can take just a few minutes. However one of the biggest selling points for us is having that guarantee that the robots aren’t going to call in sick – production can go on 24/7 without us worrying about human related factors that might stop production.” www.tcinz.co.nz www.designenergy.com.au www.universal-robots.com

NZ businesses keen to invest in robotics and automation

Four in 10 New Zealand firms say they are interested in investing in robotic processes and automation within the next 12 months. In contrast, a smaller 36.7% said the same in the equivalent research conducted in Australia.

Businesses across New Zealand indicated they want to learn more about the benefits of drone technology, artificial intelligence (AI), big data, product assembly and services automation, as captured in the latest round of the Alleasing New Zealand Equipment Demand Index (the Index).

Alleasing Chief Executive Officer Daniel Blizzard said the early interest in automation and digital integration will give New Zealand firms a future advantage over their neighbours. More than half of businesses in Australia indicated they have not considered investing in such technologies.

One-quarter of businesses surveyed said they would consider investing in product assembly and service automation. This emerged as a key investment priority for NZ firms, probably driven by the associated productivity enhancements and reduced labour input costs, particularly in sectors where repetitive tasks are common, including manufacturing. Big data and AI are also attractive for businesses (21.9% and 10.8% respectively).

“The Index data shows New Zealand firms have a clear appetite for learning more about the next wave of digitisation and automation, and indeed making the decision to invest in it.

Although corporate adoption of these technologies is still in its infancy in New Zealand, the Index data is very promising and suggests firms are already thinking of the major cost, productivity and control benefits on offer.” www.alleasing.co.nz

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Robotics & Automation

Automation can really be so simple

DMG MORI has unveiled Robo2Go, a mobile automation system for lathes that is designed for easy programming using a smartphone app.

At the AMB trade show in Stuttgart in September, DMG MORI presented the implementation of an automated process chain from the web shop to the finished workpiece. The core of the integrated turning cell was Robo2Go, a new loading and unloading system for mobile use at up to four lathes.

Robo2Go includes a six-axis robot with up to 35kg load, and features barrier-free safety technology, and is programmed via a special CELOS app with just a few entries.

Sylvio Krüger and Jürgen Groß, Managing Directors at DMG MORI Systems, discussed the new system.

How did you come to develop Robo2Go? Thanks to the use of robotic technology, investment costs in the field of automation have dropped drastically in the past few years, so that small and medium-sized enterprises are now also turning their attention more and more to the indisputable quality and cost benefits such technology has to offer. Nevertheless, a certain degree of reluctance was still noticeable in this customer segment, due to a lack of knowhow in programming in the companies on the one hand, and on the other because the uncertainty of the robot not being used to full capacity remained too great a risk for those who might otherwise be interested.

And Robo2Go overcomes these hurdles in one innovative leap?

That’s right. Firstly, the Robo2Go system can be used flexibly on up to four lathes with the aid of a lifting device, which of course maximises investment security.

Secondly, the system can be programmed on the control panel with just a few entries, which in turn minimises set-up times while optimising utilisation rates. All in all Robo2Go gives users a clear competitive advantage.

A robot programmed directly from the control is not really anything new. What in your opinion makes the Robo2Go solution so special?

The special feature is that the robot is not programmed from the control, but is parameterised simply via a special Robo2Go App from the DMG MORI graphic control and operation system CELOS. So the operator needs no knowledge of robots because once configured by our service the robot operates completely via CELOS. All the operator has to do is enter

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Robo2Go includes a six-axis robot with up to 35 kg load capacity, barrier-free safety technology and programming via CELOS app.

the dimensions of the workpiece, the chuck and the gripper, then select one of the pre-defined arrangements of the workpiece tray and finally start the automatic process. This innovative way of programming a robot enables especially smaller firms entry into flexible automation without the need of any expert knowledge.

What else sets Robo2Go apart from standard automation solutions already offered by DMG MORI? Firstly, Robo2Go offers extremely inexpensive entry into automation. From the technical side it differs from standard automations in terms of its barrier-free safety technology. The use of an area scanner means that Robo2Go can do without protective fences. Instead the system stops as soon as a worker enters the defined stop area.

Did you have to make compromises where the speed of the robot was concerned in order to achieve barrier-free safety?

Robo2Go is not a collaborative robot solution. A faster working speed is possible for the robot because the human operator and the robot do not work at the same time in the action area. So all we had to do was reduce the dynamics of the robot slightly so that overall productivity of the system is hardly restricted at all. In view of the simultaneous gain in flexibility this is an excellent compromise.

With Robo2Go the robot is programmed with a CELOS app, meaning the operator does not need any robot knowledge.

What component range can Robo2Go handle?

We have robots on our range with load capacities of 10kg, 20kg and 35kg. The weights of workpieces in the case of a single grip – whereby the gripper can be adjusted without tools – are 5kg, 12kg and 22kg. Workpiece diameters are between 25mm and 125mm and lengths from 50mm to 250mm. The workpiece tray can be loaded with weights of up to 700kg, which adds up to a maximum capacity of 210 workpieces depending on diameters. www.dmgmori.com

Sylvio Krüger (left) and Jürgen Groß, Managing Directors at DMG MORI Systems.

Advanced Materials

Steel from old tyres and ceramics from nutshells – how industry can use our rubbish

If someone said “green manufacturing” to you, what comes to mind is probably environmentally friendly products – solar panels, bamboo garments and the like. But there’s more in this space. Far greater environmental and economic impact can be achieved by looking further up the manufacturing chain. By Farshid Pahlevani and Veena Sahajwalla.

There is huge potential in rethinking the energy and raw materials that go into our favourite and essential goods. What if we could turn rubbish into an input? Instead of viewing waste as a growing global burden, we could “mine” the world’s landfills – by using old tyres to make steel, for instance.

Globally, waste is becoming a huge problem. There has been an eightfold increase in materials consumed over the past century.

There are several reasons for this: rapid industrialisation across Asia and other developing nations; the shortening of product replacement cycles; and the dramatic fall in the prices of consumer goods and an accompanying rise of consumer cultures.

The world’s three billion urban dwellers generate an average of 1.2kg of solid waste per person per day, according to the World Bank. Without innovation, landfills around the world will become increasingly clogged, exacerbating the loss of potentially valuable secondary resources and risking environmental contamination.

So let’s view this increase in waste as an opportunity. Around the world, the cost of raw materials is on the rise. Rethinking waste might help us solve both problems at once.

Our waste streams are becoming increasingly complex – mixed plastics, e-waste and auto waste, for example. As such, a lot of it simply cannot be recycled using conventional approaches like sorting through rubbish to extract glass and then recycling that into more glass. This phenomenon is another reason why our landfills are filling up.

But with new approaches we can overcome this. We can look at waste at the elemental level. The world’s waste mountains are packed with useful elements like carbon, hydrogen, silicon, titanium and other metals that we would otherwise have to source from virgin raw materials.

By identifying and processing these valuable elements, and redirecting them back into our industrial processes, we can simultaneously solve the problems of waste and the skyrocketing cost of inputs.

Waste in action At UNSW’s SMaRT Centre we have been researching ways to reuse waste. So far we have achieved success in introducing waste polymers, mostly old tyres, as slag foaming reagents in electric arc furnace (EAF) steelmaking, a chemical reaction which is significantly important in EAF – just as in a cappuccino or a beer, the foam is crucial to a good-quality product. This process not only reuses a waste material, but improves energy efficiency, and reduces emissions and demand for non-renewable coking coal.

We have also recently published results of our research into the substitution of green petroleum coke with the waste shells of Australian macadamia nuts in the production of high-value silicon carbide and silicon nitride – super-hard ceramics that can be used for a range of applications from medical devices, to drilling tools, high-temperature engine linings for performance cars.

an excellent source of carbon with a very low ash content. This means less impurity, and hence cheaper costs for removing these impurities when replacing conventional coke.

But it doesn’t end there. There is so much waste for which we have no answer yet. Every year tens of millions of vehicles are decommissioned, for example. While the metals that make up about 75% of a vehicle by weight can be readily and profitably recovered and recycled, the remaining plastics, glass, composites, complex materials and contaminants are mainly destined for landfill.

For every car, some 100-200kg of complex and potentially toxic waste ends up as “automotive shredder residue” (ASR). This poses a growing technical and environmental challenge worldwide, and represents a significant waste of finite resources.

We are investigating a range of transformations using ASR, including new pathways for creating alternative resources for the production of ceramic materials like silicon carbide and titanium nitride composites, produced using the silicon and titanium found in these residues. Instead of using conventional raw materials, like silica from quartz or carbon-bearing resources such as coke, waste automotive glass and plastic can be used.

This is just the start of reusing waste. There are still great advances to be made by combining these recovered resources with new modes of manufacturing. Imagine combining the ability to reform plastics with other new developments like 3D printers. In future we may use waste as an input that will enable us to locally print off something new, fully closing the materials loop.

Farshid Pahlevani is a senior research associate at UNSW Australia and Veena Sahajwalla is a professor and director of the Centre for Sustainable Materials Research and Technology (SMaRT) at UNSW Australia. This article was originally published on The Conversation. www.theconversation.com www.unsw.edu.au

We discovered that macadamia shell waste, tens of thousands of tonnes of which are thrown away in Australia every year, is

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Advanced Materials

Cutting down harmful chemicals in coatings and repair composites

The growing use of composite materials for coatings and repair operations has health and safety implications due to the presence of hazardous chemicals, requiring careful measures to monitor the use of these substances.

Polymeric repair composites and protective coatings were almost unheard of when they entered the industrial repair and maintenance market, yet now industries have reached a point where the use of these materials is preferred to other traditional industrial practices.

For many, they have overtaken repair methods such as welding and other forms of hot work, due to improved health and safety and additional benefits such as corrosion and erosion resistance.

The chemistry of polymers allows these systems to be produced with a broad range of properties for use on a variety of industrial environments and operating conditions.

Hazardous spraying applications require correct protection, including respirators.

Historically, soybean oils or natural based products were the main component of polymers’ base material. Today, the majority of base components used in industrial coating polymers (binders) are synthetic, such as alkyds, epoxies, urethanes and silicones.

Although most chemicals used in the composition of these synthetic binders can be made and used safely, there are those that can have unintended harmful effects.

Hazardous chemicals can pose substantial problems for both the environment and human health. Therefore, improved management procedures and preventive policies are required to monitor the use of these substances. This includes strengthening the existing controls and responsibilities surrounding hazardous chemicals and formulating materials with less harmful chemicals during design, production and application phases.

Handling hazardous substances Awareness of concerning chemicals, coupled with a proactive approach to eliminating hazardous substances, enables manufacturers to protect end-users, comply with market legislation and protect the environment. Belzona specialises in the design and manufacture of polymer repair composites and industrial protective coatings for the repair, protection and improvement of machinery, equipment, buildings and structures.

“By taking a pro-active approach to chemicals management, we stay ahead of any future regulatory changes and restrictions,” says Jason Horn, R&D Chemist for Belzona. “There is an ongoing commitment to health and safety within the Belzona organisation and we are always looking to make our materials safer to handle and use, in order to protect staff, the end users and the environment”.

As a result, there are certain hazardous substances that Belzona looks to actively remove from both repair materials and coatings alike. Among others, these include: bisphenol A and alkylphenol; organo-mercury compounds; and isocyanates. Belzona is proactive in eliminating hazardous substances from its products.

Bisphenol A and alkylphenols Bisphenol A (BPA) has been widely used in the manufacture of epoxybased building materials, high performance coatings, adhesives and composites. Used as an accelerator for epoxy systems, this component assists by providing faster cure times, particularly at low temperature. Similarly, alkylphenols, including nonylphenol and t-butylphenol, are commonly used plasticiser accelerators in epoxy-amine systems. Both are very effective plasticisers that lower viscosity and improve the cure speed of epoxy systems.

However, these chemicals are classified as CMR (carcinogenic, mutagenic, reprotoxic) substances and are also toxic to the environment. In fact, some EU member states have introduced

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national bans on the inclusion of BPA in food & drinks packaging due to the associated hazards with contact.

Undertaking the reformulation of existing epoxy-based materials, Belzona has worked to remove hazardous substances such as alkylphenol and bisphenol A in the range. Alkylphenols, including nonylphenol and t-butylphenol, are frequently components of formulated amines. Belzona has actively targeted the removal of these components in its products, to the point where nearly all Belzona materials exclude nonylphenol components.

“It is in our interest to remove both t-butylphenol and bisphenol A from our products to make them safer for use and to protect the environment,” says Horn. “It is important to do this without impacting on the performance of the materials.”

Organo-mercury compounds Many different types of catalyst can be used in the production of polyurethanes and, along with other manufacturers, Belzona has traditionally used very low levels of mercury-based catalyst in the production of its polyurethane elastomers. Organo-mercury catalysts are extremely effective at providing a good balance between working life and rapid cure, leading to high mechanical strength. However, mercury-based materials are hazardous and pose a risk as potential CMRs. In fact, the US Environmental Protection Agency (EPA) considers these compounds to be a bioaccumulative, environmental hazard and toxic to humans, ecosystems and wildlife.

First introduced in 1985, Belzona Elastomers were formulated using a mercury-based catalyst. Yet, in line with Belzona’s proactive approach to safety and the environment, there has been a desire to replace the mercury-based catalysts within the Elastomer range. Following the 2014 launch of the mercury-free Belzona MP Elastomers (2200 Series), Belzona has now released a full range of mercury-free Elastomers with the reformulated Belzona D&A Elastomers (2100 Series).

Advanced Materials

“In addition to improving human safety, we want to ensure our products cannot harm the environment,” says Horn. “Therefore, Belzona actively looks to remove and replace any ingredients that could have a significant environmental impact. By doing this, we ensure that our materials are as safe and green as possible and we aim to achieve this without compromising performance.”

Isocyanates Another significant hazard, potentially associated with polyurethane systems, is the use of isocyanates, a family of reactive chemicals that can react with compounds containing alcohol (hydroxyl) groups to produce polyurethane polymers. Repeated exposure to some isocyanates can lead to occupational asthma and other lung problems, as well as irritation of the eyes, nose and throat. Allergic skin reactions can also be possible.

Following reaction to form the hardened or cured polyurethane product, isocyanates are no longer active and therefore, pose no harm. Therefore, the potential for exposure comes during the application process, with isocyanates posing significant risk during spray application. Spray application generates a mist, which can be readily inhaled and can lead to respiratory sensitisation or occupational asthma. As a result, it is important to ensure adequate protection when handling these materials, such as adequate personal protective equipment.

Isocyanates are very difficult to replace entirely because of the performance benefits offered by polyurethane systems. Indeed, Belzona uses materials containing isocyanate, primarily in the Belzona 2100 and Belzona 2200 Series Elastomers. However, these are relatively safe isocyanates as they are predominantly isocyanate pre-polymers with little or no free isocyanate. A prepolymer has a lower isocyanate content by weight, as well as a lower volatility, which significantly reduces the hazards. As a result, they do not readily become airborne, posing only a small health risk to the user. Belzona’s cold-applied polymeric materials also do not require any hot work and allow for simple and safe application by hand without spraying, thus minimising the health and safety risks.

As an alternative to polyurethane-based systems, Belzona has also developed flexible isocyanate-free technology for some applications; for example, as seen in Belzona 3411. This system offers peelable and resealable corrosion protection for flanges and other bolted assemblies. The non-hazardous solution features the flexibility of a polyurethane elastomer but is based on a completely new technology excluding the use of isocyanates and toxic metal catalysts.

Ensuring that hazardous substances are eliminated or, at the very least, minimised is crucial as the industry continues to progress.

With increased legislation and awareness, chemical management has become integral for any manufacturer and their processes for sourcing materials and system designs. www.belzona.com

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Materials Handling

Deakin research breakthrough for better carbon-fibre polymers

A Deakin University researcher has improved the methods for the design and synthesis of high performance carbon-fibre precursor polymers.

Dr Nisa Salim, a researcher within Deakin’s carbon-fibre research facility Carbon Nexus in Geelong, has developed advanced polyacrylonitrile polymers capable of producing fibres with enhanced structure and properties, using sequential distribution of monomers in conjunction with RAFT technology. Dr Salim’s breakthrough will enable the making of polymers that are capable of producing carbon-fibres with enhanced structure and properties.

The improvements are a result of Dr Salim’s prestigious Victoria Fellowship, which last year enabled her to visit several overseas carbon-fibre composite research facilities in the US. Dr Salim spent nearly two months working with Professor Jeff Wiggins at the Polymer School at the University of Southern Mississippi. Professor Wiggins’ research group recently developed advanced protocols and customised laboratory facilities to design and synthesise the next generation of carbon-fibre precursors using a variety of technologies. The collaborative research between the Polymer School and Deakin University has led to the synthesis of nearly 10 precursor polymers with high

molecular weight and uniform order and distribution of co-monomers. Dr Salim said it was a privilege to work with a group to solve various challenges in high performance polymer materials.

Also as part of the Fellowship study tour, Dr Salim experienced hands-on training on the world-class customised wet spinning line at the University of Kentucky’s Centre for Applied Energy Research, where she worked in partnership with the carbon materials group led by Dr Mathew Weisenberger.

“I had the opportunity to make my own customised precursor fibres, by changing spinning conditions,” Dr Salim said. “The spinning of fibres on a customised pilot scale facility was a wonderful experience. A critical challenge of wet spun fibres is the presence of voids developed during the coagulation process. Previously, there were no reliable procedures to quantitatively measure the size and volume of pores in the fibres. The research program helped us to combine the right skills and shared knowledge to develop a method to quantify the porosity of these fibres.

“We are all excited about the outcomes of this research. The program I selected was perfect for me, I met so many amazing people.”

Dr Weisenberger was also pleased with the project’s success: “Dr Salim did an amazing job developing the analysis to evaluate the porosity distribution in her precursor PANbased fibres. I’m sure this work will be very valuable moving forward and we certainly look forward to staying in touch.”

Geelong is now emerging as Australia’s ‘carbon valley’ since the establishment of Carbon Nexus and the subsequent establishment of world-leading carbon-fibre stakeholders such as Carbon Revolution and Quickstep Technologies. The DeakinCSIRO partnership is now commissioning a pilot-scale wet-spinning facility, at the University’s Waurn Ponds campus, which will complete the carbon-fibre value chain from molecular level synthesis of precursors through to fabrication of composite laminates using high quality carbon-fibres manufactured on-site. www.deakin.edu.au www.carbonnexus.com.au

Mark X – Industrial-scale 3D printing in carbon-fibre

Markforged, represented in Australia by Emona Instruments, launches Mark X, a powerful fibre composite 3D printer. precision parts. With new in-process inspection for dimensional accuracy, the Mark X features a laser sensor affixed to the print head, which will scan parts at any layer designated to measure whether the most critical tolerances are met – all controlled

by Markforged’s award-winning Eiger software. In addition, the Mark X includes a high-precision build plate, encoders on the print head for high accuracy, silent stepper motors, and a high stiffness Z-axis motor to ensure a high degree of part quality.

The Mark X’s high strength carbon-fibre 3D-printed parts will be in demand for both prototyping and manufacturing scale parts printing in mining, manufacturing, renewables, medical prosthetics and electronics/telecommunications applications. In addition to a large print volume (330mm x 250mm x 200mm), the Mark X introduces a set of print capabilities that include in-process laser inspection as well as a fine (50-micron) surface finish.

“We have taken a different path from most of the 3D printing industry with innovation that will create a new bottom line benefit for many manufacturers” says Greg Mark, CEO and founder of Markforged. “We already had success with the breakthrough strength and light weight of continuous carbon-fibre in our Mark Two printer.

Now we added in-process inspection for exact dimensional accuracy, highresolution beautiful surface finish and

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scale, to open entirely new segments of the industry to efficiencies of what printing can accomplish.”

Markforged’s Mark X builds on the success of the Mark Two, but adds a leap in capability and scale for fibre-reinforced printing of

The Mark X is designed to meet the needs of engineers, manufacturers, and designers looking to print strong, precise parts for robotics, automotive parts, moulds, prosthetics, athletic equipment, and other industrial applications. The build volume and footprint (575mm x 467mm x 928mm) allows the printer to fit neatly in a shop or office. www.emona.com.au

Materials Handling

Demo3D – Simulating and testing material handling solutions

Whether you are a materials handling specialist wanting to demonstrate system capability, or a manufacturing company considering a plant expansion or greenfield site development, simulation technology allows you to plan, test and validate designs before actual capital is expended.

Demo3D is an advanced material handling demonstration tool that offers virtual reality 3D solution to designing, simulating, presenting and testing all material handling solutions. Demo3D stands out in the modelling world as it incorporates realistic physics to show the way loads and other model elements interact.

The Demo3D world takes into account mass, friction, force, inertia, gravity, and momentum to represent the interactions between various model elements. Products on Demo3D conveyors behave according to real world physics. They can bump into each other, slide, jam, and even fall to the floor. You can interact with them as the model runs, using the mouse to pick them up and put them down somewhere else in the system if you want to; you can stop and start conveyor motors, and the modelled system will respond in the same way as the real system would.

Demo3D allows to users to model the most simple conveyor or the most detailed automated warehouse, evaluate changes to an existing materials handling system before any decisions need to be made, assess ‘what if’ scenarios, and identify bottlenecks before they actually occur. Users can also experiment with ideas, test possible solutions, and assess the impact of conveyor jam-ups.

Models can be built and customised using an extensive range of components from included catalogues, or you can develop your own components and create custom catalogues to represent the specific equipment your company offers. If you can visualise it, you can build it using Demo3D. Demo3D has been designed from the outset to allow users to develop detailed operational models fast. Being able to see the model running at each stage of development means you can quickly test and progress ideas, arriving at better solutions, faster.

Demo3D is used in automated materials handling, general manufacturing, and baggage handling to create models that clearly communicate the operation of the proposed system. In order to be cost-effective, you need a modelling system that allows you to create realistic and operational models fast; Demo3D’s approach is designed to help you be responsive. It can bring to life a CAD drawing of a new layout, plug in the functional parameters and allow the user to understand how their concept will operate.

For existing layouts, Demo3D allows the user to test concepts and understand how any future upgrades or process changes will integrate with the existing system. A simulation of future upgrades would then provide the data required for proof of concept and the justification for spending capital.

Once the model has been captured, users can also take advantage of Demo3D’s virtual reality capabilities with fully navigable, 360-degree video that can be sent to smartphones and tablets or simply captured in high-resolution images and video for presentation purposes. You can also export to CAD or even create a 3D PDF to share with your team or customer. www.glenvernasc.com.au

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Materials Handling

Hubtex launches MaxX and FluX sideloaders Hubtex has announced the release of two new groups of sideloader forklift products, MaxX and FluX. The launch of the two new vehicles bolsters Hubtex’s portfolio by adding modular multidirectional sideloaders in the entry-level pricing bracket. Boasting a spacious driver’s cabin, a multifunction joystick, a next-generation info display and easy battery replacement, MaxX and FluX are ergonomically designed for both indoor and outdoor use.

With FluX, Hubtex has developed a multidirectional counterbalance forklift featuring patented steering technology. The vehicle is available in two load-capacity classes – 3,000kg and 4,000kg – with a 48-volt power system and four-wheel chassis. It can be deployed as both a front and sideloader. It is especially suited to transporting both palettes and long objects.

In addition to a very high speed of up to 12kph, Hubtex’s patented HX steering system also delivers major benefits. Thanks to the steering system installed as standard for the first time, the FluX can swiftly switch from travelling forwards to sideways without stopping, in a way that causes minimum wear and tear to the vehicle. Depending on how it is deployed, users can save a substantial amount of time, especially when the vehicle is used for handling both long objects and palettes.

The process of loading and unloading trucks is also much quicker due to the lack of mast travel. With the vehicle featuring a system that automatically reduces its speed depending on the steering angle, users can safely travel at optimised speeds. The structure of the frame is also new. The forklift features a compact frame measuring 1,850mm or 1,950mm in length, while offering substantial ground clearance of 150mm. This enables palettes to be loaded simply, even at the end of aisles.

The entry-level version of the forklift is available with a forklift carrier for long objects that spans the entire length of the frame. The carrier is also available in hydraulically adjustable form or with a lateral slider as optional extras.

The electric multidirectional sideloader MaxX is available in three variants: with a load capacity of 3,000 kg and a powerful 48-volt power unit, or with a load capacity of 4,500kg and a 48- or 80-volt power unit. As was the case with the FluX, focus has been placed on the ergonomics of the driver’s cabin when developing the MaxX. The spacious cabin provides drivers with a substantial amount of legroom and all-round visibility, while the new HIT3 multifunction display enables them to keep an eye on all key vehicle information, such as wheel position, speed and battery charge.

Furthermore, the hydraulic suspension system installed for the drive wheels ensures that the vehicle never leaves the ground, boosting shock absorption. The vehicle chassis also offers key advantages for use both inside and outdoors. The four-wheel chassis allows the vehicle to achieve tighter turns while also enabling higher residual load capacities.

Able to be deployed for a period of five to eight hours at a max speed of up to 11kph, the vehicle can be used over multiple shifts thanks to its easily replaceable battery. With its standardised vehicle concept, the MaxX represents an ideal addition to Hubtex’s trusted range of electric multidirectional sideloaders with tonnages of up to 5 tons, which are produced according to customer specifications. www.hubtex.com.au

World demand for material handling equipment to reach $176bn Global demand for material handling equipment is forecast to rise 5.3% per annum through 2020 to $176.0bn.

According to World Material Handling Equipment, a new study from The Freedonia Group, advances at the global level will be largely driven by market growth in China and other industrialising nations.

These will account for nearly two-thirds of all new material handling machinery demand generated between 2015 and 2020.

In Japan, the US, and Western Europe, sales of material handling machinery will climb at a somewhat more restrained pace during the 2015-20 period, than in developing countries. Market growth will be largely spurred by replacement product demand. A variety of factors impact material handling replacement patterns in developed countries, including the overall economic environment, access to financing, and the development of new, technologically advanced models that offer efficiency and productivity advantages.

Most mature markets will see sales conditions improve through 2020, although they are generally projected to register slower growth than their industrialising counterparts. Additional government spending on public infrastructure, growth in logistics and transportation

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industries, and the adoption of new material handling technologies will contribute to gains in many mature markets.

Automated storage and retrieval systems and automated guided vehicle equipment are forecast to register faster demand gains than all other product types. Growth for these products will be bolstered by rising global manufacturing activity and the expansion of the world’s logistics and transportation industries. As industrial enterprises around the world adopt advanced manufacturing techniques, build new factories and warehouses, and upgrade existing facilities, they will purchase new automated storage and retrieval systems and automated guided vehicles because they offer efficiency and productivity gains and reduce labour costs.

Logistics and transportation firms will also increase spending on these products to satisfy growing demand for their services and boost the efficiency of their operations. www.freedoniagroup.com

Materials Handling

Konecranes – real time monitoring for lifecycle care

One of the biggest advances in crane safety and cost-efficient management over the past decade has been the advent of lifecycle care in real time.

New remote digital monitoring and analytical technologies can look inside the performance of a crane or whole fleets of cranes to accurately predict the most suitable and timely maintenance for optimum service, as well as spot impending production risks and accident hazards. Konecranes’ TruConnect technology harnesses in a user-friendly way the power of the industrial internet, the heart of which is based on machinery sensors working together to gather and analyse data for specific purposes. Operating in this way, they can enable efficiencies unimaginable just a short time ago.

“With powerful but highly accessible technologies such as TruConnect, crane maintenance is an entire generation ahead of the days of external inspections, laborious dismantling to find and fix problems - or simply fixing something when it fails,” says John Bailey, General Manager – Service Development, Konecranes SE Asia Pacific. “With the accident liability that outdated practices entail – and the potential for expensive downtime that companies just can’t afford these days – old approaches are just no longer accepted as safe and productive risk management in the worldclass industries we serve.”

Such industries include automotive and general manufacturing, bulk materials handling, mining, power generation, petrochemical, ports and container handling, pulp and paper, shipyards, steel and waste-to-energy.

In developing TruConnect to complement its MainMan planned maintenance services to such industries, Konecranes has incorporated into the technology its experience as a major global crane and lifting equipment manufacturer and service organization, with more than 450,000 pieces of lifting equipment under maintenance agreements worldwide. Konecranes’ 10,300 remote monitoring connections and 600 service locations worldwide have fed into the understanding of industry needs that has produced the TruConnect suite of remote service products connecting data, machines and people. Through such products, Konecranes applies the industrial internet to lead the evolution of service through remote monitoring, diagnostics, analytics and usage-based predictive maintenance – providing real-time visibility and offering customers unique predictive capabilities and crane management efficiencies.

To make the process of real-time monitoring for lifecycle care as intuitive and easy to use as possible, Konecranes has integrated TruConnect remote monitoring and reporting and MainMan planned maintenance results captured by mobile-enabled technicians into an easily accessed online customer portal, ‘yourKONECRANES.com’.

This portal gives real-time browser-based access to customers’ equipment data and maintenance history, linking usage data, maintenance data and asset details, to provide a transparent and complete view of events and activities of a crane over any interval.

Aggregated data can be viewed, analysed and shared quickly, for a single asset or an entire fleet.

Data is sent to this customer portal from Konecranes TruConnect remote monitoring and reporting technology along with MainMan planned maintenance findings, which can be applied to a huge variety of lifting equipment across the range of industries Konecranes serves.

TruConnect gathers data on running time, motor starts, work cycles and brake condition and can also send alters by text or email of hazardous events such as hoist overloads, emergency stops and over-temperatures. MainMan planned maintenance

utilises Konecranes’ proprietary ‘Risk and Recommendation’ method to visually categorise findings into safety, production and undetermined risks allowing for easy prioritizsation and planning of future maintenance activities by asset.

“To make the best use of this innovative technology, insights can be drawn by observing anomalies, patterns and trends, helping users make fact-based decisions,” says Bailey.

Anomalies can show up as faults, such as overloads. These events are considered abnormal and should be addressed promptly as they occur. Knowing when an overload occurs is the first step in identifying its cause.

Patterns help reveal relationships between variables. For example, overload or emergency stop alerts or excessive starts may indicate the need for operator training aimed at reducing humanerror downtime and the risk of safety incidents. Recurring motor overheats may that indicate changes are needed in equipment or process. The study of trends can help prioritise corrective action and investments. Analysing data behaviour over time supports the development of predictive maintenance.

“Our aim is not to be confusing or overwhelming with a flood of data and analytics,” says Bailey. “We have teams of experienced staff who take a consultative approach to help guide our customers’ decision making. We share our findings, provide recommendations and discuss how each action can optimise particular aspects of operations and maintenance.”

Konecranes technicians and inspectors are mobile-enabled, which means they are constantly connected to TruConnect’s data through their phones, tablets and computers. They can access maintenance history, equipment usage and operating information and look up spare parts and manuals.

“Konecranes Remote Support experts can communicate with your crane, no matter where it is, and provide remote support and troubleshooting in the event of a breakdown or indication of a fault,” Bailey adds. “The data from TruConnect can be used to identify the need for corrective on-site maintenance and spare parts.

“TruConnect’s integration into the ‘yourKONECRANES.com’ portal is designed to improve the user experience and is a key development in delivering lifecycle care in real time, which will help extend the life of valuable assets by planning better maintenance programs and identifying faults and problems at an earlier stage”. www.konecranes.com

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Forum Training

Difficult people start with you

Ron Pollak explains the importance of personal development training – looking for new ways to better understand ourselves and others and how we interact. By controlling emotions, we cope more positively to difficult people and situations.

You have attended a training session “Dealing with Difficult People”.

It provides you with some simple steps to follow. Its’ a topic that you make it your goal to learn. You memorise the steps. You practice them. You discuss them with a colleague and even better, you seek input from your manager, both of whom help you fine-tune your approach and provide you with some personal insights and experiences.

This topic resonates strongly with you. There is someone at work who has always made you feel uncomfortable; it’s someone who has always had the upper-hand in your interactions; that person who asks you to do tasks that they should do themselves, and who gets you to do them .

You say, “The course gave me the skills I needed. I am going to give it a go.”

Once you have accepted this as possible, it’s easier to deal with the situation. It’s now less personal. Importantly, you now realise that this situation is less about ‘them and how they act’. It’s really about ‘you and how you deal with a situation’.

To help us deal with this scenario, Stephen Cover, author of “The 7 Habits of Highly Effective People”, provides a useful model. It’s simple. It’s best described using two concentric circles. The outer circle is the Circle of Concern. This relates to all of those ‘things’ that concern you but over which you have no control. In our example, you might worry about what other people think. You might be concerned about what Bruce will, say, do or act. You may worry about unforeseeable negative consequences that result from the discussion, even unlikely ones.

You approach that difficult someone (let’s call him Bruce) and ‘whoosh!’, it doesn’t go to plan. You lose your cool. Bruce does too. Maybe he loses his temper first – but it doesn’t matter who lost their cool first. It’s almost as if you haven’t learnt anything. That’s because handling a complex situation with multiple emotions in play, is not like learning how to handle an electric power-tool, or a computer program.

This scenario involves you changing the way you communicate, doing so under difficult circumstances. Perhaps, success is achievable for you, if your aim is merely to get something off your chest; gaining a short term win. That’s achievable because it revolves about one person (you) sending a message. By ‘sending’ I don’t mean emailing. I mean ‘delivering’ or ‘speaking’ the message.

But sending a message doesn’t resolve the situation that created the problem. It also does not have that difficult person (a person like Bruce) change the way he treats you.

One model that is very helpful in understanding what makes people behave as they do, is Transactional Analysis. Transactional Analysis (TA) is a theory developed by Dr. Eric Berne in the 1950s that became popular, lost its popularity, then has recently regained it as we look for new ways to understand ourselves and others.

TA is described in Wikipedia as a social psychology designed to understand how people interact. TA proposes that the way people behave is programmed into us as children. We either: • behave as we did as children, being either compliant or wilful, or, • we follow the model of parenting that we observed when we were children, with TA stating that parents can be either controlling or nurturing.

TA would say that when we allow someone to effectively, bully us, we are being a compliant child to a controlling parent. If we stand up against a controlling parent, by trying to wrest control of the situation from him/her, we end up with a unstable condition that may not resolve itself until one party changes its stance. While you play the role of compliant child to a controlling parent, the relationship, while possibly uncomfortable for you, is psychologically stable and will continue until one or the other of you changes his/her stance.

One way to handle a state of affairs like this, is to look beyond that person who makes you feel uncomfortable. If you have one person who makes you feel uncomfortable, it’s possible, even likely, that there are others who similarly make you feel uncomfortable.

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Circle of Influence Circle of Influence Natural Disasters What Others Think

Who do you work for How hard you work What You Do Who you Trust What You Think Your Friends

Weather

The Economy Interest Rates

Your Height

Covey’s inner circle, the Circle of Influence, covers those factors over which you have control. Basically, you can only control what you think or do. If you decide that you are not going to do what Bruce tells you to do, you’re in control. If you decide that you’re in control of your emotions, then you won’t let Bruce place you in a situation that makes you feel uncomfortable.

The lesson here is that no matter the management topic you are dealing with, underpinning all is your self-awareness. So, whether it’s delegation, coaching, motivation, leadership, team-building or other area of skill, its success is more readily achieved if you first understand how a particular task affects you. If you can better manage how you feel, think and act, then you’re going to handle others better.

Ron Pollak is a management trainer and coach. He has focused in the areas of Sales and Leadership, combining his experience as a chartered accountant, business founder and manager and management consultant. The courses he runs extend into coaching individuals after the training.

Two courses he runs in particular develop self-awareness.

Personal Development and Leadership. www. ronpollak.com.au

Forum Import/Export

Reason for optimism for Australia’s manufacturers Despite the negativity, not all is doom and gloom for Australian manufacturers, as explained by Andrew Watson.

2016 has been a year of significant change for Australia’s manufacturing industry. There has been considerable commentary about the loss of jobs in sectors Australia has a rich history in, such as the automotive and steel industries.

However, the headlines which predict the decline of manufacturing in Australia are often misleading and don’t tell the whole story. While it is true that some of Australia’s manufacturing industries have gone through structural change and have had to navigate sluggish world growth, there is also cause for optimism.

Positive outlook for growth Recent Australian Bureau of Statistics (ABS) figures show that the total number of Australian exports of goods and/or services increased by 9% between 2013-14 and 2014-15. Encouragingly, the ABS figures also show that this increase was mainly driven by small businesses – exporters who were exporting less than $1m worth of goods or services per year.

These figures are consistent with the findings of Efic’s latest SME Exporter Index, bi-annual research which captures insights from small and medium sized enterprises (SMEs) on current trends and issues in export markets. The research found that over a third of SME exporters are optimistic about growth for the year ahead. Small business optimism has continued to grow since Efic first conducted the research in March 2014, when only 25% of exporting SMEs predicted their sales in offshore markets would increase in the upcoming quarter.

Promisingly, this optimism is translating into business activity for the year ahead. According to Efic’s SME Exporter Index, one in five SMEs intend to launch new overseas operations within the next six months, while a further 5% intend to within the next year. This business optimism continues into the longer-term as well, with 41% of small business owners planning to establish new subsidiaries abroad from 2017.

This optimism is supported by findings in the Australian International Business Survey 2016, an annual survey of Australian small business exporters. The survey found that 97% of SME exporters are involved in the export or import of goods, with 92% planning on exporting in the year ahead, pointing to a strong export market for Australian business.

Trends for manufacturing exports The Australian International Business Survey collected data from 913 Australian businesses, of which a third were manufacturing businesses. Of these 300 manufacturers, 99% had been involved in international activities in the past year. These manufacturers also outlined an optimistic view of the year ahead.

The top five markets for manufacturing exporters were identified as the United States (16%), New Zealand (10%), China (10%), UK (7 percent) and Singapore (5%). Respondents also gave insight into their business model to support their export activities, with 63% of manufacturers likely to service their major overseas markets directly from Australia. Only 24% of companies said they prefer to service international markets through an agent or distributor based overseas.

Manufacturers expressed optimism about export opportunities, with 82% planning on expanding into additional markets in the next two years. Interestingly, of the companies that had plans to expand into new markets, 17% identified the United States as their likely destination, 12% highlighted China, and 6% expected India to be the next market they enter into.

Half of manufacturers expect that their international revenue in the next three to five years will mainly be driven by sales of existing products or services in the market in which they are currently operating. Around 20% of respondents expect future international revenue to be driven by sales of existing products or services in new international markets, while 19% expect revenue to be driven by current export markets.

Manufacturers are upbeat about the outlook for the industry in the year ahead, with 25% saying the outlook is ‘much better’ and 47% describing it as ‘better’ than last year. Only 6% of respondents said the outlook for manufacturing exporters is ‘worse’ in the year ahead.

This is excellent news for Australia’s manufacturing industries.

A Victorian example for manufacturing exporters One manufacturer which is taking advantage of the opportunities available in international markets is Victorian manufacturer of polyethylene pipe butt welding equipment, and family business, Worldpoly. Established in 2000, Worldpoly now exports to over 108 countries worldwide, accounting for about 70% of total business.

With a focus on international markets, Worldpoly saw an opportunity to establish a new distributor in South Africa, further opening up the Sub-Saharan Africa market. Their bank was unable to help finance the venture because of the cash flow nature of extended terms to a foreign country.

“The largest challenge to exporting is the cash flow required to match the credit terms, which are provided by foreign national competitors,” says Rob Hall, Managing Director and owner of Worldpoly.

With the introduction of a new loan product specifically for small business exporters by Efic, the Australian Government’s export credit agency, businesses like Worldpoly are able to access smaller, unsecured loans with flexible repayment terms. “Efic’s funding allowed us to send our machines to a new distributor in South Africa. The Small Business Export Loan from Efic made this sale possible, and has allowed us to facilitate more stock in South Africa,” says Hall.

Andrew Watson is Executive Director, Export Finance, Efic (Export Finance and Insurance Corporation). Efic is a specialist financier that delivers simple and creative solutions for Australian companies - to enable them to win business, grow internationally and achieve export success. Through its loans, guarantees, bonds and insurance products, Efic has helped many Australian exporters and subcontractors take advantage of new contract opportunities that may otherwise have been out of reach www.efic.gov.au info@efic.gov.au ph: 1800 093 724

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Forum Law

Changes to food labelling laws good for Australian food businesses

Food labelling reforms are a win for Australian food manufacturers and consumers, as explained by Paul Kirton and Georgia Davies-Jackson.

On 1 July 2016, the new country of origin food labelling regime came into force under the Australian Consumer Law (ACL).

Manufacturers now have a two-year period to transition to the new arrangements. The new regime will apply to all retail sale of foods, with current stock in trade allowed to “see out its use-by date” until 1 July 2018.

Businesses can adopt the new scheme now on a voluntary basis.

However, if businesses choose to wait, the country of origin labelling requirements set out in the Food Standards Code and the misleading conduct provisions of the ACL continue to apply.

At the end of the transition period, the Food Standards Code will remove its country of origin labelling requirements and just the expanded ACL provisions will apply.

The Food Standards Code will otherwise continue to regulate other aspects of labelling, for example in relation to ingredients, allergens, nutritional information and health claims.

Rationale for change The reforms have been developed in response to consumer claims that current origin information is often misleading and confusing.

This was highlighted by the contaminated berry recall in 2015, where some Australian consumers contracted Hepatitis A after allegedly eating berries grown overseas (but labelled as packaged in Australia or New Zealand).

The often-used statement “Made in Australia from imported ingredients” was highlighted as being inconsistent and inadequate to give consumers proper information about the products they were purchasing. Whether a label with greater origin clarity would have averted the damage caused to the consumers of the berries is arguable. However, such events do (at least for a time) cause consumers to more carefully inspects and make choices about the source of their food.

The new labelling regime is intended to provide consumers with clearer, accurate and more meaningful information about the products they buy - where it’s produced, grown, made or packaged. The new regime should assist in overcoming the difficulty in interpreting food labels and confusion caused by terms such as ‘made in’ and/or ‘product of’ and how this translates to the whole product that appears on the shelf. The changes aim to make it clear to consumers where food is actually produced, instead of reflecting the location where it is processed or ultimately packaged.

Labelling requirements The new labelling requirements will apply to food for retail sale only, and will therefore not be applicable to food prepared and sold in cafes, restaurants, schools, etc. The new regime will not apply to “non priority” foods such as confectionery, biscuits and snack food, seasonings, bottled water, soft drinks and sport drinks, tea and coffee and alcoholic beverages. These foods will be required to include a text statement of origin on the packaging label. All other foods not in the above categories will be classified as a priority food.

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All priority foods grown, produced or made in Australia will be required to display on its label: • A triangle kangaroo logo.

• A bar chart showing the percentage of Australian ingredients; and • An explanatory statement inside a box e.g. “Made in Australia from at least 80% Australian ingredients”.

For imported priority food, the country of origin will be required to appear on the packaging label in a text box. Manufacturers can voluntarily choose to specify that the product is packaged in Australia and utilise an empty bar chart to show that there are no Australian ingredients.

Manufacturers have the option to voluntarily provide extra information about the origin of specific ingredients. This is not a mandatory requirement under the new regime.

Enforcement Financial support has been provided to the Australian Competition and Consumer Commission (ACCC) for compliance and enforcement activities relating to the new regime. Funding is also being provided to implement an information campaign to support consumers and businesses to understand and implement the regime.

Once the new regime becomes mandatory, the ACCC is able to enforce the standards and issue infringement notices and may pursue fines and other legal action. Local Governments can also review labelling whilst conducting food safety inspections and alert the ACCC to any breaches of the standard.

Benefits for consumers and manufacturers In our view, the reforms to country of origin food labelling provide Australian food manufacturers with a competitive advantage.

Consumers can purchase with greater confidence, now that claims made are more realistic and accurate.

The current food labelling rules are also streamlined by bringing both country of origin and other misleading and deceptive claims, under the same piece of legislation.

Food producers and manufacturers who utilise local ingredients can more clearly distinguish their products from imported ones. In addition, this removes the burden on manufactures of having to apply the time-intensive production cost test.

Early voluntary adoption of the regime may benefit manufacturers where consumers choose Australian products over imported products, as the new regime is more simply understood and provides greater detail and, importantly, effectively highlights the difference between Australian goods and imported goods.

Macpherson Kelley’s food group acts for many food producers, processors and importers. If you would like further information about the changes, or food safety or labelling requirements more generally, please contact Paul Kirton, Principal, at paul. kirton@mk.com.au or 03 9794 2621.

Macpherson Kelley Lawyers www.mk.com.au

Forum OHS

Improvements in powder coating industry WA recently launched a follow-up safety inspection program into powder coating. The results are a timely reminder about the hazards of TGIC – the potentially toxic additive in powder coating used in the metal finishing industry.

A proactive inspection program looking at safety issues in powder coating and abrasive blasting in workplaces has found a noticeable improvement in safety practices.

The program was conducted over the 2015/16 financial year in metropolitan and regional workplaces in WA where powder coating and abrasive blasting activities were taking place, following on from an earlier inspection program looking at similar activities.

WorkSafe Director Joe Attard said the inspection program had noted improvements in safety since the earlier program.

“An earlier program looking at powder coating found that many businesses were carrying out the activities with limited knowledge of the risks involved,” Mr Attard said.

“During this program, inspectors found that awareness of the risks had increased and that many companies had ceased using products containing the more hazardous substances once common in the industry.”

Powder coating is a process by which powder is applied electrostatically to an item before being heat-cured to form a skinlike casing.

The powder can contain a hazardous substance called Triglycidyl isocyanurate (TGIC) that can increase skin and respiratory tract sensitivity, is toxic if inhaled or ingested, can cause serious eye damage and can cause reproductive effects in the offspring of males exposed to it.

Powders can also contain other hazardous substances such as hydrofluoric acid and Chromium 6, and there are also electrical hazards associated with electrostatic spray painting.

“As part of this inspection program, inspectors visited 58 workplaces in which powder coating and/or abrasive blasting activities were undertaken,” Mr Attard said. “They issued a total of 152 improvement notices and one prohibition notice.”

The main issues identified in workplaces were: • Hazardous substance registers; • Risk assessment for hazardous substances; • Induction and training in the use of hazardous substances; • General duty of care – provision of a working environment in which employees are not exposed to hazards; and • Provision of appropriate first aid facilities specific to working environment, and training of personnel.

“Although there is obviously still work to be done in this area, the inspectors did note changes for the better over recent years,” Mr Attard said.

“Awareness of hazardous substances such as TGIC has increased noticeably, and many companies have ceased using them.

“This inspection program aimed to further raise awareness of the hazardous substances that may be used in the industry and provide employers with information on how to comply with workplace safety laws to make workplaces safer.

“We firmly believe that raising awareness with proactive inspection programs is the best way in which to lessen the risk of work-related injury and illness.”

Persons at risk

Workers who may come into direct contact with TGIC powder coatings include persons: filling hoppers; manually spraying powder coatings (including ‘touch-up’ spraying); reclaiming powder; emptying or cleaning industrial vacuum cleaners; cleaning spray booths, filters and other equipment; and cleaning up major spills of powder coating.

Employers have an obligation to eliminate, so far as is reasonably practicable, the risks associated with the use of hazardous substances (such as TGIC). This means employers should ensure TGIC-free powders are used. These are readily available, and according to powder coating suppliers, the performance differences between TGIC-free powders and TGIC-containing powders are minimal.

If it is not reasonably practicable for an employer to use TGICfree powders, an employer must reduce the risk as far as is reasonably practicable, by implementing suitable controls such as those outlined below: • Arrange for all powder coating to be performed in a spray booth, where the average air velocity through each booth opening is not less than 0.4 metres/second.

• Spray gun operators and persons cleaning the booth or powder coating areas should wear hooded coveralls, non-insulating gloves, a P1 or P2 rated dust respirator and goggles.

• Ensure all equipment is earthed to prevent a build-up of static charge, which could potentially cause powder ignition or a dust explosion.

• Ensure compressed air and dry sweeping are not used when cleaning the booth and powder coating area.

• Spray gun air pressure must be minimised to prevent overspray as this could result in unnecessary powder build-up within the spray booth.

• The power supply and powder coating feedlines must be interlocked with the air extraction system so that if a fault develops in the ventilation system, the powder coating and power supplies are cut off.

It is the responsibility of the Commonwealth, states and territories to regulate and enforce work health and safety and administer workers’ compensation schemes in their jurisdiction. The Regulator in your state or territory is listed here: Australian Capital Territory - www.worksafe.act.gov.au New South Wales - www.safework.nsw.gov.au Northern Territory - www.worksafe.nt.gov.au Queensland - www.worksafe.qld.gov.au South Australia - www.safework.sa.gov.au Tasmania - www.worksafe.tas.gov.au Victoria - www.worksafe.vic.gov.au Western Australia - www.worksafe.wa.gov.au

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98 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

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.

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.

• Reduced cost of deployment.

• 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

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Manufacturers Pavilion

Complete engineering solutions As times change, one thing that hasn’t changed is TRJ Engineering’s company mission: “We apply our expertise and experience to create high-calibre engineering for all industry sectors”.

TRJ Engineering was established a little over 40 years ago. Perhaps the best aspect of TRJ is its ability and desire to build bespoke items; making TRJ very approachable. TRJ enjoys the challenge of a new or established customer coming in to discuss a new product regardless of the quantity; as it is felt that this ‘learning’ process can be beneficial to this customer as well as the next one.

Currently TRJ has a very wide array of clientele for which engineering solutions are produced. The company is proud of its ability to produce completed b-double chassis every week to one customer whilst producing a generous number of chassis rails for another. Not only is fabrication using mild steel performed, but there are many satisfied customers for which TRJ also manufactures stainless steel and aluminium products. These can range from the small repetitive products to larger items such as stainless steel hoppers for the food industry, while also producing a large, continuous number of aluminium furniture frames for high-end customers in Melbourne.

Many councils and cities employ TRJ. Using

stainless and mild steel, TRJ has fabricated a large array of street furniture which adorn the streets and docklands.

Next to its fabrication department, TRJ has two robots producing continues parts for car companies. These robots can be programed to produce anything the customer desires in large, consistent results.

In its new modern factory, the following is contained under the one roof: • • • • • • •

laser cutter drafting department press shop machine shop fabrication department robot welders enclosed assembly area.

TRJ Engineering Group 47-51 Westpool Drive Hallam Victoria 3803 T: 03 9703 1701 F: 03 9702 3288 W: www.trjengineering.com.au E: jeremy@trjengineering.com.au David Murphy Managing Director T: 03 9703 1701 E: david@trjengineering.com.au TRJ has the ability and experience to fabricate and machine using all types of steels and quantities to excel beyond customers’ targets. This sets the foundation for TRJ to fulfil its company’s goal of: “To be recognised as the complete engineering solution provider in Australasia”

With these departments, TRJ can produce all items without leaving the factory, enabling the precise location of customers’ products.

At TRJ, the company direction is “To be recognised as the complete engineering solution provider in Australasia”. TRJ feels it has the right personnel and equipment to be able to help you reach your goal.

earthmoving

Corporate Identity for TRJ Engineering group

TRJ Engineering Group…

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 Dec 2016/Jan 2017 Corporate Identity for TRJ Engineering group

Manufacturers Pavilion

High-volume, precision, custom-machined

Successful repetition engineering company manufacturing custom-machined components to a wide range of customers in diverse fields worldwide.

One of the biggest component manufacturers in their field, Jodek has been operating for over 20 years. That timespan has seen the development of a dedicated team with complementary skillsets which has grown to cover all aspects of the industry. The ISO 9001-accredited company boasts well over 3,000,000 components produced per annum, machining more than 120 tonnes of steel per month.

The company has invested considerably in equipment, tooling, processes and people, enabling it to run 24/7 with up to 8 hours per night running unattended. Its positive outlook is evidenced by the company’s recent investment over the past three years.

Relocation to a larger premises – almost double the size of the previous one – and the installation of another eight CNC machines, an extra bandsaw, various special-purpose machinery, inventory management systems and the hiring of 10 new staff.

Jodek’s acquisitions include 21 late-model CNC machines (including Mori Seiki, Mazak, Miyano, Star and Hardinge.) Many machines are multi-spindle, multi-turret lathes with milling capability. Material types

that can be machined include steel, hightensile steel, stainless steels, brass, plastic, aluminium, copper and castings. Machinery is continually updated, with at least 1-2 new machines purchased per year.

When Jodek commenced operations 20 years ago, there were 100 or more companies in Australia performing highvolume machining work – now there is only a handful left. The company’s consistent investments have resulted in extreme flexibility, with the ability to react quickly to market needs – swapping from high-volume jobs on all machines to low-volume work very quickly when required.

At present, around 60% of Jodek’s components are supplied into major projects worldwide. A recent project involved the dispatch of almost 50 tons of finished components to Hong Kong for the construction of the Hong Kong–Zhuhai– Macau Bridge.

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.

“You would be hard pressed to find a major project completed within Australia during the past 20 years that does not contain something manufactured at Jodek,” concludes Managing Director Derek Hyde.

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

Heavy-duty industrial shelving and hybrid drawer storage for flexible layouts BAC Systems is best known for its award-winning range of drawer storage cabinets and workbenches, but a lesser known fact is that BAC Systems has a very dynamic range of heavy-duty industrial shelving for all applications.

The BAC 77 system combines different types of shelving with BAC’s worldfamous drawers to create what is likely the world’s most flexible hybrid shelf storage system. The BAC 77 starts as a racking system and can be fitted with a quality pallet rack, a long span shelf or a mesh shelf with mesh separators. The shelves can be either the width of a single pallet or of two pallets in order to get best use out of your floor space.

What is unique about the BAC 77 is that the BAC Pallet Rack, the BAC Mesh Shelves and the BAC Long Span can be fitted into a single bay using one structure! This means flexible warehouse layouts may be created, perhaps placing hand-loaded items on the bottom and pallets up high, or whatever suits the particular application.

BAC has a range of drawer options to enhance the BAC 77 system. BAC’s design award-winning high-density drawers are a key element of the BAC 77, providing a solution for storing small or medium-sized

parts with minimal space wastage. These drawers can be integrated among the racking, forming an allpurpose storage system.

Another drawer system that is part of the BAC 77 structure is the BAC Heavy-Duty Drawer. Available in two different sizes, the larger of which will accommodate a full-sized pallet, the BAC Heavy Duty Drawer can hold up to 500kg. It can be loaded with a forklift or an overhead crane and is popular in manufacturing facilities for this flexibility.

The BAC 77 system does not stop with racking and drawers. The system also incorporates a Vertical Drawer, which is a pull-out shelving system, and a long pullout rail, fitted with hooks or a large mesh frame, that can be used for storing large and irregularly shaped items. This modular system is so flexible, and can be assembled in so many different combinations, that a storage solution can be configured for nearly every application.

BAC Systems 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 Dec 2016/Jan 2017

Manufacturers Pavilion

New end-of-line palletising solution Seeing the need for a simple, small footprint end-of-line palletising solution, ADDE has developed an exciting new collaborative palletiser using a Universal Robots UR10 It is a common sight across manufacturing operations in Australia to see a person at the end of a packing line hand-palletising cartons onto a pallet. ADDE has been building custom automation solutions for Australian manufacturers for over 20 years, and while they have built many large, centralised and high-rate palletisers, there has never been an effective palletising solution for smaller operations and lower rates – until now.

ADDE has developed an innovative and exciting new end-of-line palletiser that can be quickly, easily and economically applied in a wide range of operations. By utilising a Universal Robots UR10 collaborative robot the system does not need guarding, meaning the whole palletiser has a foot print no larger than the current space of an infeed conveyor, an operator and a pallet on the floor. Because of this, ADDE has dubbed their new system the Zero Footprint Palletiser. When ADDE first started working with Universal Robots, the potential for palletising was obvious. The UR10 arm has a payload rating of 10kg and can pick at rates over 6 cartons per minute, and now

with this innovative design from ADDE, the robot is mounted on a vertical lift column so it can reach the full volume of an Australian standard (Chep) pallet.

The system has been developed as both a single pallet system for the smallest footprint or in a two-pallet configuration to allow production to keep flowing while the pallets are changed. It can even be moved from line to line with a standard pallet trolley to be deployed as needed.

The system features a very easy to use touch screen interface to simply select the pallet pattern required, define the box details, and set the system going. No robot programming skills are needed and the system can be running within minutes of being plugged in.

ADDE 6B 841 Mountain Highway Bayswater, Victoria 3153 T: 03 9760 9600 F: 03 9760 9611 W: www.adde.com.au E : info@adde.com.au Barry Hendy Managing Director T: 03 9760 9605 E: barry@adde.com.au Andrew Donald Design Engineering (ADDE) serves the local manufacturing industry with innovative, custom automation solutions from concept to completion. ADDE designs and builds turn-key systems to your unique needs, from simple end-of-line packing using collaborative robots to complete manufacturing, inspecting, packaging or palletising systems.

Baxter Laboratories has recently committed to be the launch customer for the new palletiser. Conveniently located just up the road from ADDE, the Baxter team have been helping to refine the design and plan to deploy five systems to bring this efficient end-of-line palletising solution to their operations.

AMT Dec 2016/Jan 2017

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Manufacturers Pavilion

Australia’s largest manufacturer of soft jaws offers customised solutions Dimac Tooling’s success in a very competitive marketplace is aligned to a high quality product range and a strong focus on customisation.

Dimac’s focus is to develop and deliver productivity-enhancing accessories by combining in-house design and manufacture with products sourced from quality suppliers worldwide, tailored to customers’ needs. As well as being Australia’s largest manufacturer of soft jaws for CNC turning, Dimac also exclusively imports machine tool accessories from around the world and is a full-service support distributor for those brands. The company’s success in a very competitive marketplace is aligned to a high-quality product range and a strong focus on customisation. As a significant part of business includes imports from overseas, Dimac’s strategy to remain competitive and relevant to the Australian and New Zealand market is to couple these products with expertise for designing and in-house manufacture of customised solutions; much of this around workholding. One of the biggest challenges the company regularly sees for its customers is dealing with small batch quantities and this characteristic of the market drives solutions aimed at reducing setup times and setup complexity. Dimac

regularly attends overseas tradeshows to work with international suppliers and partners and to look for emerging trends and technologies and bring them to CNC users who are seeking to stay competitive and ahead in the market. The company frequently supplies customers with a turnkey package by not only offering them products, but more importantly a finished solution, tailored to their needs. A significant area where customers can see productivity and quality benefits is with custom workholding for CNC turning and milling (mill/turn). Dimac’s history and experience in this area is extensive. By providing a solution that safely anchors the workpiece (even if irregular in profile), with consideration for balance and tooling access, they have found many parts that might have been previously only considered for CNC milling can be processed in one setup on a mill/ turn lathe with clever and innovative workholding. This reduces WIP, improves quality through reduced setups and overall reduces manufacturing costs, leading to a more productive and profitable outcome.

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

AMT Dec 2016/Jan 2017

Dimac Tooling Pty Ltd 69-71 Williams Rd Dandenong South VIC 3175 T: 03 9771 6121 W: dimac.com.au E: sales@dimac.com.au Paul Fowler Managing Director T: 03 9771 6121 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.

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Amtil Inside

The year in review

As we close out 2016, I thought it was a good time to look back on the year in review, and outline our plans for 2017.

In May 2016 the Board and senior staff reviewed our two-year strategic plan, in line with a two-year budget forecast, and identified nine key strategies for us to address in the short term (see opposite).

Our event calendar this year was comparatively subdued given that our flagship exhibition: Austech, is now held every two years and therefore did not run in 2016.

We did, however, run around 20 events including Business Breakfasts, Plant Tours, Member Focus Sessions, Networking Functions and Social Activities.

We believe a broad range and type of events is the best way to engage with the membership and provide them with the networking and opportunities they are looking for. We are now well advanced in the planning stages for Austech 2017 and are looking forward to a really strong event in May. The decision to produce a bi-monthly AMT magazine was a positive one. The magazine continues to go from strength to strength and our resources now allow us to have even more focus on great Australian stories and positive news that is happening in our precision engineering and advanced manufacturing sector. I would like to thank our members who have supported our magazine over the past year. We are very proud of the regular feedback we receive which iterates AMT is very well regarded and respected in the industry.

We continued our regular Hotspot communication with members. This is our way of passing on anything that comes across our desks that we feel is of interest to members, whether it be opportunities for work, networking functions, information on running a business, funding prospects from Government or specific industry information, the Hotspots have been well received by members and we look forward to continuing this service in the future.

Our work with the Federal Government continued through our work as a Partner Organisation for the Entrepreneurs’ Programme (EP). We now have nine staff delivering business reviews and specialist hard and soft technical advice at a National level and we continue to support all the components that make up the EP. This is a great national initiative and one we intend to be even more involved with in future.

I would like to take the opportunity to thank all our members who have been involved in our activities over the past 12 months. Your input is valued highly. I would also like to thank the Board and Directors of AMTIL, who have given such good guidance and support to the Institute over a long period of time. I would like to single out Mr Pat Boland, who stands down as a Director and Past President after eight years of service. Pat’s industry standing, knowledge and input into our organisation have been significant and he will be missed on our Board.

Finally, enjoy the Christmas festivities. Be safe and I look forward to renewing communication in 2017.

AMT Dec 2016/Jan 2017

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Amtil Inside

Three new members for AMTIL Board AMTIL’s Annual General Meeting on 20 October saw the confirmation of Annaliese Kloe, Adam Nichol and Andrew Rodgers as the latest appointments to AMTIL’s Board of Directors.

Annaliese is the Managing Director at Headland Machinery Pty Ltd and CEO of Klugo Pty, based in Burwood, Melbourne.

Adam is the Managing Director of Nichol Industries Pty Ltd, from Nunawading, Melbourne.

Andrew is the General Manager of Bolts & Industrial Supplies Pty Ltd. “I’m delighted to welcome Annaliese, Adam and Andy to the AMTIL Board,” said AMTIL Annaliese Kloe CEO Shane Infanti. “All three are well-known figures who enjoy a great deal of respect and credibility across the industry.

The experience and acumen they will be able to provide will be of enormous value to AMTIL and to our members. They will be great additions to the team.”

Annaliese, Andrew and Andy join existing Board Members Brigitte Stavar, Mark Dobrich, Paul Philips and Phil Xuereb, with Paul Fowler continuing as AMTIL’s President. The new arrivals coincide with the departure of two longstanding members: Pat Boland of ANCA Pty

Adam Nichol

Andrew Rodgers

Ltd and Saxon Fletcher of Metal Cutting Technology Pty Ltd. Both have stepped down after eight years, with Pat also putting in a twoyear stint as AMTIL President.

“On behalf of all AMTIL member companies and our staff, I’d like to express our gratitude to Pat and Saxon for their outstanding contributions over the years,” Infanti added. “All of our Board members put in a lot of time and commitment without expecting anything in return, so again I want to thank them all for their efforts.”

Our nine key strategies AMTIL’s priorities for the coming year are as follows.

1. Grow Austech and increase margins. We will identify potential growth in exhibition areas, conference activity, affiliated events and sponsorship opportunities. We will also look to increase the visitor numbers, particularly interstate, and reduce costs to AMTIL and our exhibitors.

2. Maintain integrity of our Publications and increase margins. We will scope the feasibility of additional supplements, unique value added products, advertorial content and potential new areas of advertising support. We will also look to utilise resources in other areas and look to reduce costs of production where possible.

3. Increase member engagement through cost-neutral events/activities. We will conduct regular surveys of our members to ensure we develop an event calendar which will engage a minimum 75% of our members. We will also look to increase sponsorship revenue and utilise resources in other profitgenerating activities.

4. Increase member benefit through third party alliances and industry support. We will identify key high level industry supporters, service partners and alliances that will add to the value proposition for our members.

5. Develop a profitable major activity every second year to replace Austech. We will conduct the due diligence on a replacement event such as Technology Roadshow, stand-alone events, conferences/seminars and international activity.

6. Grow Government Relationships. We will develop stronger relationships with government and associated departments to improve the AMTIL brand and increase funding for AMTIL and our members.

7. Development of Digital AMTIL. We will identify member benefit and revenue opportunities through web activity, e-marketing, social media and other digital media. We will also increase website traffic, undertake statistical analysis and develop an infrastructure plan for the future.

8. Grow Membership. We will develop our service offering to improve our retention levels and increase new membership. We will also conduct regular feedback sessions and develop better communication methods.

9. Good Governance. We will have good governance processes and strong leadership and management in place. We will also focus attention on accountability, financial sustainability and risk management.

At your service.

1271AMTIL

AMTIL supports its members through its select range of AMTIL Service Partners.

AMT Dec 2016/Jan 2017

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Amtil Inside

Five signs your accounting system is out of date

The Australian accounting software market is estimated to worth over $500m a year, so it’s little wonder the country’s top software providers are jostling for share of market and share of voice.

The choices for manufacturing businesses are many and varied and the capability requirements extend across inventory, payroll, foreign currency and any number of other functionality aspects. With the major players such as Xero, MYOB, Netsuite and Sage competing for your business’ dollars, how can you separate the benefits for your business from the marketing hype? Is it worth upgrading your software? Or are these well-advertised new packages just the same products with unnecessary bells and whistles?

Making the right choice for your business is critical but the first step before embarking on a major overhaul of your accounting system is consideration as to whether you need to update. If you’ve been considering your options or are simply curious, here are five signs that your accounting system could be out of date.

1. Your business is reliant on Excel We’re accountants, so naturally we love Excel – in fact it’s a daily part of business life. However, if the majority of your business’ accounting processes are taking place in Excel, it may be time to upgrade.

Business today moves at a faster pace, there is more information to process and analyse, regulations are continuously changing, and it’s more than likely your business requires multiple performance reports. Manually entering information and formulas into Excel is not only timeconsuming, it can slow everything down while you check for typos and other user-errors – just ask your bookkeeper or finance team.

Additionally, the ability to pull together information from across the business to make timely decisions is critical. And if your business is reliant on Excel, or worse still if Excel doesn’t integrate with your current accounting software, you could be falling behind your competitors.

2. You’ve lost data in the past 24 months Maintaining your data on hard drives or an internal computer network requires a rigorous regime of back-ups. Human error, hardware malfunctions and malicious attacks can all lead to a loss of data, costing your business substantial time and money.

If this has happened to your business in the

AMT Dec 2016/Jan 2017

last 24 months, it may be time to look at a more automated back-up process.

Accounting systems in the Cloud all include some level of automated off-site data backups, either directly in the software or via third-party service providers. Knowing that your inventory records, financial reporting and payroll data is proactively managed and protected from security risks can provide invaluable peace of mind. Moreover, with a Cloud-based solution, software updates occur automatically - eliminating those time-consuming upgrades to your PC and issues juggling old back-ups captured with prior versions of software.

3. Data from one system is manually entered into other systems to produce your accounts Advances in technology have significantly reduced the need for data entry. Modern accounting systems can integrate with multiple third parties such as your bank, receipt management and payroll.

Transactional data can be readily available in your accounting system via a ‘live feed’ reducing the need to manually upload information. Having a close look at the cost of data entry and administration to your business may be a real eye-opener.

4. Not all users of the data have access at the same time For any one business there may be multiple users of the same information. Waiting for reports to be updated and managing version control can be time consuming, frustrating and allow a significant margin for error. Accounting systems with multi user-functionality allow you, your team, and importantly your advisor to access the same data and work on it simultaneously.

Take for instance, a business with a large sales team. If each sales executive is out on the road taking orders at the same time, how is inventory managed? Using a traditional accounting system, the sales executive is reliant on the latest stock list, which at best has been generated that morning, at worst at the beginning of the week.

The latest software allows staff to process a sale on their smartphones or tablets in real time, instantly updating stock levels for the whole team to access. Team members are also able to monitor their own sales targets and management has real-time access to the business’ performance.

Spending less time on data management translates to less cost to your business.

5. You can’t get the information you need away from the office Ask yourself, where do you do the majority of your work? At the office, out in the field, at a client’s premises, or perhaps on the road? Advances in technology have led to a mobile workforce, with business owners and management working from laptops, tablets and smartphones. These changes allow you to be closer to your clients and employ flexible work arrangements.

But has your accounting software caught up? Most modern software packages allow you to access critical information such as your business account balances, outstanding invoices and cash position from anywhere with an internet connection.

Not only that but most providers also offer a range of apps for use on tablets, smartphones and other devices.

Accounting software and information systems have advanced in capability and functionality significantly over the past five years. Many of the improvements have also resulted in price reductions as well, particularly with some of the cloud based systems. If you’re bound to your PC, you may be imposing unnecessary restrictions on yourself and your business.

Damian Sutherland is a director of William Buck (Vic) Pty Ltd Chartered Accountants. AMTIL has a service partnership with William Buck as an exclusive benefit to our members.

For more information, contact AMTIL’s Corporate Services Manager Greg Chalker at gchalker@amtil.com.au.

Damian Sutherland can be contacted on 03 9824 8555. www.williambuck.com.au

Hotspots is proudly owned and managed

by AMTIL

Press our buttons and we’ll be there to help you •

You need a specific component made, but don’t have the capabilities in house.

•

Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

•

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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Amtil Inside

Events round-up

AMTIL held a number of events for its members in October and November, most notably its Annual General Meeting (AGM) on 20 October.

Held at Riversdale Golf Course in Mount Waverley, Victoria, the AGM included a thought-provoking keynote address from business futurist Morris Miselowski. In his presentation, entitled ‘FutureCurious’, Miselowski explored the ways in which digital technology is disrupting every aspect of our lives and the ways we do business.

opportunity to thank all our members that have been involved in our activities over the past 12 months.”

Site tours

Following Morris’ presentation, AMTIL CEO Shane Infanti gave a roundup of the association’s activities over the course of 2016, and provided the members present with some details of our plans for the coming year, most notably concerning the Austech exhibition, to be held in Melbourne in May, 2017. AMTIL President Paul Fowler also spoke on the current outlook of manufacturing in Australian and AMTIL’s position within the industry. A number of changes to the AMTIL Board of Directors were also confirmed (see page ).

“I’d like to say that the 2015-16 year was a good one but I’m afraid it was another year in which the manufacturing industry faced some difficulty,” said Infanti. “This had an impact on AMTIL members, so it was another year in which we endeavoured to help our members through these times as best we can. I would like to take the

The AGM was just one of a number of AMTIL events held in October and November. On 5 October, Amaero opened its doors for a tour of its ground-breaking additive manufacturing facility in Notting Hill, Vic. There were also tours of Swinburne’s Factory of the Future and and RMIT’s Advanced Manufacturing Precinct, both stateof-the-art facilities where universities and industry can collaborate to develop the innovations that will shape the future of Australian manufacturing.

“AMTIL’s program of site tours continues to attract a strong turnout from our members and we’re getting great feedback from everyone who’s attended them,” said AMTIL Events Manager Kim Warren.

“As we move into 2017, Austech is going to dominate the schedule between May but we’re looking forward to running more site tours and other member events going forward.” www.amtil.com.au/events

Real Members lead new AMTIL campaign AMTIL has launched a new membership drive, in a campaign that focuses on ‘Real Business, Real People, Real Members’.

The campaign places real AMTIL members front and centre, with a cross-section of businesses that highlights the diversity both of the association’s member base and of Australian manufacturing in general. The campaign features: • Peter Sutton of Sutton Tools.

• Grant Anderson of ANCA Group.

• Mark Dobrich of John Hart.

• Erika Hughes of Integra Systems.

• Brad Drury of New Touch Laser Cutting.

• Mark Hardman of Hardman Bros.

• Dean McCarroll of OKUMA. “AMTIL only exists because of our members,” said Greg Chalker, Corporate Services Manager. “That’s why we’ve launched this campaign, and that’s why we’ve built it around real members. These guys represent the kind of dynamic, forward-looking companies that are going to take Australian manufacturing forward.

On behalf of AMTIL I’d like to thank them for giving up their time and agreeing to take part.” www.amtil.com.au/Membership

Real Business Real People Real Members Real Business Real People Real Members of AMTIL? is there to be a member benefit what other reason an abundance of and globalisation provides The world is getting smaller tools and support to stay AMTIL provides us with the opportunities and threats. are driven to harness with businesses who strong a connected and collaborate retain and the threats together, opportunities and counteract

Apart from any financial

manufacturing footprint Erika Hughes, Integra

here in Australia.

Systems

, informing of been connecting business Since 1999, AMTIL has ity. the manufacturing commun opportunities and growing

A full page ad from the campaign amtil.com.au

1311AMTIL/EH

member contact our To be become an AMTIL , Greg Chalker on Corporate Servcies Manager gchalker@amtil.com.au 03 9800 3666 or email

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1311 AMTIL Memb A4

AMT Dec 2016/Jan 2017

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Industry Calendar

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event

INTERNATIONAL Steelfab United Arab Emirates 16-19 January 2017 Metal working and steel fabricating sectors.

Includes technical seminars with live demonstrations of machinery & equipment.. www.steelfabme.com Undersea Defence Technology Asia Singapore 17-18 January 2017 Innovations, challenges and future requirements of the Undersea Defence sector. www.udt-asia.com Smart Factory Expo Japan, Tokyo 18-20 January 2017 Next-generation factory exhibition: advanced FA, IoT and energy saving systems.

Automation, robotics, manufacturing technology, production engineering, automotive parts. www.sma-fac.jp/en RoboDEX Japan, Tokyo 18-20 January 2017 Robot development & application expo. www.robodex.jp/en AME Roundup 2017 Canada, Vancouver 23-26 January 2017 Mineral Exploration Exhibition & Conference.

Event for mineral exploration leaders.

Geoscientists, prospectors, investors, suppliers and partners that will help shape the future of mineral exploration and development. http://roundup.amebc.ca IMTEX India, Bangalore 26 January – 1 February 2017 Includes turning;drilling/boring/milling machines; CNC; machining centres, automation, dies/moulds, metrology, accessories. Concurrent event: Tooltech www.imtex.in Medical Design & Manufacturing West USA, California 7-9 February 2017 Annual medtech event, includes latest products and services, materials, intelligent sensors, testing solutions, components, contract manufacturing, and packaging. http://mdmwest.mddionline.com Expo Manufactura Mexico, Monterrey 7-9 February 2017 Includes specialised pavilions: Plastimagen (plastics); Additive Manufacturing, Medical Manufacturing & Automation® www.expomanufactura.com.mx Advanced Manufacturing Expo & Conference USA, California 7-9 February 2017 Includes adhesives; automation - cleanroom tech; contract manufacturing; design services; raw materials http://anaheim.ubmcanon.com/designmanufacturing

AMT Dec 2016/Jan 2017

TMS USA, San Diego 26 Feb – 2 March 2017 Encompasses the entire range of materials and engineering, from minerals processing and primary metals production to basic research and the advanced applications of materials. Co-located with Energy Materials 2017 and Pam American Materials Congress www.tms.org/meetings/annual-17 Houstex USA, Texas 28 February – 2 March 2017 Interactive experience, featuring hundreds of exhibitors highlighting the latest manufacturing technologies, and innovative solutions. www.houstexonline.com TECMA Mexico, Mexico City 7-10 March 2017 International machine tool exhibition.

Machine tool technology, related equipment & peripherals.200+ companies representing more than 800 brands http://tecma.org.mx/the-event TIMTOS Taiwan, Taipei 7-12 March 2017 Taipei International Machine Tool Show.

Includes: metal forming, casting, forging, cutting, welding, grinding machinery, surface treatment equipment, machine tool accessories, metrology, software, laser punching, welding, surface treatment equipment, software, design engineering, China, Swiss, German Pavilions. www.timtos.com.tw IMTE China, Tianjin 9-12 March 2017 International machine tool exhibition. www.chinaexhibition.com/trade_ events/8517-IMTE_2017.html MTMS-MACHINEERING 2017 Belgium, Brussels 22-24 March 2017 Materials transformation & machining show.

Includes transformation technologies for all types of materials, while Machineering covers production or assembly line setup from engineering & prototyping to final product. www.mtms.eu/en/concept MECSPE Italy, Parma 23-25 March 2017 Die & mould, presses and injection machinery exhibition and conference. Includes 11 thematic halls comprising materials, machines and innovative technologies (ie Digital Factory Beyond Automation). www.mecspe.com/en STOM-TOOL Poland, Kielce 28-30 March 2017 Includes metal-processing technologies and machine tools, automation, welding, software, safety, accessories. www.targikielce.pl/en

MTA Singapore 4-7 April 2017 Precision engineering exhibition: advanced technologies for high-value manufacturing.

Concurrent show: Metrology Asia 2017. http://mta-asia.com Metal Japan Japan, Tokyo 5-7 April 2017 Cutting tools, casting, pressing die cast equipment, powder metallurgy, sheet metal working machines, surface treatment equipment, metrology. www.metal-japan.jp/en Vietnam Manufacturing Expo Vietnam, Hanoi 5-7 April 2017 Exhibition of machine tools for mould & die making and injection technologies for plastics manufacturing. Includes machine tools; boring/drilling;griding machines; welding, metrology. www.vietnammanufacturingexpo.com CIMT China, Beijing 17-22 April 2017 China international machine tool show. Listed as one of the four most famous international Machine tool exhibitions in the world. www.cimtshow.com/enindex.jsp Motek India, Mumbai 8-10 June 2017 Showcasing production and assembly automation, feed technology and material flow, streamlining through handling technology, and industrial handling. The only trade fair to clearly focus on all aspects of mechanical engineering and automation and on the presentation of entire process chains. http://motek-india.in.messefrankfurt.com METEF Italy, Verona 21-24 June 2017 A comprehensive exhibition on raw materials, processing, machining, technologies, machinery. Special focus on automotive and metals recycling sectors. This edition has chosen the US as partner country to promote and more easily convey the European knowhow, especially in the diecasting sector..

Co-located with the Aluminium ICEB World Congress. www.metef.com M-Tech Japan, Tokyo 21-23 June 2017 Mechanical components & materials technology expo www.mtech-tokyo.jp/en EMO Germany, Hannover 18-23 September 2017 The world’s premier trade fair for the metalworking sector. www.emo-hannover.de/home

Industry Calendar local Australasian Oil & Gas Expo & Exhibition Perth Convention & Exhibition Centre 22-24 February 2017 Includes the following zones: Maritime; Asset Management; Instrumentation, Control & Automation; Subsea; Health/Safety. http://aogexpo.com.au Australian International Airshow 2017 Victoria, Geelong (Avalon) 28 February – 5 March 2017 The Australian International Airshow and Aerospace & Defence Exposition - AVALON 2017- will again showcase products, technologies and services in this vibrant and vital region. High levels of economic growth and technological development have resulted in growing demand for aviation and aerospace services, products and technology - from general aviation to airlines, air forces and space. www.airshow.com.au DesignBUILD Sydney, International Convention Centre 3-5 May 2017 An event for Australia’s architects, building professionals, manufacturers and suppliers in the residential and commercial industry sectors http://designbuildexpo.com.au Austech Melbourne Convention & Exhibition Centre 9-12 May 2017 Australia’s premier advanced manufacturing and machine tool exhibition. The only show specifically targeted at the metalworking, machine tool and ancillary market held in Australia. Inside 3D Printing will once again be co-exhibiting with Austech, presenting a showcase of the very latest innovations in the fast-developing field of additive manufacturing. The Inside 3D Printing Conference will be held on 9-10 May, while its exhibition component will run throughout Austech. Co-located with Safety First conference &expo safety show. www.amtil.com.au/austech AusMedtech Conference & ICMMB 2017 Melbourne, Crown Conference Centre 24-25 May 2017 AusMedtech & International Conference on Mechanics in Medicine and Biology (ICMMB).

Will bring together key stakeholders of the

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Australian and international medical devices and diagnostics sector to explore topics such as biomaterials, medical devices, assistive technologies for an ageing population, tissue engineering, 3D Printing and the mechanics of future medicine. www.ausmedtech.com.au Adelaide Boat Show Adelaide Event & Exhibition Centre 30 June – 3 July 2017 Leading recreational boating event, www.adelaideboatshow.com.au Sydney Boat Show Sydney International Convention Centre, 3-7 August 2017 Largest recreational marine event in the southern hemisphere. www.sydneyboatshow.com.au

600 Machine Tools

69

Alfex CNC

18-19

Andrew Donald Design Engineers Applied Machinery

103 11

BAC Systems

102

Blackfast Chemicals

89

Bolts & Industrial Supplies

27

Complete Machinhe Tools

63

Compressed Air Australia

23

Dimac Tooling

104

ECI Solutions

21

EIF Australia

91

Guhring 17 Hare & Forbes

4-5

Headland BC

AWRE expo Melbourne Convention Centre 23-24 August 2017 Commercial event dedicated to the Australasian waste and recycling marketplace. Bringing together the industry to generate quality sales leads; discover the latest trends; showcase innovation; network with key waste and recycling decision makers from industry and government; and attend high quality practical seminars and workshops. www.awre.com.au

IMTS 37

Renishaw Oceania

43

AIMEX Sydney Showground 29-31 August 2017 Asia Pacific’s inernational mining exhibition.

Includes conference: Future of Mining and live demonstrations of new mining processes and technologies for all mining techniques. www.aimex.com.au/home

Robert Bosch

83

Industrial Laser

13

Integra Systems

99

ISCAR 2-3 JODEK

101

Machinery Forum MTI Qualos

Okuma 7 Raymax 39

Sandvik 65 SECO Tools

15

Sheetmetal Machinery

61

Thyssenkrupp Materials Australia Pty Ltd 41 TRJ Engineering

Safety in Action Melbourne Convention & Exhibition Centre 5-7 September 2017 www.safetyinaction.net.au/melbourne Pacific 2017 Sydney 3-5 October 2017 Exhibition of the latest maritime and naval defence technologies for the Indo- Asia Pacific region for industry, government and defence professionals. www.pacific2017.com.au

115 Cover, 25, 51

100

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Advertise in Australia’s No. 1 precision and manufacturing magazine Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asameulsson@amtil.com.au

Forming & Fabrication Material Removal Motorsport & AutoMotive

Nanotechnology & Micro Machining Cutting tools Forming & Fabrication Material removal additive Manufacturing software Compressors & air technology

Additive Manufacturing Quality & Inspection Compressors & Air Technology

AMT Dec 2016/Jan 2017

113

114

history

Big wheels & little wheels – the story of Sir Laurence John Hartnett (1898 – 1986)

“AUSTRALIANS WON’T DO AS THEY’RE TOLD!”

Part 16

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. It is now 1933 and Laurence has been asked to take on a “very sick concern” in Australia, known as “Howard’s Folly”.

I

t was during a world tour when I briefly visited Australia in 1929. Australia appealed to me as a country of great challenge - so much to be done so quickly! Four years after that brief visit, while attending the Paris Motor Show in 1933, I was summoned for a conversation with GM Director, Graeme Howard. This conversation was to change dramatically the whole course of my life. Graeme began to lay before me the details of a deal that, he said, had become known in GM as “Howard’s Folly”. It was the merger of the GM operation in Australia with Holden Motor Body Builders Ltd, of Adelaide, into a company called General Motors-Holden’s Ltd. And, said Graeme, the product of the merger was a very sick concern.

I well knew the headaches involved in exporting to Australia. To protect its wellestablished motor-body-building industry, Australia put a prohibitive tariff on panels and bodies made overseas, making it impossible to send the complete cars there in CKD form. So Holden Motor Body Builders made the bodies to “marry up” with the chassis shipped from GM and competitor firms in Britain and America.

When I visited Australia four years earlier, there was considerable tension between GM (Australia) and its body suppliers, Holden Motor Body Builders Ltd. Innes Randolph had been in charge of GM (Australia) then, and he didn’t have a clue on the technical aspect of cars. I heard him say on the telephone to Ted Holden, during my 1929 visit: “Well, you must follow the drawings we sent you of the Pontiac instrument panel and you’ve got to make one exactly like it. Similarly, with the Chevrolet ... No, I don’t know anything about ‘tooling’. That’s not my concern. We want it just as it is in the drawings from America. And please don’t vary it.”

When he had put down the phone he said to me, “Amazing people, these Australians; they just won’t do as they’re told.” He didn’t like it when I told him: “I think you’re wrong.

You’ve got five or six different makes and umpteen models, and you’re producing only a handful of each of them. You can’t expect them to follow exactly what is

The birth of Holden: Two Holden & Frost floats, with saddlery circa 1890.

done in America where they’re producing hundreds of thousands of each different model. The tooling-up at Holden’s for each type must be costing a mint!” Innes threw up his hands, almost in horror. “Don’t say that, Larry. You sound just like Ted Holden.

You’ll rock the ship if you talk that way. We just produce exactly what the factories in Detroit make - no change.”

Knowing of these troubles, I wasn’t surprised to learn that since my visit to Australia, the two companies, when they merged, had got into really serious trouble.

As Graeme poured another champagne cocktail, he went on with his sad tale.

“Larry, things are very sick. We’re still losing money; probably this year we’ll add another £300,000 of red ink. No wonder they’re calling the show ‘Howard’s Folly’.

I’m getting tired of being ribbed about it in New York.” “Well, Graeme,” I said, “I’m very sorry for you, and it’s a very interesting story, but why are you telling me about it? How does it concern me?” Then Graeme laid it on the line: “We’d like you to go out there, take charge of it, and see if you can put it straight”. To be continued…

Birth of Holden: Australia’s own car Australia had only been colonised for 64 years when James Alexander Holden immigrated to South Australia from England in 1852, establishing a saddlery and leather goods business in Adelaide in 1856 named J.A. Holden & Co. The name changed to Holden & Frost when Henry Frost became a partner in 1885.

In 1908, the company morphed from horses to horsepower and in 1919 Holden’s Motor Body Builders Ltd was formed, specialising in car bodies. In 1924 Holden became the exclusive supplier of car bodies for GM Australia, opening its plant at Woodville, Adelaide, with a state-of-the-art production line which produced 22,150 bodies in its

first year. A wholly Australian-made car for Australian conditions evolved in 1948 from this foundation. The design of the famous Holden nameplate by sculptor George Rayner Hoff in 1926, was inspired by a legend: Ancient legend tells the tale Of a lion rolling a stone An observer, intrigued, The wheel did conceive And Holden’s logo found a home.

Bronze sculpture, original Holden nameplate, 1926.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT Dec 2016/Jan 2017

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