AMT DEC/JAN19

AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

DECIJAN19

Your 20 Year Laser Solution Partner Industrial Laser would like to thank all our customers and suppliers for supporting our company over the past 20 years

AUTOMOTIVE & ROAD TRANSPORT Nanotechnology State Spotlight: New South Wales

www.industriallaser.com.au

WE HAVE THE SOLUTION! Industrial Laser offers OEM’s and End Users latest laser solutions that match your application and budget.

OEM Division Lasers for Scientific, Defense and Industrial Beam monitoring equipment Latest processing technology Customised laser systems

Service and Parts Division Australia’s largest supplier of consumables Large stock-holding Onsite technical support

Systems Division Laser turnkey systems for: Cutting – Welding – Cladding – Marking Additive manufacturing Automation and product handling

For more information, contact Industrial Laser on +61 (0)3 9796 3055

Factory 8, 17 Keppel Drive, Hallam VIC 3803 AUSTRALIA T: (03) 9796 3055 • E: sales@industriallaser.com.au AMTDECJAN19FLAP

www.industriallaser.com.au

AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

DECIJAN19

AUTOMOTIVE & ROAD TRANSPORT Nanotechnology State Spotlight: New South Wales

Charge right through your most challenging projects!

The Rhino Cart Mobile Fixturing Station is a turnkey system for fixturing and clamping in welding and fabrication.

Clamp and fixture at any point on the reversible, flat, nitrided (heat treated) 1200 x 750mm tabletop for accuracy in all setups.

Rhino Cart Package Includes: 66 piece fixture kit.

3,500

EX GST

Work Piece Shown Setup Ready For Welding

Setup with Inserta Clamps, Stops & Rest Buttons

Weld Spatter Rust & Scratch Resistant - 50 x 50mm Grid

Available from

www.machineryhouse.com.au Specifications are subject to change without notice. All prices exclude GST and are valid until 31-12-18

08_AMTIL_011218

$

HEADING

See the Full Range of Accessories Available Online www.machineryhouse.com.au/Welding-Clamps-and-Fixtures NSW

(02) 9890 9111

1/2 Windsor Rd, Northmead

QLD

(07) 3715 2200

625 Boundary Rd, Coopers Plains

VIC

(03) 9212 4422

4 Abbotts Rd, Dandenong

WA

(08) 9373 9999

11 Valentine St, Kewdale 08_AMTIL_011218

Xpert Tool Changer Intelligent automation for fast and precise tool changing

ByStar Fiber Fiber laser cutting without compromises

Mobile Bending Cell Mobile automation for high-speed bending

ByTrans Cross Modular automation for loading and unloading laser cutting systems

Cutting | Bending | Automation www.bystronic.net.au

008

CONTENTS

Volume 18 Number 06 DEC/JAN 2019 ISSN 1832-6080

FEATURES AUTOMOTIVE & ROAD TRANSPORT The road ahead Nissan: Australian Made, for the long haul Keeping Kenworth moving Axiom – Taking a new road 3D Printing drives Renault Formula One Laser structuring makes plastics shine

44 48 50 52 54 56

ROBOTICS & AUTOMATION ANCA’s robot project = collaboration Maintenance through digitalisation Swisslog’s synchronised automation Smart Future: AI and Robots

58 60 62 64

STATE SPOTLIGHT – NEW SOUTH WALES Taking precision machining to a new level Market revolution with 3D metal printing Infrastructure boom has mixed impact for NSW

70 72 74

CUTTING TOOLS Jacob Harpaz – Love what you do Realities of today’s manufacturing production

80 82

NANOTECHNOLOGY Inside Adelaide’s nanofabrication hub Nanotechnology is more than just a buzzword

86 88

FORMING & FABRICATION DJN expands with Yawei pressbrake Welding reactive metals It IS rocket science: Workcell for aircraft components

89 90 92

MATERIAL REMOVAL Elmass Australia marks 20th birthday

94

SOFTWARE DataSuite solution for Kelly Engineering New ways to improve supply chain performance Digitalisation critical for the competitive edge Global Job Solutions – Taking a lead in software Reimagining through digital transformation How things got touchy at Integra

96 98 99 100 101 102

SAFETY Reducing noise-induced hearing loss Five tips to support the return-to-work process Addressing industrial noise OH&S at the source

103 104 105

44 The road ahead Despite the closure of the local car industry, road transport manufacturing in Australia is upbeat.

66 Nicholas Hacko Watchmaker NHW became Australia’s first and only watch manufacturer in an act of defiance against big overseas corporations.

76

REGULARS From the Editor From the CEO From the Ministry From the Industry From the Union

10 12 14 16 18

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

38

COMPANY FOCUS Nicholas Hacko Watchmaker

66

ONE ON ONE Ray Kirby - Director, UTS Tech Lab

76

AMTIL FORUMS

106

AMTIL INSIDE The latest news from AMTIL

110

MANUFACTURING HISTORY – A look back in time

118

AMT DEC/JAN 2019

One on One Ray Kirby is the Director of the UTS’s new Tech Lab new facility. He spoke to AMT.

86 Inside Adelaide’s nanofabrication hub The ANFF-SA is helping academics and industry bridge the gap between research and commercial prototypes.

HEADING

REAL PEOPLE, REAL PASSION -

DISCOVER OKUMA

Okuma strive to partner with you from the very first meeting, guiding you through project planning and supporting you throughout implementation, training and after-sales care.

Okuma Australia: • • • •

offers an extensive machine tool range are a single source machine & control supplier provides unlimited applications support for 12 months has a Japanese factory trained engineer on staff providing a direct link back to the Okuma factory in Japan • employs highly trained and skilled engineers in every state • provides Automation solutions to suit every workshop

Discover the Okuma difference

“Okuma Engineers always carry out their work in a timely and professional manner. Which is why we continue to purchase and work with Okuma.”

Philip Clayton Production Manager, Rockdrill Services Australia Pty Ltd

WHEN YOU DEAL WITH OKUMA, YOU’RE DEALING WITH THE EXPERTS.

010

FROM THE EDITOR WILLIAM POOLE

Keeping the human factor in mind My son’s at that age now where he’s got into Doctor Who, and he’ll often drag me in to watch the show with him in case he needs any “sciency” bits explained to him (his faith in me as a reliable authority in that area is questionable, to say the least). Anyway, I’m at that age now where I’ll usually use these weekly appointments in front of the TV as an opportunity to take a little nap. But one recent instalment did catch my attention.

In this episode, the Doctor was investigating suspicious developments at a futuristic, Amazon-like online retailer that can deliver purchases anywhere in the galaxy. Who was behind these sinister goings-on? The robots that performed most of the work? The shifty, clipboard-wielding bosses? Or was it the humble caretaker…?

Well, I won’t spoil it for anyone. But the story explored (in pretty broad terms) a theme much on the minds of people at the moment: automation. Everyday we see headlines about the imminent replacement of human workers with machines and digital systems in pretty much every industry, but nowhere more so than in manufacturing (see pages 58-65 of this magazine for evidence).

However, there’s a danger of overstating the extent to which technology will supplant people.

In the Doctor Who episode, for instance, regulations required that 10% of the workforce be human. But in the real world, according to a new report, such a rule is far from necessary right now – and won’t be for some time yet.

The report – from management consultants AT Kearney and AI startup Drishti – reveals that humans still perform 72% of all manufacturing tasks. Based on a survey of more than 100 manufacturing leaders, it suggests that people remain central to manufacturing, creating significantly more value on the factory floor than machines.

What’s also notable is the inadequate understanding of the ways in which humans do contribute. Many respondents cited a significant, widespread lack of data on the activities that people perform in the factory. The report notes that many of the techiniques used for gathering and analysing tasks performed by humans are still essentially derived from timeand-motion study methodologies dating back to the days of Henry Ford, and have not been updated for the digital age.

This severely limits manufacturers’ ability to make informed decisions on capacity planning, workforce management, process engineering, and so on. It also suggests manufacturers may actually be overprioritising automation due to the difficulties in quantifying investments in the human workforce that would yield greater efficiencies.

Moreover, the overemphasis on machine performance, and comparative disregard for the human element, risk hindering our ability to exploit emerging technologies to their full potential. As Michael Hu of AT Kearney explains: “The companies that improve their human factory analytics are the ones that will be best positioned to compete in Industry 4.0.”

Like any industry, manufacturing exists to serve the needs of humans (as in, customers), and it’s also an endeavour undertaken by humans – often with the assistance of technology.

Amid all the hype about automation, it’s worth keeping this in mind and not underplaying the role people play and the value they bring. *** With this being the final edition of AMT Magazine for 2018, I’d like to round things off by thanking our readers, contributors and advertisers for their support throughout the year.

On behalf of myself, Anne, Gabriele and Franco, and all of the AMTIL team, I’d like to wish all our readers and everyone involved in our industry a Merry Christmas and a Happy New Year.

YOUR INDUSTRY. YOUR MAGAZINE.

AUSTRALIAN MANUFACTURING TECHNOLOGY

Editor William Poole wpoole@amtil.com.au Contributors Brent Balinski 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.

1419AMTDEC/JAN2018

AMT DEC/JAN 2019

PM&M/AMTOCTNOV18

Partnering in Quality Manufacturing Solutions Precise Machining & Manufacturing is an industry leader in designing, machining and manufacturing projects to customer specific requirements. Supplying all Industries with a diverse range of services including: prototyping, process development, modifications and RAPID repairs, manufacturing of components and sub-assemblies, special purpose equipment, moulds, tooling, general and specialised engineering, 2D and 3D machining.

Contact Precise Machining & Manufacturing to learn more about our full range of services.

5 Axis Machining Centres 3 & 4 Axis Machining Centres CNC Wire Cutting CNC EDM Machines Laser Welding Laser Etching Comprehensive Toolroom Facilities

Precise Machining and Manufacturing 9 Deloraine Road, Edwardstown Adelaide, SA 5039 Tel: 08 8277 2899 sales@precisemfg.com.au

www.precisemfg.com.au

012

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Looking back on eight years of import stats I know this may be considered as dry and uninteresting, and I certainly get that, but this is our industry right in front of us, so I would encourage you all to just give it a few minutes to peruse the recent trends in machine tool investment.

I consider technology suppliers to be a barometer for industry confidence, that is if confidence is high then businesses are more likely to invest in their future and if it is low … well it goes without saying too much. Now it should be very well known by all that it has become tougher over the last few years, but look at the past 12 months and it is clearly evident in the import data that things are turning around. Combine that with the sustained strength of the Australian PMI as indicated by the Ai Group and we can safely say business confidence and investment are at an eight-year high.

AMTIL has been collecting import statistics for many years. Of all the data collected, I will extract the most recent eight years – the 2011 to 2018 calendar years – and only for a selection of technology listed below. If we look at the list below, you can see it is broken into two lists: a machining technology list and a fabrication technology list. I have done this because it was easier to get a quick handle on the situation and rough trends.

• Machining technology • CNC Horizontal Lathe • CNC Machining Centre • Fabrication technology • CNC Laser and Photon Beam • CNC Bending, Folding, Straightening and Flattening

It is incumbent for me to insist you are aware the data is collected by the Australian Bureau of Statistics via the various machine agencies importing paperwork. AMTIL knows it is not perfect and we do our best to filter out the obvious errors.

I think it would be good for you to draw your own conclusions from this data, and please don’t think this is the extent of what we have.

AMTIL members are able to login to our website and download the complete statistics, unpack and dissect it any way you want.

This was just a result of a moment in time where I was interested to see what the statistics might show. What they indicate is a positive position for investment in manufacturing technology in this country and one that we hope will continue over the coming years.

250

200 CNC Bending, Folding, Straightening and Flattening

150

CNC Horizontal Lathe CNC Laser or Photon Beam

100

CNC Machining Centre 50

0 2011

Year

2012

2013

2014

2015

2016

2017

2018 (projected)

CNC Bending, CNC Horizontal Laser or CNC Machining CNC Machining Total Grand Total CNC Bending, Folding, CNC Horizontal Lathe CNC Laser orCNC Photon Centre Grand Folding Straightening Lathe Photon Beam Centre Straightening and Beam and Flattening Flattening

2011 147 Year 2011 147 2012 131 2012 131 2013 134 2013 134 2014 125 2014 125 2015 102 2015 102 2016 121 2016 121 2017 135 2017 135 2018 208 2018(projected) (projected) 208

AMT DEC/JAN 2019

142 54 143 486

142 54 143 170 53 163 517 486 107 170

163 53 53 87 381 517 107 53 87 381 87 41 83 336 87 41 83 336 94 39 92 327 94 39 92 327 113 45 129 408 408 113 45 129 132 48 151 466 466 132 48 151 110 61 170 110 61 170 549 549

HEADING

Victorian Master Builder of the Year 2018 Dulux Merrifield Coatings Plant is the recipient of the Master Builders Victoria, Commercial and Excellence in Construction of Industrial Buildings award Dulux engaged Vaughan under an ECI (Early Contractor Involvement) arrangement to explore all available options and technologies for their Merrifield Facility in Victoria.

Moving to a Design & Construct contract Vaughan completed both the base build and fitout, of what is now the largest coatings factory in Australia and New Zealand.

Highly automated with the latest technology from across the globe the new factory has the capacity to produce in excess of 100 million litres per year, stepping Dulux into the next generation of paint manufacturing technology.

014

FROM THE MINISTRY THE HON KAREN ANDREWS MP – Minister for Industry, Science and Technology

Positive times for Aussie automotive October was a significant – and very positive – month for Australia’s automotive businesses. The Coalition Government launched initiatives to help businesses further expand into international automotive markets and to encourage highquality graduate engineers to work in Australia’s automotive sector.

The first of these, the $7m Automotive Innovation Lab Access Grants program, supports businesses across Australia to develop new automotive products. The measure means businesses can receive up to $200,000 in matched funding for eligible project costs. Eligible costs cover design, prototype and testing activities at established commercial and research facilities and official Automotive Innovation Labs.

As part of the initiative, the Australian Automotive Aftermarket Association (AAAA), will also receive a $3m grant over the next two years. The grant will be used to build an Automotive Innovation Lab facility in South Australia and enhance an already approved facility in Victoria. As an engineer myself, I was also delighted and proud to open a program that will identify and encourage some of our best and brightest graduate engineers to pursue research projects with automotive businesses.

GM Holden, Toyota and Ford report that more than 80% of their former workers have either found a new job, retired or have commenced study. In addition, over 70% of former supply chain businesses remain in business through a combination of downsizing and diversifying.

It’s been more than a year since the last Australian-made car rolled off the assembly line.

The Automotive Engineering Graduate Program, which I launched in mid-October, aims to create a steady flow of qualified, job-ready engineers into the Australian automotive sector. With GM Holden recently announcing 150 new design and engineering jobs at Port Melbourne, bringing its workforce to more than 500, we need more highly skilled engineers to compete internationally. Graduate students involved in the program will put forward research proposals – and the best of these will receive funding. It will increase the level of advanced engineering skills in the sector, which is great news.

Engineers, designers and technicians have a key role to play in the transformation of Australian automotive manufacturing. Their work is going to help us better compete internationally in the rapidly changing field of vehicle design. And this is important as car makers around the world look to the future, when many vehicles will be shared, electric and self-driving.

The initiatives launched in October are just two examples of the way the Coalition Government is continuing to help individuals, businesses and regions impacted by the closure of automotive manufacturers. Our $47.5m Advanced Manufacturing Growth Fund is helping automotive-related companies to upgrade their technologies and innovate.

For example, Carbon Revolution received a $2.5m grant to develop a high-volume moulding process for carbon fibre wheel manufacturing. Nissan Casting Australia received $2.5m to make next-generation electric vehicle parts for the global market. And Harrop Engineering received almost a $1m grant to enable driveline and induction innovation for global vehicle platforms.

It’s been more than a year since the last Australian-made car rolled off the assembly line. But the Coalition Government and car companies continue to provide help, through measures like the $155m Growth Fund and the $100m Advanced Manufacturing Fund. These programs are already bearing fruit.

GM Holden, Toyota and Ford report that more than 80% of their former workers have either found a new job, retired or have commenced study. In addition, over 70% of former supply chain businesses remain in business through a combination of downsizing and diversifying. These suppliers have successfully diversified into sectors such as defence, medical and construction.

AMT DEC/JAN 2019

Looking at manufacturing employment figures, the Coalition Government’s policies are working. There were 93,100 new manufacturing jobs generated in the 12 months to August of this year. In South Australia, there are 41,500 more jobs today than in December 2013, when GM Holden announced it would cease manufacturing in Elizabeth. Additionally in Victoria, in the manufacturing sector alone, there are 7,100 more manufacturing jobs since 2014 when Toyota announced its closure.

Meanwhile, the Australian Industry Group’s Performance of Manufacturing Index stood at 58.3 points in October, the 25th month and longest consecutive run of expansion in the manufacturing industry since 2005.

The road ahead for Australian manufacturing looks bright and these positive numbers confirm we’re headed in the right direction, despite the challenges we’ve faced. Our auto companies are growing, diversifying and attracting business in new markets. And the Coalition Government will continue to assist in many ways to ensure this positive trend continues well into the future.

’S APPLIED

World class performance, without the price tag.

That’s Applied thinking.

LE TO U

ED PRO

T

EX

A

G

HIG H

E ACCUR

CY

SIN

CE P SE M IM S low Soperating RE sistency of cut, combined withSPE very e perfect way to take your business to the next level.

e of its own, opening up possibilities for companies art-ups through to full production, 3-shift Precision sheetmetal processing solutions.

focus cutting head, IPG laser source, Siemens s-relieved fully annealed frame it really is a cut above

Fiber Lasers • Turret Punch Presses • Pressbrakes • Guillotines • Automation

Connect with us socially

To find out more, call: 03 9706 8066, Email: sales@appliedmachinery.com.au, or visit: www.appliedmachinery.com.au 22/12/16 9:27 am

016

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Skills crucial to manufacturing’s digital future The pace of change in digital technologies continues to increase across the globe, creating digitally enabled environments that will affect every manufacturing company. Education and training has been identified as one of the most critical factors shaping workforce outcomes that lead to future-focused companies.

New approaches to education, training and re-skilling must be implemented to maximise the benefits of the digital economy.

Change is progressing in our education and training systems – but are they keeping up with the rapid pace?

The Australian Industry Group’s 2018 Workforce Development Needs Survey report, Skilling: A National Imperative, suggests that in many areas this is not the case. The survey, which provides an important gauge of employer sentiment around skill needs and training practices at a critical time for industry transformation, has found major skills pressures facing employers. Without an education and training sector that can adapt quickly to the needs of the digital economy, Australia’s business sector will suffer competitively into the future.

As businesses adapt to new technologies and the changed conditions under which business is done, they are facing new demands on their workforce capabilities and cultures. Imperatives include higher level skills, advanced technical and soft skills, digital literacy and changed management capabilities to effectively negotiate autonomous work roles and partner with machines.

Frequent re-skilling is becoming a constant.

The major pressure points identified in our survey include: Skills shortages: It is apparent that skills for both current and future-oriented occupations are not meeting demand. Among our respondents, 75% report skills shortages, most often in the technician and trades worker category. Difficulties remain with the recruitment of employees with STEM skills. For the first time in this annual survey, skills shortages were reported for those with skills in business automation, Big Data and artificial intelligence solutions.

Digital skills: The rapid changes through digitalisation are requiring a number of occupational categories to be prioritised for digital technology training and changes anticipated or caused by its rollout. Managers require significant capability improvements in technology/digitalisation, with employers prioritising them (33%) over technicians/trades workers and administration staff (both 18%), followed by professionals (16%). In the age of digitalisation all workers will need digital skills at various levels.

Literacy & numeracy: With the workforce increasingly requiring foundation skills that include not only literacy and numeracy but digital literacy and advanced soft skills, it is disturbing that 99% of employers are affected in some way by low levels of literacy and numeracy in their workforce. They are dissatisfied with the basic numeracy and literacy levels of more than one in five school leaver entrants. It is also a concern that dissatisfaction levels are high for the self-management, planning and organising, problem solving, initiative and enterprise skills of school leavers.

Leadership and Management: The digital economy requires a major change in the way work is done and managed as entire business processes and organisational cultures are upended.

Being aware of the activities that are most likely to change from a technical perspective allows managers to rethink how workers engage with their jobs and how digital platforms can better connect workplaces. The survey found that 62% of employers believe a lack of leadership and management skills is having a high impact on the business – an increase on 2016. They report the most significant capability improvements required by managers are in technology/

AMT DEC/JAN 2019

digitalisation, resulting in managers being prioritised for this training.

Reflecting the need for managers to navigate constant change, employers said their capabilities must also improve for problemsolving, initiative and enterprise.

Employer actions: Employers are active in implementing strategies to alleviate some of these skills pressures. A greater percentage of employers intend to increase expenditure on training in 2018: the highest level since we began the survey in 2012. There has been an increase in the percentage of employers engaging apprentices/ trainees, with a substantial proportion being of mature age (42.9%).

Employers report a significant increase in their internal company training and support from supervisors and mentors to boost literacy and numeracy skills. And companies have steadily increased their links with education and training sectors since 2014 – a vital strategy in the faster moving economy.

As Australian industry transforms through digitalisation it requires the necessary skills to adapt. This in turn will increase the number of people able to be involved in the digital economy. Change is happening at a frightening pace and our education and training systems need to renew at this same pace. These new survey findings provide rich data important in the development of education and training policy, systems and approaches that enable an effective workforce for the future.

Ai Group’s Workforce Development Needs Survey Report, Skilling: A National Imperative, is available at: www.aigroup. com.au/policy-and-research/reports

An improved design makes the already outstanding Perfomax drill even better. Innovative features – such as a new flute design, wave pattern and laser hardening – add strength, stability and accuracy to ensure consistent performance and dependability for all applications.

WWW.SECOTOOLS.COM

THE BEST JUST GOT BETTER SECO TOOLS AUSTRALIA PTY LIMITED TEL 1300 55 7326 FAX 1300 65 7326 EMAIL: SECOTOOL@SECOTOOLS.COM

018

FROM THE UNION PAUL BASTIAN – National Secretary Australian Manufacturing Workers Union

Bargaining brings benefits for the industry It is good business practice to regularly review the systems and policies used in a business, to assess whether these are still fit for purpose in light of changing circumstances, and to overhaul them accordingly.

The ACTU’s call for an overhaul of Australia’s labour laws, in particular enterprise bargaining, in response to the realities of a postGFC, digitally disrupted economy have been met with hysterical warnings of doom from the Coalition, the Murdoch papers, some business groups, and CEOs like Qantas CEO Alan Joyce. If we take a moment to step back and evaluate whether enterprise bargaining is still fit for purpose, however, the need for an overhaul of the system becomes clear.

Enterprise bargaining was originally introduced to support productivity improvements at the enterprise level by enabling workers, their unions, and employers to negotiate working arrangements that suited that specific enterprise.

These productivity improvements have largely been exhausted, however, with labour productivity only improving by 1.1% in 2016-17. Instead bargaining periods have become time and resource-intensive periods of conflict, often centred on wage negotiations. That’s not good for businesses, and it’s not good for workers.

At the same time, the share of workers covered by enterprise bargaining is also shrinking, leaving a greater proportion of workers reliant on the minimum standards of awards. The number of workers covered by enterprise agreements has shrunk by 750,000 since the beginning of the election of the Abbott/Turnbull/ Morrison government. Workers who are reliant on the award safety net are precluded from engaging in any kind of bargaining over their wages and conditions. It’s clear that enterprise bargaining is no longer serving the purpose for which it was created, and has failed to keep up with the evolutions of the 21st century working environment.

In his defence of the current system, Joyce has argued that a move away from enterprise bargaining to industry bargaining would lead to “anarchy”. Funnily enough, he didn’t seem too concerned about anarchy when he grounded the entire Qantas fleet in 2011, stranding customers and locking out workers. He has never backed away from this decision. The current system leaves plenty of room for occurrences of anarchy like this – all around the country, employers have locked out their workers, sometimes for years on end, as part of a bargaining tactic to get workers to agree to lower wages and cuts to job security.

The thing is, it’s never the small businesses – the ones that Joyce and Industrial Relations Minister Kelly O’Dwyer claim will be so damaged by a move to industry bargaining – that are shutting out their workers. It’s giant multinationals. It’s multinationals like Qantas, and Esso, who pay their CEOs millions of dollars every year and who make multibillion dollar profits, that are locking out their workers. It’s these big businesses that have invested the time and energy in restructuring their workforce so that they directly employ as few people as possible and can subcontract work out at rates well below those set out in their very own enterprise agreements.

A system predicated on enterprise-level bargaining necessarily punishes employers and companies who value their staff and remunerate them accordingly. In the absence of industry or sector

AMT DEC/JAN 2019

bargaining, these model employers are forced to compete with less scrupulous employers who undercut them on wages, leading to a race to the bottom.

Joyce stated that a move to a system where all businesses had to deliver the “highest common denominator” would be “terrible for employment, terrible for efficiency”. Apparently a system that encourages elaborate corporate structures, subcontracting arrangements, and an abrogation of company responsibility for its workforce through the use of labour hire, is efficient. Of course, that is assuming that by efficient, you mean it permits companies to pay workers the absolute bare minimum (or with wage theft a rampant business model, arguably not even that).

Alternatively, the Australian Economic Review has found that as long as reducing wages is the quickest and easiest route to profit, enterprise competition will be focussed on this, rather than on innovation, productivity, or service and product improvement. Rather than enabling businesses to improve their efficiency in ways that are of benefit to them, to workers, and to the wider economy, our current enterprise bargaining system simply puts downward pressure on wages growth.

The result is a sluggish rate of inflation growth, and workers taking home a record low share of the GDP they work to generate.

Countries that are famed for their manufacturing prowess, like Germany, have long used systems of industry bargaining. Far from it bringing manufacturing to its knees in these countries, industry bargaining has delivered world-leading companies and happy workers with secure jobs.

We believe its time to bring business focus back to where it belongs – delivering high-quality goods and services. Moving to a system of industry bargaining would help to achieve this.

The current enterprise bargaining system encourages employers to outsource their labour costs through the use of labour hire companies or subcontracting. Not only does this result in an insecure workforce – leaving individuals, families, and sometimes whole communities, in a constant state of anxiety about their employment and finances – it undermines the co-operative relationship between businesses and their employees. It undermines the social compact between companies and the communities in which they operate. Trust in big business in Australia is at an all-time low. The introduction of a system that removes the incentive to cut costs by cutting wages and cutting secure jobs would go some way to redressing this.

The AMWU firmly believes the best outcomes are achieved when unions, workers, and businesses can work together. Our aims are not mutually exclusive. Unions and the workers we represent want the businesses and industries in which they work to thrive. We want them to be profitable, and internationally competitive. That’s why we’ve campaigned (successfully) on issues like building our trains, ships and submarines in Australia. Industry bargaining does not have to be a destructive force wreaking chaos and havoc on the Australian business landscape. Instead it could support companies paying their workers fairly, create more secure jobs, and drive a new wave of Australian innovation.

Austech proudly owned and operated by AMTIL

Australia’s Premier Advanced Manufacturing & Machine Tool Exhibition

NOW

OPEN FOR EXHIBITOR

BOOKINGS! 14th – 17th May, 2019 Melbourne Convention & Exhibition Centre www.amtil.com.au/austech 1406AUSTECH

For more information contact AMTIL Events Manager Kim Banks at kbanks@amtil.com.au

020

INDUSTRY NEWS

Australia’s competitiveness improves marginally in 2018 Australia has been ranked as the 14th most competitive economy globally, according to the annual World Economic Forum (WEF) Global Competitiveness Report 2018.

The Australian Industry Group partnered with the WEF in collecting the business data in Australia. Australia ranks in the top 10 for only three of the 12 ‘pillars’ in the WEF Report: macroeconomic stability, health and product market. Australia shared top spot with 31 other countries for macroeconomic stability and obtained a near perfect score for health, while Australia also obtained a high score for the breadth and depth of the financial system. Australia’s weakest pillars were for the labour market and innovation capability.

market. We are also being held back by relatively lower scores for our market structures and our innovation ecosystem.

“This year’s WEF results indicate Australia’s performance deteriorated most notably in infrastructure,” said Ai Group CEO Innes Willox. “This was balanced out by improvements in ICT adoption (mainly mobile phone and broadband uptake) and innovation capability.”

“This indicates the current focus on building out our national infrastructure (in transport, telecomms and skills) is the right path,” Willox added. “But it also indicates we need to sharpen our skills, our workplace flexibilities and especially our ability to bring innovation all the way from R&D through the development phase and into the market. Maintaining and improving these aspects of our global competitiveness is crucial to maintaining prosperity for all.”

“As in 2017, Australia still performs relatively well with regard to our macroeconomic stability and general standard of health, but relatively poorly with regard to the flexibility and responsiveness of our labour

The ranking represents a move up by one place from last year’s position of 15th, as the WEF’s Top 10 continued to be dominated by large highly advanced economies, including the US (1), Germany (3), Japan (5) and the UK (8), as well as smaller northern European economies such as Switzerland (4), The Netherlands (6) and Sweden (9). Singapore (2) and Hong Kong (7) also rank in the Top 10.

New industry partnership explores Australia’s manufacturing potential A new partnership between St.George Banking Group, UNSW Sydney and the Advanced Manufacturing Growth Centre (AMGC) aims to advance Australian research and accelerate the introduction and commercialisation of new manufacturing technologies. It will help Australia unlock its competitive edge in manufacturing by bringing together three different streams of the Australian economy – research, industry and banking.

Recent job figures illustrate the re-emergence of the manufacturing sector, with domestic employment increasing 6.1% over the past five years. In Australia, the sector employs approximately 978,000 people (August 2018 ABS trend data), which is approximately 7.7% of the total workforce. Michael Sharpe, State Director of AMGC believes that every Australian manufacturer can transition to the digital age to build their business and compete globally.

“To improve our country’s innovation and competitiveness, manufacturers need to become highly integrated, collaborative and export-focused so we can provide high-value, customised solutions to global supply chains,” said Sharpe. “This complementary partnership will forge the industry ahead by helping manufacturers to think more laterally about how they can use the latest technology to scale their businesses and seek new opportunities both onshore and overseas.”

Matthew Kelly, Head of Manufacturing and Wholesale at St.George, said: “Manufacturing is an export-focused industry, and digitisation, data, automation and new materials are driving the reemergence of manufacturing in Australia. Our customers are forward-thinking and want to tap into research to differentiate their businesses and make their processes more efficient, such as using real-time data to drive better decision making. We have a very clear understanding of Australia’s potential in this sector which is why St.George is backing manufacturers for the longterm through this partnership and other initiatives.”

Professor Gangadhara Prusty, Director of UNSW-based ARC Centre for Automated Manufacture of Advanced Composites (AMAC), said the collaboration will give potential partners access

AMT DEC/JAN 2019

Professor Gangadhara Prusty, Director at the Centre for Automated Manufacture of Advanced Composites, UNSW; Matthew Kelly, Head of Manufacturing & Wholesale at StGeorge Bank; Michael Sharpe State Director for the Advanced Manufacturing Growth Centre (AMGC); and Patrick Mooney, Director, Strategic Partnerships at the Division of Enterprise, UNSW.

to the nation’s most advanced manufacturing facilities, and where appropriate, secure funding through AMGC or other government funding sources.

“This partnership will enable St.George customers and AMGC members to leverage technologies developed at UNSW and take advantage of the University’s skills and expertise in the engineering field,” said Professor Prusty. “Using advanced manufacturing automation and innovative material solutions, we can assist potential partners in solving their real world engineering challenges. We are excited to collaborate with new industry partners to ensure Australian manufacturing remains competitive in the global market.”

MACHINERY FOR ALL ASPECTS OF METAL WORKING

INDUSTRIES SERVICED: Engineering Sheetmetal Fabrication Steel Merchants HVAC

Complete Machine Tools, Your Partner in Innovation T - 07 3279 3344 E - sales@completemachinetools.com.au W - www.completemachinetools.com.au

022

INDUSTRY NEWS

Deakin launches $1.5m facility for next-gen metal fabrication A first-of-its-kind $1.5m facility dedicated to advanced metal development and 3D roll forming has been launched at Deakin’s Institute for Frontier Materials (IFM), supported by the Federal Government through the Australian Research Council (ARC).

The IFM Flexible Forming Facility will have the capacity for complex roll forming – a process involving incrementally bending metal strips into highly specified shapes.

ARC Chief Executive Officer Professor Sue Thomas joined Deakin University Deputy Vice‐Chancellor Research Professor Joe Graffam in September to launch the Facility at Deakin’s Geelong Waurn Ponds Campus.

Solutions. Roll stands are no longer fixed in place during the process, allowing for more parts flexibility, faster fabrication, and greater potential cost savings compared to conventional forming methods such as metal stamping.

Roll forming of structural and crash components is now widely applied across the automotive industry, thanks to the creation of high-performance materials such as ultra high strength steels, advanced aluminium alloys and metal laminates. Using a specially-developed roll former, the new Deakin facility is capable of developing super-strong final products with applications across the automotive, rail and aerospace industries. Professor Graffam said the facility would be used for proof-of-concept studies on the flexible roll forming process, rapid prototyping and the manufacture of complex profiles from hard-to-form materials.

Professor Thomas said: “I am pleased that Australian Research Council funding is supporting a rich ecosystem of manufacturing research expertise, a significant component of which is industry-led, at Deakin University.

Quality research infrastructure is a critical component of Australia’s research and development system. The ARC’s LIEF scheme is designed to enable researchers to participate in co-operative initiatives so that expensive infrastructure, equipment and facilities can be shared between higher education organisations and industry.

“The world-first IFM Flexible Forming Facility presents an exciting new opportunity for industry collaboration and research at Deakin University,” Professor Graffam said. “Higher strength steels are increasingly being used in the automotive industry for the manufacture

The facility was supported by a $280,000 ARC Linkage Infrastructure, Equipment and Facilities (LIEF) scheme funding grant.

Deakin Deputy Vice‐Chancellor Research Professor Joe Graffam.

of lightweight structural and crash components and roll forming is more and more becoming the manufacturing process of choice for these hard-to-form material solutions. This new facility will extend our critical mass of dedicated and high-calibre researchers breaking boundaries in next generation manufacturing, strengthening our leadership in the international area in this important field.”

The IFM Flexible Forming Facility features a dynamic 3D roll forming process developed, patented and manufactured by German research partner data M Sheet Metal

“This funding has enabled Deakin University to leverage extensive support from an impressive array of collaborating industry partners to establish a research facility that promises to deliver major advances for Australian manufacturing of complex components for automotive, aerospace, truck and rail industries.”

Manufacturing reports strongest employment outlook in seven years The manufacturing sector is set to finish 2018 with one of the most positive employment outlooks in seven years, according to the latest analysis from the ManpowerGroup Employment Outlook Survey.

However, despite hiring intentions being in positive territory, they remain below the national average. The Net Employment Outlook across the Manufacturing sector sits at +10% for the final quarter of 2018, three percentage points lower than the national average of +13%. Other than at the start of this year, the sector has not reported such robust hiring intentions since the third quarter of 2011.

When compared nationally, the manufacturing sector showed the second weakest outlook across the country, coming in just before the wholesale & retail trade sector (+8%). Nonetheless, manufacturing is set to end the year in a positive position and will be looking to sustain jobs growth into 2019.

The ManpowerGroup survey collects data from more than 59,000 employers in 43 countries, including more than 1,500 in Australia.

AMT DEC/JAN 2019

The Net Employment Outlook is calculated by subtracting the percentage of employers anticipating a decrease in hiring activity from the percentage of employers anticipating an increase in employment. Seasonal adjustment is then applied to the data.

Precision Matters

Machines Engineered to Impact Life DT-2

711 x 406 x 394 mm travels

30 / 3 / 10k / 20+1

TAPER AXIS

The medical industry is different; you

RPM

TOOLS

need speed, precision, and repeatability.

That’s why we’ve designed machines and options specifically for your needs.

Haas Drill/Tap Series machines are high speed, lean-style machining centers that make very efficient use of floor space.

Add a high-precision Haas 4th- or 5th-axis rotary table to your DT, and boost your productivity even further, through affordable, plug-and-play simplicity.

DT-1

BUILD-&-PRICE Configure and price the perfect Haas solution for your shop.

508 x 406 x 394 mm travels

30 / 3 / 10k / 20+1

TAPER AXIS

RPM

TOOLS

Go to: www.HaasCNC.com

Haas Factory Outlet - Australia Australia: 1300 20 12 30 / www.Haas-Australia.com

F O C U S E D. D R I V E N. H A A S.

024

INDUSTRY NEWS

Joint $2.6m research project to develop Titomic Kinetic Fusion standards Australian metal additive manufacturing company Titomic Limited has announced a $2.6m program with the Innovative Manufacturing Cooperative Research Centre (IMCRC), CSIRO and RMIT University to develop new industry standards based around its patented Titomic Kinetic Fusion (TKF) process.

The Additively Manufactured Titanium Complex Structures Project will focus on enhancing TKF as a transformational technology for the highest standards of aerospace and defence industries as outlined by The Metallic Materials Properties Development and Standardization (MMPDS). The MMPDS is a widely accepted source for metallic material and recognised by the US Federal Aviation Administration (FAA), the US Department of Defense (DoD) and NASA. Currently, industries that use laser and electron beam melting processes in metal 3D printing have significant limitations due to the melting of the metal causing layering inclusions, evaporation of some alloys, and thermal distortion within the parts, meaning they cannot be certified for the production of aerospace structures components.

The Titomic-led program will create new industry certification standards for the TKF process allowing it to be used for producing aerospace structures in continuation of the already approved processes for repairs on aircraft such as the B-1 bomber, F/A-18 Fighter and Black Hawk and Sea Hawk helicopters. Successfully creating new aerospace standards for the TKF process will help to position Titomic as a global leader in industrial-scale metal additive manufacturing, offering significant commercial opportunities for TKF as a next-generation digital manufacturing process of titanium and titanium alloy complex-shaped structures. In addition to benefitting Titomic, evidence and enhancements resulting from this research are expected to place Australia at the leading edge of a transformational shift of the global metals industry, utilising Australian technology and resources.

“The aerospace and defence industries are seeking new additive manufacturing capabilities for industrial-scale titanium alloy structures to improve upon time-consuming, wasteful traditional subtractive manufacturing processes” said Titomic’s Managing Director Jeff Lang. “Titomic will utilise this IMCRC Project to develop Australian

export capability for the supply of TKF systems and consumables to meet the demand of the aerospace and defence industries.”

The project partners IMCRC, CSIRO, RMIT University and Titomic will contribute a total of $2.6m in funding and in-kind investment, with Titomic and IMCRC each contributing $0.47m in cash over the two-year project period.

“With metal additive manufacturing on the cusp of large scale industrialisation, this research project explores Titanium and its enhanced performance properties as an alternative for sustainable manufacturing across multiple industry sectors,” said David Chuter, CEO and Managing Director of the IMCRC. “When proven, this new technology not only transforms additive manufacturing processes but provides Australia the opportunity to capitalise on the global demand for titanium utilising our significant reserves of titanium ore.”

As part of the project, improvements to CSIRO’s background IP and the project IP will be utilised by Titomic in accordance with the terms of the licence agreement between CSIRO and Titomic. The technology advancement will provide a new industry standard for titanium and titanium alloy, complex shaped structures manufactured using TKF.

Siemens software grant to University of Queensland Siemens has announced a software grant with an in-kind commercial value of over half billion Australian dollars to the University of Queensland (UQ).

The grant is the fourth in the series of grants in a broader strategic program of software grants helping students in Australia transition to the fourth industrial revolution (Industry 4.0), which to date have included Swinburne University of Technology’s ‘Factory of the Future’, the University of Western Australia and the University of South Australia. The announcement was made by Siemens Australia Chairman and CEO Jeff Connolly at UQ’s Atrium in Brisbane, and supported by Queensland’s Premier and Minister for Trade Annastacia Palaszczuk and Professor Høj, Vice-Chancellor and President of UQ. Speaking at the announcement, Connolly said, “I’m delighted to be here today announcing the grant of Siemens’ advanced industrial software to the UQ. Our history in Queensland dates back over 100 years – and this grant reiterates our commitment to continued technology partnership with the State. “Put simply, for Australia to take advantage of the opportunities that come with the Fourth Industrial Revolution, we need to build a future workforce now, with the skills needed to participate – and that’s exactly what this grant

AMT DEC/JAN 2019

is about. Partnerships such as this with UQ are critical to giving students exposure to digital technologies being used by leading companies globally.”

The grant is part of Siemens’ commitment to helping enable Australian students and universities to develop the skills needed to successfully participate in Industry 4.). The announcement is linked to the recommendations and work of the Prime Minister’s Industry 4.0 Taskforce – an industry-led group established to support improved bilateral relations between Australia and Germany.

“The Queensland Government has a ten-year plan to transition the state’s manufacturing sector to more advanced manufacturing highpaid, knowledge-based jobs by 2026,” said Premier Palaszczuk.

“Advanced software is crucial to this transition. I welcome the grant from Siemens into our State and look forward to their continued collaboration with our local researchers and students at University of Queensland to progress our industry not just in Australia, but globally.”

ur t Yo en d ar stm gu e fe Inv Sa P ER

Engaging User Experience

Actionable Insights

Why SYSPRO ERP? Personalize Your Workspace

En a Bu ble si Di ne gi ss tal

al ab le

d an y ce ilit oi ib Ch lex F

Sc

Industry Built

026

INDUSTRY NEWS

Alfex CNC – 40 years and going strong Alfex CNC Australia celebrated a milestone anniversary in Melbourne in November as it marked 40 years in business.

To mark the occasion, the company’s entire staff from across Australia was brought together at Alfex CNC’s headquarters in Broadmeadows, north Melbourne, for a company-wide meeting. It was the first time that the whole national team had gathered together in several years.

“Having everyone in the same room, created great excitement and pride in what we have achieved together as a team,” said Maryanne Buhagiar, Operations Manager.

The following evening, the real celebration began, as the Alfex team, partners and guests were treated to a luxurious event with a grand view of the Melbourne city skyline to mark the special occasion.

Esteemed guests included Alfex CNC’s original founders Tony and Linda Boult; suppliers and partners; as well as representatives of AMTIL. “We wanted to share this momentous occasion with everyone who has provided services and guidance to Alfex CNC over the years and helped us on our journey,” said George Buhagiar, Company Director.

Tony and Linda Boult established Alfex in 1978, and since then have watched the company grow from strength to strength. As Tony recounted stories from the ‘old days’, it was very nostalgic for long-standing employees and gave everyone a great

The national Alfex CNC team

include Haas Factory Outlet Australia, representing the Haas Automation range of CNC machine tools, and Alfex Laser, representing world-class laser systems.

The company’s success has come from its continual focus on providing premium solutions and an unparalleled customer support experience. None of this would be possible without its loyal employees, most of whom have been with the company for many years.

“I’d like to thank everyone for being here,” added George, over a charged glass. “But in particular would like to thank the Alfex team for their great work and loyalty over the years and we look forward to our continued growth and success into the future.”

Alfex CNC founders Tony and Linda Boult (centre), with present-day directors Maryanne and George Buhagiar at the 40th anniversary celebration.

sense of pride and a better understanding of the company’s humble beginnings and achievements.

“I am very proud to be here and see the growth of the company over the years,” said Tony over a toast.

Today, Alfex CNC supplies Australia with the largest range of lasers for cutting, marking and engraving. Its two divisions

Alfex CNC has served the Australian laser industry since 1978, supplying machine tools and accessories to Australian manufacturers and job shops. Its product range includes Haas Automation, Epilog Laser, Lotus Laser, Acsys Lasertechnik, Kern Laser Systems, Vision Engraving & Routing Systems, Bofa Fume Extraction and Duets Professional Engraving Materials

by Gemini. www.alfexlaser.com.au www.haas-australia.com

CSIRO invests $35m in future of space and AI for Australia CSIRO is investing $35m in frontier research in Space Technology and Artificial Intelligence. The investment will include the development of advanced imaging of Earth from satellites, in addition to cutting-edge data science to support the growth of AI technology.

The investment is part of CSIRO’s Future Science Platforms (FSP) portfolio, aimed at dedicating research to new and emerging opportunities for Australia.

They aim to help reinvent old and create new industries, as well as grow the capability of a new generation of researchers through specially-created student places in these ‘future’ fields.

Space Technology and Artificial Intelligence join eight other areas of future science, including in the fields of health and energy. By 2022, the CSIRO Future Science Platforms program will have invested $205m since it was launched in 2016.

AMT DEC/JAN 2019

Space Technology will receive $16m to identify and develop the science to leapfrog traditional technologies and find new areas for Australian industry to work in. It will initially focus on advanced technologies for Earth observation, and then address challenges such as space object tracking, resource utilisation in space, and developing manufacturing and life support systems for missions to the Moon and Mars. Artificial Intelligence and Machine Learning will receive $19m to target AIdriven solutions for areas including food security and quality, health and wellbeing, sustainable energy and resources, resilient and valuable environments, and Australian and regional security.

CSIRO Chief Executive Dr Larry Marshall said the CSIRO Future Science Platforms have an important role to play in inventing and securing Australia’s path to prosperity.

“Our Future Science Platforms aim to turn Australia’s challenges into opportunities where new science can break through seemingly impossible roadblocks to give Australia an unfair advantage on the world stage,” Dr Marshall said.

“Innovation needs deep collaboration, so our FSPs bring together this nation’s world-class expertise across all fields of science, technology, engineering and maths to deliver real solutions to real world problems.”

Genius at Work Please Come In CARBON FIBER CARRIAGE

INTELLIGENT PROCESS SENSORS

LINEAR MOTORS ON ALL AXES

SYNTHETIC GRANITE FRAME

PROPRIETARY CNC AND SOFTWARE

ECO-FRIENDLY

Laser Genius New. Lightning fast. With clockwork precision. Ideal for complex jobs. We call it Laser Genius and you will know why as soon as you see it in action. With superior performance through extraordinary speed and accuracy, the Laser Genius will make your work easier and dramatically increase your productivity. It also provides unlimited flexibility through its automation modules and suite of dedicated options.

Laser Genius is the new jewel in the crown of Prima Power’s 2D laser line, the first choice for those who aim high.

Prima Power. Next to you.

Partner of Prima Power

IMTS Machinery 110 Proximity Drive Sunshine West, VIC 3020 www.imts.com.au

The Bend | The Combi | The Laser | The Punch | The Software | The System

primapower.com

028

GOVERNMENT NEWS

$2bn fund to transform SME access to funding The Federal Government has announced plans to significantly enhance access to funds for small business across the country through the introduction of a $2bn Australian Business Securitisation Fund and encourage the establishment of an Australian Business Growth Fund to provide longer-term equity funding.

Small businesses find it difficult to obtain finance other than on a secured basis – typically, against real estate. Small businesses that have already obtained finance secured against real estate, but wish to continue to grow, also find it difficult to access additional funding.

Even when small businesses can access finance, funding costs are higher than they need to be.

To overcome this and ensure that small businesses are able to fulfill their potential and continue to underpin economic growth and employment, the Australian Business Securitisation Fund will invest up to $2bn in the securitisation market, providing significant additional funding to smaller banks and non-bank lenders to onlend to small businesses on more competitive terms. The Australian Business Securitisation Fund will be administered by the Australian Office of Financial Management (AOFM).

The Government is also in consultation with the Australian Prudential Regulation Authority (APRA) and a number of financial

institutions in regard to the establishment of an Australian Business Growth Fund that would provide longer-term equity funding to small businesses. Many small businesses find it difficult to attract passive equity investment, which enables them to grow without taking on additional debt or giving up control of their business.

The Australian Business Growth Fund is expected to follow similar international precedents. By way of example, since its establishment in 2011, the UK’s Business Growth Fund has invested some $2.7bn in a range of sectors across the economy.

A similar fund has not emerged in Australia, in part, as a result of the unfavourable treatment of equity for regulatory capital purposes.

APRA has indicated that it is willing to review these arrangements to assist in facilitating the establishment of the Australian Business Growth Fund. To fast track its establishment, the Government will host a meeting of key stakeholders in Canberra during the next sitting period.

Strategic plan launched to grow WA’s defence industry and create jobs Western Australian Premier Mark McGowan launched the WA Defence and Defence Industries Strategic Plan on 30 October, during an address at the inaugural Indo-Pacific Defence Conference.

The strategy represents the first time the WA Government has committed to a strategic plan dedicated to defence and the defence industry, bringing the state in line with every other State and jurisdiction in the country. The priorities for assisting the defence sector are centred on harnessing WAs competitive advantages and pursuing industries of the future.

The plan outlines six key strategies: • Supporting a strong enduring defence presence – Develop and promote the case for WA to be the principal location for maintenance and sustainment for the future submarines and frigates. These contracts are expected to exceed $50bn through the life of the new fleets.

• Growing the State’s defence industry capability and contribution – Facilitate business opportunities and collaboration overseas to maximise domestic and international defence opportunities.

• Developing strategic infrastructure – Establish an across-government taskforce to undertake strategic planning for the expansion and management of Henderson and the Australian Marine Complex.

• Building research and innovation partnerships – Work with the Federal Government to establish a Defence Science Centre to enhance research collaborations and engagements between universities, industry and defence.

• Advancing education, training and skilling – Establish a Defence Office in the South Metropolitan TAFE to lead a coordinated and collaborative approach to the development of a WA defence workforce.

AMT DEC/JAN 2019

• Supporting veterans and families – Develop a Veterans and Defence Families Strategy to better support veterans and their families.

The Defence Science Centre will be a collaboration between the State Government, the Defence Science and Technology Group (DSTG) and Western Australian universities. The centre will maximise WA’s defence-related research opportunities and will be a primary source of facilitating research and development connections to foster a globally engaged, competitive and innovative defence sector.

The Strategic Plan outlines a vision and roadmap for how the State Government will pursue opportunities to support defence and industry requirements. It provides the basis for guiding the State’s public sector and Defence West, and identifies the key actions required to progress the Government’s vision.

“As part of the Plan for Jobs, I made a commitment to make the defence sector a priority, to continue to diversify our economy and create jobs for Western Australians,” said McGowan. “The defence sector is worth billions of dollars to the economy and WA has been crying out for a strategic plan to further unlock its full potential.

“Western Australia has incredibly strong manufacturing capabilities, with many local companies at the forefront of world-leading technology to service the defence sector. For the first time, we now have a strategy to build on these alreadyestablished strengths and champion Western Australia to secure a greater share of defence contracts for our State and create new opportunities for innovation.”

The Western Australia Defence and Defence Industries Strategic Plan is available at: www.defencewest.wa.gov.au

Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

It’s all about you.

Business Growth Services and Supply Chain Facilitation

The Entrepreneurs’ Programme (EP) is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. The programme forms a part of the Australian Government’s Economic Action Strategy and will deploy over 100 experienced Advisers and Facilitators, offering support to businesses through three key elements: 1. Business Management a. Business Growth Services b. Supply Chain Facilitation 2. Innovation Connections 3. Accelerating Commercialisation 4. Incubator Support Growth Services A Growth Services engagement will enable your business to identify and capitalise on growth opportunities more rapidly, easily, and capably, with less risk. The engagement will help your business build the capacity to accelerate growth.

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.

Every business has different needs.

www.amtil.com.au

1302AMTILEP06

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

030

VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Is “Manufacturing Value-Added” under-valued?

While manufacturing’s contribution to Australian national GDP has been in decline for decades, many have identified advanced manufacturing as an opportunity to rebuild the sector. However, manufacturers may need help in taking the steps required to achieve excellence on the road to growth and success, writes Linsey Siede.

The history of Australian manufacturing industry’s contribution to gross domestic product (GDP) reflects the prominence of industry for almost 60 years, peaking at just below 30% of GDP in the late-1950s and early-1960s, before a long period of decline in its share to around 11% of GDP in 20002001, as depicted in the graph below from the Australian Bureau of Statistics.

The missing time series in the graph above from 1939-40 to 1947-48, corresponds with what is probably the period of fastest growth in Australia’s manufacturing industry.

The manufacturing industries developed during World War II, were supported and encouraged by government policy in the post-war years, but ultimately began to decline in importance.

In the time since 2000-2001 the value-added provided by the manufacturing sector in Australia has continued to fall, and includes the recent loss of the automotive passenger vehicle original equipment manufacturing (OEM) sector. According to the World Bank it seems that the Australian manufacturing value-added as a percentage of GDP has now fallen to below 6%. This figure is the second-lowest of all 32 OECD countries, and more than two and a half times less than the OECD average of 15.6%. This should prompt some immediate questions, including: • Where has the 24% gone since the peak of manufacturing?

• How does Australia compare to other countries around the world?

• What is Australia doing about this?

• Does the loss of manufacturing really matter, and does anyone really care?

An article published by IbisWorld can at least help to answer the first question.

Long gone is the dominance of the Primary sector (agriculture and mining), peaking at almost 50% of GDP in the 1820s, and the Secondary sector (manufacturing and

AMT DEC/JAN 2019

utilities), peaking in the 1960s. IbisWorld describes a shrinking of the Primary and Secondary sectors, a relative stability in the Tertiary sector (Construction, Wholesale & Retail Trade, and Transport), and huge growth in the Quaternary and Quinary sectors. IbisWorld forecasts that in 2020 the Quaternary sector (including Media, Telecoms, Finance, Insurance, Professional & Technical Services, Administration, Public Administration, Safety and Education) will account for more 50% of Australia’s GDP. By 2020 the Quinary sector (Hospitality, Health & Social Assistance, Arts & Recreation, Personal and Other Services) is forecast to account for 12% of GDP, and will have shown significant further growth by 2050 to reach 17%. By 2050, it is also forecast that the two previously dominant sectors of Primary and Secondary industry will account for less than 15% between them.

The World Bank can help answer the second question – of how Australia compares to other countries – but the data provided the Bank raises even more issues. The graph below shows the data for ‘Manufacturing Value-Added as a percentage of GDP’ for Australia (the black line with diamondshaped point markers) compared with a number of other OECD Countries.

Interestingly, following the Global Financial Crisis (GFC) in 2007-2008, the graph of manufacturing as a percentage of GDP for many countries, including the UK, the USA, Germany, Japan, France and New Zealand, stopped its downward trend, and in 2009 either stabilised – or in many cases, including for Germany, Japan the UK and the US, actually increased. The stabilisation trend also followed for the graph of the world average.

031

the Operational Excellence phase and into the Business Excellence phase, so they can successfully grow and become larger.

Larger companies are much more prepared to invest in innovation, and implement the tools and processes related to advanced manufacturing and Industry 4.0. Using the concept from ASEA, a company’s typical journey can be demonstrated as shown below.

The questions that still remain are – does this continual fall in manufacturing valueadded really matter, and if so, what do we do about it? Based on the latest directions and conversations surrounding the defence sector, and more specifically around

However for Australia – which didn’t really experience a major impact from the GFC – the trend has continued on its previous downwards trajectory, almost as if nothing actually happened. And when compared with our neighbours around the Asia Pacific Region, the relative decline of Australia’s manufacturing sector is amplified even further, with countries such as China, South Korea and Thailand all above 27%.

Even compared to some countries that are not really that well known for their manufacturing such as Kosovo, Uganda, Costa Rica and the Democratic Republic of the Congo, Australia still does not rate that well. Indeed, even in Borat’s homeland of Kazakhstan, manufacturing as a percent of GDP is almost double the figure in Australia.

Advanced manufacturing?

But what about advanced manufacturing?

Australia is focused on the implementation of innovation, advanced manufacturing and Industry 4.0, which these other countries do not have. This is excellent news for those companies that are technically and managerially ready to meet those challenges, but let’s take a look at a couple of facts first.

Firstly, according to the ABS data, there were 2,132,412 actively trading businesses as of June 2011. Almost 96% of these were classified as small businesses (2,045,335), 3.8% were medium-sized , and 0.3% were large. Of the small businesses, 85% employed between one and four people.

While the size of a business definitely does not define its innovativeness or its levels of technology, it usually does define its ability to find adequate funding for advanced technologies, and to provide additional employment.

Secondly, there is usually a typical path that most manufacturing companies follow. It was first published by Automotive Supplier

Excellence Australia (ASEA) in 2011, and showed the path of a typical SME company on the way to growth and success. It began with the inwardly focused “Operational Excellence” stage commencing with a Business Plan, then moving through the “Lean” phase to improve competitiveness and reduce cost, and ending with a focus on company culture and leadership, to ensure sustainability.

Many companies were happy to stop there, but some took the next step and entered the “Business Excellence” phase. Here the company changed from an internal to an external focus, and concentrated on broadening its product and customer base, with a commitment to marketing, diversification, branding and exports.

Typically small-to-medium-sized manufacturing companies are focused on Operational Excellence, and need different types and levels of support than their larger counterparts. SMEs typically need support and assistance to help them move through

the importance of sovereignty, it would appear that Australia’s ability to be able to manufacture key products is now becoming increasingly important again.

It would therefore appear clear that if Australia wants to halt the decline and begin to re-grow its manufacturing sector, there needs to be a significant shift in both the thought processes and the funding mechanisms, with a renewed focus on not only helping companies with their Business Excellence at the pointy end of their journey, but also helping those companies at the beginning of theirs to achieve Operational Excellence.

Linsey Siede is the Director of Likatibro Consulting. Siede began his career in engineering with GM Holden, before becoming Managing Director of Delphi Australia in 1990. He was also General Manager of ANCA Machine Tools, prior to spending the last ten years as the Director of Automotive Supplier Excellence Australia (ASEA). likatibro@bigpond.com

AMT DEC/JAN 2019

032

VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Are you who Google says you are?

Digital technology is bringing about the biggest changes in business since the Industrial Revolution, and manufacturers risk being left behind if their online presence isn’t up to the mark. By Deb Croucher.

“We don’t GO online… we LIVE online” – Google, 2018 And it’s true. Look around. On a train or a bus, in your office, at home with family and even over meals in restaurants… people are interacting with screens rather than directly with the people around them. Hate it or love it – screens are where we spend our time.

Where your customers are spending their time. And while you still might initiate a business relationship by pressing the flesh, once the meeting is over, your new prospect is going to look you up. And guess what? You are who Google says you are.

a fear of investing significant cash into something they have no clear strategy on, and that quite frankly they don’t understand.

Start in an old-fashioned way Here’s some advice. Your first step onto the wave is not to call in a web designer or a social media expert. They are important down the track … but not yet. The first vital skill you need is more oldfashioned. It’s a writer.

You are who Google says you are

People are busy. And when they land on your website or social media knowing nothing about you, the first thing they want to know is what you do, who you do it for, and why.

I wonder if you are excited about this reality? Pumped that Google is going to offer your prospect a link to your awesome bio on the website and LinkedIn, links to articles you’ve written and videos you’ve recorded, and most importantly a gateway to the front door of your business: the superb website that showcases your company in a wonderful way.

A good writer can eloquently articulate what you do for who in a few words. So within a few seconds of landing on your website I can understand you and decide to stay if you can help me with what I am looking for. For an example of a manufacturer who has nailed this first landing message, take a look at Sydney-based Romar (www. romareng.com.au).

Or like many business owners are you feeling more than a bit embarrassed by your digital presence? Concerned that Google will send your prospect to a sub-standard website that is not in any way reflective of how great your business really is.

The why behind the business is the next part of the message to nail.

The reason you get up in the morning and come to work is important to your customers. It connects them to you and shows that you care about what you do. You must articulate the why behind your business on the homepage of your website and again in the About and Team pages.

Ride the wave… or be knocked over Here’s the stark reality as I see it in 2018.

We are just starting to be hit with a digital tsunami. The biggest change in business since the Industrial Revolution. I believe manufacturers who tell a great online story, making sure their website is true reflection of their worth and value, have a chance of emerging triumphant in this new age. And I believe manufacturers who ignore their digital footprint will be out of business inside 5-10 years.

But if you browse Australian manufacturing websites what do you see? Poor quality sites, badly designed, badly written, hard to navigate, heavily technical and product-based, with no real way to gain an understanding of the passion and drive behind the founders and the great work the company does.

You have to conclude the standard is low. Yet the companies themselves are good.

So why do so many manufacturers market themselves so badly online?

I think the first problem is confusion. Manufacturers (like most businesses in Australia) are confused by the array of platforms and social media channels. They have no idea what to put where, or even what to do first. The second problem seems to be skills. Business owners are not clear who to bring into the business to help them.

Do they need a designer, a programmer, a social media expert or an SEO person? And finally I believe, quite understandably, there’s

Next layer on some stories “The most powerful person in the world is the Storyteller.”

Do you know who said that? Steve Jobs said that.

He’s right. I’d like to bet that every single person who has made a sale has used stories to help close that sale. The best salespeople are born storytellers. People connect with stories, remember them and most importantly take action.

So the second skill set to bring is… the writer again. It’s still too early for a designer, video specialist or social media specialist. Layered stories are the best way to show what you do. Design stories, stories of the transformation your products and services deliver to your customers, stories of how your team has worked to deliver breakthrough moments. Blood, sweat and tears. It all combines to connect people with your business, remember you, and most importantly, take action and buy.

And once you have your message nailed and your stories clear? Well now you can talk to a designer. And guess what? Instead of them telling you how you need to design your website, you will be in a much better position to take control and tell them what you need to showcase your business in the best possible light.

Deb Croucher is the Founder and CEO of Brilliant Digital www.brilliantdigital.com.au

Your advertising never sleeps with AMT

Market your business 24 hours a day, 7 days a week from only $250 per week.

AMT DEC/JAN 2019

Your Industry. Your Magazine.

1391AMTIL

AMT & AMTIL Digital Media Kit 2018 Call Anne Samuelsson at AMTIL on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

033

VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Sussex Taps – Branding for success It’s been an eventful year for Vanessa Katsanevakis, Director of Sussex Taps. She was named the Young Manufacturer of the Year at the 2018 Victorian Manufacturing Hall of Fame awards in May, while at the Victorian Manufacturing Summit in Geelong in September, she gave a talk on the role marketing has played in her company’s success.

This is an edited extract of her presentation.

It’s no secret that marketing is important, but what I didn’t realise is how important marketing could be. When I was 17 years old I started in the family business. My dad’s book-keeper was retiring and I took on accounts and a bit of payroll, and I learned super-quick how to lose favour with our 20 staff when I got the pays wrong!

Throughout my uni studies I continued with my family’s business.

Continuing my father’s legacy was super-important to me, his lifetime of work and dedication to manufacturing in Australia was something that really resonated with me. But in the late 2000s, it got busy. I got married, in 2008-09 we had the GFC, and my dad also felt quite unwell. In 2011 we lost dad. And with that we lost our visionary, our leader for the business, and also our lead engineer.

We had 50 staff looking to us for direction at that time, and it was a difficult time, because at that point we had flat-lined, the business was declining 10% each year, it was quite a tough challenge. So my husband George and I did what I presume most people would do.

We rallied together. We looked at our Lean manufacturing – George spent a lot of time on improving efficiencies, cost-saving and really working on our efficiencies as a business as a whole.

I found that there was a gap between the perception of who we were as a business in the wake of the GFC. Being an Australian manufacturer was perceived as a bit of a negative. But for us what that actually created was a niche. Being one of the last remaining tapware manufacturers in Australia, we were then able to offer customisation and bespoke solutions for our customers. And I found there was quite a gap between who we used to be perceived as – a manufacturing arm for large retailers – to who we had become.

So I took the plunge, and I spent a lot of money that I did not have at the time, and we embarked on a marketing and branding exercise.

We wanted to enable transparency into our business. We wanted people to look, and see, and learn, and read about why we were so passionate about manufacturing tapware. We wanted people to look

see that we were individuals, crafting products for other individuals, that we were obsessed with the detail, that we are a second generation business, following a great legacy, that we’re superpassionate about the highest quality, and manufacturing in Australia.

Bathroom trends in Europe were a couple of years ahead of us here in Australia, and so we saw an opportunity to then offer 31 customisable finishes, which ultimately gave our customers unlimited possibilities.

We can custom-make orders, with all of our manufacturing done on-site.

And as our brand changed, I started to notice some different things happening at work. Our staff started to stand a bit taller, and feel super-proud to represent Sussex Taps. As our brand evolved, I had to step up with our office facilities; so we fitted out a super-trendy office. But then even more amazing things happened.

We started to get dream customers knocking on our door, instead of us chasing them.

Our product was still the same; our operations and our procedures were mostly the same as well. But the change in our customers’ perception – that was priceless.

I feel like in manufacturing, we have all that amazing work that goes on on the factory floor: the know-how, the innovation, the R&D, the years of experience… But amid all the hardships and challenges – because as manufacturers we are true gladiators – I feel like that can sometimes get lost. The beauty of that process can sometimes get lost. I would like to encourage more emotional story-telling and transparency, because now more than ever our customers want to believe in the transparency of the business, and believe in the integrity of the brand they’re buying into. And that can ultimately provide customer loyalty.

I feel we all have so much more than just great products to sell. We have amazing stories behind those products, to tell. www.sussextaps.com.au

AMT DEC/JAN 2019

034

TECH NEWS

USA: 3D printing with sound Researchers have developed ‘acoustophoretic’ printing that uses 3D printing and highly localised soundwaves to generate droplets from liquids with an unprecedented range of composition and viscosity. This has created a new technology that enables myriad materials to be printed in a drop-on-demand manner. The higher the sound waves’ amplitude, the smaller the droplet size. Inkjet printing is used to pattern liquid droplets, but it’s only suitable for liquids that are 10 times more viscous than water. Yet many fluids are far more viscous. The researchers tested the process on a wide range of materials from honey to stem-cell inks and even liquid metals. Importantly, sound waves don’t travel through the droplet, making the method safe to use even with sensitive biological cargo.

Apart from the pharmaceutical industry, this will be important for multiple industries. Unlike other methods, this is independent from the material properties of the fluid.

Germany: Biodegradable plastic may be eaten by fish A type of compostable bioplastic (Nuatan) made of corn starch, sugar and used cooking oil, could replace “all the packaging we know”, according to its designers - Crafting Plastics Studio in Germany. It is more durable than previous bioplastics and degrades harmlessly when composted or ingested. The result of six years of research, it is a blend of two different biopolymers. Polyactic Acid is a natural plastic derived from corn starch while Polyhydroxybutyrate is made from corn starch that has been metabolised by microorganisms.

The designers claim the material can withstand temperatures of over 100deg.C without losing integrity and has a lifespan of up to 15 years. It could be used to replace all single-use plastic products and it degrades inside the human body or animals, so fish can eat it.

Dezeen

Harvard John A. Paulson School of Engineering & Applied Sciences.

UK/USA: Revolutionary new material for future vehicles A new material that is as stiff as metal but flexible enough to withstand strong vibrations could transform the car manufacturing industry. The team achieved this near impossible combination in a material by using 3D woven technical textile composite sheets, with selected unbonded fibres – allowing the inside of the material to move and absorb vibrations, while the surrounding material remains rigid. Researchers believe their new material could usher in a new wave of trains, cars, and aircrafts, allowing customers to experience little to no vibrations. The idea of a composite that resolves the paradox of stiffness and damping was thought to be impossible.

The new materials are 3D-woven lattice materials created by brazing only select lattice joints, resulting in a load-bearing lattice frame intertwined with free, ‘floating’ lattice members to generate damping.

Canada: 3D-printed skull cap for dog with cancer Researchers at an Ontario university have used 3D printing technology to replace about 70% of a dog’s cancer-ridden skull with a 3D-printed titanium skull cap. ADEISS, a 3D printing company in Ontario, Canada, made the customised titanium skull cap for Patches - a nine-year-old Dachshund. The novel procedure is being heralded as a major advancement in veterinary medicine. Vets in Britain have performed a similar surgery, but on a significantly smaller scale. Within 30 minutes of waking up after the four-hour operation, Patches was walking outside for a bathroom break.

3ders.org

University of Surrey and mixed

Japan: Metal withstands ultrahigh temperature & pressure Scientists have identified a metal able to withstand constant forces in ultrahigh temperature (1400°C-1600°C), offering promising applications including aircraft jet engines and gas turbines. The first-of-its-kind study describes a titanium carbide-reinforced, molybdenum-silicon-boron-based alloy which is extremely strong compared with Nickel-based single crystal superalloys, which are commonly used in hot sections of heat engines of aircrafts and gas turbines. The study reports that, contrary to previous studies, the alloy experiences larger elongation with decreasing forces. This behaviour has so far only been observed with superplastic materials that are capable of withstanding unexpected premature failure.

Tohoku University

AMT DEC/JAN 2019

Switzerland: The next step for 3D printing Researchers have developed a bioinspired approach to 3D print recyclable materials using cheap desktop printers that outperform state-of-the-art printed polymers. Currently, the available polymers

TECH HEADING NEWS for FDM are relatively weak and the printed parts show poor adhesion between the printed lines. For the first time, researchers were able to print objects from a single recyclable material with mechanical properties that surpass all other available printable polymers and can compete even with fibre-reinforced composites.

The 3D printed liquid crystal polymer structures are much stronger than the state-of-the-art 3D printed polymers and do not require the labour and energy-intensive steps involved in current composite manufacturing. Thus, the technology is expected to be a gamechanger in applications where high-performance lightweight materials are required.

ETH Zurich

Germany: The robot eye with an all-round field of view Specialised sensors perform a robot’s “seeing” function, most of which operate via laser triangulation. However, there is a problem: the shadowing effect limits the flexibility of existing sensors. The only alternatives are to use several sensors or additional axes which sometimes cost more than the robot itself. An innovative solution has been developed called SensePRO. This compact sensor system measures 15cm and is equipped with specially developed image processing algorithms, thus providing a shadow-free allround field of view, and generating a 360° measurement field. No matter where the robot moves, at least one laser line is always optimally positioned, supplying precise positional information to the camera. This approach also solves another problem – shadowing of the laser light by components with complex shapes. The technique significantly simplifies process control and quality assurance – with just one sensor. The sensor is designed to fit robots made by all leading manufacturers and can be easily integrated into existing production systems.

Fraunhofer

Switzerland: “Memory steel” A new material for the strengthening of buildings A new building material has been launched: “memory-steel” can not only be used to reinforce new, but also existing concrete structures. When the material is heated (one-time), prestressing occurs automatically. Till now, the steel reinforcements in concrete structures are mostly prestressed hydraulically. The strengthening of older structures sometimes fails due to the high space requirements of this method. There is now an alternative to series production readiness: shape memory alloys based on iron, which contract during heating and thus permanently prestress the concrete structure. It is sufficient to heat the steel briefly (by electric current or infrared). In industrial buildings, the load-bearing capacity of an old suspended slab sometimes has to be increased. Thanks to memory-steel, such tasks can now also be easily solved in confined spaces. The new building material will be marketed under the name “memory-steel”.

EMPA

Germany: World’s first hydrogen fuel cell trains enter service The world’s first hydrogen fuel cell-powered trains have entered commercial service in the Lower Saxony region of Germany. The two Alstom Coradia iLint trains will serve a 100km route and can travel up to 140km/h. The new trains will be fuelled at a mobile hydrogen filling station, where gaseous hydrogen will be pumped into the trains from a 12m high steel container. According to Alstom, one tank will provide enough fuel for 1000km of travel. Hydrogen is considered a low-emission and efficient alternative to diesel, especially where the trains are able to operate on secondary lines where overhead lines are uneconomical or not available yet.

The Engineer

USA: Reconfigurable modular robot

USA: A simple 3D printer for metal 3D printing of metals is still challenging and limited because metals generally don’t exist in a state that they can be readily extruded.

Additive manufacturing of metal components has been developed previously, where a powder bed fusion process is used, however this exploits a highly-localized heating source, and then solidification of a powdered metal shaped into the desired structure. This approach is costly and complicated. This new technique simplifies 3D printing of metallic components by exploiting the unique softening behaviour of bulk metallic glasses (BMGs). Paired with this plasticlike characteristic are high strength and elastic limits, high fracture toughness, and high corrosion resistance.

Science Daily/Elsevier

Modular robots composed of several interchangeable parts, or modules – are far more flexible than general-purpose robots. If one part breaks, it can be removed and replaced. Components can be rearranged or the robots can figure out how to reconfigure themselves. With the hardware still in research stages, this is the first time modular robots have been demonstrated with autonomous reconfiguration and behaviour that is perception-driven. The robots are composed of wheeled, cube-shaped modules that can detach and reattach to form new shapes with different capabilities.

The modules have magnets to attach to each other, and Wi-Fi to communicate with a centralized system.The team proved the effectiveness of its system with three experiments. In the first, a robot was instructed to find, retrieve and deliver all pink and green objects to a designated zone marked with a blue square on the wall. The robot used the “Car” configuration to explore, and then reshaped itself into “Proboscis” to retrieve a pink object from a narrow pathway, finally returning to its car shape to deliver its haul.

Cornell University

“This is an exciting development that could send shock waves through the car, train and aerospace manufacturing industries.”

Dr Stefan Szyniszewski, Assistant Professor of Materials & Structures at the Uni of Surrey remarking on a new “paradox” composite material that has both high stiffness and damping – thought to be impossible. (see “Revolutionary new material for future vehicles”)

AMT DEC/JAN 2019

035

ADVERTISEMENT

MEET YOUR NEW CO-DESIGNER

Image courtesy of General Motors

You’ve seen what the cloud can do for data security, remote collaboration and responsive workload growth, but did you know it’s also ground zero for a new paradigm in design and manufacturing?

Welcome to generative design, where countless high performance geometries are calculated and executed in the cloud, giving you as many choices as you need to analyse and prototype to find the optimum design.

For the first time, the ‘aided’ part of CAD is coming truly to life. As the design lead, you need only specify the materials and project specs the 3D model requires and generative design does the rest.

It’s an approach tailor made for the computing world we live in today. AI analyses the project requirements and can build thousands of design permutations, calculating the impact of changes in materials or dimensions and seamlessly repurposing other elements to maintain the performance constraints you’ve established.

Just like life forms react to environmental pressures, your design evolves according to performance parameters like retaining strength while using less material, staying flexible despite changes in materials, etc.

And it’s all done and delivered by the storage and processing power of the cloud, faster than we ever could in the standalone PC or mainframe era.

If you’re familiar with topology optimisation, you could think of generative design as the next logical step. An established part of 3D design science has always been to manually manipulate your model to find the optimal geometry, testing and reshaping your design according to your needs after the application generates it.

Generative design not only does all that for you, it gives you as many options as you could possibly review, all of them adhering to the project parameters.

Even during the eras of manufacturing lathes, computers and stone flints, the history of the built world has always been a process of figuring out the best methods through trial and error.

But a lot of design constraints like heights, weights, flex or stress and materials can be expressed numerically. As our tools or parts get more complex, the ever-finer calculations needed are simply too much for a human engineer but as we know, calculations are exactly what computers do best.

You’re still the project lead, selecting the best design iteration for the job. But now, generative design gives you a limitless virtual R&D factory producing as many choices as you could possibly want. Even variables particular to the manufacturing process down the track – whether additive or CNC machined – can be accounted for.

Autodesk is putting the power of generative design into the hands of all our users, and the interoperability of AI in the cloud has been the inspiration behind some exciting product additions. All users of Autodesk Product Design and Manufacturing Collection including Fusion 360 now have generative design tools at their fingertips.

As an Autodesk user, you also have access to cloud credits, our pay-as-you-go service to supercharge your design applications with the full power of generative design technology.

GENERAL MOTORS CASE STUDY The future of the car will revolve around improvements in environmental impact and customisation, and it’s a future auto maker General Motors is embracing now. With 30,000 parts in the average vehicle, tools like generative design and additive manufacturing gives GM a huge opportunity to do things better.

GM engineers had an encouraging proof of concept recently with development of a new seat bracket, the tool that secures seatbelt fasteners to the inside of the car body. The software produced 150 alternative designs and a seamless single-piece geometry was selected that outperforms the box-like, eight-piece traditional version in both weight and strength.

Not only is the new seat bracket a more optimal design, it reduces the supply chain costs associated with fitting so many parts together. Scale that up to the entire car or factory and the potential savings to both cost and development timelines become clear.

Not only that, generative design is enabling entirely new ways of prototyping, methods long-entrenched and restrictive methods like milling and molding have kept out of reach. New product classes like electric vehicles might not be so expensive to design and build, for example, radically reducing the R&D cost by coming up with endless permutations of the best way to do something.

Try generative design for yourself.

Download your free trial here: www.autodesk.com.au/gd

Image courtesy of General Motors

038

PRODUCT NEWS

Hexagon announces new flagship Absolute Arm range Eight years after the launch of the first ROMER Absolute Arm, Hexagon’s Manufacturing Intelligence division has unveiled its new Absolute Arm range.

A ground-up redesign has seen one of the world’s most recognisable portable measuring arms modernised to meet the needs of today’s metrology users, with a key focus on improved usability and versatility without compromising on speed and accuracy.

A standout feature of the new Absolute Arm is its modular wrist design. This allows both the RS5 Laser Scanner and the pistol grip to be completely removed, facilitating easy probing in tight spaces. When reattached for laser scanning applications, a variety of grip sizes are available to ensure a perfect fit for every user. The new wrist also now features a display screen that allows for measurement result oversight, profile switching and calibration right at the point of measurement, reducing time spent switching attention between the arm and its control computer.

“Over the last eight years we’ve received a lot of positive and constructive customer feedback, and hopefully people will see how this has informed our design,” says Anthony Vianna, Product Manager for the Absolute Arm range.

“Many customers told us they needed to measure in smaller and smaller spaces, like cavities or inside complex fixtures, and it was that sort of direct-from-the-user intelligence that drove us to create the most compact scanning configuration on the market today.

“We examined everything about the arm: how people were using it; how users measure different parts; how they move their arm around their facility; how the arm communicates with them; how

to make the arm more serviceable. And that process is what brought us to where we are today – with a new arm that offers improvements in every single area, across accuracy, speed, efficiency, weight, serviceability and versatility.”

This new Absolute Arm range retains all the features that made the previous generation of ROMER Absolute Arm systems so successful. These include the proprietary Absolute Encoders that eliminate referencing and warm-up times and diagnostic reporting, as well as low-friction rotating grips and a unique counterweight system that facilitate easy movement and measurement. Notably, also still present is the capacity to measure at full speed without a reduction in accuracy.

The new Absolute Arm models are also available in a six-axis version designed for dedicated probing applications. Within this category is the new Absolute Arm Compact, which assumes position of the previous ROMER Absolute Arm Compact as the most accurate portable measuring arm in the world, with accuracy now to within just 6 microns. The full Absolute Arm range is available across seven sizes, with measurement radiuses from 1.2 to 4.5m, and three levels of accuracy, resulting in 36 unique arm configurations – an arm for every application.

The complete Absolute Arm range is now available to order from Hi-Tech Metrology in Australia and New Zealand. www.hitechmetrology.com.au

Milling with “Xtended Technology” – Xtra·tec XT Walter has launched the next generation of its milling tools, in the form of Xtra·tec XT. “Xtended Technology”, or “XT” for short, is designed to achieve increased productivity and process reliability.

It is not just the black look of these products which distinguishes them from the previous Xtra·tec tools; they are in fact a completely new generation of milling cutters. Walter is initially launching shoulder milling cutters and a face milling cutter from this generation – for virtually all requirements in shoulder and slot milling, in all common material groups.

The most striking design feature of the new milling tools is the installation position of the indexable inserts – at a greater incline and with a larger contact surface. This reduces the surface pressure in the seat while increasing the stability. The larger screw hole cross-section stabilises the indexable insert and the longer screws which are now available hold it in place more securely. The cutter body has also been made more stable, as it now has much more material behind the insert seat. Besides greater process reliability, the new installation position of the indexable inserts also allows for the addition of an extra tooth, thereby increasing productivity. The precise 90-degree shape of the shoulder milling cutters helps to reduce additional finishing operations. Clamping screws which are easier to access optimise handling and help prevent assembly errors.

Another new feature is the smaller indexable inserts which can be fitted to the milling cutters. They are continuing the current trend towards reduced machining allowances. This applies even more so to the M5009 face milling cutter: it combines small depths of cut with the advantages offered by double-sided Walter Tiger·tec indexable

AMT DEC/JAN 2019

inserts. These inserts have eight useable cutting edges instead of the usual four. Thanks to these cutting edges, as well as a reduced number of finishing operations, the M5009 achieves increased efficiency.

As part of Walter Green, Walter’s policy of innovation in sustainability, the production and supply chain of the Xtra·tec XT milling cutters is CO2-compensated. www.walter-tools.com

Metal design optimized blades for the aerospace industry (left). Source: EOS Hip implant develope with Alphaform & Instrumentaria (right) Source: EOS

Shatter Manufacturing Boundaries with Industrial 3D Printing Adapt your production to the needs of a connected world. Whether rapid prototyping or serial production, EOS systems allow you to manufacture innovative and high-quality parts in both metals or polymers.

EOS, the world’s leading industrial 3D printing supplier, now work alongside Conflux Technology, to bring Additive Manufacturing to the Australian and New Zealand markets. We support your production with local service.

Benjamin Michelfelder Business Development Manager C/O Conflux Technology Pty Ltd Building NP 2. 110, Pigdons Road, Waurn Ponds VIC 3216, Australia anz@eos.info | www.eos.info

040

PRODUCT NEWS

German RepRap L280 unveils first 3D printer for liquid additive manufacturing German RepRap has launched the L280, the first production-ready 3D printer for liquid additive manufacturing (LAM).

LAM works with material such as liquid silicone rubber (LSR) that is in liquid form, which is vulcanised under heat exposure to its final form – in contrast to existing technology based on melting material and solidifying it again. This means the individual layers deposited by the printer bond together, rather than simply welding together. In this way, objects can be produced that have the same properties as injection-moulded parts – a clear advantage where insights from the 3D-printed prototype can be transferred directly to injectionmoulded serial parts.

With the LAM technology, even the application direction and thus the vulcanisation at the macromolecular level can be influenced. In that case, the material partly offers better strength compared with injection moulding. In addition, the process offers all the benefits of additive technology, such as design freedom and opportunities to fill the interior with honeycomb or other structures. Many companies are already using LSR for a wide range of products; this gives confidence to customers that want to use 3D-printable LSR in the future.

German RepRap has been working on the development of LAM processes for several years and showed the first prototypes at last year’s Formnext exhibition. The L280 is a series-ready

LAM 3D printer that offers a space of 280mm x 280mm x 200mm and a layer thickness between 0.22mm and 0.9mm. Nozzles with 0.23mm, 0.4mm and 0.8mm enable very accurate but relatively long-lasting objects as well as less detailed but rapidly printed components.

A heated print bed increases the adhesion of the printed parts and ensures optimal cross-linking. A high-temperature halogen lamp is used selectively in the process to accelerate the cross-linking. This significantly reduces printing time while improving print quality. Compared to conventional production processes such as injection moulding, this often saves time.

The EVOLV3D LC 3335 LSR material developed

by Dow can be supplied in the form of cartridges, additionally there is also an option for pails. Touch display and printing from a USB stick enable standalone printing though the L280 can also be connected to a network. German RepRap has also thought about safety and installed a safety technology in the L280 that monitors the curing process and immediately stops the process in case of irregularities. A special light system provides information about the current status. www.germanreprap.com

MOVUS easy monitoring helps manufacturers avoid downtime Manufacturers looking to keep running over Christmas and summer can do so more easily and affordably thanks to MOVUS, the provider of FitMachine, a simple-to-use and cost-effective solution for equipment monitoring.

Fulfilling back orders and preventing critical equipment failures is a constant battle for Australian manufacturers, notably during November, December and January, with more extreme weather and fewer staff on hand against the backdrop of demand for products.

Consequently, MOVUS has launched ‘Industry 4.0 Made Easy’, an offer to remove the headache for manufacturers for just $85 per machine per month, allowing customers to deploy predictive maintenance in a cost-effective way.

FitMachine is a condition-based maintenance solution that detects machine failures in advance using artificial intelligence and machine learning. The solution comprises an industrial sensor, industrial gateway, mobile application, analytics and trending dashboards, and artificial intelligence engine. The system automatically monitors equipment 24-7 and learns what the normal operation of machinery is to detect any abnormalities and alert the organisation before failures occur. Insights provided include machine health, degradation, utilisation, energy consumption and more.

Once a MOVUS installer is onsite, the units can be installed in under five minutes each, with no need for shutdowns, cutting or drilling.

The installer will also train your team to install more sensors, should they be required.

AMT DEC/JAN 2019

The pack contains everything manufacturers need to get started on their Industry 4.0 journey. For just $85 per machine per month, MOVUS Industry 4.0 Made Easy offers: • 10 FitMachine sensors.

• 1 FitMachine Gateway.

• The MOVUS fully-featured Dashboard, customised with your company logo, with machine trending and alerts via email and SMS. • Installation and training at your plant/factory/site.

• Access to online help, training guides and support from the friendly MOVUS team.

“This offer is about making life easy for manufacturers during a seasonal time hallmarked by high product demand, staff shortages and weather extremes impacting equipment,” says Brad Parsons, founder and CEO of MOVUS. “We’re giving people access to the latest technology in a really easy, low-risk way. It’s a cost-effective solution that’s rapidly deployed, easy to use and easy to adopt.” www.movus.com.au

PRODUCT NEWS

Rugged dependability: Kaeser launches M210 series portable compressor Kaeser Compressors has just announced the launch of its Mobilair 210 series portable compressor. Part of its larger range of diesel-powered portable air compressors, the M210 is the ideal solution for continuous operation in tough environmental conditions – such as those applications found on mine sites – where free air deliveries of up to 21.2 cubic metres/min are required.

Powered by a 146kW diesel engine from Caterpillar with exhaust emission Tier 3, and featuring the flow optimised Sigma Profile screw compressor block, the new Mobilair 210 rotary screw compressors provide a free air delivery of 21.2 cubic metres /min at 7 bar (g). In addition, 8.6 and 10 bar versions are available respectively delivering 19.7 and 18.0 cubic metres/min.

At the heart of the M210 series portable compressor lies the Sigma Profile screw compressor block. Developed by Kaeser some years ago and continuously enhanced ever since, it achieves power savings of up to 15% compared with conventional screw compressor block rotor profiles. This contributes to the overall high efficiency of these compressors.

Part of the renowned Mobilair range of portable compressors from Kaeser,

conditions, the M210 can optionally be supplied with a larger and stainless steel 450 litre fuel tank. Thanks to the availability of a wide range of optional compressed air treatment components, the M210 can deliver compressed air at the required quality at all times. It is also available with a certified spark arrestor for refinery applications. And, even under extreme conditions, for example ambient temperatures of -10 up to +50 degrees Celsius, the new M210 portable compressor from Kaeser dependably delivers the required compressed air at all times. User- and service-friendly, the M210 comes equipped as standard with the internal Sigma Control Smart controller. As such, the compressor is easy to operate, and the monitoring system can automatically shut the compressor down if necessary or report required maintenance.

manufactured at a state-of-the-art production facility in Germany, the recently launched M210 comes complete with a steerable axle chassis, foldable tow bar and parking brake. For the end user this ensures secure and space-saving positioning of the compressor.

The M210 portable compressor features an impressive 420 litre PE fuel tank. Such a large capacity ensures the compressor has sufficient fuel to last an entire work shift.

And, for extremely harsh environmental

www.kaeser.com.au

MTI PE200 SWING DOORS The most robust solution for food industry, retail and logistics The new PE200 HDPE double acting impact traffic door, exclusively available from MTI See-Thru, offers the perfect solution for insulation, functionality and durability.

Benefits of the MTI PE200 Swing Door; • Made of solid polyethylene – non breakable • Hygienic (EU/FDA approved) • Maintenance-free • Made to measure • Short production time • Easy installation • Long service life • PVC finger protection • 10 year guarantee on door leaves • Stainless steel hinges

MTI PE200 AMT_HalfPage.indd 1

Trusted by food and retail companies worldwide;

Contact M.T.I. Qualos today to discuss your industrial door needs.

• Kraft Foods, Bahrain • Nestlé, Germany • Aldi, Ireland • Lidl , Germany, England • Edeka, Germany • Kaufland, Germany • IKEA, Turkey

INDUSTRIAL DOOR SOLUTIONS www.mtiqualos.com.au Free call: 1300 135 539 sales@mtiqualos.com.au 25/10/2018 10:55 AM AMT DEC/JAN 2019

041

042

PRODUCT NEWS

New IO-Link Master from Wenglor permits intelligent data communication With the new Wenglor EP0L001 IO-Link master, Treotham is offering an ideal multiprotocol module for consistent communication right on up to the field level. Up to eight IO-Link-compatible sensors and actuators in accordance with IO-Link standards 1.0 and 1.1 can be easily and flexibly incorporated into the control level via industrial Ethernet with this innovative product.

Within the context of fully networked Industry 4.0 production and logistics centres, as well as smart machines and process optimisation by means of predictive maintenance, the new EP0L001 I/O-Link master is the perfect interface between the controller and intelligent field devices. In particular for the new generation of photoelectronic sensors included in the PNG//smart series with highly communicative, high-performance sensors, it is the ideal connection module for linking up to higher network levels. Participants exchange real-time data concerning system statuses during the running process, and can thus be dynamically adjusted to changing operating conditions.

This permits continuous process optimisation, assures production quality and avoids system standstills.

The eight IO-Link-compatible, freely configurable M12 ports offer greatest possible flexibility where module allocation is concerned, and reduce the costs of each channel to a minimum. Four of the eight ports are laid out as class B variants in order to be able to make increased load current available – as frequently required by actuators.

Even powerful actuators are not left in the lurch thanks to continuous load current of up to 2 A per class B port (total: 8 A). Supply power to all components is assured by the new L-coded M12 plugs, which also provide the opportunity of connecting additional field modules. In the event that a terminal device should fail, electrical isolation ensures that module communication is not interrupted and that disturbances are quickly eliminated. A total of 12 digital inputs, eight digital outputs or configuration by means of eight IO-Link-compatible ports offer greatest possible connection diversity and efficient use of the master.

A further advantage of the IO-Link master is its ability to communicate with the PROFINET and EtherNet/IPTM industrial Ethernet protocols.

The respective protocol can be selected at the master with the rotary encoder switch, thus making further devices superfluous. The two switch ports permit connection via line or ring topology. Depending on the utilised protocol, the IO-Link master fulfills functions such as fast start-up, shared device and Device Level Ring, and supports the media redundancy protocol.

The extremely rugged and compact zinc die-cast housing is ideal for harsh industrial conditions thanks to IP65/IP67/IP69k protection.

Whether cold or hot ambient conditions prevail, the IO-Link master works reliably at temperatures within a range of -20 to +70 degrees Celsius. Its minimal weight of just 500g also qualifies the unit for moving applications or mounting directly to machines. Treotham also offers suitable connection components. www.treotham.com.au

Shaping productivity in die & mould Dormer Pramet’s family of economical milling tools has been enhanced with several new ranges for semi-finishing and finishing in die and mould applications.

The launch features an assortment of CNHX05 double-sided inserts, with up to four cutting edges. Its unique patented wiper edges generate a high-quality surface finish, resulting in reduced machining time in both shoulder and face milling applications. This is supported by a range of SCN05C cutters for productive copy milling of steels, hardened steels and cast irons. Available in 12mm20mm diameters, the tool’s close pitch increases the number of teeth and enables at least 20% higher productivity than standard pitch cutters. It has been designed for contouring, profiling, plunging and face milling applications. Offering decreased levels of vibration, the tool has been optimised for smooth cutting of corners and pockets.

Meanwhile, Dormer Pramet has launched an insert with six-cutting edges, the double-sided WNHX04 insert. This too features a unique patented wiper edge to generate superior finish on component walls and face, reducing time in cut. This latest insert is compatible with a new range of economical and productive copy milling tools. The SWN04C cutter, available in diameters between 20-35mm, offers a variety of differential pitch options to enhance surface finish and support the six-cutting edge insert. Designed for smooth cutting in operations with long overhang, it can be used in contouring,

AMT DEC/JAN 2019

profiling, plunging and face milling applications with a depth of cut up to 2mm. As with the SCN05C cutter, the SWN04C range is suitable for semi-finishing and finishing applications in steels, hardened steels and cast irons for the mould and die segment.

In a recent example, the WNHX insert with WM geometry and new M4310 grade was used to machine tool steel at 0.50mm depth of cut. With a cutting speed of 196 metres/min and feed rate of 3,600mm/min, the tool reduced machining time by 45%, compared to a competitor’s equivalent. www.dormerpramet.com

Accelerate the additive revolution!

SLMÂŽ280 v2.0 Selective Laser Melting System Make complex parts Create new designs Speed up manufacturing Target new markets

Hip implant

Conformal cooling a tool insert

Hydraulic valve block

Titanium door bracket

Tyre mould

Maritime propeller

Hybrid –SLM+Forging

Dental caps

Call us to test and trial selective laser melting. Get information, advice and support.

Raymax Applications Pty Ltd 37/5 Ponderosa Pde Warriewood NSW 2102 02 9979 7646 info@raymax.com.au www.raymax.com.au

044

AUTOMOTIVE & ROAD TRANSPORT

T H E

ROAD

AHEAD Despite the closure of the local car industry, there are still big reasons to be hopeful about the future of road transport manufacturing in Australia. By Brent Balinski.

Image courtesy of Volgren.

AMT DEC/JAN 2019

HEADING Although many headlines were written in 2017 about the death of Australia’s automotive industry, no such thing ever happened.

While Australia’s last three passenger carmakers became importers (while retaining a design and engineering presence) over 2016 and 2017, the sector still produces bus, trucks, trailers, special-purpose vehicles and components.

The last two years have seen Australia’s three truck manufacturers – Volvo Group, PACCAR and IVECO – grow, says Steve Bletsos, Senior Analyst, Research and Policy at the Victorian Automobile Chamber of Commerce (VACC).

“Bus manufacturing has also been buoyant as a result of increased state government expenditures on rail replacement buses and trams, particularly in Victoria and Queensland,” says Bletsos, adding that the sector’s employment level has remained “relatively steady” at around 33,000.

The VACC’s CEO, Geoff Gwilym, points out that the full effect of the end of local assembly by Ford, Holden and Toyota probably won’t be known for five or six years, but there are around 2,500 companies making vehicles or parts in Australia. And there are reasons to be optimistic about the sector, especially following the October announcement that SEA Electric plans to assemble as many as 2,400 electric vans a year in the Latrobe Valley.

Besides vehicle electrification, other trends such as connectivity offer potential for technology providers. This is an area Australia is “avidly experimenting in” at the moment, observes Ian Christensen, Managing Director of the iMove CRC. This is a good thing, because Christensen predicts that what’s currently optional will soon become a requirement. In addition to being fuel-efficient, fit for purpose, and a pleasure to drive, vehicles will have to interact electronically with other vehicles, pedestrians, and infrastructure.

“For manufacturers of vehicles, Australia still fortunately has a bus and truck manufacturing centre,” says Christensen. “There is a need to be proactive, to build into the vehicle the sensing, the telemetry, and the interface to the driver. At the moment, it’s an option. It’s going to become progressively more and more a requirement and ubiquitous for the good functioning of the vehicle.”

Cohda Wireless – Vehicle to everything Cohda Wireless was spun out of the University of South Australia’s Institute for Telecommunications Research in 2004. Its focus is on robust outdoor mobile communications, and it has found a “sweet spot” in the vehicle-to-everything (V2X) market, says CEO Paul Gray.

“Originally we were just doing the physical layer, the actual communications, over-the-air communications,” says Gray.

“But now we’ve expanded to the whole software stack including applications which are actually giving warnings to the drivers and the like.

Cohda now provides technology to over 65% of autonomous cars in V2X trials, is a Tier 2 supplier of software, and also sells onboard units and roadside units for smart city applications. It uses contract manufacturers for this. Its technology has been used in trials for platooning for Peloton trucks, navigating bumpy terrain in an autonomous vehicle for Jaguar Land Rover, and recently demonstrated world-first localisation and collision avoidance in an “urban canyon” situation in the Adelaide CBD. In 2017 the Cadillac CTS included Cohda’s software as standard, via its inclusion in Aptiv’s vehicle-to-vehicle communications modules, which generate safety warnings.

“That vehicle started production last year, and then we also have a design with VW for a vehicle going into production next year,” says Gray. “Again, as a Tier 2 vendor; so the Tier 1 supplier is LG Electronics.”

Gray believes this an area where Australian automotive manufacturers have a real chance to play a role globally: “I can imagine a future not too far away where all cars are capable of autonomous driving, and so that becomes a real disruption. In any era of disruption it is gonna cause some heartache for the incumbents, but also create opportunities for younger companies.”

Continued next page

Ian Christensen, Managing Director of the iMove CRC.

Paul Gray, CEO Cohda Wireless

AMT DEC/JAN 2019

045

046

AUTOMOTIVE & ROAD TRANSPORT

Cohda recently demonstrated its localisation and collision avoidance technology in Adelaide CBD.

Mario Dimovski, founder and CEO of Tradiebot Industries.

Continued from previous page

Tradiebot – Opportunities for the early adopter Mario Dimovski, founder and CEO of Tradiebot Industries, is also studying the relationship between disruption and opportunity, having recently completed a mini-world tour during which he attended several conferences themed around the Internet of Things (IoT). He believes “everyone’s pretty much on the same starting line” and that fortune will favour the early adopters.

Tradiebot began in 2017 and aims to shake up the automotive repair industry by developing Industry 4.0-style solutions for it.

“What we’re doing is putting a lot of effort in … to demonstrate how in other industries this stuff is being used,” says Dimovski. “We’re saying ‘It’s already being done: robots are performing cataract surgery!’ Why not do some labour-intensive auto stuff?”

The company announced two projects using robotics applications in 2018, named Repair-bot and Prep-bot. Repair-bot uses 3D printing for same-day mending of plastic trim and assembly components, and is being brought to reality through an Innovative Manufacturing CRC project with Swinburne University and AMA/Gemini Group.

Prep-bot involves the University of NSW, Capital Smart, PPG Industries and others, and is supported by an Advanced Manufacturing Growth Centre (AMGC) grant. This aims to create a control system and robotic solution that will repair damaged panels (for example by scuffing or painting) using CAD files. Tradiebot aims

to sell this solution through PPG’s value chain once the technology has been validated.

A third project with Deakin University will create a training platform using augmented and virtual reality. Tradiebot has spent 2018 launching these projects and preparing the groundwork for further development over 2019.

“Some stuff we’ve identified as pretty much ready to go and ready to market now and are developing solutions around it,” Dimovski explains. “And then there’s some that we’ll look at later on and take it on as a project.”

With an estimated combined shortage of roughly 6,000 panel beaters and spray painters, Dimovski says the repair industry is in serious need of automation, as well as ways to make training more appealing.

“What we’re doing is we’re tackling problems that are in the industry,” he says. “It’s just a given. If it’s not going to be us, it’s going to be others following suit.”

For 2019, the company plans to begin rolling out its solutions, which might be an 18-24 month process, and will exhibit some of these at the Australian Automotive Aftermarket Association’s Collision Repair Expo in April.

“What we’re trying to do is to be first to revolutionise or evolutionise our industries,” Dimovski adds. “And it’s just the new phase of manufacturing, really.”

Volgren – Agility in delivering quality According to Volgren CEO Peter Dale, his company will have produced 600 buses in 2018 by the end of December, putting it on track for its best volumes since 2011, its record year. Volgren was established in 1979, and has been owned by Brazil’s Marcopolo since 2017. Dale puts the bus body manufacturer’s performance down to its speed in adapting to customers’ and partners’ needs, its flexibility, and its high quality.

“It really needs to be a niche market, you know we’re not a commodity producer,” says Dale, citing recent successes in Japan, where the company exported 29 low-floor buses this year. “We’re very much a highly customised product, and so you look at the Japan market: right-hand drive, high quality demanded, and a specification that is quite exacting. They’re all things that we do in Australia, and they’re all things that are required to be successful in Japan, so we’ve just got to align that within what could be a niche market.”

TradieBot’s Prep-bot project aims to create a control system and robotic solution that will repair damaged panels.

AMT DEC/JAN 2019

Japanese companies could not produce a complete low-floor bus, and European providers could not satisfy Japanese regulations.

This presented a niche where Volgren could operate.

AUTOMOTIVE & ROAD TRANSPORT Volgren is on track to produce 600 buses by the end of 2018, its best volumes since 2011.

Being first to market is another place where the company has identified an edge, this time a domestic one, for example in an Australian-compliant bus body on a new chassis product.

“The most recent example is Volvo releasing their Euro 6 diesel electric hybrid chassis,” explains Dale, citing the company’s work with Volvo’s team in Sweden on the delivery of eight hybrid buses for Latrobe Valley Bus Lines. “We’ve got a very good history of that, of being the first producer of Australian compliant bus body designs on new chassis products … whether it be the first double-decker, the first articulated chassis, or the first of a particular Euro emission chevy. There’s quite a lot of collaboration required technically to achieve a product.”

An area where Volgren is adapting to market changes is in bus electrification. Dale says he sees more change in powertrain technology in the next five years compared to the previous 30. Electric vehicles have gone from future strategy to operational planning.

An extreme effort to respond to this is a mission to strip a tonne out of the company’s Optimus aluminium bus bodies. For this, it is looking to aluminium alloys, using scandium, a wonder material that is fascinating to metallurgists but currently very expensive. This is being pursued through a project with Deakin University’s Institute for Frontier Materials.

Dale declines to name chassis partners, but mentions Volgren is currently also identifying the best-in-class electric powertrain technology to adapt to Australian conditions.

“So that is on the way,” he says. “And that’s exciting.”

SEA Electric – Minimal moving parts An EV future is also an exciting prospect for SEA Electric, a Dandenong South-based integrator of drivelines. The company has been around for around 14 or so years, says CEO and founder Tony Fairweather, mainly as an importer and distributor of buses “and a few trucks”. SEA has developed five different drive lines, suited for vans, all the way up to 23.5-ton rubbish trucks or mixers. It also has global aspirations, albeit by licensing its technology rather than through export products.

“We’re an assembler of proprietary driveline technology built on a flexible architecture, and one that uses the world’s largest

component suppliers,” says Fairweather. “Which makes it very efficient in terms of labour hours, which is why it works in high labour cost markets like Australia. It’s a CBU [completely built unit] product, but we’re still not producing vans. We’re importing the van as a glider – it comes in without an engine, transmission, exhaust system and so on, and we fit out our electric driveline technology.”

The company recently received a vote of confidence when Victorian Premier Daniel Andrews announced support for a new factory in the Latrobe Valley, part-funded by a rescue package designed to help the region’s economy adjust to the closure of Hazelwood Power Station. The factory is expected to produce 2,400 vans annually with the creation of 500 jobs; SEA currently currently employs around 50.

Some hold out hope that Australia can develop an industry around electric vehicles. One justification is that an electric engine is far less complex. It has around 20 moving parts, rather than around 2,000 for an internal combustion engine.

“There’s a whole lot of systems that used to wrap around the engine that aren’t there anymore, which means that the process of fitting that to a vehicle is easier,” reasons Gwilym. “Which means that if your focus is only on the body of the vehicle, then that does raise the prospect of building cars sometime in the future.”

Fairweather adds that the market segment offers a lot for Australian manufacturers, “though it’s a small window of opportunity to grab hold of” and there’s no time to be lost. He suggests there are many areas in components supply and technology development that the country could target and make a contribution to globally.

“We have the skills and capabilities in Australia to do so,” says Fairweather. “It might be around telemetry side of things, it could be around the provision of the communications and display screens. There’s a lot of smaller electric components like power steering pumps, air compressors, heating systems, air conditioning systems, inverters and controllers, that could all be developed and supplied out of Australia.” www.vacc.com.au www.imovecrc.com www.cohdawireless.com www.tradiebot.com www.volgren.com.au www.sea-electric.com

AMT DEC/JAN 2019

047

048

AUTOMOTIVE & ROAD TRANSPORT

Nissan: Australian Made, for the long haul The last Australian car-maker may have closed down its operations a year ago, but one big automotive brand remains fully committed to continuing to manufacture here, writes Peter Jones, Managing Director of Nissan Casting Australia.

At Nissan, we have been manufacturing parts in south-east Melbourne for more than 35 years. While Australia’s automotive manufacturing industry has taken a battering in recent times, it is a source of enormous pride that we continue to manufacture parts locally for vehicles that wind up on Australian roads and on motorways all over the world.

The parts we produce in our Nissan Casting Plant (NCAP) are carefully manufactured by a team of 192 highly skilled workers, spread across three shifts per day, seven days a week. This concentration of skill and experience results in approximately 2.6 million die-cast aluminium parts and over 16,000 tow bars annually, with an export value of $82.5m.

We have experts in high and low-pressure die casting, precision machining, component assembly and accessories manufacturing, and we currently create 60 different parts specific to oil pans, gearbox and final-drive housing, as well as parts for electric vehicles, including the Inverter Water Jacket and Stator Housing. These parts are critically important to our global business, seeing distribution to Renault-Nissan-Mitsubishi (Alliance) vehicle assembly plants, and Nissan affiliate powertrain plants as far and wide as Japan, the UK, the US, Thailand, Mexico, and South Korea.

For anyone concerned that we will follow the prevailing trend of Australian automotive manufacturing, let me reassure you: we are dedicated to local manufacturing for the foreseeable future, with exclusive supply contracts awarded by Nissan Global that will keep the plant operating well into the next decade. There should be no doubt that Nissan is still a fully integrated original equipment car manufacturer here in Australia, and we are determined to continue to defy the belief that automotive manufacturing doesn’t have a place in our country.

If you want evidence that ‘Made in Australia’ is alive and kicking in our automotive industry, you need look no further than the 90,000sqm block of real estate in Dandenong South (SE of Melbourne) – one of the nation’s busiest manufacturing hotspots. There, you’ll find us proudly including a kangaroo insignia on all of our parts, helping promote local manufacturing to the world.

These components ultimately find their way into vehicles like the Nissan QASHQAI, which includes a locally built gear carrier and rear cover; the Pathfinder, featuring Aussie-made oil pan assembly; and the Nissan X-TRAIL, which includes final drive unit parts.

Nissan isn’t the only make that benefits from our manufacturing prowess, with the Renault Koleos also including Aussie-made final drive unit parts, and the INFINITI Q50 rolling out of the dealership packing our expertly crafted gear carrier. The use of our parts extends to more than 30 overseas models, including the world’s highest-selling electric vehicle (EV), the Nissan LEAF, which includes an EV water jacket inverter, inverter cover, inverter case, and motor stator housing that all come directly out of Dandenong.

Committed to manufacturing products of the highest quality, we have worked with companies like the CSIRO to develop technologies that guarantee the very best in workmanship. Together we have improved the welding methods for die repair, and improved the materials in dies and the coating of die steels, to ensure we get the most out of our equipment. This means our equipment lasts longer, bringing down our costs.

Our quality department uses the same kind of measuring machines and granite tables used by Formula One teams. These parts are so precise that they match up exactly with parts made in Japan to a tolerance of 15 microns, less than the diameter of a human hair.

AMT DEC/JAN 2019

Peter Jones, Managing Director of Nissan Casting Australia.

And it’s this precision that has earned us exclusive contracts for the supply of specific parts. I’m very proud to say that the team in our quality department played a large role in securing even more business from Nissan Global, some of which is exclusive to Nissan Casting Australia.

In the last two years we have committed over $11m to our NCAP facility. During this time we have updated the tooling equipment and the dies, introduced more assembly equipment and upped the number of new machines. This has helped us increase capacity and it ensures the quality of our product is to a global standard.

With plenty of work keeping the casting plant busy as it heads towards 2025, we are investing a further $1.8m on cost reduction activities using automation. We have a number of robots at NCAP and we are increasing numbers. But we are also investing in co-bots – or collaborative robots. This is automated equipment that works with an operator, and this is exciting for us because we are one of the first to use this state-of-the-art technology. We also have further plans to increase the number of Automated Guided Vehicles – which are common in automotive manufacturing plants around the world.

As the world turns its attention to EVs, so too will we, investing in new and existing equipment to ensure we maintain our global reputation for quality, state-of-the-art EV products that are designed for new and next-generation electric and hybrid vehicles. To achieve this, we have updated the control systems on the die cast machines, and installed new technologies, such as oil-based die spray, helium leak testing, and the continued investment in automated assembly to allow NCAP to achieve the increased quality requirements of EV parts.

AUTOMOTIVE & ROAD TRANSPORT

MINING & PUMPS WATER & AERATION OIL, GAS & ENERGY

WINE & VINEYARDS

DAIRY

FOOD & BEVERAGE MIXER DRIVES ABATTOIRS SHREDDERS

Nissan Casting Australia proudly includes a kangaroo insignia on all of its parts.

GENAT AND WOOD™

The only Australian Made Industrial Gearbox

Australia Australia

In fact, NCAP has the most advanced oil-based die-spray equipment across the Nissan network, and we are the only Nissan manufacturing plant, globally, to conduct helium leak testing. This investment was supported by financial grants from the Victorian State Government and the Federal Government, both of which understand the importance of continued local manufacturing.

While this innovation is exciting, we are also determined to invest in people. We employ and continually train a highly skilled workforce made up of Aussies who are passionate about the brand and dedicated to producing the very best products, ensuring global demand for ‘Australian Made’ won’t go away any time soon. www.nissan.com.au

Engineering Solutions to Empower Your Ideas www.AmigaEng.com.au Ph: +61 3 9330 0688 E: SalesGW@amigaeng.com.au AMT DEC/JAN 2019

049

050

AUTOMOTIVE & ROAD TRANSPORT

Keeping Kenworth moving Kenworth Australia avoided delays, and saved millions of dollars in costs, through the use of 3D printing in collaboration with Objective3D Direct Manufacturing.

The size of the Australian continent, its geographically dispersed population base and the importance of major commodities to its economic output means that freight transport sector performance has a significant influence on national productivity and efficiency.

Figures surrounding the industry are significant. Trucking handles more cargo than trains, ships or planes, carrying more than 2,100 million tons.

Moreover, according to the Australian Bureau of Statistics the trucking industry is worth over $40bn and employs 140,00 Australians. Trucks are an essential part of our economy. Without trucks, goods would never get from suppliers to manufacturers and into the hands of consumers. Just as the economy depends on the trucking industry, the trucking industry depends on high-quality equipment.

Kenworth Australia has built a reputation around superior-quality, custom-engineered trucks with proven reliability over 47 years of local manufacturing. It manufactures around 2,200 trucks every year for delivery, and has the largest amount of 2015 models on the market. So, when Kenworth was faced with a late design change that threatened the production timeline of its major selling truck lines, it couldn’t let tooling lead time get in the way.

The original duct component (above) traditionally moulded out of PCABS, which takes six weeks to complete, and the 3D-printed component (below), completed on a Stratasys Fortus FDM System.

The challenge In May 2014, Kenworth had designed a new HVAC (Heating, Ventilation and Air Conditioning) system with Delphi Automotive Systems on its “T” series of trucks, but a late tooling change to the under-dash ducting system meant the HVAC units couldn’t be fitted. The under-dash duct component connects the HVAC outlet bezel to an air distribution manifold on the underside of the dash.

The tooling modification was necessary to accommodate both the new HVAC unit and incorporate a new design to improve airflow, assembly and suit the method of manufacture.

The duct component was originally set to be rotationally moulded out of PC-ABS, but the tool modification would take six weeks to complete, putting production of 320 trucks on hold. Kenworth was planning to assemble seven trucks a day for seven weeks from May into June. Halting assembly for even a day would potentially cost the company $2m in revenue.

“Parking half-assembled trucks, making the duct a ‘dealer fit’ requirement or delaying production was out of the question,” said Delphi engineer Ben Dejong. “We needed a process that could build the parts while the was tool was being updated.”

With an approaching deadline, a production solution needed to be found – and fast.

The new Stratasys Fortus FDM System built for Advanced Prototyping and Production.

The solution Delphi had been working with Stratasys Direct Manufacturing’s global partner in Australia, Objective3D Direct Manufacturing, for over six years for various prototyping and injection moulding projects. Stratasys Direct Manufacturing’s Global Manufacturing Network consists of member facilities connected around the globe that have many of the same services and expertise as Stratasys Direct Manufacturing.

“We had already been working with both Kenworth, and with Ben and Delphi, on the prototypes to ensure assembly and fitment, ” said Matt Minio, Managing Director at Objective3D Direct Manufacturing.

“Both companies had confidence in FDM technology, and it seemed like a logical progression to then scale up from prototype to a production solution. Our role then transformed from rapid prototyping shop into a just-in-time manufacturing supplier.”

Objective3D Direct Manufacturing’s project engineers recommended fused deposition modeling (FDM) 3D printing technology to manufacture the ductwork for several reasons: • Material – Delphi wouldn’t have to change the material of the designed component. They could build it in the same engineering-grade thermoplastic (PC-ABS). Changing materials would have demanded additional design modifications and set back production again.

• Speed – Objective3D Direct Manufacturing optimised the build orientation and packing to nest three parts across three Fortus FDM systems to manufacture nine parts a day, meeting production needs and reducing build time from 15 hours to nine hours.

AMT DEC/JAN 2019

AUTOMOTIVE & ROAD TRANSPORT The 3D-printed duct mounted on to the air distribution unit of the manifold.

How do you structure your business for growth and profitability?

• No finishing – The ducts are considered ‘under hood’ components and purely functional (not visible), so therefore they didn’t require sanding, smoothing or any coatings. All the finishing team had to do is dip the parts.

“Speed was our main objective with this project,” added Hugh Tevelein, Objective3D Operations Manager. “We had to optimise everything we could to help Kenworth keep production moving. We worked to a 24-hour schedule with parts building overnight and then fitted to vehicles same day.”

The results “Thanks to the capabilities and expertise of the Objective3D Direct Manufacturing facility and staff, we were able to produce end-use parts that allowed production to proceed unhindered, saving us from crippling delays,” says Dejong.

Objective3D Direct Manufacturing built 320 units over a sevenweek period for Delphi until hard tooling was finished and ready to be incorporated into the production line. Putting production on hold for hard tooling modifications would have cost Kenworth millions of dollars and many unhappy customers. This just-in-time manufacturing solution allowed Kenworth to bring 320 vehicles to market on time and put into operation trucks that are vital to the economy. When there are bumps in the manufacturing road, engineers can count on 3D printing to maintain momentum and keep assemblies moving.

“Within every business there are key considerations that will create the best environment for growth.”

Ian Cattanach Director, William Buck Contact Ian or a member of the manufacturing team for a

FREE CONSULTATION

T: +61 (3) 9824 8555

E: vic.manufacturing@williambuck.com

www.paccar.com.au www.direct3dprinting.com.au www.objective3d.com.au

AMT DEC/JAN 2019

051

052

AUTOMOTIVE & ROAD TRANSPORT

Axiom – Taking a new road Adelaide manufacturer Axiom Precision Manufacturing has reinvented itself since the decline of Australia’s auto industry, launching its own brand of aftermarket product aimed at four-wheel drive enthusiasts. By Andrew Spence.

Axiom Precision Manufacturing began in 1979 as Diemould Tooling and was an OEM manufacturer for the automotive industry.

However, as Australia’s automotive industry started to wind down towards closure about five years ago, Axiom was already on the path to a diversification that is now helping it thrive again.

“A lot of businesses probably threw their hands into the air and blamed others but Axiom actually said ‘It’s happening so what are we going to do about it?’” says Business Development Manager Peter Howard. “They identified where they thought the market was going and it looks they made a pretty good call.”

That direction has been spearheaded by defence, aerospace and medical devices, with Axiom completing work for numerous defence primes including ASC, Raytheon Australia and BAE. The workforce has grown to about 60 at its Wingfield base, and Howard expects this number to swell further in the next couple of years.

“Everything that finished when Ford, Toyota and Holden closed, we’ve been able to replace,” Howard adds. “Our turnover has grown slightly but it’s more the fact that we’ve been able to replace the millions of dollars of work that was lost.”

A number of the staff at Axiom are avid off-roaders and that has helped inspire the next phase of diversification and a return to the auto industry, albeit in the aftermarket category. The company has launched its AX4 brand with a range of products including winches, rooftop tents, recovery kits, sand tracks and tailgate covers for transporting bicycles.

Howard says the interest in off-road driving among Axiom staff, coupled with the company’s automotive experience and design skills, leave it well placed to enter the specialised area.

“We’ve all got slightly different interests: some are your true off-road four-wheel drivers who don’t want to see a power point for weeks on end so they’ll go as remote as possible,” he said. “Others want to ride their motorbikes and push bikes off-road and their four-wheel-drive enables them to get to places where that can be done. And then there are those who just want to do general travelling across Australia.

Axiom is working with retailers and distributors to carry its AX4 range.

“Our intention is to do our own products or co-branded products predominantly,”

AMT DEC/JAN 2019

says Howard. “We’re not really looking to become another retail store of fourwheel-drive products, we really want to bring something new to the market and leveraging our experience and expertise in the engineering field is something that is a good point of difference for us. We’re also looking at a drop-off and pick-up service where people can drop off their new or used four-wheel-drive and we will fit it out to suit the specifications they require.”

Axiom has also partnered with another South Australian company, Lightforce, to produce a replacement radiator grille with an integrated pair of Lightforce’s highperformance Venom LED driving lights. The grille is designed to be rigid and durable to eliminate the need for any extra mounting bars or rails, and supports each light at three points to provide precise alignment adjustment.

The AX4 product has been designed to fit a Ford Ranger PX2 and PX3 models, with similar products to suit Toyota HiLux and Holden Colorado to be released in 2019. In 2017, more than 42,000 new Ford Rangers were sold in Australia, making it the second most sold vehicle behind the Toyota HiLux with 47,000 sales. The Australian-designed

Ranger is now in production in Michigan ahead of its US release in early 2019.

The X Grille eliminates the need for bull bars, nudge bars or bulky mountings to add driving lights. It is available for preorder with the first deliveries expected in early 2019. The product was soft-launched at the Adelaide 4WD and Adventure show in South Australia in late October and is also on display at the Lightforce stand at SEMA in Las Vegas in early November – one of the world’s biggest auto specialty product showcases. Lightforce is already well established in North America and it is hoped its existing relationships will help drive X-Grille sales in the US. “The key things with the partnership between Axiom and Lightforce is we are both well-established South Australian businesses and we have worked together previously on some pretty good projects but never in a co-branded product,” says Howard. “Lightforce’s international market is certainly an advantage but Axiom is known internationally as well. We see it as a big opportunity for us and it’s definitely an area we are looking to expand our business.” www.axiompm.com.au

AUTOMOTIVE & ROAD TRANSPORT

Innovation Labs support Aussie auto manufacturing The Australian Automotive Aftermarket Association (AAAA) has announced the establishment of two automotive Innovation Labs based in Victoria and South Australia.

Co-funded by Federal and Victorian Government industry development grants, the operation of these new Innovation Labs will be led by the AAAA, providing Australian automotive product designers, manufacturers and start-ups with the the tools, technology, vehicles, expertise and collaborative environment required to innovate, design, test and manufacture for local and export markets. Advanced manufacturing services will be provided, including 3D scanning and printing, measuring sessions, technology transfer, CAD and prototyping. Advanced product development and testing facilities will significantly reduce the time and cost in developing innovative new products. According to AAAA Chief Executive Officer, Stuart Charity, the establishment of these Innovation Labs will grow an industry that is already punching well above its weight on the global stage.

expertise needed to take Australian automotive industry innovations to the world, regardless of how large or small their businesses are.”

“Australian automotive aftermarket industry manufacturers are currently producing parts, components and technology worth more than $5bn each year,” said Charity. “Our companies are world leaders in the design and manufacture of specialty products with a technological advantage, such as 4WD, high-performance and motorsport components. These products are purchased on innovation, performance and features rather than on price.

Our businesses have been successful because they have made significant investments in R&D and capital equipment and have a strong export focus.

“We look forward to inviting automotive manufacturers to take advantage of the services and facilities our Innovation Labs will offer to assist in taking their products from concept to domestic and global market success,” added Charity. “This initiative would not have become reality without the significant financial support provided by the Commonwealth and Victorian Governments, in addition to the support of 25 ‘Lab Champion’ companies who contributed to the Innovation Lab feasibility study. We would also like to thank Centre Alliance Senator Rex Patrick for his strong advocacy on behalf of Australian Automotive manufacturers. Everyone should be very proud of this exciting new development that secures the future of Australian automotive design and manufacturing.”

“Establishing this collaborative infrastructure will position our industry for future domestic and export market growth by providing the innovators of the industry with the leading-edge technology and

The AAAA has appointed automotive industry engineering specialist Luke Truskinger as Innovation Lab Project Manager. Along with his Bachelor of Mechanical Engineering, Luke brings extensive local and international OEM experience and a history of supporting the Innovation Lab project, understanding the critical role the Labs will play. The AAAA will be engaging in extensive discussions with Australia’s automotive parts and accessories industry to build on the significant work already undertaken as part of the Innovation Lab feasibility study. The next few months of the establishment phase will ensure equipment and services offered by the Innovation Labs are closely aligned with the industry’s needs.

www.aaaa.com.au

AUSTRALIAN INDUSTRY TURNS TO RONSON

www.ronsongears.com.au Telephone +61 3 9276 8900 AMT DEC/JAN 2019

053

054

AUTOMOTIVE & ROAD TRANSPORT

3D printing drives R&D at Renault Sport Formula One Team A partnership between Renault Sport Formula One Team and 3D Systems has accelerated development and fuelled innovation, from wind tunnel testing, to flow rigs, to robust on-car parts.

Formula One racing is an endurance engineering sport fuelled by relentless innovation. Teams work tirelessly to reach and beat an everevolving standard of peak performance, and the spirit is no different at Renault Sport Formula One Team. There, the R&D machine never stops and the contributions of technical partners play a crucial role in helping the organisation reach its targets.

“Race after race, new components made of complex composites and aerospace alloys see the light after surviving a harsh selection in the R&D and simulation labs,” explains Renault Sport Formula One Technical Director, Nick Chester. “At the end of a racing season, we expect our race car to be in excess of a second per lap quicker than when we started, and our technical partners have to survive the same ruthless selection. We aren’t interested in relationships that don’t bring value in our quest for performance.”

This requirement for ongoing innovation and active collaboration is the foundation for Renault Sport Formula One Team’s choice of 3D Systems and its array of 3D printing technologies and expertise.

An R&D partnership Based in Enstone, UK, the Renault Sport Formula One Team has been using 3D Systems’ technologies in its core operations since 1998. As an early adopter of 3D printing for prototyping, the racing team’s use of 3D printing has followed the trajectory of the technology itself. Early uses included function & fit design verification, as well as jigs and fixtures for accurate assembly.

As the partnership has grown, 3D Systems’ application engineers have helped Renault Sport Formula One Team understand and seize the opportunities, materials and methodologies available to them. The team’s ability to feed the voracious appetite of its wind tunnel facility is testament to the positive impact of its partnership with 3D Systems, as well as new innovation in on-car parts through 3D printing for investment casting and explorations in direct metal printing (DMP).

Renault Sport Formula One Team has opened up new avenues for innovation through an R&D partnership with 3D Systems.

AMT DEC/JAN 2019

“The support the team has received from 3D Systems has evolved during our journey,” says Chester. “If we look back, you can see that, as material properties have improved, the team has been very keen to expand the application of rapid materials to more engineering challenges. The number of on-car components produced with additive manufacturing grows every year, with considerable benefits to the team in terms of design versatility and reduced production times and costs.”

The fleet of 3D Systems machines currently in use at Renault Sport Formula One Team includes six stereolithography (SLA) printers and three selective laser sintering (SLS) machines. Materials span from the Accura range to build jigs and fixtures, fluid flow rigs, investment casting patterns and wind-tunnel parts, to DuraForm PA and DuraForm GF for parts used on the car itself, such as electrical boxes and cooling ducts. From match-making with materials to working through designs for greater efficiency, the partnership between Renault Sport Formula One Team and 3D Systems drives better performance both on and off the track.

A daily evolving racecar Each year, Renault Sport Formula One Team designs and builds a new car responding to rule changes and the natural R&D cycle aimed at improving car performance. As an example of the challenges that Formula One regulations changes can entail, the 2017 season updates included larger and heavier tires, a wider front wing, a lower and wider rear wing, and a higher diffuser, which meant no parts were carried over from 2016 to 2017. Once the racing season begins, the pressure only continues to escalate: sometimes there is only a week between races to deliver engineering changes. Varying from purpose-built circuits to bumpy and tortuous street tracks, each race presents engineers with its own challenges related to architecture, climate and asphalt type.

AUTOMOTIVE & ROAD TRANSPORT 3D-printed investment casting patterns provide accelerated access to large, high complexity metal parts.

The team prepares relentlessly for each circuit’s unique challenges and uses what little downtime it has between races to deploy the fruit of its research on cars and equipment. It is not difficult to envisage how the speed and accuracy of 3D printing can add value to this development race.

“The car is evolving daily during the racing season,” says Patrick Warner, Advanced Digital Manufacturing Manager at Renault Sport Formula One Team. “We require new components at every track and the benefits of additive manufacturing is becoming increasingly relevant.”

Rapid design validation From the beginning, 3D printing for rapid prototyping proved a useful capability in a sport where internal racecar components are tightly packed and constrained by aerodynamic surfacing paneling.

Renault Sport Formula One’s aerodynamicists quickly saw the potential of 3D printing technology for fit & function testing as they saw the complexity of the components 3D Systems’ machines could produce. With this awareness, the use of 3D technology began to grow, gradually expanding from rapid prototyping to wind tunnel model manufacturing.

“In wind tunnel testing, aerodynamics is an empirical science,” says Warner. “We design and compare new ideas and choose directions to follow. The more ideas we can compare and evaluate, the more successful we will be on the track.”

In terms of part quality, machine uptime and throughput, 3D Systems’ SLA is a boon to the racing team’s productivity.

Driving aerodynamics through wind tunnel growth The Aerodynamics Department at Renault Sport Formula One has grown significantly in recent years and it now includes 120 staff between aerodynamicists, wind tunnel technicians and model makers. Much of this growth has been spurred by the increased use of 3D Systems’ additive manufacturing technologies, according to Warner. He cites the ability to incorporate complex internal channels into the design of wind tunnel test models as a key impact of using 3D Systems’ technology and the opportunity that creates to take more pressure readings.

Partnering with 3D Systems enables new innovation in on-car parts through explorations in direct metal printing (DMP).

gives us a one-stop shop. We have the equipment we require, the materials we require, and the expertise we require from application engineers who provide us with service instantly.”

Manufacturing speed and precision for on-car parts In terms of productivity and efficiency, 3D printing has dramatically increased Renault Sport Formula One Team’s ability to respond to the challenges presented from consistently new racing environments.

Using SLA and SLS, complex jigs and fixtures, fluid flow rigs and on car components can be produced in hours rather than weeks, making 3D technologies ideal for the logistical challenges of Formula One racing.

In addition to the massive quantities of components tested monthly in the wind tunnel, Renault Sport Formula One builds a number of racecar parts directly.

“3D Systems’ technologies have powered an effective new manufacturing process that enables us to reduce both cycle times and cost, adding invaluable benefit to the team,” says Rob White, Chief Operating Officer at Renault Sport Formula One. “On one hand, we enjoy the ability to test multiple iterations of the same part in the wind tunnel, while on the other we see the number of sintered components in the actual car grow every year.”

3D printing has helped the team achieve lighter-weight parts that increase speed and fuel efficiency as well as accurate and informative flow testing for better engine performance and reduced wear and tear.

Once a design is complete, it is sent along with its material selection to the team’s ADM Department for production. Using SLA and SLS, complex car components can be produced faster than ever, and in some cases the part is ready for inspection before the drawing has even passed through the system.

3D printed investment casting patterns using SLA are also gaining traction at Enstone for applications such as gearbox and suspension components, allowing the team’s engineers to be more creative in part design now that restrictions on permissible complexities have been removed. Because the SLA process is so accurate, time is saved both on front-end pattern production as well as on back-end proof machining for the finished casting.

New avenues of development

“The car model in the wind tunnel features a complex network of pressure sensors,” says Warner. “Before SLA technologies were available, these were positioned by drilling pressure tappings into metal and carbon-fibre components. The ability we now have to produce complex solids with intricate internal channels has revolutionised our ability to place these sensors and increase their numbers. It’s an aerodynamicist’s dream come true.”

The benefits of 3D Systems’ technologies, expertise and services connect deeply with mission-critical priorities for Renault Sport Formula One Team, including innovation, productivity and improved accuracy and precision. For Bob Bell, Chief Technology Officer at Renault Sport Formula One Team, 3D Systems is more than a technology supplier: the two companies have a true partnership that delivers results and vast future potential.

Warner estimates that wind tunnel testing alone requires the production of 600 additive manufactured parts per week, all accomplished by a five-person engineering team in Advanced Digital Manufacturing (ADM).

“Our partnership with 3D Systems has made us more productive and efficient over the last 20 years or so,” says Bell. “It’s opened up new avenues of development and usage that I expect will only escalate in the future.”

“We couldn’t come close to doing that conventionally,” says Warner.

“We’d need a machine shop the size of a small city. 3D Systems

www.renaultsport.com au.3dsystems.com

AMT DEC/JAN 2019

055

056

AUTOMOTIVE & ROAD TRANSPORT

Barracuda – Laser structuring makes plastics shine Based in Kaufbeuren in Germany, Kunststofftechnik Bernt (KTB) has developed a new day-night design for decorative panels in car interiors that can produce coloured light using laser technology passing through chrome-plated plastics.

The system manufacturer ACSYS Lasertechnik is supporting KTB in technology development with the delivery of two laser systems.

Chrome-plated decorative panels with 3D lettering in two different matt finishes that also glow in different colors at night have only been available in series production from a German OEM for a few weeks.

The changing day-night design – the haptics above the 3D lettering by day, the illuminated color selected by the driver at night – is an eyecatching feature, at a time when customisable interior ambience is currently a trend among OEMs. Dr Carsten Brockmann, KTB’s Managing Director, is enthusiastic about the new design: “This greatly increases the value of the interior design. This day-night design also allows further customisation of the car’s interior. The panel’s surface and contour lighting gives us a new design element that appeals to the senses.”

Using a multi-component injection moulding process, KTB manufactures components of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) and finishes them in its in-house electroplating system. The polycarbonate is located on the back side of the component and cannot be electroplated. This means that the component remains without chrome at these points. However, a metallic plate is applied to the ABS areas. Then an area of the front undergoes laser processing, making it translucent. After laser processing, the panels receive a final outer plating and undergo a visual inspection.

KTB has years of experience and extensive competencies in plastics manufacture, mouldmaking for injection-moulding and electroplating for interior and exterior applications and various surface finishes. KTB chose the ACSYS solution for its laser structuring. Brockmann recalls the beginning of the co-operation between the KTB developers and the specialists from the ACSYS technical centre.

“We had commissioned various suppliers to structure a prototype component,” he say. “Only ACSYS came close to what we were looking for. We were enthusiastic about the precision of the laser system from the very beginning.”

The solution was then created by means of painstaking tests in the ACSYS laboratory.

“We work proactively as an idea generator with great development, application, and service competence, and tackle every customer order with fresh eyes,” says Gerhard Kimmel, Managing Director of ACSYS. “The customer can feel this team knowledge when he comes to us with a task.”

ACSYS’s Barracuda system is used to process KTB’s components.

With a spacious, easily accessible working area, the Barracuda is an all-rounder. For the KTB laser application, the system, made of high-strength steel, stands on a vibration-free machine base of temperature-stable granite. The laser process has several steps, in each of which a sub-area of the panel is structured with a fine diamond pattern (200 by 200 micrometres). The elongated panel area is also subdivided into sections.

“We have been testing the system for a year, and it is stable and very precise,” says Brockmann. “There are no edges between the processing sections, such as might be expected to arise due to traverse tolerances, for instance.”

The laser system is also equipped with a two-camera Live Adjust System (LAS) solution. The first camera provides an overview of the processing area, while the second camera is directed straight through the laser beam path, capturing the processing area and allowing a partial, high-resolution view of the section to be processed.

AMT DEC/JAN 2019

Technical Data: Barracuda Multi • Traverses xyz: 750mm x 350mm x 370 mm • Granite machine base • LAS HD Pro – Live Adjust System • Polished steel – T-groove plate • Flexible control panel on rollers • Laser Class: 1 • Housing dimensions (W x H x D): 1,320mm x 1,890mm x 1,880mm • Weight: ~1,100kg • Maximum workpiece weight: 120kg • Inner surface: 1,150mm x 580mm • Axis positioning accuracy at 300 mm: X x Y: ±25 micrometres

“In the last two years, we have developed the processing technology together and are very happy with the quality of the parts,” says Brockmann. “We recently bought a second laser system of the same type to secure our planned annual volume of 200,000 units.”

Series production started at the end of the second half of 2017.

“Ever since we started delivering our decorative panels for luxury cars to a German OEM, we have constantly received positive feedback,” says Brockmann. “We are very happy with the laser system.” www.ktbernt.de www.alfexlaser.com.au

MICRO & HI-FEED ENDMILLS

• More sizes • New solutions • Higher productivity

SINCE

1917 For more information, contact your local Sales Representative or visit our website at www.suttontools.com QLD Steve Dwyer 0425 202 703 Mark Gooding 0438 226 616 Michael Johnson 0411 707 980 Troy Simpson 0417 726 039 NORTH QLD Glenn Buttler 0417 390 569 | CENTRAL QLD Bruce Anderson 0418 775 226 NSW Steve Dwyer 0425 202 703 Michael Bromhead 0425 721 750 Stacey Karberis 0425 278 901 VIC Adam Reed 0438 537 218 David Old 0425 778 910 Wayne Adams 0433 914 943 | TAS Adam Reed 0438 537 218 SA/NT Andrew Nieuwenhoven 0411 707 979 | WA Gary Winters 0409 234 385 Phillip Vokes 0411 707 981 SURFACE TECHNOLOGY COATINGS Natalie Schembri 0425 778 909 www.surftech.com.au

058

ROBOTICS & AUTOMATION

ANCA’s robot project underscores value of collaboration Australia can boast a number of accomplishments in robotics, including the world’s first automated container terminal and a collection of pioneering mining applications. Building on them, the experts say, will require teamwork.

One recent achievement, bringing ANCA’s AR300 SCARA robot arm and control system to market, took collaboration between the company, its suppliers and customers, and university researchers.

The project dates back to 2014, when the ANCA noticed an unmet need for flexible automation for tool loading. Developing a local solution, instead of importing robot hardware, might also have applicability in a variety of other industries.

“As a local contributor to advanced manufacturing, we’re continually looking for ways to grow,” explains Tom Nathan, New Products Development Manager at ANCA CNC Machines. Moreover Nathan adds that these opportunities can’t always be pursued, and there are times when the cost of engineering in Australia can cruel a business case.

Another difficulty is quite simply that “robotics is hard”. This well-known adage has been very much in evidence over the last few months, following the demise of promising US robotics businesses Jibo, Mayfield and Rethink Robotics. The challenge of creating a robot from scratch is a daunting one. Or as Nathan puts it: “Making a multi-axis robot is one of the pinnacles in advanced manufacturing.”

Mike Grogan, Director for Victoria, South Australia & Tasmania, at the Advanced Manufacturing Growth Centre (AMGC), concurs: “There’s no doubt the manufacture of a robot is the height of advanced manufacturing. They are extremely complex pieces of equipment.”

The AMGC contributed $325,000 in cofunding to a project to bring ANCA’s SCARA machine from technology readiness level (TRL) 6 to TRL 8. It linked ANCA Machine Tools with its sister company ANCA Motion, suppliers Total Precision and Harmonic Drive, customer and beta tester Sutton Tools, and Swinburne University, which contributed to design. “The AMGC made us look to suppliers that we could use that are local, like Total Precision and ANCA Motion, but also at the way in which we collaborated with the local suppliers and customers and universities,” says Nathan.

Australia has pockets of excellence that can serve robotics development, but it lacks critical mass. Collaborating and clustering companies and researchers – as recommened in the recent Robotics Roadmap for Australia from the Australian Centre for Robotic Vision – is essential for success.

AMT DEC/JAN 2019

The first ten units of the AR300 are expected to be shipped by the end of December.

The release continues ANCA’s efforts to serve “the whole Industry 4.0 chain” for its customers, including the digitalisation of blank materials, tool preparation, tool marking, machine monitoring and analytics, and more.

Demand for industrial robots, one facet of Industry 4.0, is booming, as manufacturers chase productivity gains, and the availability of effective, user-friendly options increases.

According to the 2018 World Robotics Report, annual unit sales increased 30% in 2017 and have more than doubled over the last five years.

The completion of the project, enabled by teamwork, gives ANCA a globally relevant product to take to the fast-growing robotics market. The affordable price and its ability to be used in harsh industrial environments (dust, liquids, chemicals) make it appealing to the pharmaceutical & cosmetics, and food & beverage sectors, which increased robot purchases 24% and 19% respectively in 2017.

The AMGC supported the project as it encouraged “advanced characteristics”, identified from an analysis of 3,000 manufacturers. This includes increased R&D spending, patent portfolio size, and collaboration with other researchers and manufacturers. According to Grogan, the SCARA project “is an example of continuous advancement through R&D in order to stay in front”.

It has also allowed ANCA to continue diversifying from a traditional focus on CNC grinding. Paul Bochi, ANCA Motion General Manager believes believes that commercialising the robot, as well as its motion control technology, will present an array of broader opportunities.

“It also means we can sell more into the Australian market, which hasn’t been possible due to the niche nature of CNC grinding,” says Bochi. “For example, we are looking at the packaging, food & beverage industries, where we can provide high-tech robotic and motion solutions such as our LinX tubular linear motor. We will continue to invest in developing automation solutions for the market and are excited about our prospects locally which to now has not been possible.”

For ANCA, there are new markets and new challenges ahead. The AR300 also presents an “exportable, Australian-made robotics capability” for the country, enabled by teamwork.

“We’re fiercely Australian, and we’re fiercely proud that we do all our engineering in Australia, and we want to keep and promote advanced manufacturing in Australia,” says Nathan. “And I think the more the Government can do to help local industries, and also incentivise local industries, it will be better for industry in general.” www.amgc.org.au www.anca.com

Bosch Australia Manufacturing Solutions Leading User Leading Provider

I4.0 describes the networked Manufacturing of the future. p The real opportunity Bosch can offer you is to provide it’s experiences from which you can take advantage from. p Open standards are essential to integrating equipment and software of various suppliers into connected concepts. p Real-time analysis of relevant manufacturing and logistics data.

Contact us for your path in the i4.0 journey M (61) (0) 434 185 329 T

(03) 9541 5086

E

john.croft@au.bosch.com

W bosch-manufacturingsolutions.com.au

060

ROBOTICS & AUTOMATION

Mobilising maintenance through digitalisation Digitalisation is increasingly making inroads into maintenance. A few years ago the word ‘maintenance’ immediately evoked an image of a man wearing blue overalls: today, however, it is increasingly characterised by digital services and mobile devices such as tablets and data glasses. Exhibitors will be presenting examples of these at EMO Hannover 2019.

The Smart Factory and the related digitalisation offer wide-ranging potential for long-term and predictive maintenance. But what are the benefits for companies? And what are the prerequisites for ensuring that the data necessary for planning, processing and documenting maintenance measures is exchanged reliably? What is certain is that maintenance staff are, by definition, production service providers – even if the job description has changed considerably in recent years. “Today, maintenance staff are no longer called in only when there is a mechanical, hydraulic or pneumatic problem that has brought a machine to a standstill,” explains Peter Strohm, Global Service Project Manager at Emag Systems. “Today it’s crucial for maintenance technicians to be fully familiar with the hardware and software of their machines in order to plan repairs in advance and procure any required materials.

They increasingly have to use digital services to help them monitor the condition of the machines.”

Before purchasing a machine, companies should make sure that the manufacturer offers service solutions that are tailored to their individual requirements. Emag responds flexibly here: “We offer customers maintenance provided by our own specialists, but we also support customers who want to carry out their own maintenance. Basically, however, it is important for every solution to be future-proof with regard to digitalisation,” says Strohm.

Management tool for structuring plant maintenance But what is the most effective way for companies to structure and implement their maintenance processes? A new EU standard provides a useful management tool here: DIN EN 17007:2017 structures and describes the typical maintenance processes of a company in a universally applicable form.

These processes serve as a reference, for example for companies co-ordinating their own processes with the services of service providers or for comparing themselves with other companies. The standard also suggests suitable key figures for measuring the individual maintenance processes.

DIN EN 17007:2017 is based on a French standard and its scope has been considerably expanded in co-operation with various other European countries.

In Germany, maintenance managers from various manufacturing and process

AMT DEC/JAN 2019

dry run of the machine, we will in future be able to use an algorithm to evaluate which machine components are likely to fail. This gives the maintenance engineer optimum support for his repair and maintenance planning.”

The aim of such preventive and predictive maintenance is to eliminate downtimes in the future. The Emag system has already proven itself in practice; it is currently being successfully tested by pilot customers.

industries were involved in the development.

One of the leading figures in the project is Professor Dr Lennart Brumby, head of the Service Engineering Department at the Baden-Wuerttemberg Cooperative State University in Mannheim.

“In the networked world of work in Industry 4.0, it will be important not only to co-ordinate the information systems, but also to mesh the respective business processes with one another,” says Brumby. “Maintenance needs reference processes for the key tasks, both for the core processes of reactive and corrective maintenance as well as for the wide range of support processes. Only then can networking succeed.

“Like all standards, this standard is not mandatory. However, it is advisable for all companies to adapt their own maintenance processes to the DIN EN 17007:2017 processes. Only then will they be ready for the world of Industry 4.0.”

Regarding the scope of the standard, Brumby says: “DIN EN 17007:2017 not only describes the classic core maintenance processes, such as repair and preventive maintenance, but also includes the many supporting processes without which maintenance would not function. The multitude of links and information flows between these processes are also covered.

Because, generally, it is the co-ordination and networking of processes that offers the greatest potential for optimisation.”

Predicting axis and spindle failure Companies are orienting their daily operations to the new standard. “At Emag, we have been working for some time on a product that facilitates wear analysis of the machine axes and spindles using a vibration sensor,” says Strohm. “Based on a defined

Another example is a service app from Emag.

“This makes it easy for maintenance staff to get in touch with our service department,” explains Strohm. “The app scans a QR code on new Emag machines and recognises the machine type and location. This then allows the appropriate service staff member to be contacted. Old machines are retrofitted free of charge – and there is no age limit.”

Customers can then choose to contact the specialists by telephone, e-mail or live video chat.

The analysis knowhow for the extensive sensor and production data is of strategic importance for Emag. Accordingly, in September the Emag Group acquired a minority stake in anacision, a specialist data analysis company based in Karlsruhe, Germany. The two partners are now jointly developing software solutions for the machine tool industry – in the area of predictive maintenance, for example.

“We regard our minority interest in anacision as the start of a far-reaching strategic development partnership for Industry 4.0,” says Markus Heßbrüggen, CEO of the Emag Group.

Companies must train up their employees Today’s experts not only have to maintain and optimise machines and automation systems; they must also ensure that the different systems communicate with each other. Furthermore, they must ensure that is possible to conduct data analyses across different interfaces. This should ultimately help identify further potential for the selection of suitable efficiency measures.

The interface between IT and maintenance in particular is an important cornerstone of modern maintenance. “This is also a major challenge for the companies because they have to ensure that their employees are appropriately qualified in this complex environment,” says Dr Jens Reichel, Head of

ROBOTICS & AUTOMATION

Technical Services & Energy at thyssenkrupp Steel Europe. This is sometimes difficult, particularly in view of the shortage of good IT specialists on the labour market.

For Reichel, data security is another important issue in digitalised, mobile maintenance. Smart services today often involve production companies feeding production data into the Cloud via an interface. Appropriate background analyses are then carried out in the Cloud: these provide an insight into what is happening in the plant, but can also be used to issue alerts of possible failures.

“Many production companies are reluctant to give third parties access to their data,” Reichel explains. “For one thing, it allows conclusions to be drawn about process parameters which could reveal company know-how. And it also opens up access channels to the production processes, which could lead to abuse.”

To counteract this, dedicated filters – firewalls – are created for the open channels.

Companies use these to make intrusion as difficult as possible. A second way is to open up data access only to the extent required by the case at hand. This means filtering available data in advance to reduce it to the appropriate level for the intended analysis.

MTI_A5.indd 2

In this case, employees must know which security procedures need to be installed at the appropriate interfaces.

“Basically, it’s important to realise that maintenance is an area of corporate expertise which is worth protecting,” says Reichel, emphasising the significance of the topic. Emag guarantees data and access security by granting access to defined machine control data via a separate evaluation PC. “This writes the data to a local server at the customer’s premises,” explains Strohm.

“The customer can then decide whether and which data should be synchronised with a cloud server. This means that the machine control system is not directly connected to the internet and the customer can then choose himself how he wants his data to be handled.”

Competitive advantage through precisely tailored condition monitoring However, maintenance also offers potential for greater efficiency. At thyssenkrupp Steel, experts are currently refining condition monitoring systems, which will then allow them to be coupled with data from process control, process automation systems and quality management.

“The aim is to be able to draw conclusions regarding optimum operation of the system – optimised either for maximum service life or, depending on the parts involved, for the maximum throughput or the best possible quality,” Reichel explains.

What is certain is that maintenance is a very complex field that offers a lot of potential for increasing efficiency, but that also holds many challenges. The new DIN EN 17007:2017 standard will reflect this and provide practical guidance.

“Maintenance processes have never been described so comprehensively before,” says Brumby. “Previous descriptions only ever focussed on individual aspects of maintenance. But what was often ignored was the networking of the processes – which is where the real complexity of maintenance lies.”

EMO Hannover 2019 will take place from 16 to 21 September 2019 at the Hanover Fairgrounds in Hannover, Germany. www.emag.com www.dhbw-mannheim.de www.thyssenkrupp-steel.com www.bose-munde.de www.emo-hannover.de

25/10/2018 8:44 AM AMT DEC/JAN 2019

061

062

ROBOTICS & AUTOMATION

Swisslog’s synchronised automation signposts the future of automated processes Synchronised automation offers a solution to problems bedevilling automated processes across a range of industries, such as engineering, logistics, materials handling, pharmaceutical, warehousing, food & beverage and transport.

Global robotics and logistics automation technology leader Swisslog has found that as automation accelerates, a common concern is that if a machine goes offline, the entire system suffers. But this is becoming less and less of a problem through synchronised automation, which is a natural evolution of islands of automation, explains Martin Kohl, Senior Consultant at Swisslog.

Kohl has more than 18 years experience in global logistics automation.

He says that the megatrends driving digitalisation and industry 4.0 – such as urbanisation, an ageing society, increased health focus, e-commerce, increasingly digital lives and regulations – mean that better technology utilisation is needed to optimise supply chains and achieve tangible benefits.

From islands of automation to synchronised automation “The concept of islands of automation means users can have several automated processes working in isolation, which can be linked up with Automatic Guided Vehicles (AGVs), with end-to-end integration,” says Kohl. “Swisslog takes this one step further with its synchronised automation systems. The technologies are still separate, meaning that a problem with one machine won’t affect the whole system, but the major difference is that each island can talk to each other and work together to achieve efficiency benefits.”

The major benefits of this approach include:

Swisslog’s logistics automation technologies look at end-to-end supply chain and how to optimise product movement through the system, while maintaining reliability and traceability.

Coca-Cola Amatil is one globally recognised company that uses Swisslog’s ACPaQ mixed pallet robot-based order picking system.

• Redundancy – If one cell goes down, there are several others accessible, or use of a temporary manual cell.

• Flexibility for growth with additional cells, and ability to grow in specific areas.

• Full integration of robots and AGVs. Swisslog is currently working on a major logistics automation project in Sydney with leading robotics integrator Andrew Donald Design Engineering (ADDE) for bio-pharmaceutical company AstraZeneca, where synchronised automation is being utilised to optimise flexibility and redundancy. This advanced solution involves ADDE’s robotic palletising, shrouding, wrapping and labelling technologies, linked with Swisslog’s platform AGVs on two levels to manage all pallet logistics.

Crucially, there are no major single points of failure in the system, with a manual cell used for redundancy if any process goes down temporarily, explains Kohl. “This is a great example of utilising synchronised automation, advanced robotics and platform AGVs to deliver benefits in efficiency, flexibility and redundancy.”

The future of warehouse automation “When we think about the future of warehouse automation, fully automated case picking is the final mile to deliver end-to-end efficiency and traceability,” says Kohl.

Swisslog’s ACPaQ fully automated mixed pallet robot-based order picking system is an example of an advanced warehouse automation technology that utilises islands of automation to deliver mixed-case, store-ready pallets for end customers. Coca-Cola Amatil is one globally recognised company that uses Swisslog’s ACPaQ mixed pallet robot-based order picking system. The ACPaQ technology analyses and processes data and optimises the best stacking pattern, to ensure stability. The system can also build the pallet in reverse drop sequence for replenishment at store level.

AMT DEC/JAN 2019

“This is a perfect example of an end-to-end supply chain that optimises how product moves through the system while maintaining reliability and traceability throughout,” says Kohl.

Human-robot collaboration Another example that’s changing the way companies are thinking about automation is human-robot collaboration.

“When we think of robots, we typically think of repeatable tasks being automated with a robot in a fenced off cell,” says Kohl. “This thinking is being completely shifted by human-robot collaboration, which allows humans to continue doing what they’re best at, and the robots assisting where possible. For example, in the automotive industry, a robot can be carefully positioned in just the right area by an operator, then the robot performs a torque screwing application.”

Automation has always been utilised for gains in efficiency and improvements in process, but the way automation is implemented is crucial to optimising its benefits. According to Kohl, Swisslog’s synchronised automation and human-robot collaboration technologies are two of many innovative ways that automation can be used differently for genuine benefits in efficiency, quality and safety. www.swisslog.com www.adde.com.au

ROBOTICS & AUTOMATION

Mobile robots are the new soldiers on factory floors The industrial robotics sector is seeing growth as manufacturers embark on the journey of automation.

The revenues of commercial robots in manufacturing are forecast to grow from US$166m in 2018 to US$22bn by 2027, according to ABI Research. The newest trend is complementary robotics technologies that put mobile robots on the factory floor. Made up of automated guided vehicles (AGVs) and autonomous mobile robots (AMRs), these robots will complement existing robotic arms in factories that are becoming increasingly autonomous and smarter.

There has been plenty of debate within the industry on the different benefits of AGVs and AMRs. While AGVs are a cheaper precursor to AMRs, they require floor markers to guide their movement and are better suited to greenfield deployments. For those wanting infrastructure-free navigation and flexible production lines, AMRs represent the future standard. Ultimately, manufacturers will benefit from either of these solutions as they can push carts and deliver parts within or between the factories, optimising workflows, minimising workplace hazards, and freeing up valuable staff resources.

“The advancements in machine vision, simultaneous localisation and mapping (SLAM), swarm intelligence, and sensor fusion are making it possible for mobile robots to operate in unstructured environments such as the factory warehouse and the assembly area,” said Lian Jye Su, Principal Analyst at ABI. “These technologies are being supported by many cameras and sensors, such as LiDAR and radar.

Moving forward, the robot can benefit from the integration of deep learning algorithms with sensor fusion and swarm intelligence.”

In addition, as factories undergo digital transformation, more factories will start to adopt smart manufacturing platforms. With this development, the value proposition of cloud robotics becomes more relevant. Nonetheless, there are still many challenges related to the adoption and deployment of cloud robotics. Data security, data analytics, and the power of cloud computing will have to be in place before connecting any robot to an industrial cloud platform.

As robotic technologies continue to mature, different vendors are starting to engage in ecosystem play. Universal Robot, the world’s largest collaborative robot arm vendor, has its own ecosystem called UR+, which features over 50 partners in grippers, accessories, and software platforms. This is further augmented by the acquisition of MiR, an AMR vendor, by Teradyne, Universal Robot’s parent company, in April. Teradyne currently owns both collaborative robotic arm and AMR technology under one roof, providing an end-to-end solution for manufacturers.

“The Industrial factory embrace of collaborative robots, AGVs, and AMRs indicates that manufacturers are also embracing versatility and modularity,” Su concluded. “The increasing number of stock keeping units (SKUs) and short product life cycles necessitate the deployment of robotics solutions that can be retrained and redeployed for different manufacturing processes and factory layouts.” www.abiresearch.com

AEROSPACE

AUTOMOTIVE

DEFENCE

MEDICAL

INDUSTRIAL PARTS

The only company in Australia providing Metal 3D Printing, CNC Machining, Fabrication and Industrial Gearboxes in the one location. Efficiency and Quality is what Amiga Engineering provides.

Engineering Solutions to Empower Your Ideas

www.Metal3D.com.au Ph: +61 3 9330 0688 E: Metal3D@amigaeng.com.au AMT DEC/JAN 2019

063

064

ROBOTICS & AUTOMATION

Smart Future: Three ways AI and Robots are changing manufacturing We’re entering a whole new world of making things, away from cumbersome, single-use infrastructures to flexible, modular, scalable methods that are completely digitally driven, writes Rod Hunt.

Connected data and the supply chain

Consider a child playing with Lego. Watch how adaptable he or she is to multiple tasks and how adjustments are made effortlessly on the fly. We’re using that innate human talent as inspiration today in a program that trains robots to build with bricks, and while such a capability seems flippant, imagine the power in a robot that can perform any number of movements and actions and teach itself how to remember and build on them, just like a kid playing with Lego.

The same AI systems that will drive tomorrow’s smarter, more responsive robots will go much farther down the supply chain to improve the manufacturing process at ground zero.

Take your sales figures, geographic data and even the political mood and weather in your market sectors after mining millions of social media updates, connect it to your manufacturing floor and design studios and you can immediately respond to projected changes, your robot altering its behaviour proactively to respond to upcoming demand. Raw material provision, staffing and product maintenance decisions can be back-channelled right to your factory, which can scale up or down or shift focus in response.

As consumers demand further customisation and speed, the factories of tomorrow won’t have single-purpose ‘dumb’ machines that do one repetitive action. They’re going to be as responsive and constantly evolving as we are. Here are three of the most impactful changes they’ll impose on manufacturing in the coming years.

Generative design

And the swarms of sensors at every point along the supply chain are building a more detailed snapshot of your entire business than ever before. Internet of Things (IoT)enabled devices deployed everywhere from your AI-driven manufacturing robots to the retail outlet where your products are sold, and even when the product is in the hands of your consumers, this feedbacks into the next iteration of its design and production.

In Marvel’s Iron Man, Tony Stark (Robert Downey Jr) designs the streamlined Iron Man suit digitally and then tells his artificial intelligence (AI)-equipped helper Jarvis (Paul Bettany) to fabricate it while he goes to a fancy shindig.

It was – perhaps unwittingly – the perfect elevator pitch for the ideal design project.

What if we could leave the ‘grunt’ work of design to robot partners and concentrate more on the project’s big picture, relegating the laborious or dangerous work to machines who understand our intent.

Generative design, where AI algorithms take your goals and constraints and give you thousands of options to work with, does just that. It’s a virtual factory full of as many designers as you need; all churning out large amounts of permutations for the project with incredibly fine computational detail, leaving you free to simply analyse and assess the choices. The world is already full of products that were made better, faster, safer, lighter and stronger than centuries of human engineering expertise could manage. And we’re not talking about nimble little startups either – generative design projects have already come from the global-scale manufacturers like Boeing and General Motors.

Local manufacturing Imagine the incredulous look you’d get if you walked into a Nike factory in China or Thailand and asked for a single pair

AMT DEC/JAN 2019

of custom-made shoes with your name on them. AI-driven robotics will make it possible.

In the production line economy, we make huge numbers of a single thing. When robots learn to make new movements and adapt their behaviour to solve incoming design problems (or put your name on a pair of shoes), it instantly retools the entire factory.

Crucially, it also means a single device can do a lot more, which will open the field up to local makers who don’t have the billion-dollar factory infrastructure of big manufacturers.

As we demand more customised products, a whole new maker class will spring up with small factories that can make a single product, then quickly and cheaply retool to make something else. The savings on shipping alone will reduce costs – both to consumers and the environment.

Like in a lot of emerging fields, there’ll be some short-term pain; jobs will be replaced.

But in the long term it’ll merely be a matter of adjustment. We’ll remake our economy in response to technology, reskilling just like blacksmiths or samurai warriors once had to. A decade ago, generative designers and robot trainers did not exist but they will be in high demand in the near future.

Some aspect of manufacturing is also turning small and local, without even displacing the huge, production line manufacturing the 20th century gave us, encouraging a new, customisation-based economy.

Overall, AI-driven robots will enhance human ingenuity, not replace it, just like technology has always done. Even though we might have a robot to chop onions or carrots in the kitchen, there’ll always be a call for an experienced and creative chef who understands how to combine flavours and textures to create delicious food.

Rod Hunt is the Manufacturing Lead, ANZ for Autodesk. www.autodesk.com

Another quality product from Global Job Solutions; a fully Australian owned company.

Software guaranteed to make you money.

How? Reduce quoting time by up to 90%

Instant access to historical data

Automatic accurate costing

Integrate with MYOB, Quickbooks & Xero www.globaljs.com

Most User Friendly

08 8443 7244 Automatic data collection

066

COMPANY FOCUS

Nicholas Hacko Watchmaker – Doing it their way, in their own time Nicholas Hacko Watchmaker became Australia’s first and only watch manufacturer in an act of defiance against big overseas corporations. But its ambitions extend far beyond that. By William Poole.

When anyone talks about advanced manufacturing, there’s a tendency to think of certain definitively modern, high-tech applications: aerospace parts, medical devices, maybe smartphone components. But arguably one of the oldest segments in advanced manufacturing is often overlooked: watchmaking. People first started wearing portable timepieces some 500 years ago, and ever since, watchmaking has been a key driver of technological development and innovation, combining engineering challenges around accuracy and reliability, with a critical focus on aesthetic design.

Moreover, the history of watchmaking is characterised by disruption.

Much has been made of the impact of smart-watches in recent years, but that battle has been going on since the ‘Quartz Crisis’ of the 1970s, when cheap, mass-produced electronic watches overturned the Swiss-led dominance of traditional mechanical watches. And yet, lots of people still recoil at the idea of wearing a miniaturised smart-phone on their wrists, and will pay a premium for something more classical. So traditional mechanical watchmaking endures, a craft sustained largely by dedicated independent practitioners.

Nicholas Hacko Watchmaker (NHW) made its first watch in 2013, but for the full story you have to go back further, to the 1950s, and the former Yugoslavia. Nicholas Hacko’s grandfather took up watchmaking in a village in what is today Croatia, focusing on servicing and repairing his customers’ watches. In time his son joined the business, and later his grandson, Nicholas. But in 1991 the Yugoslavian civil war broke out, and Nicholas was forced to flee to Australia.

“It’s the classic refugee story,” says Josh Hacko, Nicholas’s son and now NHW’s Technical Director. “My mother and my father moved over with three suitcases, and one was lost in transit. So one-third of their possessions were lost.”

In Australia Nicholas started anew, opening a shop in Sydney for the service, repair and overhaul of high-grade mechanical watches,

AMT DEC/JAN 2019

with Josh coming onboard as the fourth generation of Hacko watchmakers. In tandem with the service and repair business, Nicholas developed a profitable sideline buying, restoring and selling high-end second-hand mechanical watches. That sideline proved vital, because in 2011 the company’s entire business model was forced to change when several luxury Swiss watch brands cut off the supply of spare parts to independent watchmakers.

“This was a huge, momentous shift in the watchmaking industry,” says Josh. “Suddenly you as the consumer could no longer go your local independent watchmaker that you’d been going to for 10 years and ask him to repair your watch. Because your independent watchmaker had no spare parts. This effectively killed the repair side of our business overnight. We had parts one day and then the next day we didn’t.”

The Swiss corporations defended the decision arguing that they merely wanted to ensure quality control and ensure their customers were treated in the best possible way. But as Josh puts it, the move was “a huge insult, for my father, myself, and everyone in the industry”. It essentially implied that independent watchmakers simply weren’t competent to service these brands.

Nicholas refused to take the decision lying down. He devised a plan: he would purchase off-the-shelf components from suppliers across the watchmaking world, and assemble nine watches. NHW had a mailing list of about 10,000 people for its email newsletter, so Nicholas wrote to them, explaining the whole story and inviting them to become custodians of these nine timepieces.

He received 140 orders.

“That first model would be called ‘Rebelde’, which is Spanish for rebellion,” says Josh. “Because it was an act of rebellion. It was saying ‘Well you’re saying I’m not good enough to fix your watch; I can make my own watch.’ And this idea of rebellion against these huge Swiss corporations was an integral part of our identity. My father still has that fighting spirit. We would have made the watches just as a statement, we didn’t care if they didn’t sell.”

NEW SOUTH WALES HEADING

Josh Hacko, Technical Director at Nicholas Hacko Watchmaker

Nonetheless, the unexpected interest in that first batch prompted a rethink. Nicholas and Josh realised the sheer number of orders meant it wouldn’t be enough to merely assemble a watch from offthe-shelf components. Instead, Nicholas sat down and designed a watch, then sub-contracted production of parts from 11 manufacturers around the world. Only the mechanical movement – essentially the heart of the watch – was purchased from Switzerland as a complete assembly. The parts came to Sydney, where Nicholas completed the assembly and adjustment of the watches.

Since then NHW has sold about 640 watches. It has diversified its range with several other models, at prices from around $2,500 up to $15,000, for a series produced in solid gold. Alongside Nicholas and Josh, they have brought in a watchmaker apprentice and machinist, with three further staff running the buying and selling side of the business. The company continues to do servicing and repairs, but at much-reduced capacity, primarily for existing customers. This is largely down to the continued difficulty and expense of accessing spare parts. As Josh puts it: “We don’t want to grow that side of the business because there’s no future in it.”

Instead the first glimpse of the future will appear in March, when NHW delivers its latest model. This 25-watch series marks a significant departure from its predecessors. Whereas those earlier models were assembled from parts sourced almost entirely overseas, in the new watch some 45%-50% of the components will have been manufactured in-house at NHW’s workshop in Brookvale, north Sydney.

Josh explains: “In 2015 we sat down and asked ‘Where is this heading? What are we going to do with this?’ By then we’d sold about 400-450 watches, and we could have continued doing that.

It was an easy thing, extremely simple. You talk to 11 different suppliers once a month to maintain that business relationship, you send them money and they send you parts. But there are practical limitations in lead times and quality control. And there’s a far more important limitation: knowledge transfer.

“If you’re not transferring knowledge, not learning, not developing in any way, you’re stagnant. Your brand will die. It will wither away. We wanted to not do that. We wanted to stay here and make sure the next generation was in on this, and had a job and a place to learn, and a knowledge to receive. In our industry the only step forward to do that was to start making parts. So in 2015 we made that decision to head into manufacturing.”

Defying convention As a company with the word ‘rebellion’ written into its branding, it’s no surprise that NHW tends to do things differently from most fledgling manufacturing businesses. This is probably epitomised by the fact that when they decided to start manufacturing their own parts, they had pretty much no manufacturing experience at all.

“We’d never made anything,” says Josh. “The closest thing to manufacturing was woodworking in high school, that I’d done.

My father would sit behind a watchmaking lathe and refinish a part, but he never made anything from scratch. So we went through a series of very abrupt learning points.”

Some of that learning has taken place in training overseas, with machine tool builders in Germany and Switzerland. Josh also acknowledges the support they’ve received from local suppliers such as MasterCam and Headland Machinery. But the team at NHW have also had to work pretty hard on working things out for themselves.

This in turn has entailed a rather unconventional definition of research & development (R&D). For NHW, R&D was about learning the fundamentals of how to make a watch.

“There’s one method of making a watch: you buy a hand lathe, spend 10 years behind a bench, and you make a watch,” says Josh. “But what we’re doing is many orders of magnitude more difficult. We’re trying to serially manufacture a watch, so a watch we make today and a watch we make in six months are exactly the same. And no-one is going to tell you that. No-one in Switzerland is ever going to reveal their trade secret to you. Our R&D process was figuring out how to do that.”

Continued next page

AMT DEC/JAN 2019

067

068

STATE SPOTLIGHT The company’s latest acqisition has been a Makino U32j wire EDM machine, supplied by Headland Machinery.

The watches are produced with a combination of the latest advanced manufacturing technology and meticulous manual processes.

Continued from previous page

Watch this space

That tendency to defy convention is also reflected in the company’s machinery investments. Over the last two to three years, NHW has progressively been kitting out its workshop, with each new acquisition bringing new capabilities, in turn enabling production of another category of components. First in was a Citizen R04 lathe, followed by a Kern Pyramid Nano five-axis mill, and then an Affolter gear-hobbing machine. The latest arrival has been a Makino U32j wire EDM machine, and the company has also invested in MasterCam CAD/CAM software.

As Josh recounts the story, it’s hard not to regard the big Swiss watch manufacturers’ decision to withhold spares as a monopolistic ploy, if not downright bullying. But the move also seems shortsighted.

Excluding small independent players from any marketplace tends to stifle creativity and innovation, as well as narrowing the options for talented young people keen to join the industry. Moreover, alienating small businesses who had once effectively been your partners can instead turn them into rivals. And when you deprive those partners of vital business, it can often bring the best out of them. So while NHW’s origins may have been spurred by a simple act of defiance, its ambitions for the future are centred on building a strong business with a solid brand – perhaps strong enough to rival the Swiss giants.

However, while the average manufacturer might identify a specific requirement, buy the appropriate machine and set it to work immediately, this hasn’t always been the case with NHW. The Affolter machine arrived in 2017, but it still hasn’t been used.

“We found this machine kind of by accident,” says Josh. “It was a second-hand machine from IWC. It had 120 spindle hours, which is nothing. It was such a good deal and such a rare machine we just had to buy it. So the capability of gear-hobbing is in-house, even though we’ve never made a gear just yet. The knowledge required to get to that level is something that we’re not at yet, but we will.”

This unconventional approach is in part made possible by NHW’s funding model, which is – again – somewhat unusual. While each new batch of watches is largely pre-sold in advance, and the sideline in restoring and reselling second-hand watches is a valuable revenue stream for the business, the company is largely bankrolled from the Hackos’ own funds, in what seems like something of a labour of love.

“We’ve been saving for something like this over the past 15-20 years,” says Josh. “So we have no external investors, no loans, no banks on our back. It’s all self-funded; we’re not in debt. So we’re taking things slowly. And it means we’re very comfortable in spending three years in R&D. We didn’t need to have an RoI.” These idiosyncrasies in the way NHW operates are perhaps to be expected given the unique challenges it faces. No company has manufactured watches in Australia before, so one of the biggest difficulties for NHW is the absence of any kind of relevant “industrial infrastructure” here. In a country like Switzerland, watch manufacturing is big business, and accordingly is supported by established networks and structures: suppliers understand the watch manufacturers’ requirements and can service them; training organisations turn out a steady stream of apprentices with applicable skills; and so on. In Australia, NHW enjoys none of those benefits.

“No-one in Australia has serially produced watch components ever,” says Josh. “And there’s no culture of precision manufacturing in Australia. There’s pockets of it here and there, a few companies.

But if you compare it to somewhere like Switzerland or Germany, they have this culture, this idea that when you’re 16 or 17 years old, unless you go to university, you’re making something. We don’t have that. Outside of the technical challenges, this is biggest challenge.”

AMT DEC/JAN 2019

For the time being, however, the plan is to continue expanding capabilities. The company has purchased a block of around 1,200sqm of land in Mittagong, south of Sydney, where it plans to build a dedicated watchmaking factory. As well as allowing further expansion of the company’s machine capabilities, it would offer various features specific to the requirements of watchmaking, such as temperature-controlled rooms, and thick slabs to minimise vibration – operations at the current plant have to be confined to times when local road traffic is minimal.

But in keeping with NHW’s aversion to doing things conventionally, the timetable for the move is … flexible.

“Who knows?” Josh smiles. “It’s going to cost millions of dollars, so our short-term goal is to make enough money to finance that project. All the profit that comes from the manufacturing side is going directly into reinvestment in this factory. We want to move in within five years. But the building might be there in two.”

It’s often remarked that the future of manufacturing in Australia is in high-value-add, low-volume sectors. Most people cite medical, or defence, or aerospace. But those criteria apply equally well to the mechanical watch. NHW may be Australia’s first ever watch manufacturer, but maybe a decade or two from now, it won’t be the only one. A few decades ago, for example, Australian wine-making was widely dismissed on the international stage, but not anymore.

So why not Australian watchmaking?

“Can I dream? Am I allowed to dream?” says Josh. “There’s the obvious idea of selling more, making more money, but I’d love to be in a position where we can train the next generation of Australian watchmakers to really start making something in Australia by themselves. There’s a huge fear that if you train an apprentice and they leave and start doing their own thing, that’s disastrous, that now there’s competition. For us, that’s the best-case scenario.

If there’s 10 other companies like us in Australia, that would be amazing. In 10 years maybe this business would be in a position to offer other businesses that are trying to manufacture watch parts in Australia an opportunity to grow.” www.nicholashacko.com.au

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 Services Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

amtil.com.au 1311AMTIL/EH

070

STATE SPOTLIGHT

NEW SOUTH WALES

Taking precision machining to a new level

A new machine tool described as “a production powerhouse” has been installed at Meeke Engineering in Wetherill Park, Western Sydney, and its new owners believe that it takes precision machining to a new level.

The new machine is a Kingfisher RAL12 CNC vertical lathe by Radar Industrial, a Taiwanese manufacturer of high-precision machine tools. The vertical spindle is supported to a full 360 degrees, eliminating ‘spindle droop’ and increasing the maximum weight allowable on the spindle. As Isaac Newton would have noticed, gravity provides a downward force on the workpiece, assisting the workholding. Minimal clamp force can be applied where desirable, and gravity keeps each part in the chuck. This not only provides additional stability, especially when machining delicate parts, but also dissipates the cutting forces created by heavy cutting.

Increasing capability These facts were in the thoughts of the management team at Meeke Engineering as they considered the needs of their current and prospective customers. The team was seeking to add more capability and capacity to the company’s workshops by installing a new machining centre. They worked together with the engineers at 600 Machine Tools to identify they right machine for the envisaged tasks. After visiting an innovative manufacturer, the team chose a CNC vertical lathe built for heavy-duty cutting while maintaining remarkable levels of accuracy. After the configuration of the lathe was decided, including a Fanuc Oi-TF control, an order was placed with Radar for early delivery.

The Kingfisher RAL12 is a CNC vertical lathe designed, engineered, and built to very high specifications by Radar Industrial at its manufacturing facility in Taichung City, Taiwan. This company boasts a formidable reputation in the world’s engineering workshops, especially among those requiring fine tolerances in components for such market segments as aerospace and health.

The one-piece column is made from Meehanite cast-iron with a wide-span ribbed box structure, a machine design that provides excellent stability and rigidity. The new lathe is primarily built from a high-quality alloy steel, and its fully-covered and high-torque octagon-shaped structure is designed to handle the stress of inner and outer diameter cutting, and ensures cutting accuracy.

“We are delighted with the RAL 12 for a number of reasons, but most importantly for its precision” says Satish Sawant, General Manager of Meeke. “This is a direct result of the design, engineering, and build-quality. The Kingfisher RAL12 is a cleverly designed, costeffective production powerhouse. Its sturdy construction provides rigidity and stability for longer tool life, toolroom accuracy, thermal stability, and fast run-times.”

Throughout Australia, Radar machine tools are sold, serviced, and supported by Sydneybased 600 Machine Tools, a member of the global machinery manufacturer and distributor 600 Group, a company with more than a century of expertise.

The Kingfisher RAL12 CNC vertical lathe.

AMT DEC/JAN 2019

From left to right: Mr Yang, engineer with Radar Industrial; Patrick O’Doherty, 600 Machine Tools CNC Sales Representative; Deric Vuong, Meeke Engineering Workshop Foreman; Satish Sawant, Meeke Engineering General Manager; Spencer Lin, Euro Source Liaison Manager; and Mr Huang, engineer with Radar Industrial.

“When I first watched a demonstration of the RAL12, it became obvious that the design was a key factor,” says Cliff Purser, Managing Director – Asia-Pacific for 600 Machine Tools. “It enables the CNC vertical lathe to deliver machining excellence through rapid feed rates, fast and precise cutting, and smooth surface finishes.

The octagon RAM provides superior damping characteristics, excellent thermal expansion control, and stronger rigidity than traditional square designs. The octagonal design counterbalances the machining forces on inner and outer surfaces, and ensures accuracy on both sides.”

Purser added: “Meeke will be able to count on the machine’s consistent accuracy, even when engaged in heavy-duty cutting, despite the RAL12 having half the footprint of a horizontal lathe.

Renowned problem solvers Meeke has earned a reputation for providing world-class manufacturing, engineering, fabrication, machining and assembly services for a variety of customers in Australia and overseas.

According to Sawant, this is down to the relationships his team build with clients.

“Our Wetherill Park workshops provide a lot more than just production capacity,” he explains. “Senior staff members frequently interact with customers to devise knowledge-based solutions to specific problems, often going on to design and engineer a prototype, before the chips start to fly.”

Meeke provides hydraulic cylinders and refurbishing, complex welding jobs, specialised CNC machining, and quick turnarounds when required. Sawant says that some of the typical challenges that the company might face include centre barrels for the mining industry, gearbox cases for the gear industry, moulds for the rubber industry, and hydraulic cylinders for the earthmoving industry. The company’s workshops are about 15km from Badgerys Creek, which is the site of the West Sydney Airport now under construction, with facilities for fast handling of express air-freight.

“At our base in Sydney’s industrial heartland, Meeke has the expertise and experience to produce everything,” says Sawant.

“From a tiny component to a complete system that has been designed, manufactured, assembled, and tested under a ISO 9001:2008-accredited QA regime.”

NEW SOUTH WALES The Kingfisher RAL12 CNC vertical lathe is built at Radar Industrial’s manufacturing facility in Taichung City, Taiwan.

Stop press As this issue of AMT Magazine was going to press, Meeke has announced that it was in the process of installing and commissioning a very large swing lathe from US manufacturer Clausing Industrial capable of handling workpieces of up to six metres in length.

Based in Kalamazoo, Michigan, Clausing’s four series of large swing heavy-duty gap standard CNC lathes are designed, engineered, and built for industrial-strength performance – in particular for heavy-duty stock removal. All the company’s lathes, drills, and other machine tools are tested to the most stringent accuracy, and test cuts are made before shipping.

“The powerful MA45 we have configured for Meeke is one of

Clausing’s large swing lathes that is capable of machining, for example, 6m barrels for hydraulic cylinders,” says Pat O’Doherty, Sales Manager of 600 Machine Tools. “A member of the 600 Group, Clausing has led the charge in the world of heavy-duty machining since its founding in 1911, and at least one of its machines can be found in every major shipyard of the US Navy.” www.600machinery.com.au

NSW toolmaker and general engineering shop focuses on high-end components Based in Blacktown, NSW, Anglade Toolmaking & General Engineering has firmly established a name for precision in meeting challenging designs and in the manufacture of a variety of special-purpose machines and tools for industry.

Founded in 1978 by Michael Byrnes – still the company’s owner and chairman – Anglade completes all work in-house, including design, drafting, manufacture, electrical, pneumatics, hydraulics and PLC programming, with capabilities in CNC milling, CNC turning, wire EDM and precision grinding. Using the latest high-end machines, this 40 year-old, second-generation family company designs and manufactures specialist injection, blow, vacuum, thermos vacuum and polystyrene moulds, along with press tools, special-purpose machines, jigs, fixtures and gauges for a broad range of clients quickly and efficiently.

Michael and his son David Byrnes – now the company’s general manager – have built up an impressive range of machines and equipment, such as the Okuma MB66VA S15 OSP-P200M vertical machining centre and Fanuc Robocut Alpha 1iD 310isWA, to meet the ever-changing demands for precision components. This has won them work on some impressive projects, including providing parts for two ambitious CSIRO radio telescopes.

Anglade was commissioned to manufacture ortho-mode transducers (OMTs) and other specialised components for the multi-beam (19-beam) receiver for the Five-hundred-metre Aperture Spherical Telescope (FAST) radio telescope. This telescope dish – now set in the mountains of Guizhou, China – is the largest telescope in the world with a massive 0.5km diameter.

David Byrnes explains: “Using our Okuma fully integrated Kitagawa fourth axis and a trunnion table (designed and manufactured internally, offering 4+1 machining ability) and with the assistance of our NX11 CAM system, we manufactured the main OMT components with speed and incredible precision on this large CSIRO project which has contributed to the receiver’s impressive performance.

“We have also been involved in the phased array receivers for the 36 telescopes installed in the Western Australian desert for the Australian Square Kilometre Array Pathfinder (ASKAP). For this

The Okuma MB66VA S15 OSP-P200M vertical machining centre is a key piece of equipment in Anglade’s workshop.

outstanding work the company received acknowledgement from CSIRO with the citation ‘Invaluable contribution to the construction of the ASKAP Radio Telescope.”

Today the company boasts a team of 10 experienced staff, including mechanical and electrical engineers, toolmakers and fitters, who can confidently undertake any project presented to them by an expanding client base. Anglade also has a strong focus on ongoing training and apprenticeship training to safeguard the industry.

Michael Byrnes notes that the consistent precision accuracy of Okuma’s machines and their ease of programming has been an important factor for his company’s success. With exceptional service, training and back-up, Byrnes believes Okuma has been the best supplier to his company. Anglade services customers in NSW as well as developing export sales of specialised equipment.

The company also undertakes machine maintenance and project management projects to meet customers’ requirements. www.okumaaustralia.com.au www.anglade.com.au

AMT DEC/JAN 2019

071

072

STATE SPOTLIGHT

NEW SOUTH WALES

Revolutionising the market with 3D metal printing Located on Sydney’s northern beaches, Raymax Applications has supplied innovative laser solutions to companies, universities, government departments and research institutes across Australia and New Zealand for over 25 years.

Lasers can be used for a myriad of tasks and situations: attached to a robot arm, or on the side of a bottling line, or inside a protective chamber for 3D printing metal parts. This wide variation in applications requires expert installation, support and training to ensure effective incorporation of the laser system. Sometimes, Raymax is presented with the challenge of a ‘never done before’ solution: a new application or use for a laser system.

“These are the challenges we love,” says John Grace, Managing Director of Raymax.“We not only get to apply our knowledge and skill, but we are giving the user an opportunity to do something they could never have done before, and that’s pretty satisfying for everyone.”

Lasers provide the opportunity to innovate, change and improve processes. For example, materials-processing applications such as welding, cutting and cladding in fields as diverse as consumer electronics, automotive manufacturing and defence, are now dominated by industrial lasers. This uptake changes traditional processes, influenced by the advantages of a more precise alternative to traditional processing.

In today’s fast-paced industrial and manufacturing sectors, demand for the latest technology has led Raymax into the realm of additive manufacturing (AM). By introducing laser cladding and welding systems with the installation of Laserline lasers, damaged parts can be repaired that are otherwise expensive to replace or take inordinate time to be delivered. Such economic advantages are being provided to mining and drilling operators, for aircraft part maintenance, in repair of generator turbine blades, and so on. Lasercladding has been shown not just to be an economical solution, but parts are proving far more robust that the original part, extending usable life.

Over the past three years Raymax has become the distributor of Europe’s leading 3D metal printing laser systems: SLM Solutions.

SLM predicts that in Europe and the US, metal AM is set to revolutionise the automotive market; from high-performance racing cars to production vehicles, the benefits of design freedom and maximised functionality are increasing demand.

Terry Wohlers, a renowned commentator on 3D printing, emphasises the importance of design for AM (DfAM). Courses in this area are being offered in collaboration with RMIT in Melbourne, where four SLM laser systems are housed. Parts designed for conventional manufacturing are expensive to produce by AM. However, when parts are redesigned, benefits can be realised in terms of greater functionality, consolidation of assembly, inclusion of cooling channels, along with the benefit of using metals that offer reduced weight of the finished part. Wohlers emphasises that one of the biggest barriers to the uptake of AM is the lack of knowledge and skills among the design and engineering workforce – a skills gap that needs filling quickly if manufacturers are to reap the benefits. Australia’s universities are filling an important role, providing research centres while offering testing facilities and application support to local industry as well as specific training.

“Our partnerships with universities is crucial to the introduction of new technology, particularly where it requires training and skills development,” says Grace. “Most major universities across the country offer access to SLM laser systems. Companies only have to ask!”

In the last decade we have witnessed a sudden advance of AM that continues as the technology available improves. 3D printing is already being applied in the aerospace and medical sectors, with SLM predicting the next big challenge will be the integration of selective

AMT DEC/JAN 2019

John Grace and the team installing laser system in a clean room environment on university campus in South Australia.

laser melting technology into series production in the automotive industry. OEMs and Tier One suppliers focus on productivity and quality in their evaluation of the laser sintering process, as well as checking the final product or ‘built’ components. The SLM500 and SLM800 quad laser metal AM systems from SLM aim to satisfy these goals, with up to four 700W lasers offering high throughput.

According to SLM, the biggest advantage of laser sintering is the realisation of highly complex components, which cannot be produced cost-effectively with existing manufacturing processes.

Small parts with significant complexity are highly suitable for 3D printing, but exciting developments are emerging in the automobile industry. Expert applications support from SLM aids in developing components optimised for selective laser melting, from prototype to production. For example, Audi is using metal AM with an SLM280HL purchased in 2016.

Reported as a ‘world first’ in the automotive industry, Bugatti Automobiles designed and 3D printed a titanium brake caliper for its new Chiron supercar. Offering considerable higher performance than aluminium with the alloy strength of titanium, the final geometrically complex component took 45 hours to build using an SLM500 machine. A total of 2,213 layers formed the structure, which on testing can stand 125kg per square millimetre pressure required for the Chiron braking system. Bugatti claims the final product is significantly stiffer and stronger than would have been possible using conventional processes. Prior to actually printing, three months were spent on design to optimise features, indicating the role and importance of DfAM. At Audi, withi whom SLM continues to work closely, 3D metal printing is used to manufacture both prototypes and spare parts on demand. Audi’s vision is to ensure supply of original spare parts that can be built economically and sustainably in regional 3D metal printing centres, a whole new concept that would simplify logistics and reduce expensive warehousing.

“We acknowledge that 3D metal printing is disruptive technology, but laser systems bring manufacturing opportunities that may have never been possible in the past,” says Grace. “At times, challenges will arise, but we know by providing support and training to companies who have identified a way forward with 3D metal printing, local manufacturers and service providers will be well positioned to build a niche market and keep pace with the international AM sector.” www.raymax.com.au

Materials Services

Sourcing specialist materials has never been quicker

ALUMINIUM 2000, 5000, 6000, 7000 series TITANIUM Grade 2-5, 6AL4V, ELI. STAINLESS 13-8PH, 15-5PH, 17-4PH, STEEL 17-7PH, 304, 316, 321, Custom 455, 465

HIGH TENSILE 4130, 4140, 4340, 300M STEEL SUPER ALLOYS NICKEL ALLOYS

thyssenKrupp Materials is Australia’s leading supplier of materials to the aerospace, defence and advanced manufacturing industries.

We carry over 1000 tonnes of certified aluminium and stainless steel in plate, sheet and bar in our Sydney facility.

Duplex, Molybdenum, Nitronics

In addition to this, we can readily supply exotic materials from our global supplier base conforming to the highest aerospace, defence and advanced manufacturing specifications.

Invar,Monel,Hastelloy,Maraging 350 Alloy (Inconel) 600,601,625,718

With our global supply network of mills and distributors we can source the most difficult alloys and materials with ease.

Contact thyssenkrupp Materials Australia Pty Ltd Unit 2, 7−10 Denoci Close Wetherill Park, NSW 2164, Australia

T: +61 2 9757 7777 F: +61 2 9757 7700 sales.tkmaterials.au@thyssenkrupp.com www.thyssenkrupp-materials-australia.com

074

STATE SPOTLIGHT

Infrastructure boom has mixed impact for NSW manufacturers With huge changes sweeping the sector, the long-term outlook for manufacturing in New South Wales (NSW) is positive. However, while major infrastructure projects in rail, light-rail, road and airports are positioning NSW as the state of the future, it’s having an impact on the state of manufacturing and the SME market at the same time. By John Spender, Director of Business Advisory at William Buck Chartered Accountants & Advisors.

NSW is the state for manufacturing, accounting for around 30% of Australia’s total manufacturing output. Manufacturing employs 7% of the NSW workforce, and Western Sydney is the key driver of the advanced manufacturing sector.

John Spender recently spoke at an event about Western Sydney’s infrastructure boom.

Australian manufacturing is predominantly a SME market, with 24,319 firms having fewer than 19 employees, 1,663 with 20-199 employees, and only 164 with more than 200 employees. While the infrastructure boom currently sweeping NSW is set to enhance the state’s economy, the paradox is that the SME manufacturing sector is suffering a skills gap within both ‘blue collar’ and ‘new collar’ workers as a direct result. A survey conducted by Business Chambers found that 63.3% of participants who owned manufacturing businesses reported a perception of a skills shortage.

Kevin Adler, Managing Director at Ogis Engineering, agrees, saying the loss of employees in engineering and steel, to the new boom is enormous.

“On one hand I am happy for the infrastructure to happen, government haven’t focused on infrastructure for such a long time,” says Adler.

“On the other, with so much infrastructure going on, there are many manufacturers like myself, who are losing key employees to bigger companies who can afford to pay extra for those skills. It’s a bit like a mining boom in Sydney. They are offering enormous remuneration for two-year contracts and they take it, and I don’t blame them. The reality is, I’m losing some staff and this makes it difficult for us to produce the high-quality product that we are renowned for. I have to turn work away as we don’t have the capacity as before.”

Adler says he worries about the SME engineering and steel manufacturing market in NSW over the next few years.

While the NSW Government has reported TAFE trade enrolments are being driven up by the infrastructure boom, the skills gap is still apparent, particularly for trade skills. However, this is not just a blue-collar issue; employment of highly skilled workers is crucial for the advancement of advanced manufacturing, and this has been identified for action in the NSW State Government’s strategy for manufacturing, released in June.

New initiatives can’t come soon enough. Adler says he has a number of pieces of high-tech machinery considered to be in the realm of advanced manufacturing. However, he would like to purchase more.

“There are high-tech machines that I would buy tomorrow, but at the moment we can’t find the staff to operate them,” says Adler.

Filling the gap These sentiments are being echoed across my networks with William Buck, with clients asking how they can address the skills gap? My reply is there’s not one straight answer.

I recently spoke at an event about Western Sydney’s infrastructure boom, discussing how what’s becoming more important is for businesses to focus on collaborative partnerships in order to remain competitive. The plans to transform NSW – in particular, Western Sydney – means that there is a lot of potential for growth and collaboration, yet there are also challenges being faced in getting there.

AMT DEC/JAN 2019

What’s needed is lawyers, accountants, advisors and banks and other institutions to give manufacturers forums to discuss trends and opportunities as well as acting as links to increased collaboration.

As a result of these sentiments being heard across our networks and to help fill this gap, William Buck Chartered Accountants and Advisors, Coleman Greig Lawyers and St George Bank are creating ‘manufacturing lab’ events.

This initiative brings together innovators, business leaders, industry bodies and government to drive collaboration and initiatives that would benefit the manufacturing industry. These events provide a platform for thought leadership and networking to make a positive difference and address ongoing manufacturing in NSW and Australia.

Collaboration, today’s competitive advantage The NSW government reports that less than 5% of Australian SMEs are pursuing partnerships. However, there are major opportunities for small companies if they focus on targeted collaboration and strategic partnerships with academia, industry and government. To be leaders in advanced manufacturing and create a competitive advantage, R&D needs to be at the core of the business.

Today’s business environment is one of increased complexity.

It’s difficult for companies to rely entirely on their own knowledge and skills to maintain or improve their competitive position. While some organisations have the capability to ‘do it all’, many SMEs don’t have the resources to develop and implement a collaborative model.

NEW SOUTH WALES With new digital technologies and increased connectivity there is also a lot of uncertainty. These challenges can be amplified for SMEs with limited access to the critical knowledge and expertise that they need to drive ‘collaborative innovation’.

Effective partnerships can be the key to unlocking innovation and growth, involving transfer of knowledge, skills and resources.

Businesses that recognise the strategic importance of collaborative innovation and actively invest the time and effort to pursue partnerships will benefit across a number of areas, including: • • • • •

Continuous improvement and process efficiencies.

Expanding networks and insights.

New product development.

Accessing new talent pools and skill-sets.

Increased productivity and reach.

What stops SMEs from collaborating?

One of the biggest roadblocks preventing collaboration is trust.

Working with new partners, whether that is with researchers, companies or across industries, creates a unique set of issues when it comes to knowledge sharing and protecting intellectual property (IP). Another challenge is understanding how changing technology can impact or benefit a business.

Earlier this year, the Advanced Manufacturing Growth Centre (AMGC) submitted a number of recommendations in its report ‘Industry 4.0: Opportunity for every Australian Manufacturer’, designed to break down barriers and facilitate collaboration. One suggestion is the concept of a ‘sharing economy’, which would allow manufacturers to loan and share equipment such as 3D printers and other physical infrastructure that may be seasonally idle.

Ultimately, good collaboration is built on strong relationships, trust and knowing where the opportunities are. The first step for any business considering collaboration is to have a clear awareness of the partners’ core areas of capability and their limitations, as well as which areas a partnership can complement.

How to make collaboration work for your business Understanding the current state of your business and comparing that to your two-to-three-year goals can help to identify critical gaps and potential opportunities. The Innovative Manufacturing CRC (IMCRC) has developed a business diagnostic tool to help SME manufacturers on their journey to the Industry 4.0 transition. The futuremap workshops, jointly developed by the AMGC, the IMCRC and the Entrepreneurs Programme (EP), are designed specifically for Australian SME manufacturers to help foster co-operation among research and industry.

Before diving into a collaborative partnership, it’s important for a business to know their core motivations and how this collaboration will shape their competitive advantage. The right partnerships are mutually beneficial – each business can focus on its speciality work while relying on its partner for support outside their own expertise.

Addressing the opportunities and issues of the infrastructure boom in NSW is no easy feat. However, with continued support and linking SMEs with collaborative opportunities, it’s hoped that the boom will enable them to grow into the future.

William Buck Chartered Accountants & Advisors is a Corporate Partner to AMTIL, delivering exclusive benefits to AMTIL members. For more information on how you can be involved in manufacturing events in NSW, contact William Buck. www.williambuck.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

AMT DEC/JAN 2019

075

076

ONE-ON-ONE

Ray Kirby is the Director of the new UTS Tech Lab facility in the Faculty of Engineering and Information Technology at the University of Technology Sydney (UTS).

He spoke to William Poole.

AMT: Firstly tell us about the UTS Tech Lab facility Ray Kirby: UTS Tech Lab is an entirely new facility in Botany in Sydney that we built to focus on research and to bring companies to work with us on research in this space. It will house post-graduate students mostly, post-doctoral students and PhD students, and it will also be a place for academics to come and work on their research and work on collaborative projects with companies. The place was formally finished in September. UTS has spent $60m on this facility; that includes the fit-out as well as the new equipment that we’ve put in.

What we tried to do is put in equipment that is as high-tech and as state-of-the-art as we can in particular areas, and then we’ve drawn together the different sides of engineering and technology. For example we’re bringing together the civil engineers and mechanical engineers, we’re bringing them together with computer scientists and electrical engineers, so that we’ve got everyone working under one roof. We think this will allow us to move forward with the development of technology in engineering, because engineering is going towards the integration of high-value technology into more traditional applications. What this will allow us to do is to link up with things like data analytics and data visualisation and so on. This allows us to approach engineering in a more co-ordinated way.

AMT: What sort of capabilities and facilities have you got at Tech Lab? RK: What we’re try to do is to bring together the skills in our faculty, what we’re well-known for and what we’re leading at. UTS and our faculty are particularly well known for computer sciences, data analytics and robotics and those sort of areas. What we try to do at Tech Lab is provide facilities for the computer sciences and communications and networking groups, but then join them together with our engineering facilities.

We have facilities here for civil engineering; we’ve got a a reaction floor and a reaction wall where we can test full-scale structures, concrete and timber structures. We’ve got the facilities to fabricate concrete.

We’ve got climate chambers where we can change the temperatures to test concrete through its cycle of different environmental conditions.

So what this facility allows us to do is to draw those engineering areas together with the computer sciences. What we hope in the future is to integrate our areas under the general banner of IoT (Internet of Things) so that we can integrate the testing of sensors and various other monitoring systems on real engineering artefacts and products.

We would hope that’s of interest to people working in utilities, in infrastructure, in transport – things like Smart Cities; Smart Buildings; Smart Infrastructure – and those are the areas where that sort of approach will attract potential partners.

AMT DEC/JAN 2019

AMT: Can you shed any light on any notable projects that are already underway here?

RK: Well, not all our facilities are up and running; we are getting close to finishing. But the early adopters will include Sydney Water, with whom we are fitting out an iPipes lab, as it’s called; that’s a lab that will focus on doing smart pipes for Sydney Water. It will involve coming up with new ways and technologies to reduce leakage and failures in their piping system. That will be one of the first projects that we’ll start here, and over time we will gradually move some existing projects over here.

But as Tech Lab opens, we are currently talking with partners to bring them in to do some new collaborative projects here.

AMT: What sort of work do you envisage doing with manufacturers and in what areas can manufacturing companies collaborate with UTS? RK: By integrating our robotics team and our communications and networking teams, our computer sciences, we’re hoping to try and bring those technologies together so that we can look at Industry 4.0-type manufacturing technologies and move towards advanced manufacturing in that way. We will also have additive manufacturing down here, so we’ll have metal printers, plastics printers, we will also have concrete printing down here as well. Our intention is to do that.

So over time, manufacturing becomes a natural focus for what we do here because it’s well suited especially to our expertise in robotics and sensor design, and moving that together with our analytics and so on.

AMT:: There’s a big emphasis on facilitating collaboration with industry.

How do you see that taking shape?

RK: What we see as our value-added here is our ability to innovate and provide new ideas and new solutions to problems. What we’d like ideally is for companies to come in and work with us. We have a big space in Tech Lab where companies can actually come and bring their personnel to work with us. We would like to bring some big multinational companies in, for them to bring their supply chain in, to partner with SMEs and also start-up companies, so we get this mix of people from different areas and backgrounds; we can put some students in there as well. From that we can kind of build this ecosystem where we can focus on innovation and that will add value for our industrial partners beyond what they would normally have access to in terms of doing traditional research projects with us.

We also hope to be able to offer companies access to our facilities.

We’re happy for companies to come in and hire out our facilities if they wish; we can do consultancy work based in our facilities; we can do testing according to standards and so on if that’s what companies want.

HEADING

But our ideal picture is companies working with us on research projects. What we hope to see Tech Lab do is to help companies through the process of moving from development of ideas, to proofof-concept, to actual pre-commercialisation. We’ve got the ability to do some full-scale mock-up testing, so for example in manufacturing we could put together a small mock-up of a full-scale manufacturing facility or process, and we could then flesh out all of the issues or the problems, we could run through our proof-of-concept with that, so that by the time it comes out of Tech Lab, it is almost ready to be actually implemented in a real manufacturing facililty.

AMT: A lot of Australian manufacturers, particularly SMEs, often find themselves stumped on how to approach R&D collaboration in this way. How is Tech Lab aiming to facilitate that process?

RK: I think we’re all aware in universities that universities are often seen as challenging partners to work with because of their size and legacies.

I understand that, from an SME’s point of view, working with universities can be daunting. We want to change that at Tech Lab, to offer a much more flexible, approachable way of working with universities. So we’re in the process of drawing up standard ways of working with Tech Lab. Our approach is going to be to say to companies: “What are your problems, what are your issues?” We want to go to companies and offer a kind of solutions-based approach. And because we’ve got lots of different areas under one roof here, then we can say to companies we have the capacity and expertise to offer a solutions-based approach. We would ask companies: “What are your issues?” and “What’s your problem? What’s keeping you awake at night? What’s stopping you going forward where you need to be? How can we help you solve your problem? Here’s the way to work with us - which will allow us to deliver on that.”

Ray Kirby

Continued next page

AMT DEC/JAN 2019

077

078

ONE-ON-ONE

Continued from previous page

We’re conscious that from our side we need to be easy to work with, we need to be able to turn around projects quickly. And we recognise for SMEs and especially start-ups that we need to be quick about that; that time is important. We’re working very hard to ensure our processes and our procedures are quick and responsive and agile and meet the needs of our potential partners.

AMT: You’ve come from the UK fairly recently. Having that perspective, what lessons that would you say Australian manufacturing can draw from the industry in the UK? RK: I came from the UK 18 months ago; I spent all my working life there before I came here. In the UK manufacturing went through a pretty terrible time. It’s not unusual to see lots of manufacturing industries start to disappear, and we certainly saw that in the UK. And there’s a sense if that happens you can’t get it back, it’s gone forever.

But it’s not the case. In the UK now they are starting to revitalise some of the industry by focusing on very high-tech new developments in manufacturing. This is high-value manufacturing. A lot of it is being driven by the defence industry and the aerospace industry and areas such as that, where high-tech, high-value manufacturing is important.

And that’s been done by collaborating, getting universities and companies to collaborate together, to generate that new IP and that new technology. These initiatives are also heavily supported by the UK Government.

I think in Australia there is an opportunity to do something similar. I think Australia has some great universities, some great high-tech skills, has a great SME base. Australia shouldn’t think all of a sudden that manufacturing is something Australia can’t do anymore or that it’s something we should all be getting out of. I think in manufacturing we’re certainly moving towards the high-value, high-tech areas and with proper co-ordination and investment, I think that the future is potentially very strong. Especially for rolling out new manufacturing technologies into South-East Asia and so on, where Australia is seen as the technology developers, as a centre for innovation and tech.

What turned things around in Britain was government support. We recently had Professor Graham Wren from Strathclyde University over, who helped start the Catapult Centres (a UK government programme to promote innovation) in Britain. We spoke a lot about how that happened, and to initiate that, you need government support. So I think the future of manufacturing in Australia is potentially strong, but it needs support from government – federal and state. It needs that impetus. What has happened in Britain – and this is true of Europe as well – is that governments are now starting to reinvest in manufacturing.

AMT: What form should that government support take?

RK: In Europe governments were investing on a kind of a third-thirdthird basis. So if industry would put in a third, government would put in a third, and then the universities would attract the other third from various research projects. This allowed them to put together big projects that were ambitious. And I think what Australia should focus on is putting … well my view would be Centres of Excellence in manufacturing that are supported by government, but then clearly link in to SMEs and supply chains and so on, that support a greater wider network of manufacturing technologies.

I know this is starting to be developed through things like CRCs and so on, but I sense with CRCs that they are still a little bit low down on what in Europe we used to call technology-readiness levels – the TRL levels – and that CRCs are still too close to universities and not close enough to commercialisation. What Europe has done through the Fraunhofers and the Catapults is to move it up a few TRL levels so that the outputs from them are much closer to what industry wants in terms of commercialisation.

From my point of view, being relatively new to Australia, there’s still this focus on universities very much as the holders of fundamental knowledge, and that that’s very important, and that actually getting involved in translating that into industrial outcomes is almost seen as something that is not really what we should be doing. I think there’s a cultural shift that needs to be done and that universities have lots of untapped reserve in terms of helping companies.

AMT: What would you like to see Tech Lab working on in five years time?

RK: I would love to see Tech Lab being a host for digital transformation, IoT, advanced manufacturing, Industry 4.0, additive manufacturing technologies, and the translation of that technology into real industrial processes. I would love to see a mixture of multi-nationals, SMEs and start ups from New South Wales and across Australia, working together on delivering new technologies that are rolled out both locally, nationally, and also internationally.

What I want to see is ambition. We have potential to take up more space here, to grow, to lead the translation of university research into outcomes.We have to translate the outcomes of university research into real products, processes, commercialisation, much faster than what we’ve done in the past.

AMT: Tell us about your background and how you came to become involved RK: I’ve been an academic all my life. I started my academic career in Britain; I’m a mechanical engineer by training; I did my research in acoustics and my research is generally in acoustics. Noise control and guided waves and structures. In Britain I worked in the mechanical engineering department at Brunel University, which is a technology university a bit like UTS. I was there for 18 years, I was head of mechanical engineering, and at that point I was kind of thinking it was time to do something different!

UTS advertised for a new position in my research area, which was acoustics. They were setting up a brand new group in acoustics. They were also moving into this place called Tech Lab, which looked quite exciting. It all looked to me like an exciting move and a change. And sometimes you’re just ready for a different challenge.

So I came over to join our new centre for audio acoustics and vibration and focussed on research, and then the job of Director of Tech Lab was advertised. I thought it looked like fun and I was fortunate enough to be successful in my application. So since January I’ve been in charge of Tech Lab; I’ve got kind of a split role: Director of Tech Lab as well as continuing my research. And I’m enjoying it. It’s a fantastic role; every morning I come in here and feel lucky I work at this place. It’s very exciting; we’re going to enjoy developing Tech Lab. www.uts.edu.au

AMT DEC/JAN 2019

1400AMTDECJAN19

APPROX

31,500

READERS

DON’T LET 2019 START WITHOUT YOU The New Year is fast approaching and now’s the time to ensure you’ve booked your 2019 AMT advertising. Join the many successful businesses who use AMT, the No. 1 trusted industry publication – to get results.

AMT Magazine – Your Industry. Your Magazine.

AMT proudly owned and published by Australian Manufacturing Technology Institute Limited (AMTIL)

AMTIL Digital Media Kit 2019

PRINT INSERTS AMTIL DIGITAL BANNERS EDMs NEWSLETTER BANNERS 2019 PRINT & DIGITAL MEDIA KITS NOW AVAILABLE ONLINE

For information or advertising rates visit www.amtil.com.au or contact Anne Samuelsson, Sales Manager on 03 9800 3666 or email asamuelsson@amtil.com.au AMT proudly owned and published by Australian Manufacturing Technology Institute Limited (AMTIL)

MEDIA KIT 2019

MEDIA KIT 2019

Australian Manufa

cturing Techno

logy Institute Limited

(AMTIL)

080

CUTTING TOOLS

Jacob Harpaz – Love what you do Jacob Harpaz is the CEO of cutting tools giant Iscar, and President of its parent company, the IMC Group of Metalworking Companies. He sat down for a chat with Barbara Schulz.

I found myself sitting down to talk to Jacob Harpaz in the cafeteria at Iscar’s head office in Tefen, Israel. Chatting with Harpaz, you would never think you were talking to a man responsible for more than 12,000 employees in 140 subsidiaries and 61 countries. He’s perfectly pleasant and charismatic, with achievements to his name few in Israel can match; yet he isn’t a spotlight-seeker.

Nevertheless, he has shaped his company like no other since joining in 1972, 20 years after its foundation by Stef Wertheimer, who had the foresight and vision to challenge an established industry. Iscar’s humble beginnings in an old shack in Nahariya, Israel, along with intense, hard work and commitment to continued innovation, have led Iscar to become an industry leader today.

Since 1982, Harpaz and Wertheimer’s son, Eitan Wertheimer, have run the company from one of the most rural and remote corners of the country, far from the commercial capital Tel Aviv. Harpaz’s office offers a commanding view of the region’s open spaces. His closest neighbour is a Druze village, and the rolling hills beyond that mark Israel’s border with Lebanon.

While he says he is happy to be the world’s No. 2 cutting tool producer, all Harpaz really wants is to be No. 1. That may take a while, because Sandvik Coromant is enormous. But the “Iscarites” are patient and are generating steady growth.

The breakthrough came in 1982-83, when Harpaz became the Marketing Manager of the company. He realised that in order to be internationally successful, you have to think outside the box, travel a lot and work with local companies to actually tap into new markets.

“I realised that in order to gain people’s attention we needed a product that would be a breakthrough, something that people would ask for as an alternative to well-known names Jacob Harpaz, CEO of Iscar and President of the IMC Group in the cutting tool business,” Harpaz recalls. “I think that R&D is driving the company and I can tell you that I am still the head of R&D, giving the guidelines not only for Iscar, but also for the whole IMC Group. You need to have a vision. I believe I have a feeling for what products can be sold in the market.”

You need your own people selling one product line

“The key is to love what you do,” says Harpaz. “Right from the beginning, I was in love with the mechanical part of the cutting tool. When I joined Iscar in 1972 as a student doing research, the company was hardly known.”

Harpaz travels a lot. The first time I met the man who became Iscar’s CEO in 1992 was at a seminar in Australia, a small market and quite far away; but he still insists on appearing there in person, and to have subsidiaries instead of distributors in all the different markets.

After his studies, Harpaz joined the company in the research and development (R&D) department. Had he ever envisioned being in the position that he is in today? Not really, he says, but he has always been ambitious: “I never thought I would work for Iscar for such a long time, nor be in the position that I am today, but I was ambitious and always aiming to achieve more; it was a big challenge to turn a very small company into the large one that we are today.”

“You need your own people selling one product line, working for one company and not selling a basket of different products,” he explained. “In the early 1980s I started to open subsidiaries, but then I found it was hard to penetrate the Korean or Japanese markets and decided to work with a local company instead. Every time I started to work with a local company, it became an important part of us, and we ended up discussing an acquisition. It happened with Taegutec, Ingersoll, Tungaloy and many other companies that are part of the IMC Group today.”

When Harpaz joined the company in the early 1970s, 97% of Iscar’s sales were domestic. Today that is a mere 1%. The company has always remained privately held, and never publicly discloses its finances. Today, Iscar is the largest company in the IMC Group, which also has facilities in the US, Korea, Brazil, China, Germany, India, Italy and Japan.

In 2006, Warren E Buffett, the multi-billionaire investor, put up $4bn to buy 80% of the IMC Group of Metalworking Companies. In 2013, Buffett’s organisation Berkshire Hathaway completed the purchase of the IMC Group, paying $2bn for the remaining 20% of the Group.

Iscar’s headquarters in Tefen, Israel.

AMT DEC/JAN 2019

CUTTING TOOLS

Harpaz emphasises that the acquisition never changed Iscar’s unique company culture.

But what is that often-cited unique company culture? Harpaz finds the question difficult to answer, but says that it’s an Iscar culture, not an Israeli culture.

“No matter if I am at Iscar Germany or Japan or any other subsidiary around the world I feel like I’m working here in Tefen; the way people are doing business is the same,” he explains. “We make everything easy, there is no Israeli culture as such, for us it is easy to adopt all types of cultures.”

Harpaz cultivates an open-door culture: “You will never see my door closed, it doesn’t matter how important the meeting is. Everybody can come in.”

He is a hard-working man, working at least 12 hours a day, six days a week. For him, to be successful you have to work hard and be good at what you do; and he expects the same from his managers and employees. And success proves him right. Almost all of Iscar’s managers have worked at the company for decades. They grew up together. They come, and they don’t go. www.iscar.com.au

Multi-Master – 15,000 possible configurations for machining small parts Advances in machine tool engineering have brought new opportunities to production, prompting a “rethink” for the manufacture of various components. Multi-tasking machines and driven-tool lathes enable different cutting operations to be performed on one machine. Realising the capabilities of machining a whole part in one setup has been a long-held dream of every manufacturer, particularly for producing small parts where cycle time is short.

Iscar provides a wide range of products intended for high-efficient production of small parts on multi-tasking machines and driventool lathes. There are two different directions in the product range.

One is connected with “traditional” solid carbide design, while the other adopts an assembly-cutter concept proposing effective tools with replaceable cutting heads. The assembled tools with heads relate to Iscar’s perennially successful Multi-Master and ChamDrill lines and include various families for milling and hole-making.

With over 40,000 possible tool configurations in all its applications, the Multi-Master concept is based on three key elements: centering a head by taper, a face contact between the head and tool body (shank), and a thread connection between the head and the shank.

Taper centering provides high accuracy. The face contact ensures a head overhang within strict tolerance limits, resulting in high dimensional repeatability of the assembly. The thread connection makes replacing heads simple and operator-friendly.

The Multi-Master tools wholly meet the requirements of the important “no-setup time” principle, as replacing a worn head does not require additional setup operations. The head can be changed without removing a tool from a machine, which significantly decreases downtime. The Multi-Master unified thread connection allows the shank to carry different cutting heads and vice versa, converting the shank to a universal holder and so reducing both tool inventory and storage.

The Multi-Master line features a variety of integral shanks with different types of adaptation, such as the HSK taper (DIN 69893, Form A), the CAMFIX polygonal taper (ISO 26623-1) or a taper for direct clamping in ER collet chucks. This drastically expands mounting options by ensuring rigid securing from axial and rotational movement, and minimises tool overhang. These features considerably contribute to high-efficiency machining, which is especially important in serial, large-volume production of small parts on multi-tasking machines and driven-tool lathes. In addition, the wide choice of extensions and reducers ensures the necessary tool configuration for machining hard-to-reach part areas.

These characteristics make the Multi-Master line a viable alternative to solid carbide tools in various operations. Milling applications include milling square shoulders, planes, 3D surfaces, chamfers, slots and grooves, screw threads and more, and the capabilities in hole making cover center drilling, spot drilling, and countersinking.

However, the line has already moved beyond tools fitted with a solid carbide head; it now covers indexable tools as well. A newly designed steel head, fitted with a male thread connecting area and carrying indexable inserts, provides a cost-effective solution, particularly in cases where machining accuracy is not high. Recently introduced under Iscar’s latest LogIQ campaign and incorporating this innovative design, NanMill, Heli3Mill, LogIQ4Feed, and Tor6Mill heads with Multi-Master adaptation look very promising.

The customer demands ever more advanced and versatile tools. A brief review of the new lines would be incomplete without mention of at least two more products: MM SS solid carbide heads for milling involute splined shafts and MM FM solid carbide heads for face milling.

Impressive performance, multiform cutting geometries, reliability and easy-to-use – these features make the Multi-Master very popular, notably in small-part production. A large number of Multi-Master customers belong to this manufacturing sector, and consider the line as a very powerful tool to have on hand for increasing productivity and cutting production costs.

AMT DEC/JAN 2019

081

082

CUTTING TOOLS

The realities of today’s manufacturing production economics Machine shops seek to produce a certain number of parts of a certain quality, in a certain amount of time, at a certain cost. Consistently achieving those goals involves controlling a myriad of factors including cutting parameters, tool cost and changeover times, machine tool utilisation, workpiece handling expense, and material and labour costs. Production economics is the art and science of balancing process factors to achieve desired results.

By Patrick de Vos, Corporate Technical Education Manager, Seco Tools.

Over more than two centuries of machining history, the elements of production economics have multiplied in number. Manufacturing first evolved from craft-level single-item output to mass production of standardised parts using machine tools. Improving manufacturing methods brought about a second generation of mass production featuring production lines and output of increasingly greater numbers of identical parts: a high-volume, low-product mix (HVLM) scenario.

Then CNC machines and robots fostered a third generation of mass production efficiency. Most recently, digital technology applied in programming, machine tool controls and workpiece handling systems is facilitating a fourth generation of manufacturing production, known as Industry 4.0, that enables cost-efficient, high-mix, low-volume (HMLV) production.

To effectively accomplish the shift from HVLM to HMLV production it is crucial that manufacturers recognise the changing and growing realities of production economics and take advantage of the information and technology available to analyse their operations and meet their goals. A key element of the transformation involves abandoning overly simplistic beliefs and practices and uncovering hidden costs that can undermine attempts to maximise productivity.

High volume, low mix, simple economics Standardised machining processes were developed in the 19th century to speed production of identical products with interchangeable parts. Automotive manufacturing refined this HVLM approach to a maximum degree, establishing transfer lines and other methods to make hundreds of thousands or millions of the same part over and over for years. The long-term nature of HVLM production allows manufacturers to fine-tune multiple process factors for maximum output, consistency and low cost. Ancillary technology including tool and pallet changers and robots further minimise variability. It is assumed that the operation runs perfectly and provides 100% yield with predictable costs, no unplanned idle times, no rejects, no rework and no secondary operations such as deburring.

One assumption is that tool cost is typically about 3% of total production cost. The 3% number is a convenient benchmark but is rarely valid. Workpiece material machining characteristics, for example, have great effect; a switch from steel to titanium in machining a part can increase tool usage by a factor of five. The 3% proportion becomes 15%, all else being equal.

AMT DEC/JAN 2019

Focusing solely on tool engagement time results in neglect of other factors such as idle times for tool changing. This approach is effectively hiding from reality. Manufacturers should understand that machining time, setup time, tool change time, loading and unloading, and other factors affect and interfere with each other.

A simplified example of unanticipated interaction of process factors involves a shop machining a part that requires two minutes cutting time and a total of two minutes to load and unload the workpiece.

Indexing the tool consumes a minute, and tool life is five workpieces, making tool indexing time 0.20 minutes per part. Because every part requires 4.2 minutes processing time, output is slightly more than 14 workpieces per hour. Each tool costs €15 ($24), and tool life of five workpieces dictates that 2.8 tools (€42) ($66) are needed to produce 14 workpieces. Machine cost is €50 ($78) per hour. Altogether, production cost for 14 workpieces in one hour is €92 ($144).

Then, attempting to speed output and productivity, the shop increases cutting speed by 10%. That reduces cutting time by 10% (to 1.8 minutes) but also cuts tool life roughly in half, meaning that one cutting edge will produce only two and half workpieces before indexing is required. Tool indexing time is still one minute and workpiece load/unload takes two minutes. Production time for one workpiece remains 4.2 minutes (1.8 minutes cutting, 2 minutes workpiece manipulation, and 0.4 minutes tool indexing) or 14 workpieces per hour. The machine and tool costs are the same, but now 5.6 tools (€84 tool cost) are required to run for an hour. Despite the effort to speed output, production time for 14 workpieces is the same and cost rises from €92 ($144) to €134 ($210) In this case, increasing cutting speed does not make the operation more productive. Changing cutting time affects other factors in the machining system – in this example, tool life and tool indexing time.

Accordingly, a shop must carefully consider the full consequences of process changes.

Another form of hidden cost involves execution of steps in the process. In many machine shops the time spent indexing inserts, for example, is a textbook case of hidden cost. The designated time to index an insert may be one minute. However, when measured in actuality on the shop floor, it can be two, three or ten minutes, a difference of 60 to 600 seconds.

CUTTING TOOLS

High mix, low volume, complex considerations More recently, global competition is prompting manufacturers to create different versions of their products to match the needs of smaller subsets of users. Advanced computing technology permits rapid change of part designs and machining programs and also enables easy tracking of product variations and inventory. The result has been a shift to HMLV production scenarios. Today, that approach has been developed sufficiently to enable efficient manufacture of single-digit or even single-item production runs.

The extended time horizon of HVLM production permits deliberate planning and fine-tuning of process factors. Planning is different in HMLV situations. Computerised engineering and inventory technologies support rapid changes in product type and output, but consequently the HMLV planning process must be complex and reactive. An order for ten parts may be followed by 2, 5, or even single-item lots of different parts. Workpiece materials may change from steel to aluminum to titanium, and part geometries from simple to complex. There is not enough time available to determine tool life through trials.

To manage tool life in HMLV situations, a workshop typically makes a conservative guess regarding a tool’s projected life and, to be safe, employs a new tool for each run, discarding it well before it reaches its full productive lifespan. Cutting time is only one factor in the overall picture. In HMLV production, the time required to manipulate different workpieces and fixtures, change tools and index inserts will often be longer than the actual cutting time. Tooling, machine tool, idle time, direct labour and workpiece material factors may contain hidden costs. The most recent approach to production economics takes into account tool and workpiece material costs, equipment and production cost, equipment cost during downtime and salary and maintenance costs.

cost itself as well as the time lost in stopping machining and indexing the tool. Determining when to change a tool requires examination of the change’s relation to the entire machining system, creating a tool change protocol, and then having the discipline to follow it.

Conclusion

Rapidly changing HMLV product requirements increase the difficulty of achieving high percentage yields. In the case of long-run HVLM production, trials and adjustments can produce yield percentages in the high nineties. On the other hand, HMLV yields may be binary.

A successful single part run represents 100% yield, but when the part is unacceptable or a workpiece is ruined, the yield is zero.

Demands for quality and cost and time efficiency remain the same, but first-time yield becomes an overriding requirement. In that case, avoiding tool breakage is perhaps the most important consideration.

One advantage is that tool wear is a minimal concern in short-run situations and a shop can apply, within reason, more aggressive and productive cutting parameters.

A related variable is determining when it is appropriate to index a tool. Waiting too long can result in a broken tool and at least an interruption in production, if not a damaged workpiece. On the other hand, changing the tool too often increases expense in terms of tool

The relationships of factors in a metal cutting system are not oneto-one. Changing cutting conditions, workpiece materials or product volume will impact tool life as well as many other aspects of the machining system. The challenge for production economics in a manufacturing facility is to be aware of those relationships and develop strategies to work with them in a pragmatic way. Unfortunately, every shop worker cannot be a professor in mathematics and lacks the time to deeply explore the relationships anyway. As a result, suppliers offer process analysis and management services that give manufacturers a comprehensive picture of their specific operations and provide direction on ways to maximise the productivity and economic strengths of their efforts.

A frequent lament of shop owners is that they have plenty of work and paying customers, but still lose money. The solution to their problems is recognising the realities of the many factors at work in present-day production economics and uncovering and eliminating neglected and hidden costs so their manufacturing operations can attain maximum returns. www.secotools.com

AMT DEC/JAN 2019

083

084

CUTTING TOOLS

Plug and Play – Making deep boring easy Kennametal claims that its latest weapon in the war on chatter is one that will have machinists everywhere saying: “I need that.”

Walk into most any machine shop and there’s a good chance you’ll hear it: the high pitch whine of a deep boring operation, the chatter loud enough to have even the most hard of hearing among us scrambling for a pair of ear plugs. It’s a problem that has plagued machinists since the day that Henry Maudslay (1771 – 1831), the inventor of the lathe, first chucked up a piece of steel and tried to bore a hole through it. And the problem has only become worse as metals have grown tougher and more challenging to machine.

But not anymore, according to Kennametal. Its new boring system boasts the most effective anti-chatter mechanism that the company has ever developed, and it also offers an extensive range of indexable heads and shank sizes.

Creating a vibration-free zone Someone who knows all about this is Sam Eichelberger, a Product Engineer for lathe systems engineering at Kennametal, and part of the team that developed the internal dampening mechanism.

“Perhaps the most important thing to know about the new bar is that it’s plug and play,” says Eichelberger. “There’s no need whatsoever for tuning or adjustments – you simply pull it out of the package, mount it in the turret, and get boring.”

There’s more to the story than making the shop a quieter place to work, however. Eliminating vibration and therefore chatter greatly extends tool life, never mind its positive effect on part surface finish.

And when tools last longer, they can be pushed harder, achieving feed rates, cutting speeds, and depths of cut that many industry experts would once have thought unachievable.

Setting the head exactly on centerline is as easy as bringing the angle finder display to zero and locking the bar in place.

AMT DEC/JAN 2019

Eichelberger is one of them. He lists a number of features that not only make the vibration-free boring system the most easyto-apply bar you’ll ever bore with, but also the most productive.

These include a serrated, bolt-on connection at the bar’s business end that securely clamps a variety of styles and sizes of indexable heads.

Better yet, the heads themselves have been put on a diet, with a shorter length and lighter weight that provides greater stability, contributing to the bar’s improved performance. They’re also coolant-fed, to precisely direct a stream of high-pressure coolant where it’s needed most. The result is hassle-free chip control together with maximum cooling in the cutting zone.

Most important of all is the internal dampener. As Eichelberger says: “The bars are both vibration and maintenance-free. Within the bar there sits a mass that’s supported by a pair of elastic supports, inside of which sits a dampening fluid. This mass vibrates at a predetermined frequency during machining, attenuating the natural frequency of the bar around it to suppress vibration. There are no wear components to worry about, nor tuning – you just set it and forget it.”

Eichelberger explains that the vibration-free system offers superior performance in boring applications up to 10X diameter deep, which are much deeper than solid carbide or heavy metal boring bars are capable of. Internal and customer test results show surface finishes as good or in most cases better than competitive ‘quiet bars’, with significantly more aggressive cutting parameters possible across the board.

CUTTING HEADING TOOLS

Of course, boring bars are only as good as the method by which they’re clamped in the machine. Kennametal has addressed this critical consideration by supplying machine-specific turret adapters, along with a special split sleeve bushing for maximum rigidity.

“That’s the goal of this product,” says Kennametal Global Product Manager John Gable. “The greatest stability possible and the most effective dampening solution available, period.”

Anyone who’s ever struggled to get a boring bar exactly on centre will also appreciate the fact that setup is extremely easy.

“There’s a reference flat on the top of the head that accommodates a visual angle finder,” Eichelberger points out. “You just rotate the bar until the indicator reads zero, then clamp it in place.”

Considering the higher cost of a such a boring system, users will also appreciate the fact that the heads are replaceable in the event of a crash, avoiding damage to the bar itself. And users of Kennametal’s older boring system will find that their new heads fit perfectly with the use of an adaptor.

Kennametal’s new vibration-free boring system boasts a number of technological improvements that allows a plug-and-play operation, with an array of interchangeable heads that includes screw-on and leverstyle clamping mechanisms in positive and negative rake configurations.

“The portfolio for our Imperial bars ranges from one-inch in diameter up to four inches, while the metric version starts at 25mm and goes to 100mm,” says Gable. “There are a variety of interchangeable head styles available as well: everything from screw-on positive rake inserts for fine-finishing needs to negative rake, clampstyle geometries for heavy roughing. The bar’s designed to excel in demanding applications, and that’s exactly what it does.” www.kennametal.com

AMT DEC/JAN 2019

085

086

NANOTECHNOLOGY

Inside Adelaide’s nanofabrication hub The South Australian node of the Australian National Fabrication Facility (ANFF-SA) in Adelaide is helping academics and industry bridge the gap between research and commercial prototypes with a blend of high-tech equipment and world-class staff. By Andrew Spence.

ANFF-SA is one of eight university-based hubs around Australia, which are funded by the Federal and State Governments, CSIRO and participant universities. Complementing the University of South Australia’s Future Industries Institute’s research infrastructure at its Mawson Lakes campus, the South Australian node started out a decade ago, specialising in microfluidics. While this remains a key strength, its expertise has grown to include lab-on-a-chip technology, advanced sensing, functional coatings and separation science. It is now attracting highly specialised work from around the globe with many services in high demand.

Products developed in the past couple of years at the node include a microfluidic device offering gene-modified cell therapy, a non-invasive device to test urine for the presence of bladder cancer cells, a micro needle for an in-home blood-testing platform and a microfluidic chip for high-value mineral extraction.

Associate Professor Craig Priest is the Director of the South Australian node. He says the success of the facility in recent years has coincided with the maturation of the microfluidics industry. According to Priest, the node is playing an important role in advancing research to higher Technology Readiness Levels (TRLs) through the development of working prototypes that help researchers engage industry in serious commercial discussions.

“I see us as a de-risking site for industry product development and on the flipside we can help fundamental research travel further along the TRL scale to create a device that can then be taken to an industry partner,” says Priest. “We’re certainly not just microfluidics; we’re everything to do with interfaces and structures and materials on those surfaces, often controlling fluids, but it could be other things such as energy or biomedical devices.

“That’s the beauty of these sorts of facilities, you have a cluster of tools that work together and expertise with them but if we get a researcher who makes a new type of satellite that needs a micro-electro mechanical system in it and they want to do it here then that’s fine with us.”

More than $12m worth of state-of-the-art equipment is split between the Mawson Lakes campus of the University of South Australia and Flinders University. ANFFSA engages with industry and end-users through three models:

AMT DEC/JAN 2019

Node director Associate Professor Craig Priest.

• Partnership Model – Leading advanced manufacturing companies partner with ANFF-SA to enable knowledge-transfer and world-best practice in both academia and industry; • Consultancy Model – Industry directly request preparation and characterisation of unusual samples and devices for their business needs; • Research Model – Infrastructure access for academic researchers who conduct their research for an industry partner.

“A lot of our industry-linked work is through researchers because we are well connected with the research community, but increasingly we are getting industry coming to us directly – we have built a pretty professional outfit here,” says Priest. “We’re in a unique position to have state-of-the-art equipment in purpose-built laboratories so our users can expect a sophisticated device.

“We’re experiencing success, and more work with industry will allow us to grow further and truly help transform the economy.”

The facilities Micro-milling: One of ANFF-SA’s most in-demand pieces of machinery is its Kira SuperMill 2M, which is the only machine of its kind in the Southern Hemisphere. The Japanese micro-milling machine offers industry and researchers outstanding nextgeneration high-speed precision machining capabilities for true, simultaneous threedimensional interpretation of microstructures.

Designed specifically for single-part and small-series production milling, ranging from tool steels to Teflon and polymers, the Kira SuperMill 2M system has a positional accuracy of 0.01 microns (or 10 nanometres) with double spindles, a 50,000rpm electric spindle and a 160,000rpm air spindle which allows users to run tools down to 5 microns in diameter. The cutting-edge technology delivers one-stop-shop capabilities for the fabrication of micro-scale devices with features ranging from centimetres to microns.

Mark Cherrill is a microfabrication specialist at ANFF-SA. One of his latest projects involves a tiny titanium component, measuring 700 by 800 microns with ten miniscule 30-micron holes from different angles for the defence industry. Spares were made because the parts were smaller than a grain of sand and Cherrill was concerned they could be easily lost as they could hardly be seen with the naked eye. However, when viewed under a microscope, the precision and quality of the work is obvious.

“They 3D printed it as well and the 3D printed part couldn’t be compared to ours,” Cherrill says. “We’ve got about a 12-week backlog of work at the moment and it runs for about nine hours a day. We’ve done a lot of Lean work with it and projects with industry – there’s such high demand. When projects come along it gives us the chance to push the boundaries by accepting the challenge of making something that can’t be made anywhere else.“

NANOTECHNOLOGY

Imaging and surface characterisation: Evaluating the inner workings of such tiny components without destroying them can be a tricky business. Therefore, characterisation and imaging is a key phase of most fabrication processes as a test point in the development cycle.

ANFF-SA provides access to a broad range of instruments capable of achieving ultra-high resolution images, topographical imaging, imaging of both fixed and live cells, measurements of surface vibrations, surface steps and fluorescent imaging.

These include the MicroXCT-400 – a 3D X-ray imaging solution optimised for nondestructive imaging of complex internal structures. The microtomography machine has the unique ability to reveal the internal structure with full 3D imaging of features down to <1.0 micron resolution, making it a compelling alternative for research and the inspection and control of manufacturing processes.

Micro injection moulding: ANFF-SA has recently acquired a Juken JMW-027S20t hybrid driven vertical-type moulding machine, enabling it to deliver high-accuracy plastic components for researchers, research prototyping and industry trials. Compatible with various types of thermoplastic and specialising in polymethyl methacrylate (PMMA) and cyclic olefin copolymer (COC), the JMW HDD-system was designed to increase productivity with an innovative mechanical driving system offering precision control and faster response in high-pressure environments.

Etching: The node’s Ulvac NLD-570 deep reactive ion etcher is capable of deep etching features from the nano to the micron scale and is specifically designed for research and prototyping environments. The NLD system consists of a process chamber with three electromagnetic coils and the RF antenna is concentrically located with the middle coil.

The plasma intensity is confined to the plane of the middle coil and the diameter of the plasma is proportional to the electromagnet

current. This enables the etching process to provide an extremely high uniformity and the etching capabilities are specifically tuned for glass, quartz and pyrex. This makes the process suitable for use in microfluidics, labon-chip, microlens, and so on.

Lithography: Micro-nano lithography is necessary for the creation of the nanoscale components featured in nearly all modern technologies. Lithography is the process by which a pattern is written or transferred to a substrate. The process can be physical in nature, utilising a ‘stamp’ to press structures into a softer material, or chemical using light, ions or electron energy to write into photo- and electron-sensitive materials. ANFF-SA offers several different lithographic techniques and instruments including photolithography, hot embossing, nano-imprint lithography and PDMS soft lithography.

Microfluidics simulation: Computer simulation is helping to shorten the design cycle, increase productivity and deliver new products to market faster. Dr Moein Kashani, ANFF-SA’s Fluidics Simulation Engineer, uses Computation Fluid Dynamics to accurately predict the complex behaviour of fluids within the channels of a micro-sized device. Kashani is delivering deep insights to help solve complex fluid problems that can maximise a product’s performance and efficiency. In some cases, experiments simply can’t answer the complex questions being asked, making simulations essential.

The people The number of technicians at ANFF-SA has doubled in the past four years. It is not just the growth but the quality of the recruits that is impressive. Cherrill’s success with the cutting edge micro-milling machine is no coincidence. Before joining ANFF-SA, Cherrill worked in Formula 1 as a CNC Machinist/ Programmer for the Honda Racing Team, for Brawn GP where he completed a BSc in Engineering Design, and the Mercedes AMG Petronas team in R&D.

Senior Process Engineer Dr Donghoon Chang has an equally impressive resume.

Prior to his PhD study in fracture mechanics at the University of Adelaide, Dr Chang worked for Samsung Electronics for 12 years as a patent engineer in the field of microelectromechanical systems (MEMS).

His work at Samsung also included microfabrication of optoelectronic devices, such as vertical cavity laser diodes, PIN photodiodes and micromachining of silicon optical benches.

Since 2014, ANFF-SA has run a week-long Winter School for the state’s most promising microengineering graduates and to date more than 250 students have gone through the Mawson Lakes program. According to Priest, the Winter School ensured the next generation of microengineers entered the workforce knowing about ANFF-SA’s capabilities and its potential value as an industry resource going forward. He says the node had been very strategic about how it engaged with people.

“Over the last five years we’ve seen a commitment to professional service and the recruitment of some genuine technical experts,” says Priest. “We already had the equipment so it’s the people, service and the partnerships that we’ve built with people around the world that has set us apart.

“I see us as producing engineers who will participate in the new economy. We need to get as many people aware of this capability in industry and academia so that when the graduate goes out, gets a job and finds a problem they know that we’re here to help.” www.anff-sa.com

AMT DEC/JAN 2019

087

088

NANOTECHNOLOGY

Why nanotechnology is more than just a buzzword What does the word ‘nanotechnology’ conjure up for you? Upulie Divisekera separates the facts from the science fiction.

I’ve spent the best part of a week talking about the term ‘nanotechnology’ and whether it’s a real field, a real term or not. In its simplest sense, nanotechnology means working with materials at the scale of one billionth of a metre. The prefix ‘nano’ refers to one billionth: it’s part of the scientific scale of measurement. I use the term nanotechnology as a convenient catch-all term to describe my field of research. My research is into making nanoparticles that can be used as tiny capsules to deliver drugs to cells. I work with proteins and a range of gold nanoparticles to try and achieve this goal.

nanoscale – that is, at the nanometre, or the billionth-of-a-metre level. Because of the size of the materials and particles at this level, the quantum effects become more pronounced at the nanoscale, and can be used to generate entirely new, thinner materials.

Selling nanotechnology

Nanotechnology uses these properties to make new materials and devices — anything from soft electronics, plasmonic superlattices (ultrathin nanomaterials that interact with light), gold, silver and polymer nanoparticles, nanowires, and so on.

Like many scientific and academic terms, nanotechnology (also known as ‘nano’) is an overused, overhyped term in the mass media. Cosmetic companies advertise products with ‘nanotechnology’ – perhaps hoping to convey that tiny robots are repairing your skin. However, these products are more likely to just include liposomes – tiny, double-layered bubbles of lipid. They are nanoparticles, not quite the nano robots we would envision from science fiction.

The Tata Nano car in India, and Apple’s iPod Nano music player also use the prefix ‘nano’. It’s become a convenient prefix, in the same way that ‘micro’ and ‘smart’ are overused and effectively meaningless marketing terms.

To complicate things further, nanotech and nanoscience are now popularly synonymous with “miniature robots that will turn the world into grey goo” or miniscule invisible threats to our health and environment.

It is true there is some concern around the potential environmental effects of improperly disposed nanomaterials. The toxicology of nanomaterials and regulatory issues around their use and disposal is an ongoing discussion. But it is frustrating as a science communicator and scientist to see the term ‘nano’ used in some of these ways – not for a lack of humour but because of the amount of effort required to counter these misconceptions is often disproportionate to the ease with which they are misused.

Does ‘nano’ mean nothing?

So does the term nanotechnology apply to everything, and therefore mean nothing?

While nano is a buzzword in advertising and media, there is a more specific understanding of what it entails in science — or rather, engineering.

Nanotechnology is a wide field that covers research and inventions that make use of the quantum effects that happen at the

AMT DEC/JAN 2019

The term ‘quantum effects’ here refers to the properties of the material that shape melting point, fluorescence, electrical conductivity and chemical reactivity. For example, at the nanoscale, there are novel optical properties – that is, reactions between light and the material – that can be used for applications such as nanobarcoding.

In truth, biomolecules and viruses are the original, all-natural nanotech. Biomolecules such as DNA may store the genetic code of life, but the structure of DNA can be used to generate nanowires, and DNA can be used as a bridge between particles to connect them together. Proteins can be used as scaffolds to make metallic structures known as metallo-organic frameworks that can be used as filters or for delivering therapies, to name just two applications.

We can also make materials from inorganic materials like gold and silver – there are now pens available that allow you to draw nanowire circuits. Sunscreen has nanoparticles, and silver nanoparticles are used as anti-bacterial agents in many everyday items. Lithium batteries use nanotech for better storage: in fact, nanotech is critical for improving battery performance and capacity.

And nanotech is useful in miniaturising devices and improving their performance.

We now have hand-held DNA sequencers that can be used in the field. We no longer have to send samples back to the lab and wait for the results – we can sequence DNA on site, thanks to the intelligent use of proteins in miniaturised devices. Most nanotech research is interdisciplinary (combining different areas of expertise), or even transdisciplinary (operating across many fields of science). It requires that you delve into chemistry (inorganic and organic), electronics, analytical chemistry, surface chemistry, protein chemistry and structure, nucleic acid chemistry (both DNA and RNA), lipids (fats), and many more techniques.

So, it’s often easier to use the catch-all term ‘nanotechnology’ when describing this

Like many scientific and academic terms, nanotechnology (also known as “nano”) is an overused, overhyped term... While nano is a buzzword in advertising and media, there is a more specific understanding of what it entails in science — or rather, engineering. kind of research involving many disciplines.

We use nanoscale properties of materials, creativity and inventiveness to create new tech, new materials, new structures, and perhaps in the future, new ways of being.

Think of it this way: if you want to shrink devices, you make the components of these devices smaller. Nanotechnology just uses nanometre-size components to build these devices, using the quantum effects prominent at this scale. Nanotechnology pulls together all of these features for useful applications.

Nano isn’t all ‘BS’ At the coal face, research is mostly intriguing ideas that require tedious optimisation; trying to manufacture tiny items from a bottom-up process (that is, building at the nanoscale) rather than top-down (refining existing materials). In nanotechnology, we don’t have to break large materials up into tiny pieces, we try to generate them from the bottom up using chemistry. This sort of work can be boring, but when it works for that first time, it’s like magic.

So nanotech can, sometimes, like Elon Musk implied, be a ‘BS’ catch-all term.

But it’s also a field many scientists and engineers work in every day, and that many universities acknowledge. It’s a growing, burgeoning field full of exciting and intelligent new inventions. In many ways, it’s a truly serious attempt to cross both organic and inorganic together into devices that mimic the exquisite refinements of nature. It’s difficult – and exhilarating.

Upulie Divisekera is a PhD candidate at Monash University. This article was originally published by The Conversation. www.theconversation.com www.monash.edu

FORMING & FABRICATION

DJN Switchboards expands in-house manufacturing with Yawei pressbrake, fibre laser Good news stories from the manufacturing sector are always welcome but even more so when it relates to a regional area that has suffered with high unemployment in recent years. Traralgon-based DJN Switchboards is one such case.

Founded in 1994 by David Nabulsi and his wife, this specialist manufacturer of switchboards and switchrooms took advantage of the latest in pressbrake and fibre laser technology to boost its capabilities and efficiencies in this area. Nabulsi, an industrial electrician by trade, initially established DJN Electrical as an electrical contractor primarily specialising in industrial controls and industrial electrical work. In 2000 he spotted an opportunity to start making switchboards, and built a specialised workshop for switchboard manufacturing from which DJN Switchboards was born.

These used enclosures that were premanufactured by external companies. Early in 2017, Nabulsi decided to establish his own sheet metal department to enable him to produce the cabinets and assemblies inhouse. “We wanted to build our enclosures in the most modern way possible,” says Nabulsi. “I bought a CAD designer on board to design our own cabinetry, and looked at what CNC pressbrake and laser cutter we would buy. We ended up selecting the Yawei brand, not only because it was an excellent product that offered great value for money, but for the experience and support that Applied Machinery could offer.”

Applied Machinery recently celebrated 25 years in business and, in addition to Yawei, represents a range of other premium machinery manufacturers including Genox, Hurco, Kitamura, Chen Hsong, Alfarobot, Hermle, Akyapak, Hyundai-WIA, Weber and Polystar.

“The service aspect is something that is absolutely crucial to me,” Nabulsi adds.

“And the service we received from Applied Machinery during the pre- and post-sales process and the ongoing backup and support that we’ve had has been excellent.”

The combination of Yawei’s seven-axis 160-ton pressbrake and its HLE fibre laser has also allowed DJN Switchboards to build entire switchrooms in addition to switchboards. Using the CAD software, a design is set and the necessary files produced. The Yawei fibre laser and pressbrake then work in tandem - cutting and then bending to produce the required product.

The fabrication team at DJN Switchboards with the new Yawei CNC pressbrake and laser cutter.

“Because we’re custom-building, the accuracy and quality of the cut is very important,” Nabulsi explains. “Our primary markets evolve from quarry and mining applications, so the majority of our work is based on using 2mm stainless steel to a 2B finish. The Yawei fibre laser excels in this area, enabling us to produce cabinets of the highest quality.”

“The purchase of the Yawei equipment has also allowed us to tender on larger jobs, confident that we have the in-house capability to do this work.”

The other benefit with the Yawei fibre laser is that it uses the latest cutting technology.

The HLE allows for the option of using compressed air rather than expensive assist gases like nitrogen and oxygen – ultimately saving a business significant money.

In addition to switchboards and switchrooms, the other major part of DJN’s business is automation and control engineering. The company builds the computerised control systems for industrial plants, quarries and mining applications and now employs a total of 15 staff. The company is also looking at investing in new innovative solar technology including off-grid battery storage systems.

“Essentially we have brought the latest high-tech manufacturing technology and efficiencies to regional Victoria, allowing us to compete and stay ahead of the game,” says Nabulsi. “That’s something I’m really proud of.” www.djnelectrical.com.au www.appliedmachinery.com.au

3D Printing High Strength Composite Carbon Fibre

“Markforged Print Amazing High Strength Parts” =Continuous Carbon Fibre

Reinforcement With The Strength of Metal

=Micro-Carbon Fibre With Twice the Strength of Plastics Tools, Jigs & Fixtures

End Use Products

Prototypes

Call us now on

1800 632 953 and discuss how you can print high strength parts instead of milling

EMONA

www.emona.com.au

AMT DEC/JAN 2019

089

090

FORMING & FABRICATION

Welding reactive metals Aerospace, automotive, medical and military industries are increasingly using reactive metals, as they are durable and bio-compatible, with low density and high corrosion resistance. However, they are expensive. Welding procedures need to be carefully developed and stringently applied to avoid expensive waste, rework or risk of service failure.

The reactive metals by classification are zirconium, titanium and beryllium; in addition, tantalum and columbium (niobium) are from the refractory class and present similar challenges to the welding engineer. Successful fusion joining techniques have evolved since the alloys were first used in engineering applications. The majority of metallurgical problems, even considering dissimilar metal welding, have been resolved and filler materials are readily available.

However, their reactive nature makes it essential to address the need for thorough pre-cleaning and particularly oxidation at the high temperatures involved in arc welding.

Cleanliness Weld repair of plant that has been in service presents the most difficult situation for welding reactive and refractory alloys. The equipment is usually dirty and may have process scale on the surface. In most cases, repairs must be done outdoors where conditions are not optimal. The work area is usually dirty and humidity and wind also interfere with the welding process. Furthermore, plant shutdowns that require equipment repair usually result in pressure to complete work quickly. There is little merit in cutting corners. Repairs that must be made to partial-penetration welds or where crevices exist pose a special problem because of contaminants. Poorly prepared surfaces can result in weld contamination, leading to premature failure and repeated repairs. Overall, in work undertaken on-site, more time is spent preparing to weld than actually welding. Even under the cleaner conditions in most factory environments, surfaces must still need to be prepared by removing all contamination prior to welding. Information on cleaning techniques is available but the basic principles are to abrade surfaces to remove corrosion products and other debris, degrease, and finally dry. Prepared surfaces should then be protected by covering until joints are to be made.

Protection against oxidation Reactive metals have a strong affinity for oxygen at temperatures prevailing in fusion welding and when combined form very stable compounds. Refractory metals exhibit many of the same characteristics. Discolouration may be acceptable and may be removed mechanically after welding, but oxygen contamination also affects mechanical properties. Tensile strength is often increased but with a loss of ductility. There can also be a dramatic reduction in corrosion resistance. Since the primary uses of these alloys are in applications where strength and corrosion resistance are mandatory, oxidation is clearly unacceptable. Protection is thus essential, achieved by surrounding the joint with an inert gas such as argon or helium. However, the gas shield associated with a standard GTAW torch is inadequate, offering insufficient cover. Specialised purging equipment has evolved over the past 25 years.

Trailing shields The extra coverage provided by trailing shields protects the fusion zone and provides inert gas protection to all the hot adjacent metal.

Custom-made trailing shields are available commercially, but these are inevitably expensive and have limited use. The shields manufactured under the Argweld name have in-built flexibility. For curved shapes like pipes, tubes and cylindrical vessels, trailing shields are available to suit a specific diameter. They can be configured for either internal or external welding, with versions for mechanised welding. Flat trailing shields for plate, sheet and rectangular tanks are available in small lightweight versions for manual welders or, like the radiused versions, larger, more robust, versions for attaching to automatic/mechanised

AMT DEC/JAN 2019

welding systems. Argweld Trailing Shields have been designed specifically for use with GTAW (TIG) or PAW (plasma) welding torches and provide high levels of additional inert gas shielding to supplement that supplied by the basic torch.

Pipe and tube purging Systems for weld root protection are based on sealing the inside of a pipe on either side of the weld zone, then displacing air with an inert gas. Seals must be reliable, leak-tight, effective and easy to insert and remove. The inert gas must be of a quality commensurate with the need to protect the molten metal. Gas flow should be laminar to maintain high protection, and pressure-controlled to offer adequate coverage without expelling molten metal.

Primitive early systems, mostly home-made and individually fashioned at great expense, utilised paper, card, wood and polystyrene discs.

Often these provided poor sealing and on occasions burst into flames – satisfactory removal after welding presented challenges.

Ensuring that all oxygen had been removed during purging was down to the operator’s skill and experience. There were regular incidents where protection proved inadequate and the joint had to be remade. Surprisingly, these practices are still used, even by globally prominent fabrication companies. Argweld systems have been developed to speed up pipe welding, using a design that allows easy, positive insertion into position and by limiting the purge volume.

The product range, which includes QuickPurge and PurgElite, has been successfully used internationally during welding of reactive and refractory alloys for the nuclear, LNG, aerospace and process industries.

Flexible enclosures The highest level of protection is afforded by welding in a vacuum, as in for example the electron beam process. A less effective process uses a ‘glove box’ metal enclosure, which can be filled with inert gas. Both techniques are relatively expensive to manufacture and only justified by companies involved in high-volume production where the cost can be easily amortised. Ultraviolet-stabilised engineering polymers are used throughout manufacture of Flexible Enclosures. Material thickness is nominally 480 microns. A large principle-access leaktight zip is fitted. Additional entry points provide for operator gloves, access ports for welding torches, electrical supplies and cooling water, while purge gas entry and exhaust ports are incorporated into each enclosure.

Residual oxygen measurement instruments Any effective weld purge process must be supported by suitable oxygen-detecting equipment. Weld Purge Monitors have now been developed to meet the need for reliable, robust, sensitive measurement. For reactive and refractory alloy welding, these must be capable of measuring oxygen levels down to 10 parts per minute (ppm). The PurgEye 300 Plus instrument manufactured by Huntingdon Fusion Techniques HFT reads down to 10ppm with extreme accuracy, with a display range from 1,000ppm to 10ppm.

Mains driven, the instrument has integral switching software to control external devices like power supplies or alarms and software to give QC analysis when connected to a PC. The entire Argweld range is supported by an extensive library of publications including technical notes, white papers, conference proceedings and peerreviewed international articles, and are available online by application to Huntingdon Fusion Techniques HFT. www.huntingdonfusion.com

FORMING & FABRICATION

Technology helps Norris provide unique solutions Since 1954, Norris Industries has been manufacturing a vast range of commercial glass and dishwashers.

Australian-owned and operated, founder Vince Norris designed and produced the first Australian commercial glass washer in his backyard shed.

091

Full range of lasers, systems and automation for OEM’s and end users

Damien Berry, R&D Manager, says that while Norris fell behind its competitors for a short period of time, it’s now overtaken them from a technology point of view: “We’ve overtaken in technology; we’re techier than everyone else in our industry. For a while, we lacked development and innovation, but moving forward, we’ve spent time developing the business and we’re using 21st-century technology to produce products people want. For example, our newest range focuses on power management – our AP500 is 50% more efficient on power than its predecessor, which is what everyone’s interested in.”

Norris’ process is to make sure that it fully understands customer needs and issues, such as difficult water conditions or power restrictions.

“While our products aren’t tailor-made, we try to understand difficult customer needs and incorporate solutions, rather than produce a one-size-fits-all bulk product range like our overseas competitors,” Berry explains. “We can’t compete with price, but our development sets us away from this as we place more importance on the problems we’re trying to solve.”

Having recently purchased a TruPunch 5000R, a TruBend 5130 with Bendmaster, and a SOCO pipe bender from Headland Machinery and a Hanel Lean lift, the team at Norris have seen a huge increase in accuracy and efficiency.

“The turret punch improves quality of flat pieces of steel and works fast, the TruBend improves accuracy and folding to reduce scrap,” says Berry. “The Bendmaster handles awkward, heavy parts that require two people to fold, and the SOCO enables us to bend all tubes in-house, rather than us having to buy from an external source.”

Berry says efficiency has drastically improved, as more processes are now automated and faster, meaning a great deal of work can be carried out in a short amount of time. The company has also seen a huge increase in productivity and versatility in recent years; the combination of machinery means that several jobs can be carried out at the same time at high speed.

“We have a longstanding relationship with Headland as they supply all machinery we buy,” says Berry. “Their sales team are knowledgeable and answer any questions we have, while the service team are prompt and reliable. I often recommend Headland and Trumpf machinery to my own contacts.”

With increased demand in Australia, Norris is continually finding that customers are no longer as interested in buying cheap products from overseas as they were a few years ago, because these products are more likely to break down. It’s becoming increasingly common that customers prefer to spend more money on reliable, Australianmade products. www.headland.com.au www.norris.com.au

4kW IPG Fiber laser – twin 3m x 1.5m table

$390,000+GST

BEST PRODUCT RANGE BEST PERFORMANCE BEST PRICES BEST SERVICE BEST SOLUTIONS

20 years of trusted industry experience

EXCLUSIVE AUSTRALIAN AGENT

Agents for: IPG, Precitec, Cincinnati, Sisma, Bodor, Ophir

For more information, contact Industrial Laser on +61 (0)3 9796 3055 Cutting • Welding • Marking • Cladding Laser Metal Fusion • 3D • Scientific • Military Laser spares & consumables

www.industriallaser.com.au

AMTDECJAN19

Factory 8, 17 Keppel Drive, Hallam VIC 3803 AUSTRALIA T: (03) 9796 3055 • E: sales@industriallaser.com.au

AMT DEC/JAN 2019 IL HP Ad AMT DecJan19.indd 1

21/11/18 6:25 pm

092

FORMING & FABRICATION

It IS rocket science: A workcell for forming aircraft components US-based press manufacturer Beckwood Corporation was challenged to build a sophisticated system that could form aircraft parts with complex geometries in a low-volume, high-mix production environment, using a fully automated diehandling system and the largest staging table of its kind in the world for continuous production. The result? Die change time reduced from two hours to ten minutes.

Based in Fenton, Missouri, Beckwood manufactures custom hydraulic presses, automation systems and the Triform line of precision forming equipment. The company excels at developing sophisticated, robust aerospace forming technologies that are engineered for accuracy and repeatability.

The QDC operates in tandem with the two presses, using four 15hp motors to drive the lead screws on this massive die handling system. They are electrically geared through an onboard S7-1515 PLC to move the ram and shuttle. Additional motors and drives on the feed tables allow the next die to be positioned during press operation.

Recently, a fabricator that produces components for commercial and military aircraft came to Beckwood for a turnkey package consisting of two 1,400-ton (1,270-tonne) hydraulic presses and two automated stamping die-handling systems to load and unload the presses more efficiently than the conventional forklift and manual labor that was being used. The presses and quick die change (QDC) workcells would form a variety of parts in relatively low volumes, so the system needed automated die handling and a 42 inch (107cm) diameter deep draw sheet hydroforming press with a staging table – the largest of its kind in the world.

When a press cycle is completed, the air bags on the feed tables lift the next die for positioning onto the QDC, then a shuttle inserts the die inside the press, with all motion controlled by the PLC. These T-tables and the QDC were designed, engineered, built and tested in the Beckwood factory prior to shipment and installation at the fabricator’s facility, where personnel from both Beckwood and Siemens were active in the commissioning of the entire system.

A critical part of this project involved the need for a QDC system with 15,000lb (6,804 kg) capacity to feed each hydraulic press.

“We conducted a thorough review with all of our local die cart suppliers and they all passed on the bid, citing too many obstacles on that large a load,” explained John Harte, the lead Electrical Engineer at Beckwood. “So we decided to design, engineer and build the system ourselves.” Each press has a footprint approximately 30 feet (9m) square, and the QDC would need to service the presses with T-table staging devices that allow the next die to be prepped and ready to insert upon completion of the previous run cycle. With the degree of automation involved, Beckwood worked with the fabricator’s engineering staff to devise a workcell concept comprised of two fourpost presses, each with a QDC system including a cart, rack and T-table with 15,000lb (6,804 kg) load capacity. Each press would be over 33 feet (10m) tall and positioned in a 10 feet (3m) deep pit.

Motion control and HMI from Siemens Digital Factory was specified by the fabricator for this project, so Harte connected with Derek Eastep, an Account Manager for Siemens, and the equipment list for the project began to take shape with various drives, PLCs, displays and motion controllers. Motion control was a critical component required to operate all press movements, as well as the motor starters, QDC integration, light curtains that protect the workcell and operators, plus area scanners that maintain the integrated safety condition monitoring on the entire cell. The system logic and data logging setup was done by the fabricator, who already had experience with Siemens controls, with the Beckwood team integrating the QDC and overall cell management.

AMT DEC/JAN 2019

The S7-1515 PLC is a robust controller that integrates function control, safety and condition display in a single module with Profinet protocol for bus communication. Through the TIA Portal and Step 7 software, the end user can customise the operation of the devices remotely, integrating multiple part files and related safety commands in one controller. This “library” feature allows the end user, as they run a variety of parts during a shift, for example, to use one software package to program quickly and more efficiently.

Likewise, the safety switches on the entire system are programmed through this secure and redundant safety back-up software through the TIA Portal. All motor movements on the twin four-post presses are controlled with Siemens drive technology. In operation, the presses with the QDC systems should reduce die setup and changeover from approximately two hours to ten minutes.

“All parties had good familiarity with our protocols,” noted Eastep.

The two presses in the workcells are robust four-post frame styles with replaceable, graphite-impregnated bronze bushings and solid chrome-plated posts to ensure precision ram guidance. The Triform deep draw sheet hydroforming press is designed to form parts with challenging geometries in low-volume, high-mix production environments.

“We used the Selector, Sizer and Starter engineering tools from Siemens to spec and then commission the drives, which saved us a substantial amount of time,” added Harte. “It made our lives a lot easier.”

Reprinted courtesy of Fabricating & Metalworking magazine. www.fabricatingandmetalworking.com www.beckwoodpress.com www.siemens.com

MATERIAL REMOVAL

Hydrafeed barfeeder boosts efficiency, productivity at Campagno Campagno Engineering, a family-owned company based in Dandenong was established in 1979 by Jorge Campagno, specialising in CNC milling and turning, and the design and manufacture of special-purpose tools.

From a one-person operation with floor space of 75sqm, the company has grown to now employ 26 highly skilled tradespeople and support staff in a purpose-built factory of more than 900sqm.

Jorge, his wife Amanda and their family have invested in the latest machine technology to ensure Campagno stays at the cutting edge of engineering and maintain an ethos of fast, efficient service and prompt on-time delivery. The company specialises in product categories that include packaging, medical, truck, defence and general engineering. Prototyping is another area; the company’s extensive experience has often enabled it to suggest better, more efficient ways to manufacture new parts.

Jorge was keen to acquire a barfeeder to complement a new CNC machine to assist in producing parts more efficiently. The increased productivity the barfeeder would bring was the key reason for the purchase. “We looked at a number of different brands but it was the sheer quality and rugged construction of the servo-driven Hydrafeed that won us over,” says Jorge.

The Hydrafeed barfeeder allows a CNC machine to run unattended and is a very user-friendly unit with an additional productivity benefit over other barfeeders on the market.

“Once you’ve set a bar size and saved the setup, you are not required to open the cover again,” explains Jorge. You simply call

up the program from the touchscreen and the Hydrafeed will set itself on centreline automatically thanks to the servo drive bar lifter mechanism.”

Standard features of the Hydrafeed include a fully automated set-up through a user-friendly HMI screen and the versatility to accommodate different bar diameters and lengths, including random lengths. A wide variety of models are available to suit any application.

“The Hydrafeed is very easy to use, so it doesn’t take long for staff members to become proficient at operating it,” adds Jorge. “Price of course was also important in our purchase decision, but it’s the support and service from the supplier which I believe is crucial, as it can become very expensive in time wasted. I’ve been dealing with Dimac for 30 years and it’s their knowledge, quality products and after-sales support that was another key reason for opting for the Hydrafeed.

“Just like other products we’ve purchased from Dimac our purchase experience with the Hydrafeed was excellent, from the first inquiry to the delivery, installation and end training,” Jorge adds. “The Hydrafeed has added a large dose of productivity and I would certainly recommend it without hesitation to any company.” www.dimac.com.au www.campagno.com.au

Dynamic. efficient. reliable.

LinX® - Ideal for packaging and machinery applications • • • • • • •

Integrated position feedback Works with your existing servo drives Modular design for the ease of integration Pneumatics retrofit friendly Low maintenance Highly dynamic with velocity up to 10m/s Peak force up to 1,200N

ANCA Motion LinX® M-Series Tubular Linear Motor www.ancamotion.com/motors Facebook.com/ANCAMotion LinkedIn.com/ANCAMotion YouTube.com/ANCAMotion

AMT DEC/JAN 2019

093

094

MATERIAL REMOVAL

Elmass Australia marks 20th birthday This year sees Elmass (Australia) celebrating 20 years in business, but the company, based in Brendale, Queensland, had an unusual start. The idea to commence a specialised contract broaching service was first hatched at Queensland University of Technology (QUT)’s Graduate School of Business.

Elmass founder Martin Forrer had to write a business plan for his final MBA capstone unit. He needed to find a market niche and formulate a business strategy, defining the resources, the nature of the business, as well as financial and organisational matters.

Having studied engineering in Germany, it goes without saying the business plan was written for a company that matched Martin’s technical background.

Martin understood that to be successful, a balance had to be found between financial, competitive and human resources aspects of the business. Research had shown that a contract broaching service could be successful if the elmass technology, a highly efficient broaching process hardly known in Australia, was used. After graduating, Forrer took the business plan to local banks, but s the concept was ahead of its time, no bank was prepared to finance the start up.

Determined to establish his contract broaching service, Martin contacted Elmass Schaffhausen, a leading Swiss manufacturer of broaching machines, and sent them the plan. The Swiss company agreed to a substantial investment in Queensland to introduce its technology in Australia and to expand its worldwide market. And so on 10 September 1998, Elmass (Australia) was founded as a joint venture, with Martin as local partner to Elmass Schaffhausen. Martin was invited to Elmass Switzerland for training on the products and their extensive maintenance procedures, and to learn about the new AFX machine series.

Back in Australia, implementation commenced of the structures and procedures to meet ISO 9002 quality standards. Equipped with only a few hand tools and a small mill/drill, Martin started a manual contract broaching service in Brendale. The initial phase was used to introduce the technology to potential clients and to quickly build a customer base. Three months later the first NCcontrolled broaching machine, the P4500 AFX, was delivered to the workshop at Kenworth Place. It was the first Elmass machine installed in Australia and only the ninth machine of its type worldwide.

Elmass initially targeted the low to medium volume market for internal keyways only.

This allowed Martin to introduce the technology to local engineering companies and demonstrate its superiority. The

AMT DEC/JAN 2019

company enjoyed the full backup from Switzerland, with head office providing custom-made tools and other services quickly to meet evergrowing local demand.

Soon Elmass was asked to make its first splines. A dividing table and suitable tools were organised and the company started to broach splines, hexagons, grease grooves and many customer-specific shapes. Demand for splines and hexagons was growing very fast, so Elmass invested in CAD programs and started to design and manufacture special tools locally. This eliminated the usual two-to-four-week delivery time and enabled the company to be ready for production in less than 48 hours, if the tools were not already on hand.

In 2002, Walter Bührer, Elmass Schaffhausen CEO and inventor of the elmass system, retired and sold the company. The worldwide manufacturing rights, patents and brandname were purchased by Verlie Group, a mediumsized, family-owned manufacturer of special-purpose machines, for which broaching was a welcome diversification.

A new head office, Elmass Production, was created in Halle, Belgium, while Martin was offered a management buy-out for the Australian business.

Local demand for Elmass’ services grew continuously, causing some production issues, so the company relocated to its current address in Moonbi Street, Brendale. With just one machine to meet all the deadlines, Martin’s wife Vreni and daughters Sandy and Denise came onboard for a flexible afternoon shift producing keyways and splines. A Jones and Shipman surface grinder was installed

to resharpen the cutters or to grind them to customer requirements. In 2005 capacity doubled with the acquisition of a second broaching machine. The P20-250NC machine was smaller, but still capable of broaching about 80% of the parts usually machined. However, it could also be upgraded with a third axis to broach splines automatically.

In March 2006 Elmass employed its first school-based apprentice. Sean learned quickly, was reliable and could soon work unsupervised to a high standard. When Sandy and Denise had to leave later that year, Sean was employed full-time.

To continue to grow and to apply best practices, Elmass participated in a Micro Business Review (MBR) delivered by QMI Solutions and the Queensland Government on behalf of the Probe Partnership. The MBR saw the company graded a ‘WorldClass Rated Business’ – well above overall and industry sector averages. It also provided Elmass with valuable information on how to improve and grow. In response the company worked out a 12-month action plan that has shown good results.

Elmass further automated processes and reduced overheads, with the efficiency gains passed on to the customers, avoiding any need for a price increase. To be even more efficient, Elmass also ordered a NCcontrolled turntable for the P20-250.

In early 2008 Sean left to continue an apprenticeship as a fitter and turner.

Soon after, Jesse commenced a two-year apprenticeship. Like Sean before him, he also learned fast, even running the workshop on his own for four weeks while Martin was in hospital.

MATERIAL REMOVAL

To mark its ten-year anniversary, Elmass customers nominated the company for the Business Achiever Award 2008, in the category “Made in Pine Rivers” – an award Elmass went on to win against several wellknown companies.

Managing changing conditions In 2009 Elmass received a large order to broach 66,000 parts with indexed keyways.

Amid this unprecedented demand, Elmass was hit with a temporary staff shortage.

However, assistance came from longtime customer G&O Kert, whose third-year apprentice Ryan Beck came on board to help out. With Ryan’s assistance Elmass managed to clear their backlog and were able to deliver the keyways on time. In exchange Ryan was trained in all aspects of broaching, helping him complete the Unit of Competency in Broaching.

In late 2010 an order to broach 800,000 indexed keyways within 18 months was received. Elmass was able to bring Sean back and he was trained to be their leading hand. The large volume also demanded two new three-axis broaching machines.

Martin went to the factory in Belgium to discuss suitable machines that could expand the business’s capabilities after the contract was completed. To stay ahead of competitors the decision was made to purchase a P36-700 NC, one of the largest three-axis broaching machines ever delivered to Australia.

Shortly after his return, an accident meant Martin couldn’t work for four months. Sean stepped in and managed the company as if it was his own. He expanded the workforce with two new apprentices to manage the increased workload. Both apprentices were trained on the P20, which was very similar to the new machines, meaning they were ready to operate them once they arrived.

Lots of planning and preparation was required before the new machines arrived.

The workshop had to be reorganised to make room, with electrical wiring upgraded to pull twice as much current.

Storage facilities had to be increased to hold sufficient parts for about two weeks of mass production, with loading stations built for both new machines to optimise floor usage and production.

The first machine, a slightly modified P10250 NC, can reach speeds of up to 30m/ min, and is designed to broach keyways or splines up to 10mm wide and 200mm long. The P36-700 NC featured several significant modifications, including a rotating platform that carried four stacks of parts, a second NC-controlled broaching head, and hardware and software modifications that allow the cutters and toolbars to be cleaned after every cycle. A frequency inverter was added to the hydraulic pump, increasing the speed of the return stroke and cutting dead time by about 20%.

Sean was given the opportunity to commission the second machine in the Elmass factory in Belgium. He was given detailed machine specifications and instructed to test every function, verifying that the machine could meet the defined hourly production rate under actual production conditions. For these tests, 1,800 parts were shipped to the Belgium factory. Sean recommended some minor changes to the system that proved beneficial to both the commissioned machine and for future product improvements. With the recommendations implemented, the machine has exceeded specified production rates.

Once both machines were installed and all processes were optimised, Elmass could produce 60,000 indexed keyways per month.

With the GFC, large volume orders fell away, and Elmass sadly had no other option than to reduce the workforce. A new business strategy was created. To expand capabilities and offer a unique service, Elmass converted the P36-700 NC machine into a standard broaching machine, allowing it to broach keyways up to 700mm long or splines, hexagons and other shapes up to 500mm long. Its size meant the P36-700 NC could also broach keyways or splines in blind holes in very long parts. The machine’s full frame height of 1,400mm can accommodate a combination of long parts and short toolbars to cut keyways or splines.

To differentiate from its competitors Elmass also introduced an at-call broaching service, which is highly appreciated in

breakdown situations where a keyway or spline is needed as soon as possible to minimise production losses in plants.

Customers can call and reserve a machine for a specific time, and are asked to email detailed drawings to reduce production time. These are used to set up the machine while the part is in transit to Elmass. On arrival it goes directly into the machine; the customer can wait in the coffee shop next door, then take the completed part back.

Developing young talent Since its beginnings, Elmass has maintained a good relationship with QUT, as well as several other universities. Students at these universities have formed teams that design and build Formula SAE racing cars, and compete at international student racing events. These students often ask for advice in relations to splines. Elmass sponsors these teams by broaching their keyways and splines free of charge.

As a result Elmass has attracted interest from final-semester students, with many applying for work experience with the company. Being an engineer himself, Martin was qualified to offer three of these students the industrial practice required to complete their engineering degrees. The students were involved in design work, and in practical work in the workshop.

They gained hands-on experience in how to use measuring tools, mark parts, grind cutters, determine material characteristics using simple methods such as the colour of sparks, and to program and operate broaching machines.

The students were also invited to participate in discussions Martin had with his customers about new projects. During these discussions the students were encouraged to present their view how to solve some aspects of the tasks. This was a welcome opportunity for them to use their skills in the real world.

Meanwhile Elmass is looking forward to exploring new business opportunities and the chance to continue to build longtime, mutually beneficial business relations. www.elmass.com.au

AMT DEC/JAN 2019

095

096

SOFTWARE

DataSuite solution takes Kelly Engineering to next stage of its evolution By adopting DataSuite as a solution to automate its manual processing operations, agricultural equipment manufacturer Kelly Engineering has benefitted from a 25%-40% increase in data processing speeds. Central Innovation created a tailored solution using DataSuite for the company’s requirements.

From its beginnings 30 years ago as a relatively small family company based in Booleroo Centre, South Australia, Kelly Engineering has grown into a global concern. The agricultural equipment it produces – chiefly tillage systems for soil preparation and weed control, designed to be towed behind tractors – is now manufactured in Australia, Germany and the US. Roger Dunlop, Engineering Manager at Kelly Engineering, estimates that today some 50% to 60% of the company’s customer base is in the US and Canada. The remainder is spread across Australia, Europe and emerging markets such as Southern Africa.

Central Innovation has been assisting Kelly Engineering with its design process solutions for the past seven years, and the relationship has been a fruitful one.

The latest step of this ongoing journey is the company’s implementation of Central Innovation’s DataSuite data transformation solution, which facilitates the seamless transfer of data across multiple platforms by providing a common language between systems.

The move underscores Kelly Engineering’s commitment to utilising such technological tools to improve business efficiency. Dunlop sees this as part of an ongoing evolution from the company’s initial investment in a Solidworks PDM Professional (Product Data Management) system some six years ago, once the business had grown large enough to support multiple users.

“Investing in Solidworks PDM Professional at that stage was a smart move, as we’ve kept on growing since,” Dunlop affirms.

“When I joined the business three and a half years ago, engineering consisted of one and a half people, and we now have a team of seven including product designers and R&D engineers. We have six Solidworks licenses here in South Australia, where our R&D centre is based, and we work closely with our manufacturing partners in the US and Germany.”

Having initially utilised Solidworks PDM Professional to get its engineering documentation under control, the next step for Kelly Engineering was to consult with Central Innovation on how it could further be used to implement an engineering change workflow.

AMT DEC/JAN 2019

Kelly Engineering’s implementation of DataSuite refects the company’s commitment to utilising such technological tools to improve business efficiency.

“We needed to be able to control change within the organisation from a paperbased to an electronic system, to optimise our own requirements in terms of supply chain and production, as well as those of our overseas partners,” explains Dunlop.

“Central Innovation has been instrumental in customising that and making it work for us. That led to us developing a closer relationship, which has culminated in the implementation of DataSuite.”

With the implementation having progressively ‘gone live’ over the past few weeks, Dunlop estimates that automating the data transfer process has already sped up transfer times between 25% and 40%.

Dunlop explains the rationale behind the decision to bring DataSuite to the business: “From a Solidworks model we need to produce a lot of documentation like PDFs, STEP files, jpegs, all of which is non-valueadded activity for us. Also, using a manual process to construct this documentation is quite prone to error and not ideal when you’re working in a dynamic, fast-paced and constantly changing environment. We use Ostendo ERP (enterprise resource planning) software to run our commercial operation and we were spending a lot of time inputting data, part numbers and bills of material into the system, linking Solidworks drawings and so on.

Dunlop liaised closely with Central Innovation team members in overseeing the final steps of the transition to DataSuite and says they have been integral to the project’s success: “I’ve been working with them on it for some considerable time, and during the implementation stage their developers have been intimately involved in understanding our needs and creating workflows that will work for us.

“By providing us with the Datasuite solution, Central Innovation has enabled us to automate data transfer from Solidworks into Ostendo – everything from the generation of part numbers, 3D thumbnails and isometric views, so we can see them directly on the detail screen in Ostendo, to the creation of Model Based Definition database files.”

“And it’s not just about improving efficiency,” he adds. “But also eliminating the propensity for error that’s inherent in manual processing. We’ve got rid of the manual input and also eliminated the need for 2D drawings on the shop floor.”

“They’ve worked with us not just remotely but also on site, in terms of implementing the system, training the team and imparting best-practice guidelines, which has been an extremely important component of the process. I’ve nothing but praise for the whole Central Innovation team, not only in terms of their knowledge of best practice across a broad range of industries, but their ability to apply it to a specific situation and provide us with a customised solution.”

With the implementation phase now complete, Dunlop is already investigating the further potential of Solidworks and

SOFTWARE

Kelly Engineering produces agricultural equipment, chiefly tillage systems designed to be towed behind tractors for soil preparation and weed control.

DataSuite to enhance Kelly Engineering’s operations: “We’re already using Solidworks Composer to repurpose existing engineering models as graphic content for our assembly manuals, and ultimately we see ourselves generating 3D output formats for all our manuals. At the moment we still do printed documents but we would prefer that they were all animated.

from the written word, especially in Europe where there are something like 25 different languages! We need to represent things more graphically, and Solidworks Composer helps us do that.”

Dunlop says DataSuite’s implementation on the engineering side has proven to be a big eye-opener in terms of its further application: “If you look at it as a universal translator, we could use it, for example, to link our CRM (Customer Relationship Management) system into our ERP. We use Salesforce as our CRM tool, and being

“Given we service so many different markets, there’s a need to minimise the amount of technical content we’re generating – we want to move away

able to translate that data into our ERP is a pretty powerful proposition.

“DataSuite’s engineering implementation to date has been invaluable to our business, although we are only using the basics at the moment. We realise that the DataSuite solution from Central Innovation has great potential for further application, and undoubtedly we will explore its advanced features as we gain more familiarity and confidence with its operation.” www.centralinnovation.com www.kellyengineering.com.au

BE DYNAMIC!

THE FUTURE OF EFFICIENCY & SPEED IS HERE Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shoptested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.

Mastercam Australia | 0478 674 970 info@mastercam.com.au www.mastercam.com.au

AMT DEC/JAN 2019

097

098

SOFTWARE

New ways to improve supply chain performance Successful manufacturing businesses rely on strong supply chains to provide high quality products to their customers.

Getting timely access to the right raw materials, then being able to guarantee delivery times according to customer requirements, can help manufacturers stand out from their competitors. By Terri Hiskey, Vice-President – Product Marketing, Manufacturing at Epicor Software.

Manufacturers need to work with supply chain partners that are ethical, reliable, and stable. Choosing the right partners requires significant due diligence. In an age where consumers vote with their feet and increasingly prefer to purchase from companies that demonstrate concern for environmental and ethical practices, manufacturers can’t afford to find out that their supply chain partners don’t measure up to their high standards.

More than half of consumers have declared themselves willing to pay a premium for products from companies promoting social responsibility. A company that promotes this virtue and is then found out to purchase materials from supply chain partners that employ slave labour or child labour, for example, could experience significant reputational damage. By contrast, a company that can prove beyond doubt that each member of its supply chain is ethical and trustworthy, can use this fact to attract new customers and grow.

The challenge for manufacturers is how to manage the supply chain effectively. It can be difficult to effectively track the behaviour of every supply chain organisation that a manufacturer deals with. However, investing in this level of due diligence is well worth it — the numbers prove that manufacturers that do the right thing are more successful.

For example, a Harvard Business Review study showed that retailers with a high level of trust in the manufacturer generated 78% more sales than those with a lower level. Unfortunately, not many manufacturers are getting this right at the moment. Recent research by the Economist Intelligence Unit has uncovered significant issues in how multinational firms manage the ethical performance of their supply chains. Less than one-third were found to address issues such as ethical breaches or supply chain corruption.

This leaves a wide-open opportunity for Australian manufacturers to take the lead in demanding ethical behaviour from all supply chain partners. This includes gaining full visibility into the supply chain as well as acting immediately and decisively to address ethical violations.

There are a number of benefits to this approach. The first is obvious — it lets manufacturers gain more control over the suppliers they do business with. This, in turn, delivers operational benefits such as more reliable supply of high-quality materials, improved relationships with suppliers who share the manufacturer’s approach to doing business, and an enhanced reputation in the marketplace. Another benefit is that manufacturers can contribute to eradicating human rights abuses such as slavery and child labour.

By demanding higher standards from the supply chain, manufacturers can improve their own products. For example, if raw materials are poor quality, the products created using those materials will be substandard. By contrast, if the raw materials are of top quality, then the products are more likely to be high quality.

It’s essential to remember that, even if a poor product is the direct responsibility of the supply chain, it’s the manufacturer whose reputation will suffer. This is the same whether the manufacturer receives inferior steel or tainted food ingredients. When the finished product fails to live up to expectations, the manufacturer will bear the brunt of consumer dissatisfaction. It can be difficult if not impossible to win customers back once their trust has been broken.

The only solution is to gain increased, overarching, and clear visibility into the supply chain.

AMT DEC/JAN 2019

While this has been challenging in the past, an emerging technology is helping achieve this. Blockchain was originally developed to underpin digital currencies, specifically Bitcoin. Blockchain is a distributed ledger where a list of transactions is stored in multiple participating servers, rather than in one central transaction server.

The reason this is so useful for manufacturers is because the technology is tamper-proof. No one can fraudulently change the transactions because they’re locked down — any attempt to do so would be automatically detected. Using blockchain technology to track supply chain transactions works the same way. It shines a light into every corner of the supply chain so manufacturers can see exactly what their supply chain partners are doing and where their materials come from.

Using the inherently-secure blockchain technology, manufacturers can increase visibility throughout the supply chain, decrease administrative costs, and improve traceability. This lets them definitively achieve the control and knowledge they require to use supply chain management as a competitive differentiator.

As supply chain networks become more complex and less integrated, blockchain will become even more important since it doesn’t require a central authority to provide an immutable record of events. This helps manufacturers maintain quality, and build and sustain consumer trust.

Blockchain isn’t just a passing trend. Many companies are already using it for various applications, and manufacturers are adopting it. In a recent global survey, almost three-quarters of respondents said they were either in the experimentation or the production phase of blockchain development. Australian manufacturers should start evaluating blockchain technology to consider where this emerging tool could benefit their operations. Blockchain can potentially help Australian businesses grow manageably and strategically, so starting the investigation process now means organisations will be ready to move when the time is right.

For blockchain to be effective, manufacturers will need to it with their enterprise resource planning (ERP) solution. It expand analytical possibilities and give manufacturers comprehensive view of the business to enable more decision-making. www.epicor.com

integrate can help a more accurate

SOFTWARE

Digitalisation critical for the competitive edge Manufacturing insights firm IDC believes that, by 2020, 60% of all enterprises will have fully articulated an organisation-wide digital platform strategy and will be in the process of implementing it. They predict that by then, 50% of the Global 2000 will see much of their business depend on their ability to create digitally-enhanced products, services, and experiences.

Kevin Dherman, SYSPRO’s Chief Innovation Officer, believes the best way to prepare your business for Industry 4.0 is to implement an enterprise resource planning (ERP) system that can pave the way for digitisation by providing real, working solutions that will enable manufacturers and distributors to leverage on new technologies and trends that are shaping and redefining the competitive landscape.

For this reason the SYSPRO team has worked hard to ensure that they have embedded the most pragmatic and useful features and functionality of Industry 4.0 into their latest ERP release. The inclusion of Industry 4.0 functionality in SYSPRO’s latest release helps to create more intelligent manufacturing processes by combining humans with machines, resources with processes and systems.

Manufacturers will experience the benefit of increased accuracy and speed of automated data collection from machines and devices, for the measurement of Overall Equipment Effectiveness (OEE). Realtime status-tracking of equipment and jobs, and greater accuracy of job costings are now possible, and the software supports continuous improvement and visualisation of loss with out-of-thebox productivity and availability analysis and alerts.

The benefits of IoT Imagine being able to arrive at your customer’s store to change lightbulbs just before they go out, or to regas their fridges before they stop keeping your customer’s perishables cool. The implications are huge. Not only will you be able to fulfil your service level agreements (SLAs) with your customers; you’ll also help them fulfil theirs too.

Implementing Internet of Things (IoT) technologies opens up a world of infinite possibilities for manufacturers; however, the resulting data needs to be carefully managed and processed, which is why it is important to implement an IoT-enabled ERP system. Not only will it facilitate more streamlined and automated business processes, thereby reducing the need for human intervention, it will also improve service delivery, and enhances the customer user experience. It will allow manufacturers to manage their warehouse inventory in realtime, using IoT sensors to monitor and track incoming and outgoing items.

More than that, by incorporating data pulled from auto identification tags that are tied to GPS-enabled connections that continuously update location and movement, it is also able to improve traceability across the supply chain. This allows for business intelligence and alerts to be automatically delivered directly to relevant operators and service agents.

“When developing features for our latest release we focused on improving on our automation and data exchange capabilities to support the Internet of Things and cloud computing, to provide users with unparalleled deployment and usage flexibility, and to supply ubiquitous, real-time information through device- and platform-agnostic software,” says Dherman.

Photo by Markus Spiske on Unsplash.

The question businesses need to ask is whether they are ready for digital transformation, and whether they’ll find themselves forging ahead, or falling behind? It’s time discuss how manufacturers can better prepare themselves for Industry 4.0 and take that all important step of digitising their manufacturing facilities.

Tapping into the power of AI The coupling of ERP and artificial intelligence (AI) has allowed manufacturers to make sense of structured and unstructured data.

Previously unidentified trends, exceptions, and anomalies in your business are brought to the fore, helping to improve decisionmaking.

The integration of AI means that detecting fraud or operator errors is easier, as AI identifies anomalies in customer or internal sales orders, requisitions and purchase orders, and then alerts the relevant people immediately. AI is also able to pick up trends in customer behaviour and then push relevant information to you, taking your ERP from a simple system of record, to one of proactive engagement.

The advent of Digital Citizens The employment of Bots, or Digital Citizens, has numerous benefits in the manufacturing environment. The incorporation of AI into ERP software has facilitated the development and introduction of human-like chatbots, which answer – and even predict – customer queries quickly. The (AI) web robot resides within the SYPRO ERP ecosystem and streamlines business functions through natural conversations with the bot.

By employing a Digital Citizen in your business, you could provide your customers and your suppliers with an always-on, consistent and improved customer experience, 24/7, across the globe. Digital self-service agents provide insights and information, running price queries, stock look-ups, order status and more.

Opening the door to greater efficiencies By embracing new, exponential technologies such as machine learning, AI, and Digital Citizens, and by implementing a future-fit ERP solution that allows for their incorporation, manufacturers can not only make the digitisation process easier, but also open the door to greater efficiencies and growth. www.syspro.com

AMT DEC/JAN 2019

099

100

SOFTWARE

Global Job Solutions – Taking a lead in industry-designed software solutions Global Job Solutions (GJS) is an Australian company with over three decades of experience developing specialist solutions to enable businesses become more profitable by providing their customers with an even better service, and ensuring they keep coming back.

GJS Managing Director John Rees has been at the helm throughout, and he and GJS’ software engineers have worked directly with businesses to be sure that their Job Commander solutions have been formed with the input of customers, answering the special needs of the engineering industry.

Job Commander is a simple-to-use job costing system that produces quotes, schedules, purchase orders, job cards, delivery dockets and invoices, all personalised for the client. The quoting software allows faster, more accurate quotes by drawing on data from previous jobs and enabling storage of job-specific electronic documentation that is easily retrieved. Job Commander’s integration with MYOB, XERO and QuickBooks avoids double handling of data and reduces accounting costs.

Job Commander has taken over a decade to develop with extensive industry research, testing and substantial investment by the company. Rees says: “This has resulted in a powerful, easy to use, and innovative suite of software tools that a client can install one day, and start using the next.”

Tom Waller from Vale Steel has experienced this first-hand, as he describes how he found Job Commander to be the solution he was looking for: “Originally, we were using manual handwritten sheets and a calculator. Job Commander has given us accuracy and confidence in our calculations. We started with the quoting module and soon found it so easy to use for generating purchase orders for materials, through to invoicing and delivery dockets – it follows the whole job from start to finish.”

It was the 2015 manufacturing downturn that saw an increase in Job Commander enquiries received from businesses which were looking to improve their profit.

Steven Delfos, Managing Director of Avtech Engineering, explains: “With the implementation of Job Commander, we were able to reduce our office staff, and have real-time planning for job completion, all in the one system. Now, via my laptop, I can show my clients the progress of their job whilst in their office – impressive!”

Vicki Strickland, Administration Manager at Bosnar Engineering, says: “After running our engineering machining workshop manually for over 30 years, we were on the lookout for software that would allow us to have one system that took us from quoting all the way through to invoicing our clients. Job Commander does that. Not only does it have a simple, easy approach to learning the software, it makes the daily process within our office run smoothly and professionally. After spending time on researching the right system, we found Job Commander.”

Critical business reporting “Our focus has been on solutions for companies that need to quote, track and invoice for jobs of any kind,” says Rees. “When researching the market, we discovered there were a lot of spreadsheets and off-the-shelf accounting systems. Our ambition was to develop a product that removed any duplication and provided an end-to-end solution in one product so that everyone sings from the same song sheet. And, they could start using it straight away, without needing to customise it – so there’s no lengthy implementation phase. That’s when Job Commander was born.”

AMT DEC/JAN 2019

What has proved infinitely valuable to our clients and their bottom line, is the ability to automatically collect valuable business data such as machine time and labour costs to produce meaningful job profit reports. Rees says GJS has received many testimonials from clients who have seen Job Commander bring greater profitability and efficiencies to their business.

With precise information about staff and equipment, job progress can be viewed at any time. Capacity planning and timeline displays give exposure to potential work centre bottlenecks. The advanced but simple-to-use tools of the Job Commander job costing system assist managers in making informed decisions on organising and managing workloads.

Rees notes that the fear of change is common, especially in the shift from manual to computerised systems: “We find, sometimes, businesses which explore solutions are nervous to take the leap of faith, either to move to a computerised system from manual processes, or to change to a system they aren’t familiar with.”

First-class support “One of the first questions I’m asked is, ‘How do I get started?’” says Rees. “This is where GJS makes the process as smooth as possible; we spend time to understand how the business operates, and work in partnership to deliver a reliable, time-saving system with great results. We offer free training for the first three months, but we find our clients begin using the system almost straight away, and that’s the beauty of the Job Commander turnkey solution.”

As with any system that a business comes to depend upon, having reliable support and assistance when it’s needed is a must.

Vicky describes the experience for Bosnar Engineering: “The staff, software and service support even two years on is still first-class.”

Rees attributes this success largely to his locally-based team: “With a dedicated software development and support team locally based in Australia, our ability to service our clients is exceptional.

Unlike some of our competitors, we do not outsource software development or technical support, so we have complete control over our product and customer service.”

It’s no surprise the software performs so well for the engineering industry. As Rees explains: “Every facet of all our software is examined and tested at every stage of development, and betatested or trialled in the businesses of clients. Where necessary, we designed and refined the software until each module satisfied and exceeded the expectations of our clients.”

Rees sees a future filled with opportunities, with GJS collaborating closely with clients: “We aim to enhance our clients’ capacity to grow their business and remain a trusted long-term solutions partner. The days of being able to support and increase profitability with manual spreadsheets or off-the-shelf products is past. With the way we have packaged the products, increased profitability is within the budget of even the smallest engineering company to the medium-sized organisation.” www.globaljs.com

SOFTWARE

Reimagining manufacturing through digital transformation Australian manufacturers are moving into a new era of innovation and competition. Gone are the days of simply looking for ways to optimise production; while optimisation remains important, it’s not likely to be the deciding factor in whether a manufacturer succeeds. Instead, manufacturers must take their lead from other industries and use digital transformation to remodel their value propositions and processes. By Peter Lawther, Chief Technology Officer at Fujitsu Australia and New Zealand.

Fujitsu surveyed more than 1,500 C-suite executives in large and midsized companies in 16 countries. Of the manufacturing companies surveyed, 69% said they had already initiated digital transformation programs. While these programs tended to focus on efficiencies, manufacturers are starting to realise that there is much to gain from sectors that are further along their transformation journeys.

For example, when disruptors hit the finance sector, financial services providers started with innovations aimed at optimisation and driving down costs, which quickly evolved into offering alternative products and services. Transforming the value chain resulted in new opportunities for expansion, development, and growth.

For 40% of manufacturers, the focus remains on achieving efficiency improvements. Using emerging technologies, they’re identifying optimisation opportunities to avoid disruption using predictive maintenance and more effective monitoring of the supply chain and production centres.

Manufacturers who are more mature in their transformation journey now understand that this optimisation is only a starting point. With the right approach, digital transformation could drive an entire overhaul of the manufacturing industry that could lead to blurred lines between functions. For example, manufacturers may branch out into retail using online channels that don’t introduce the same prohibitive costs as bricks-and-mortar stores.

Alternatively, retailers may find themselves moving into manufacturing as some types of manufacturing become cheaper with lower barriers to entry. Additive manufacturing, or 3D printing, is one such example.

Meanwhile, distribution companies may create closer links directly with consumers. This creates increased competition from previously unlikely sources. Manufacturers that don’t respond strategically could find themselves squeezed out of business altogether.

Market consolidation is nothing new and many industries have experienced it. Smart agile businesses survive and thrive while those that are slow to respond can find themselves eclipsed by larger, savvier competitors.

Consolidation isn’t the only potential threat manufacturer’s face.

Increasing globalisation has already had a profound effect on Australian manufacturers, who have found it difficult to compete with offshore businesses. The relatively high cost of manufacturing in Australia compared with the lower cost borne by Asian neighbours has seen many manufacturers struggle to compete.

However, there are some industry observers who suggest that the price pressure on Australian manufacturers could recede somewhat as wages rise and working conditions improve in traditional manufacturing behemoths such as China. This is augmented by the increasing use of artificial intelligence (AI) and manufacturing automation. These emerging technologies will help drive down the cost of manufacturing at home, which erodes the advantage of countries with lower labour and energy costs.

Once these costs are accounted for, Australian manufacturers may find businesses and consumers are unwilling to pay the extra shipping costs to get products here from far-flung destinations, and are less eager to put up with lengthy supply chains.

So, while the pressure is likely to diminish to some extent, the effect of globalisation is far from eliminated. Other countries are growing and countries not traditionally thought of as manufacturing centres are likely to make their mark on the industry. For example, between now and 2050, the UN predicts that 1.3bn people will be born in Africa alone.

The rise of online retailers such as Amazon or Alibaba has let even small manufacturers reach global audiences. Now, small arts and crafts companies in Africa can sell to consumers anywhere in the world. Previously, these companies would have been limited to a small geographical area due to the complex and costly logistics involved in setting themselves up as global retailers. These companies can benefit from economies of scale that would never have been possible on their own. Indeed the entry of Amazon in the Australian market has changed the local playing field and has further widened the range of products available in this part of the world.

This kind of digital innovation in terms of getting products from manufacturers to consumers is just the beginning of how digital transformation can revolutionise the future of manufacturing.

For example, the Internet of Things (IoT), Analytics and AI can be used to create integrated global dashboards to monitor collective manufacturing. Managers can see detail down to how an individual machine is performing, can utilise the data to predict bottlenecks and maintenance issues, and can allocate materials, components, capacity and skills in the most effective locations.

Manufacturers can also use faster, cheaper processes to produce consumer-customised products at scale, delivering a customer experience that has been limited to the very wealthy in the past. From clothes and homewares to cars and boats, manufacturers can offer consumers innovative ways to ensure their products are unique. In the past, the cost and complexity of doing this would have prohibited most manufacturers from even considering such a service.

Ultimately, a business’s willingness to reimagine its purpose will determine its success. This includes flexibility in product creation and finding the right partner ecosystem. Co-creation can set the scene for manufacturers to move beyond efficiency to embrace digital transformation. The rewards for manufacturers who do this will be unparalleled. www.fujitsu.com

AMT DEC/JAN 2019

101

102

SOFTWARE

How things got touchy at Integra You might not be familiar with the term ‘haptic technology’, but if you’ve ever used a smartphone or tablet computer, certain ATMs or a self-service checkout at the supermarket, you’ve definitely been in touch with haptics.

Margaret Rouse – a writer and manager at whatis.com’s TechTarget – has described haptics as “the science of applying touch (tactile) sensation and control to interaction with computer applications”. Every time we open an app on our phones or type information into a search engine on a tablet computer, we’re using touch sensations to utilise a range of applications.

Haptic technology isn’t necessarily new.

Early use of haptic technology actually dates back to the early 1990s when companies like Nintendo incorporated touch into the Nintendo 64 Rumble Pack console, and automobile and medical equipment manufacturers began to develop hapticbased applications in new hardware (think of the way a nurse sets up an automatic intravenous push for a patient).

There are a number of features that make touchscreen technology so handy. It gives designers scope to make their applications more user-friendly, which in the end means it’s easier and faster for us to use them in our everyday lives. Another element that makes touchscreen haptics so good is the scope for designers and developers to create larger screens in smaller devices.

Compare the size of your desktop to your smartphone or tablet and the number of things you can do on them – not to mention how easy it is to carry a tablet or smartphone compared to a desktop!

Touchscreen haptic technology has significant appeal across all levels of society. Although there has been some controversy over CommBank’s newest EFTPOS terminal and its usability for the visually impaired, touchscreen technology generally makes it easier for people with disabilities to use technologies that are otherwise impractical with a conventional set-up. Likewise, haptics makes computers more accessible for people with less confidence in operating technology, which consequently helps reduce isolation and foster inclusivity in our communities.

The use of haptics at Integra Integra first dipped its toes into the waters of haptic technology back in 2013 for the Coles Group when working on some prototype kiosks. Integra’s role was to develop the enabling enclosures to maximise the usability of the touchscreen technology. During this development, Integra realised these devices played naturally towards the company’s own skills and strengths in industrial design and DFM (Design for Manufacturability), as well

AMT DEC/JAN 2019

as providing the facility to create unique solutions for Integra customers.

Those early days were a steep learning curve for everyone involved, explains Steven Parker, Product Design Engineer at Integra, given the number of challenges that needed to be overcome.

“Some of the issues that we originally faced with designing the kiosk enclosure to support the haptics development were the human ergonomics, and making this work with the screen,” says Parker. “There are lots of literature on this area; however, there are also lots of people saying how they would like it to differ in small ways – whether that’s higher or lower, different screen angles and so forth. We also had to overcome technical issues, including earthing the screen better, because we found that users were having issues with the touch sensation not working.”

Rising above these early obstacles allowed Integra to develop some industry-leading processes when it came to designing information kiosks, a big part of which involves a thorough understanding of the customer’s needs. This developed into a range of kiosks under the Integra TransForm auspices, Touchscreen Collection.

“In simple, general terms, kiosk design starts off with market research and what the customers are after,” Parker explains.

“We then turn to concept generation, while paying close attention to the hardware that is going to be used, to ensure we have enough space within the unit. When the kiosk begins interacting with people, the ergonomics is also a big factor to take into consideration.”

Integra also places an intense focus on making the build design easy to replicate.

“Once we have competing concepts, we narrow these down to a single concept and start to detail this out for manufacture,” says Parker. “While detailing the kiosk, we have to pay particular attention to DFM, and the ease of maintenance and ongoing service. Too often products are designed but the manufacturing processes and costs aren’t taken into consideration, or the ease of after-sales service.”

Parker argues that, while there hasn’t been a great deal of advancement in haptic technology per se, advances in how this technology has been applied is where the real changes have emerged.

“There are multiple different technologies with the touchscreens, which differ in how they pick up the finger touch,” he continues.

“Each type of screen has pros and cons, so it’s a matter of trying to choose the best one for the many different applications they can be used in.”

Likewise, Parker finds it hard to pinpoint exactly what the next big wave in touchscreen haptics is likely to be, especially considering the endless possibilities. Regardless, he’s sure haptics technology will continues to find its way into more everyday items and applications such as the Internet of Things.

“We’re even using the touchscreen technology in the factory at Integra where we, perhaps, might not have really considered it to be useful,” he admits.

“As a really simple example, we’ve tried to remove the paper trail from jobs with a semi-paperless system of touchscreen kiosks to receive job sheets and work instructions.”

And this is just the beginning. www.integratransform.com.au

SAFETY

103

Reducing noise-induced hearing loss Hearing loss is on the rise in Australia and around the world, and the manufacturing industry is an area where this is particularly acute.

Now, the fourth-largest cause of disability worldwide, hearing loss has become so prevalent that even the World Health Organization has taken notice, recently releasing a report to address the prediction that disabling hearing loss will affect about 13% of the world population by 2030 and one in four Australians by 2050.

Identified as one of the biggest risk factors is noise-induced or industrial hearing loss. Despite being entirely preventable, this remains all too common, especially in the Australian manufacturing and construction industries, with technicians, trades workers, machinery operators, drivers and labourers the most exposed.

The danger with hearing loss is that it often occurs gradually through prolonged exposure to moderate or loud noise levels, so by the time sufferers notice a change in their hearing, the irreversible damage has already been done. Hearing loss may present itself as tinnitus, the hearing of phantom sounds like ringing or static; or as hyperacusis, a reduction in tolerance for ordinary sounds. These conditions are often debilitating for the sufferer and can lead to feelings of isolation, depression and if left untreated, even dementia in later life.

Once recognising potential hearing loss, it takes sufferers on average seven years to seek professional help, so it is critical that prevention is a high priority. For the one million Australians who work in loud environments, removing themselves from the sound hazard, while the best solution, is often not practical. Thankfully, there are steps that can be taken at both a business and personal level to protect hearing in these hazardous environments.

The employer is responsible for preventing overexposure to hazardous noise, which means not exposing a worker to sounds of more than 85 decibels over an eight-hour shift, nor to any sound above 140 decibels at any time. Risks from workplace noise must be eliminated or minimised, but where this is not practicable and time limits have been put in place to minimise exposure, personal protective equipment (PPE) has a critical role to play in preventing permanent industrial hearing loss.

By considering hearing protection in combination with other safety requirements, as well as a worker’s individual needs, reducing the predicted rising number of cases of industrial hearing loss becomes a much more achievable goal. www.honeywellsafety.com/AU

dry-tech : ®

The lubricant-free, low-cost way to swivel, rotate, oscillate, move and achieve linear motion ... construct sustainably with dry-running polymer bearing solutions from igus . ®

There is a wide range of hearing protectors currently available. Each product is tailored to different job requirements, environments and individual needs, so there is no simple cookie-cutter solution to choosing the right hearing protection for an entire workforce.

When selecting hearing protection, audiologist for Honeywell Industrial Safety, Theresa Schulz recommends measuring each individual’s daily protected exposure level, rather than using the labelled attenuation of the PPE to estimate how much protection workers should be getting from the hearing protector. Using the labelled attenuation is far less accurate, and can often lead to overprotection, which puts workers at risk of serious workplace accidents.

the-chain:

Moving energy made easy for any motion. Simply construct using e-chains , cables and components from igus . For selection aids, service life calculations and configurations visit www.treotham.com.au ®

®

“Communication, comfort, size, shape and ease of insertion should all be considered when selecting hearing protection,” says Schulz.

Even if hearing protection is properly fitted to the individual and meets the requirements of the working environment, the necessary level of protection will not be achieved if the worker fails to wear the equipment properly, or uses additional PPE that negatively impacts its performance. For example, wearing safety eyewear at the same time as earmuffs might impact the efficacy of the earmuffs by loosening the seals, which reduces the amount of attenuation provided. Therefore, it is important to ensure that the eyewear worn has thin frames to reduce risk.

plastics for longer life

®

info@treotham.com.au

treotham.com.au

Treotham Automation Pty Ltd Phone 1300 65 75 64 ... Offices in Sydney, Melbourne, Brisbane and Perth.

AU-1071+1072-BRG+ECS 85,7x130.indd 1

AMT DEC/JAN08.05.18 2019 10:05

104

SAFETY

Five tips to support the return-to-work process Helping workers return to their normal job after an injury is called ‘return to work’ – an important step in their recovery.

Research shows work is usually good for health and wellbeing, while long-term absence, disability and unemployment can have a negative impact. WorkCover Queensland Customer Group Executive Melanie Stojanovic explains that the return-to-work journey goes smoothest when all parties work together: the worker, their employer, WorkCover, and doctors and health practitioners.

“Planning a safe, early return to work requires input from all parties to determine what the injured worker is capable of doing, and what modifications to their duties might be available for them in their workplace,” says Stojanovic. “Communication is key to a positive return-to-work outcome, which leaves the worker feeling supported and confident as they get back to their normal life after an injury.”

Here are five tips to consider when a worker is injured: 1. Support and communicate from time of injury. Employers should contact their worker as soon as they are aware of their injury to offer support. Contact should be maintained throughout recovery to ensure open lines of communication so barriers to return-towork are identified and solutions are found. Listen to the worker’s concerns and address them promptly. Regular communication also helps the worker feel valued and missed by their colleagues. Find the right balance though: some workers may interpret regular contact as pressure to return before it is safe to do so. Discuss the timing and frequency of contact early on so you are both comfortable with it.

2. Participate in return-to-work planning. Consider what other duties you may have available in your workplace that the worker could perform safely. You may have alternative duties that could minimise or even eliminate the need for time off work. Use an individual, person-centred approach to find solutions to potential barriers; don’t

assume that duties that were suitable for another injured worker will necessarily work for this worker. While it helps to have options ready, be flexible as you work with the worker, WorkCover and health practitioners to determine a way forward.

3. Stay in touch with WorkCover and the treating doctor.

Return-to-work planning works best when each party has as much information as possible about what the worker can do. WorkCover Queensland’s injury information pack includes suitable duties plan and letter templates that you can complete with your injured worker.

The worker can take these to their doctor so the doctor is aware of all possible duties the worker may perform when completing their Work Capacity Certificate. Stay in touch with your WorkCover Customer Advisor as well; they are responsible for monitoring and revising the return-to-work plan, including timeframes for treatment and recovery.

Their claims experience can help guide you along the way.

4. Review and check in after return to work. Once the worker has returned to work, check in with them to ensure they feel confident and comfortable, and are not aggravating their injury. You may need to make additional modifications to their workload as they continue their recovery and build fitness.

5. Improve return-to-work processes. It helps to develop processes and practices to manage return to work in case of an injury. This will foster a supportive culture and allow you to make improvements wherever necessary. The time immediately after a worker has returned to work after injury is ideal for reviewing what went well, and what you can change for the future.

Resources to learn more about the return-to-work process are available at: www.worksafe.qld.gov.au

Building your safety strategy According to the UK Health & safety Executive (HSE), manufacturing is one of the highest-risk industrial sectors to work in. Can more be done to protect workers in industrial environments? Jonathan Wilkins, Marketing Director of EU Automation, explains what goes into making a workplace safety strategy.

Work-related injuries and sickness costs businesses €2,680bn each year, and while Industry 4.0 technologies are expected to reduce accidents, without a robust health & safety plan that includes training on new equipment, problems can still arise. But where do you start when formulating your health & safety strategy?

Develop your work plan With any cultural change it’s important to have a strong team from across the business leading the initiative. Once formed, roles should be allocated and the group should identify key issues in their working environment.

Communicate your mission The mission and vision of the strategy should be clearly articulated across the entire company. While having top-down support is vital to any strategy’s success, it’s equally important to have backing from the rest of the company. Without their participation, the strategy’s implementation will fall at the first hurdle. The mission statement must be clear and concise and made accessible to all employees.

The current situation Some manufacturers may be further along their health & safety journey than others, with robust procedures in place already. The group must take a step back and look at the business’s current

AMT DEC/JAN 2019

strengths and weaknesses. By pinpointing critical issues, you can take appropriate action, with training or by other means.

Identify your objectives and how to achieve them With the weaknesses identified, it’s now time to determine how to address them. Each weakness should be assessed on an individual basis, with specific objectives allocated. This step is perhaps the most time-consuming as it is here where an action plan is developed to deal with the various issues. As part of the strategy, the group should also consider developing a planned maintenance programme, as regular maintenance can prevent equipment faults from arising, minimising potential hazards.

Communication and evaluation Once the safety strategy has been created, it must be communicated and implemented. The exercise is pointless if the document is simply printed and put in a drawer. The action plan should be evaluated on a regular basis and adapted accordingly if safety does not improve in the plant.

As the factory floor becomes ‘smarter’, a detailed safety strategy is vital in ensuring the plant is a safe working environment. Without proper training, procedures and protocols in place, the number of workplace accidents will continue to climb, causing considerable losses for businesses. www.euautomation.com

SAFETY

Cut To Size addresses industrial noise OH&S issues at the source Noise can be a major safety hazard in industrial, production automation and metals processing plants, where the sound of heavy materials handling machinery operating can distract attention from the job in hand and drown out the sound of malfunctioning machines, alarm signals or warning shouts.

Noise exposure is also Australia’s most common preventable cause of occupational hearing loss, with Worksafe Australia estimating that a million employees in this country may be exposed to hazardous levels of noise at work. Damage to hearing can occur when noise levels are higher than 85 decibels, which is about the loudness of heavy traffic.

“One highly effective way in which the noise problem can be addressed at its root cause (rather than through hearing protective devices, valuable though they are) is in the substitution of engineering plastics in application areas where quiet running, low weight and low friction are advantageous,” says Pat Flood, NSW Manager for engineering plastics specialists Cut To Size.

Flood has more than 30 years’ experience in tailoring light, tough and quiet industrial engineering plastics to individual application needs. He says one of the most versatile materials increasingly substituting for more expensive metals is Wearlon. The Wearlon family of nylon polymers extends from the most commonly used and cost-effective PA6 semi-crystalline polyamides, through to especially formulated types such as PA12, which is used where greater shock loads and vibrations damping efficiency are required in rollers, gears and pinions.

Producing metal components for industry can be a noisy process; engineering plastics can help provide a solution.

Wearlon nylon rollers can improve the rolling operation of flanged beam rollers, example, while offering significantly quieter operation.

Cut To Size manufactures machinery components from such materials for applications across Australasia from its head office in Sydney, where facilities include CNC machining facilities coupled with GibbsCAM and Solidworks software.

“Wearlon nylon is used across many industries to reduce noise and reduce machinery rail wear, with applications including food & beverage, mineral processing, agribusiness materials handling and industries that want to avoid corrosion or the need to use lubricants that can contaminate production,” says Flood.

Nylon rollers, for example, offer high wear resistance, low friction and lower noise where a part slides over the roller surface. Nylon rollers also offer savings in maintenance costs and, being noncorrosive, offer all-weather performance in outside installations, including mineral processing plants and logistics operations. Uses include beam trolley rollers, monorail rollers and turntable rollers, as well as vital parts on conveyors and belts.

“Cast nylon trunnion wheels can also be used to reduce plant operation noise and reduce wear on rotating barrels,” says Flood.

Nylon trunnion wheels can be used in noise- and vibration-prone applications where they support vertical barrel loads and dual thrust loads. Wearlon trunnion rollers protect their running surfaces while providing good damping of vibration and noise in applications such as rotary drum screens, wire cable windows, and rollers and guide wheels in transport vehicles, crane carriages, crane tracks, trolleys, storage and retrieval systems, as well as handling systems and applications with rolling movements (such as vertical conveyors, bucket elevators and trough conveyors).

Cut To Size extrudes components manufactured from nylon rod diameters below 50mm and casts them above this measure.

Components made from sheet material 10mm thick and lower is extruded, while 10mm and above is cast.

“Cast nylon is better for machining the larger components, because it is slightly more ductile, has less internal stresses and has more

consistent density compared with the extruded material in these sizes,” says Flood. “So, we use casting to deliver optimum longterm performance in larger components.”

While the Wearlon family often offers a highly cost-effective solution to noise, friction and wear abatement issues, Cut To Size also engineers components from a full range of engineering plastics from world-class suppliers, including nylon, acetal, PTFE, polyurethane and specialist high-performance products.

Specialist products include the Wearlon family of LiNNOTAM HiPERFORMANCE polyamides, which are partially crystalline, thermoplastic high-performance polyamides that, using carefully formulated additives and modifiers, have been specially designed for the demanding requirements of specialty components in machinery design.

These include production-critical applications, such as production automation and high-volume product processing and conveying, where downtime costs are considerable, and producers wish also to avoid the hazards of replacing heavier and more labour-intensive machinery components.

The high-performance polyamides are part of Cut To Size’s nationally available Wearlon ranges from Licharz, an international manufacturer and fabricator of engineering plastics. Licharz produces the globally proven LiNNOTAM family of light but rugged polyamides for easy machining and especially long service lives. www.cuttosize.com.au

AMT DEC/JAN 2019

105

106

FORUM OHS

Crime doesn’t pay: How asbestos training makes you the good guys every time The penalties for the unsafe removal of asbestos are now severe and include imprisonment. Brendan Torazzi highlights some recent examples and offers advice for safe asbestos removal.

Safe assessment and removal of asbestos and asbestos-containing materials is no simple task. It requires proper training, careful planning and strict adherence to legal requirements. The penalties for failing to comply with those requirements can be substantial as some companies and individuals have discovered through their reckless flouting of the law and of public safety.

Last August the NSW Environmental Protection Authority commenced prosecutions against a Sydney man who has been charged with three offences in relation to a property near Spencer on the Hawkesbury: land pollution (including asbestos), unlawfully transporting waste and using a property as a waste facility without authority. Each offence carries a maximum fine of $250,000. “The NSW EPA takes these types of matters seriously,” said the EPA’s Chief Environmental Regulator, Mark Gifford. “Our environmental laws are in place to help protect the environment and the community.”

In May we saw serial asbestos offender Dib Hanna jailed on multiple charges relating to the illegal transportation and dumping of asbestos. He is the fist person in NSW to be imprisoned on such charges and was also ordered to pay to publicise his crimes in the press. The authorities were sending a message loud and clear to anyone considering flouting the rules when it comes to asbestos management.

In July this year, Dial A Dump Industries was fined $23,000 for failing to adequately cover asbestos waste at its Eastern Creek landfill in 2016. Moreover – like Hanna - it was ordered to pay the $25,000 legal costs of the Environmental Protection Authority and to publicise its conviction in Inside Waste magazine. Another strong message from the EPA that they are not mucking around when it comes to punishing inadequate treatment of asbestos waste and will keep a close eye on known offenders like Dial A Dump.

Operators like Dial A Dump are experienced in the field and would be aware of what the requirements are. So why take such a risky shortcut? Was it the poor call of an overstretched team manager?

An attempt by senior management to cut costs? Whatever the reason, it could have been prevented with more vigilant adherence to the rules regarding asbestos removal. When proper asbestos awareness, assessment and removal training is taken seriously by senior management, these kinds of work health and safety failures can be avoided. It’s not only larger organisations that are in the EPA’s sights. Individuals and small operators are, under the law, obliged to be just as thorough in the managing of asbestos waste.

And it’s not just the EPA you’ll have breathing down your neck if you mess with asbestos. Taking proper care with asbestos assessment and management and providing the necessary training to deal with it is a key responsibility of a person conducting a business or undertaking (PCBU) as defined by the Work Health and Safety Act. Officers, such as company directors, are responsible for carrying out due diligence to make sure such care is being taken which includes making sure the right kind of training and education is being provided to help eliminate or minimise those risks.

There are different levels of training required for different kinds of work involving asbestos. For example, a plumber or electrician may need to remove small amounts of non-friable asbestos in

AMT DEC/JAN 2019

the course of their work on a property and are permitted to do so without a Class A or B licence - but they must be trained in the identification and safe handling of asbestos before doing so. Our nationally accredited Asbestos Awareness training course covers this requirement.

A Class A or B licence is mandatory for anyone removing friable asbestos or larger quantities of non-friable asbestos. Moreover, a licenced asbestos supervisor must be present or readily available to oversee such work – we offer supervisor training here. In addition for any friable asbestos removal, companies removing the friable asbestos must have a licensed Asbestos Assessor present to conduct air monitoring. The regulator must be notified of the works being carried out and asbestos waste must be disposed of at an authorised site.

Of late it has also come to light that for all good intentions, sometimes the careful safe removal of asbestos (double bagging) can be let down when removalists arrive at the local council tip. A lack of education around what is required at that end point means that sometimes the asbestos is just thrown in with general waste and broken up.

The issues with asbestos are long-lasting as asbestos related diseases such as asbestosis and mesothelioma can take many decades to show. Australia is doing its best to educate and the Federal Government in recent years has established the Asbestos Eradication Agency.

Assessing, removing and disposing of asbestos waste is no walk in the park but with proper training, the wellbeing of workers and the community can be protected and your profits can stay in your pocket instead of on fines. So be the good guys every time and get your asbestos training up to date.

Brendan Torazzi is CEO of AlertForce - a registered training organisation specialising in Health and Safety. He also runs the Australian Health and Safety Business Podcast (available on Spotify and iTunes) Ph: 1800 900 222 www.alertforce.com.au www.ohs.com.au

FORUM

HEADING

LAW

Ipso facto reforms and what it means to your business Recent changes to the law which previously allowed a party under a contract to terminate or modify a contract automatically when an insolvency takes place, has been changed. Kelly Dickson explains and offers advice.

Recent changes to the law mean you may no longer be able to rely on contractual entitlements to immediately call on security or terminate agreements with trading partners who encounter financial strife or have administrators or receivers appointed. We recommend you review your trading documents to confirm whether or not you are affected by these recent changes, and strengthen your trading terms where available so that your protection is maximised. The ipso facto reforms are wide-reaching and not limited to just the typical manufacturing agreements or supply agreements - it affects ALL commercial agreements across the board.

What is ipso facto? “Ipso facto” is a Latin phrase which is translated as “by the very fact itself”, or as an ‘inevitable result’. In legal terms, ipso facto clauses allow a party under a contract to terminate or modify the application and operation of the contract automatically, if and when a specified insolvency event takes place. That is, the contract can be terminated immediately, as an inevitable result, or “by the very fact of” the insolvency event occurring.

Ipso facto clauses are common in commercial contracts. An example is a supply agreement between a supplier and a customer that allows a supplier party to terminate if an administrator is appointed to the customer. Other common ipso facto clauses include rights to call upon security (bank/ personal guarantees), suspend services, works, credit or the supply of goods.

Why are there changes? The recent law changes have been introduced so that companies that are experiencing financial difficulties are given breathing space and allowed to continue to trade while they recover from an insolvency event.

As from 1 July 2018, when a party enters into certain formal insolvency processes, the other party is now NOT able to immediately rely on the rights in ipso facto clauses for a certain period of time if the right is triggered by: • An application or announcement for a scheme of arrangement for the purpose of avoiding being wound up in insolvency.

• A managing controller (including receiverships) appointment to the whole, or substantially the whole, of the company’s property; or • the company entering into voluntary administration.

What is the duration of stay? The stay period commences upon the occurrence of the insolvency event, and ends depending on the nature of the insolvency event.

Unless otherwise extended or modified by the Court – • Scheme of arrangement: the stay period ends three months after announcement, or if an application is made, when the application is finalised or otherwise when the company is wound up.

• Voluntary administration: the stay period ends when the voluntary administration ends, or the company is would up; and • receivership: the stay period ends when the control of the receiver or managing controller ends.

Which contracts does ipso facto impact?

The new laws only apply to ipso facto clauses in contracts or agreements that were entered into on and from 1 July 2018. All other contracts or agreements entered into before this date are not affected by the law changes.

Are there any exemptions? The Corporations Amendment (Stay on Enforcing Certain Rights) Regulations 2018 (Cth) excludes certain situations from the stay provisions. The list of non-exhaustive examples includes: • If you are novating, assigning or varying your existing contract (entered pre-1 July 2018), your contract will be excluded from this regime if the novation, assignment or variation is made before 1 July 2023.

• Certain sophisticated financial products, securities, bonds, promissory notes and syndicated loans are exempted.

• High-value construction contracts (over A$1bn) have been exempted until 1 July 2023; and • Various government and public hospital/health contracts have been exempted.

What do I need to do?

There are two main things to do to ensure that you comply with the changes: 1. You should review your trading documents to confirm how the recent changes to the law impact your contractual rights – necessary action may include making amendments to your existing trading documents, particularly to re-draft the ‘termination’ rights in your contracts.

2. You should seek legal advice before exercising rights of termination or variation under an ipso facto clause, to make sure that you are entitled to terminate – there are severe consequences for wrongful termination or acting in reliance on an unenforceable right under an ipso facto clause.

In the same vein, if your contracting party is threatening or has tried to exercise a termination or a variation against you under an ipso facto clause, please speak to us to ensure that they are exercising their rights correctly in full compliance with the new ipso facto regime.

Do not get caught out by this new ipso facto regime.

Macpherson Kelley has extensive technical knowledge and industry experience advising on contracts and commercial arrangements. To discuss how the recent changes to the law impact your business, please contact Kelly Dickson, Principal Lawyer on (03) 9794 2541 or kelly.dickson@mk.com. au and Aylmer Low, Lawyer on (03) 9794 2519 or aylmer.low@ mk.com.au. Macpherson Kelley is a full service commercial law firm committed to helping our clients succeed. Our lawyers are experts in applying their knowledge to always deliver commercial outcomes. From the outset we invest the time to get to know each client’s business and to understand the commercial drivers behind each client matter – doing this puts us in the best position to develop practical and innovative solutions for our clients each and every time.

AMT DEC/JAN 2019

107

108

FORUM FINANCE

Repercussions of the Royal Commission Lending conditions for your business are going to get tighter, if they haven’t already - Angus Macdonald explains.

As the Royal Commission continues and the horror stories of the misconduct of banking executives continue to emerge, we must stop and think about how this is going to affect the average working Australian business owner. How is it that a bank’s misconduct and subsequent punishment affects the day-to-day running of my business?

If businesses have not already begun to feel the affects from tightened lending standards, then they most likely will in times to come. Minutes from the October meeting of the RBA to consider the rise of interest rates found that “while the regulators had already overseen a tightening of lending standards, and a degree of lending tightening standards had been implemented by banks in anticipation of the commission’s findings, it was possible that banks could tighten lending conditions further given the issues raised in the report”. It is no secret that the RBA has made clear their next change of the cash rate, whenever that may be, will most likely be an increase, rather than a decrease; but there are obvious concerns about the strength of the economy to withstand an increase in rates due to the policy changes banks are making as a result of the findings from the Royal Commission. RBA board members noted that it would be important to monitor the future supply of credit to ensure that economic activity continued to be appropriately supported.

Key points to take from this as a business owner in the advanced manufacturing industry is that lending conditions for your business are going to get tighter, if they haven’t already. You’ve heard the saying “don’t put all your eggs in one basket”, this applies to lending now more than ever, where loyalty to one financial institution can be costly. They key to navigating this is to spread lending where possible and the easiest area to do this is on equipment purchases that require finance and the only security the financier requires is the equipment itself, leaving all “day to day” banking, overdrafts and property at one main transacting bank.

Just because banks are tightening lending conditions doesn’t mean that you’re not going to be able to obtain the funds to purchase that next piece of equipment. Which brings me to the second point to consider: price. The RBA has kept the cash rate at 1.5% for a record 27 consecutive months (as of November 2018), but this won’t stop the banks from increasing their rates. A way to gauge this reaction is by looking at the property lending market which has seen a recent rate increase, this is generally where new policy is implemented first and then it trickles its way to other banking areas such as commercial and equipment lending.

Over the past two years the nation has seen an increase of mortgage lending from non-bank institutions (shadow banks) by 30%. Transactions that would have usually been accepted by a big four bank are now being turned away and the other players in the market are jumping at the opportunity for more business, naturally these shadow banks are priced higher than a big four bank but are hungry for the business nonetheless. This growing number of lending start-up companies is

AMT DEC/JAN 2019

the sign of a shake-up of the banking industry where the big four banks will have to drastically change the way they operate or risk losing part of the market share in lending.

What will change and how does it affect businesses going forward?

The trend in the price of bank shares shows ANZ has declined by 10% this year, while Commonwealth Bank, National Australia Bank and Westpac shares have all declined by around 15% compared to the 4.3% decline in the broader market. As the big four banks are currently releasing their annual profits it is also expected the decline in share prices to translate to their profits as well. It is likely that lower profits for the banks will be an ongoing trend as they work to implement new operations and compliance procedures to rectify their previous misconducts that were found at the Royal Commission. How this all translates to the average business owner is in interest rates and bank fees. Ongoing costs are going to be permanently higher because of the increased regulatory and compliance costs, which has been happening for some time now but will be stepping up to another level.

As a business owner, the current climate can be viewed as having a short-term negative affect due to these increases in costs, but the changes that are happening will clean up and strengthen the banking and lending industries in the long run which is beneficial to all business. The increased competition in lending is important to have and will be a long-term benefit along with the changes that the big four banks are making internally as a result of the royal commission - bringing them back to a more simplified, lending focused model. Whilst it is difficult to navigate the finance world while running a business at the same time it can be made simple by having the right people working for you to ensure the correct financial strategy.

Interlease has over 40 years specialist experience in commercial financing, working with clients, accountants and suppliers to structure finance to meet almost any requirement, as well as extensive expertise in structuring transactions, whether it’s another forklift or large imported machinery, which requires managing currency, interest rate and supplier risk.

Please contact Angus Macdonald on 03 9420 0000 or amacdonald@interlease.com.au www.interlease.com.au

FORUM

HEADING

LOGISTICS

Why are ethical and sustainable supply chains important?

Lawrence Christoffelsz explains the importance of an ethical and sustainable supply chain - particularly in today’s information age where consumers base their choices on these criteria.

Do you know the complete sourcing and life-cycles of the products you sell? Are the packaging and transportation methods you use good for the environment? What about the labour and working conditions of the factories across your supplier base?

If you can’t answer all of the above questions immediately and accurately, then your business is potentially at risk of reputational damage, but more importantly, not taking your corporate and social responsibilities as seriously as you should. In today’s information age, consumers are quickly able to identify and select products and companies who operate ethically and sustainably in order to ensure their business and brand/s represent much more than basic commercialism models.

There have been some highly publicised cases of well-known global brands suffering immense public humiliation when the working conditions of the actual people manufacturing their products have been appalling. This has not only damaged their brand and corporate reputation, but also severely impacted their bottom-line profits.

There is simply no longer any excuse for any company selling products not taking steps to: a) identify the environmental and social impacts of their business, and b) taking positive steps to improve these impacts for the greater good as part of their overall corporate culture and policies.

In Australia, we’re often enviably referred to as ‘The Lucky Country’, and as such, I believe we have taken our environment, working and living conditions for granted for many decades.

As a previous lecturer on ethical and sustainable supply chains, I often found it challenging to find Australian companies to use as positive case studies for my students to research and use for benchmarking.

More often than not, it was European companies who are leading the way when it comes to truly living ‘corporate and social responsibilities’ and embedding these values within the very fabric of their organisation’s culture.

Yes, there is time and money involved to develop proper supplier evaluation and selection policies, recycling and renewable alternatives in your products and/or packaging, and implementing initiatives such as carbon tracking across your logistics or freight utilisation. However there are numerous benefits to making the effort.

To begin with, your organisation’s culture immediately starts to improve and, (when implemented correctly), most staff consider their individual impacts on wastage, which in-turn reduces costs and improves accountability across departments and functions. As we all already know, the ability to measure anything then enables us to identify ways to improve them.

Innovative solutions are often identified by teams themselves in order to resolve or improve any environmental or corporate social areas of concern. Your suppliers begin to implement the same guidelines, measuring and values as a result of your own, local initiatives. Thus, making a positive difference to the suppliers’ workers and their broader communities.

In many instances, your marketing department gets very excited about the ability to promote your company and its products with key points of difference – with positive impacts to the global economy.

And, as a result of your initial investment in time and money to set all of this up, your customers typically reward you with more sales revenue and greater customer loyalty. Sure, the journey of implementing initiatives such as an EMS (Environmental Management System) and/or a CSR (Corporate Social Responsibility) Framework for your organisation will no-doubt have a number of key challenges.

However, in my opinion, companies no longer have a choice. With the increasing data capturing and logistics innovations such as blockchain and environmental reporting, every single stakeholder across your organisation’s supply chain will be intensely scrutinised and held to account, by industry, local and foreign government reporting agencies and, most importantly, by your customers.

The future of global business and supply chains is a very transparent one, with everyone being forced to participate.

I believe this is an extremely positive way for the future. As business owners, we all aspire to leave a positive legacy - for our workers, our families, and for the community at large. The difference is; we need to broaden our perspective. Our businesses are no longer ‘local’, or even ‘Australian’ . Every company, in every Country, is now part of a ‘GLOBAL’ economy and community.

It is an exciting time in history, where doing business is becoming truly borderless and there appears to be an increasing groundswell of organisations all across the globe who are ensuring their business goals are fully aligned with those of the current and future consumers.

It’s time to embrace this as a positive opportunity in your own organisations and ensure we leave our businesses, our customers and our planet in the best possible conditions we can.

If you don’t know how to start the process of changing your corporate culture to enhance your ethical credibility, I welcome your questions.

My background and experience in ethical and sustainable supply chains will assist you as you embark on this important mission.

Good luck on your journey of implementation and transformation.

Lawrence Christoffelsz is the CEO of ‘The Australian Trade & Logistics Corporation’ and has been the previous Chairman of the Australian Chamber of International Trade, along with a number of boutique consultancy firms in export, logistics and supply chain. He is passionate about global business and actively supports all organisations to grow their business across borders. Ph: 1300 817 055 www.australiantradelogisticscorporation.com.au

AMT DEC/JAN 2019

109

110

AMTIL INSIDE

Australian Manufacturers visiting Jimtof 2018 Quite a few AMTIL members were in Tokyo in November for Jimtof 2018, the International Machine Tool Fair.

AMTIL regularly attends the major overseas exhibitions and this November it was Jimtof in Japan. AMTIL had a booth within the International Associations area of the show, alongside manufacturing assocations from countries all over the world. As well as enabling us to provide information and advice about manufacturing in Australia to anyone who came by the stand, it offered the opportunity to network and interact with those other associations, sharing insights about the state of the industry and exploring opportunities to collaborate.

Moreover, having a fixed presence on the exhibition floor meant we were able to support any Australians who were visiting the show, offering a port of call where they could drop by for a chat and a refreshment â&#x20AC;&#x201C; our team were pleased to bump into a fair few familiar faces from back home during the week of the show. The ANCA Group also made their presence felt in the exhibition, having a prominent stand in Hall 2.

A delegation of over 50 Australians attended the event this year and most reported a successful visit, whether it be for catching up with overseas principals, investigating technology solutions or simply looking for new opportunities.

Whilst we are talking about overseas shows, AMTIL will be present at EMO 2019 and I am in the process of booking accommodation for September next year. If you would like to attend and need a hotel room, please let me know.

AMT DEC/JAN 2019

AMTIL HEADING INSIDE

Additive Manufacturing Hub launches new website The Additive Manufacturing Hub unveiled its new website in October. Accessible at www.amhub.net.au, the new site contains a wealth of resources for anyone with an interest in the fast-evolving world of additive manufacturing.

The Additive Manufacturing Hub is a new initiative delivered by AMTIL in partnership with the Victorian State Government to provide an industry-driven collaborative network of additive manfacturing technology users, suppliers and supporters that will foster and grow the adoption of this breakthrough technology. The new website will act as the key online portal for the Hub and its activities, as well as providing up-tothe-minute information on the latest trends in additive manufacturing.

The site features a comprehensive industry directory of manufacturers, technology suppliers and service providers operating in the additive manufacturing space, as well as information on the grant funding available through the Additive Manufacturing Hub. It also includes news on what’s going on in additive manufacturing, and a calendar of notable upcoming local and international events. Further features will be added in the near future, including a Press Centre where Additive Manufacturing Hub members will be able to post their own media releases, and a host of other useful resources.

A key activity within the Manufacturing Hub will be to identified skill gaps within the developing capability in areas

Additive address industry, such as

assistance to companies that want to develop business cases for investment in Additive Manufacturing technology, undertake design services or re-engineer existing products. Grants of up to $20,000 will be issued to access the expertise of a Registered Service Provider. All grants must be matched with a minimum cash contribution of $1 for every $1 granted.

Along with the new website, the Additive Manufacturing Hub has also launched Addition, a monthly e-newsletter that rounds up the Hub’s current activities, as well as the latest additive manufacturing news from across Australia and the world.

business case analysis and design for manufacture through Registered Service Providers. To deliver on this, a significant service offered to Additive Manufacturing Hub Members will be the ‘Build It Better’ Additive Manufacturing Hub Grants Program. These grants will provide

“We are very excited to have formally launched the Additive Manufacturing Hub website,” said Alex Kingsbury, Additive Manufacturing Hub Consultant. “It is great to finally have an online presence up and running! We will continually be improving and enhancing the Additive Manufacturing Hub website and would love to hear any feedback from users.”

Membership of the Additive Manufacturing Hub is free. For more information on the Additive Manufacturing Hub, please contact Alex Kingsbury, Additive Manufacturing Hub Consultant, on amhub@amtil.com.au. www.amhub.net.au 1382AMTIL

AMTIL is delighted to welcome Association Insurance to its Corporate Partnership Program.

AMTIL’s corporate partners offer a selection of products and services that will benefit our members in their business.

For any enquiries about our Corporate Partnerships, and how they can benefit you, contact Anne Samuelsson on 03 9800 3666 or email asamuelsson@amtil.com.au

Our Partners. Our Members. Your Benefits.

www.amtil.com.au

AMT DEC/JAN 2019

111

112

AMTIL INSIDE

AMTIL AGM looks to the future AMTIL held its 2018 Annual General Meeting on 18 October at Riversdale Golf Course in Mount Waverley, Victoria.

The AGM was preceded by a networking breakfast followed by a pair of expert presentations. The keynote address, ‘Fit for the Future’, was given by futurist, author and consultant Gihan Perera. In an entertaining and wide-ranging talk, Perera explored the global megatrends shaping business and society, and how you can take more control of your own future.

Perrera was followed by a presentation by Dr Rita Choueiri of William Buck Chartered Accountants & Advisers, who discussed the Federal Government’s Research & Development (R&D) Tax Incentive,

shedding light on how AMTIL members can take advantage of the scheme. For the AGM itself, AMTIL CEO Shane Infanti gave a round-up of the association’s actvities over the course of 2018, and offered details of the Association’s plans for the coming year – most notably the Austech exhibition, to be held in Melbourne in May. AMTIL President Paul Fowler also gave a speech about AMTIL’s ongoing work in support of Australian manufacturing, after which AMTIL board member Paul Philips delivered the financial report. “We are closing in on yet another activity-packed year at AMTIL,”

said Fowler. “On behalf of the Board I once again pass on our thanks to Shane and his team for their diligence and passion. I would also like to acknowledge and thank my colleagues on the Board who volunteer their valuable time to provide support, leadership and guidance to AMTIL. Hearty thank yous also to all of our members who are clearly the reason for AMTIL to exist and we sincerely trust that AMTIL is delivering real value to you and your businesses.” www.amtil.com.au

AMTIL CEO Shane Infanti addressing the 2018 AGM.

AMTIL Press Centre – Start making headlines The AMTIL Press Centre is a new service exclusive to AMTIL members, helping you to secure media coverage for your products, services and other activities.

Introduced as part of the recent relaunch of AMTIL’s website, the Press Centre is a new member benefit designed to assist AMTIL members in promoting their businesses. The AMTIL Press Centre is an online resource where media outlets will be able to find the latest press releases and media announcements concerning the manufacturing industry and manufacturing techonology in Australia.

In addition, AMTIL has secured access to a database of more than 375,000 journalists in Australia and internationally. In the near future we will be sending out a regular digest of the latest material to appear on the AMTIL Press Centre, meaning your press release will get exposure worldwide.

Any AMTIL member can submit their press releases direct via the AMTIL website. To submit a press release, log in to the Members Only area of the website (www.amtil.com.au/wp-admin) and click on the tile marked ‘Press Centre’. Then you just have to fill in

AMT DEC/JAN 2019

the online form, pasting the text of your press release into the relevant fields; please also ensure you include your company’s logo. Along with the basic text, you can also upload up to three accompaning image files (in jpg format), as well as as a pdf or Word doc version of the press release.

The AMTIL Press Centre can be found under the News tab of the AMTIL website. For more information, please contact William Poole, Editor – AMT Magazine, at wpoole@amtil.com.au, www.amtil.com.au/news/press-centre

113

AMTIL INSIDE

Austech 2019 set to be record-breaking show Austech 2019 appears to be on course to be a record-breaking show, with advance bookings from exhibitors far surpassing expectations, and high levels of interest from across the industry.

Scheduled to take place at the Melbourne Convention and Exhibition Centre (MCEC) from 14-17 May 2019, Austech is Australia’s premier advanced manufacturing and machine tool exhibition. Owned and organised by AMTIL (the Australian Manufacturing Technology Institute Limited), Austech 2019 will be co-located with National Manufacturing Week (NMW), with more than 10,000 industrial decisionmakers expected to visit the show.

Sales of floor space for next year’s show are currently significantly ahead of levels recorded at this point during preparations for Austech 2017, which became one of the most successful shows in the event’s history. To date, more than 4,500sqm of space have already been sold, representing around 85% of the available exhibition area.

Moreover, floor space sales to date have come from just 90 exhibitors, indicating that many manufacturing technology suppliers are planning on taking bigger stands at Austech 2019.

As this issue of AMT went to print, AMTIL had just made the decision to significantly expand its booking with the MCEC, to accommodate the additional exhibitor numbers expected. This enlarged footprint sets the scene for a show featuring several major exhibits of heavyweight equipment among a diverse line-up of the latest, most advanced manufacturing technology.

“Bookings have been incredibly strong,” says Kim Banks, AMTIL’s Events Manager.

“As well as those companies who have already finalised their bookings, we are also currently awaiting several large bookings that we believe are very close to being confirmed, so we’re anticipating having allocated 85% or more of the floor space by mid-December. At five months out from the start of the show, that would be an amazing outcome.”

In addition to the exhibition itself, Austech will also feature an extensive speaker

program at two presentation theatres, run in partnership with NMW. The Industry 4.0 Theatre and the Connected Manufacturing Theatre will feature a range of expert speakers exploring a number of different issues. AMTIL and NMW are currently inviting speakers to come forward who are interested in delivering a presentation, with submissions due to close on 30 November.

Alongside Austech’s traditional focus on machine tools and ancillary equipment, Austech 2019 will feature a number of dedicated technology areas. The Additive Manufacturing Pavilion will once again showcase the latest advances in 3D printing, while the Digitalisation Pavilion – returning after a highly successful debut in 2017 – will explore developments at the cutting edge of manufacturing technology. The latest addition is the Air Technology Pavilion, a new area displaying the latest state-of-theart compressors and air technology.

Interest has also been strong in the Manufacturers Pavilion, an area devoted to highlighting some of the most innovative manufacturing companies working in Australia. First launched at Austech 2013, The Manufacturers Pavilion has enjoyed consistent growth in the number of companies exhibiting, and next year appears set to see that trend continuing.

“We’re certainly gearing up for a big show in May,” adds Banks. “We’re expecting to see many more bookings in the coming weeks, making Austech 2019 an unmissable event for anyone with an interest in manufacturing in Australia. I guess for companies holding off on deciding whether to participate, with space selling so fast, the question is whether they can afford not to be there in May.” Companies who are interested in exhibiting at Austech 2019 should contact AMTIL on 03 9800 3666 or by emailing AMTIL’s Events Manager Kim Banks on kbanks@amtil.com.au www.amtil.com.au/austech

targetted audience 9000+ contacts

impact 20.02% average open rates

outcome 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.

AMTIL1305

www.amtil.com.au

AMT DEC/JAN 2019

114

AMTIL INSIDE

Tee up for the AMTIL Golf Day

Queensland members get together

AMTIL’s annual Corporate Golf Day and Barbecue Lunch will take place on 8 February at Riversdale Golf Club.

AMTIL members in Queensland came together at the Novotel Brisbane Airport on 11 October for a meeting of the local AMTIL members’ group.

The Golf Day will be a four-ball ambrose event with participants invited to nominate teams of four. The event includes a light breakfast, lunch and drinks plus trophies, prizes and giveaways.

Golf will commence at 7.30am, with lunch served as the golf finishes – at around 1.00pm.

Date and Time: 8 February 2019.

7.30am – 2.30pm Location:

Riversdale Golf Club Cnr Huntingdale Road and High Street Road Mount Waverley, Victoria 3149

Places are limited, and preference will be given to AMTIL members if demand exceeds availability. Any individuals who book will be placed in teams by the organisers. AMTIL would like to thank William Buck Chartered Accountants & Advisers, for their generous support as the major sponsor of this event.

To book your place at the AMTIL Golf Day, please visit the Events page on the AMTIL website or scan the QR code.

For more information about AMTIL Golf Day or any of AMTIL’s upcoming events, please call 03 9800 3666, or email Events Manager Kim Banks on kbanks@amtil.com.au. www.amtil.com.au/Events

The meeting was an opportunity for AMTIL members in Queensland to come together and discuss some of the issues affecting them and their businesses, share information, explore opportunities to work together collaboratively, and simply to catch up with old friends. It was also a chance for AMTIL to discuss its work in state and nationwide, get feedback on current initiatives, and plan future activities for the Queensland group going forward.

Along with the regular meeting business, the event featured a presentation from Dr Rita Choueiri of William Buck Chartered Accountants & Advisers, on the Federal Government’s Research & Development (R&D) Tax Incentive, and how manufacturing business can take advantage of the scheme.

In attendance on behalf of AMTIL were CEO Shane Infanti, Events Manager Kim Banks, and Business Development Manager Derek Gancar. The AMTL board were also represented by AMTIL President Paul Fowler of Dimac Tooling, and Andrew Rodgers of Bolts & Industrial Supplies. Following the meeting, there was a networking session with drinks and refreshments.

The Queensland meeting was one of a number of member gatherings that AMTIL regularly organises across the country.

To find out more about AMTIL events in your area, contact Greg Chalker, Corporate Services Manager at AMTIL, on 03 9800 3666 or email gchalker@amtil.com.au.

Save the date: The 2019 AMTIL National Conference With Austech dominating the first half of next year’s industry calendar, AMTIL can now confirm the date for another event you should definitely mark into your diary for later in 2019.

The 2019 AMTIL National Conference will be held on Tuesday 10 September, at Leonda by the Yarra. This all-day conference follows on from highly successful events run by AMTIL at the same venue in 2017 and 2018.

Details of the theme for next year’s Conference and the speaker program will be confirmed over the coming months. As well as the speaker program itself, the Conference will feature a number of exhibition stands, and will include a series of networking breaks during the day, followed by an evening cocktail function.

For more information on the 2019 AMTIL National Conference or any other upcoming AMTIL events, please contact Kim Banks, AMTIL Events Manager, on 03 9800 3666 or by calling kbanks@amtil.com.au. www.amtil.com.au/events

AMT DEC/JAN 2019

AMTIL INSIDE

Brian Leckie joins AMTIL’s Entrepreneurs’ Programme team AMTIL has appointed Brian Leckie to work as a Business Adviser on the Federal Government’s Entreprenuers’ Programme. Leckie will be working with AMTIL to deliver the EP in South Australia.

AMTIL is a partner organisation in the Entrepreneurs’ Programme (EP), a flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. The EP forms a part of the Australian Government’s Economic Action Strategy, deploying more than 100 experienced advisers and facilitators offering support to businesses through five key elements: • • • • •

Business Management Innovation Connections Accelerating Commercialisation Incubator Support Business Growth Services & Supply Chain Facilitation

Leckie is a qualified accountant, business consultant, project manager, trainer and assessor. He has an Advanced Diploma in agriculture as well as in competitive manufacturing. He has been in executive management of some of the largest regional fruit-based companies in the country and has a unique knowledge and understanding of business in Australia.

Leckie has used his accounting knowledge and manufacturing experience across many industries, ensuring improvements in efficiencies, costs, financial control and overall company performance.

“I believe that waste in any business represents the first opportunity for improving company performance,” says

Over the last 10 years Leckie has worked with many SMEs and has been involved in an impressive number of company ‘turnarounds’, and he is looking forward to continuing to assist many more similar companies. Leckie has been described as a ‘hands-on’ consultant and a very good leader of people, who takes responsibility and authority extremely seriously.

Leckie. “Once the waste opportunity is accepted, there is always a way to valueadd, finding the way is the opportunity and challenge.”

Leckie has extensive experience in export marketing, being Chairman of the Australian Food Exporters Group and a member of the South Australian Premiers’ Food Council. His demonstrated strengths in lateral thinking have resulted in a number of innovative, world-first fruit-based health products being produced by companies with whom Leckie has been involved.

Additional strengths include strategic and business planning, operational and continual improvement, team building and quality management.

Leckie anticipates that his work with AMTIL in delivering the EP will benefit many regional companies. He believes the Programme offers much that can be of benefit to companies, and many businesses are not aware of the assistance that is available. According to Leckie, there are many businesses in Regional Australia that are merely looking for a little assistance and guidance to take them to their next level. The EP can help here.

Leckie is married to Kathy, his wife of 40 years, with two grown children and two grandchildren. He lives in Barmera, South Australia, approximately 250km north-east, of Adelaide. On his appointment, Leckie said: “I’m looking forward to working with AMTIL, and the excellent people that make up the team.”

For more information about the Entrepreneurs’ Programme, please contact Greg Chalker, Corporate Services Manager at AMTIL, on 03 9800 3666 or email gchalker@amtil.com.au www.amtil.com.au/members/ entrepreneurs-programme

1285AMTIL05

The right job, the right piece.

•

You need a specific component made, but don’t have the capabilities in house.

•

You’ve 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. Gain access to a wealth of Australian manufacturing capability and expertise. www.amtil.com.au/Membership/Hotspots

Hotspots is proudly owned and managed

by AMTIL

AMT DEC/JAN 2019

115

116

INDUSTRY CALENDAR

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event More events can be found on AMTIL’s website

INTERNATIONAL Inside 3D Printing Mumbai: 19-20 December 2018 Melbourne: 14-17 May 2019 Brazil: 10-11 June 2019 South Korea: 26-28 June 2019 www.inside3dprinting.com

St. Petersburg Technical Fair Russia, St. Petersburg 12-14 March 2019 en.ptfair.ru

BLECH India India, Mumbai 25-27 April 2019 www.blechindia.com/2019/english/

2019

INTERMOLD KOREA South Korea, Goyang 12-16 March 2019 www.intermoldkorea.com/2019/en

EXPOMAFE Brazil, Sao Paulo 7-11 May 2019 www.expomafe.com.br

SteelFab United Arab Emirates, Sharjah 14-17 January 2019 www.steelfabme.com

Metal + Metallurgy China China, Shanghai 13-16 March 2019 www.mm-china.com/En

INTERMACH Thailand, Bangkok 8-11 May 2019 www.intermachshow.com/en-us

IMTEX India, Bangalore 24-30 January 2019 www.imtex.in

WIN EURASIA Turkey, Istanbul 14-17 March 2019 www.win-eurasia.com/en

Made in Steel Italy, Milan 14-16 May 2019 www.madeinsteel.it/en

EXPO MANUFACTURA Mexico, Monterrey 5-7 February 2019 www.expomanufactura.com.mx

Mashex Siberia Russia, Novosibirsk 26-28 March 2019 www.mashex-siberia.ru/en-GB

SWISSTECH Switzerland, Basel 14-17 May 2019 www.swisstech-messe.ch

Intec Germany, Leipzig 5-8 February 2019 www.messe-intec.com

Machineering Belgium, Brussels 27-29 March 2019 www.machineering.eu/en/concept

Saw Expo Germany, Augsburg 14-17 May 2019 www.saw-expo.com/en

TURNING DAYS Germany, Friedrichshafen 19-22 February 2019 www.turning-days.de/en

MECSPE Italy, Parma 28-30 March 2019 www.mecspe.com/en

LAMIERA Italy, Milan 15-18 May 2019 www.lamiera.net/en/home

MachAutoExpo India, Punjab 22-25 February 2019 www.machautoexpo.in

SIMM China, Shenzhen 28-31 March 2019 www.simmtime.com/simm_en.htm

China Machine Tool Exhibition China, Shanghai 26 February – 1 March 2019 www.cme-shanghai.com

Advanced Factories Spain, Barcelona 9-11 April 2019 www.advancedfactories.com/en

Moulding Expo Germany, Stuttgart 21-24 May 2019 www.messe-stuttgart.de/moulding -expo/en

TIMTOS Taiwan, Taipei 4-9 March 2019 www.timtos.com.tw

Powder Metallurgy Belarus, Minsk 9-12 April 2019 www.minskexpo.com/poroshkovayametallurgiya

TECMA Mexico 5-8 March 2019 www.tecma.org.mx INDUSTRIE Lyon France, Lyon 5-8 March 2019 www.industrie-expo.com/fr BLE.CH Switzerland, Berne 5-7 March 2019 www.ble.ch/ble-de CIEX China, Tianjin 7-10 March 2019 www.chinaexhibition.com (search for CIEX) Asiamold China, Guangzhou, 10-12 March 2019 www.asiamold-china.cn. messefrankfurt.com

AMT DEC/JAN 2019

METAL OSAKA Japan, Osaka 22-24 May 2019 www.metal-kansai.jp/en BUTECH South Korea, Busan 22-25 May 2019 www.butech.or.kr

DST Südwest Germany, Villingen-Schwenningen 10-12 April 2019 www.dstsuedwest.de

Subcon UK, Birmingham 4-6 June 2019 www.subconshow.co.uk

MachTech & InnoTech Expo Bulgaria, Sofia 15-18 April 2019 www.machtech.bg/index.php/en

AmeriMold USA, Chicago 12-13 June 2019 www.amerimoldexpo.com

CIMT China, Beijing 15-20 April 2019 www.cimtshow.com

IMTOS India, New Delhi 14-17 June 2019 www.kdclglobal.com/imtos

INTERMOLD Japan Metal Stamping Die & Mould Asia Japan, Tokyo:- 17-20 April 2019 Japan, Nagoya: June 19-22 2019 www.intermold.jp/english

EMO Hannover Germany, Hannover 16-21 September 2019 www.emo-hannover.de

INDUSTRY CALENDAR HEADING LOCAL Australian International Airshow/Avalon Geelong, Avalon (Victoria) 26 February–3 March 2019 Technology of tomorrow with special insights into space exploration and man’s foray into this “final frontier”. Hundreds of the world’s leading innovators:aerospace,aviation and defence products and inventions. www.airshow.com.au Auspack Melbourne Convention Centre 26-29 March 2019 Australia’s largest bi-annual exhibition for the processing and packaging sectors.

Showcasing innovation and megatrends for the food, beverage and pharmaceutical sectors. Includes: Fast and flexible machinery; Track and trace; Smart packaging; Digital printing; E-commerce; robotics; Factory of the future www.auspack.com.au Australasian Oil & Gas Expo 2019 Perth Convention & Exhibition Centre 13-15 March 2019 The latest products and technological breakthroughs for the Australian oil and gas industry. Includes specialised industry zones showcasing the latest in Instrumentation Control and Automation, Asset Integrity, Subsea and Health, Safety and Environment. www.aogexpo.com.au Australian Auto Aftermarket Expo Melbourne Convention Centre 4-6 April 2019 Comprehensive exhibition of vehicle repair and servicing equipment, replacement parts, tools and accessories. www.aftermarketexpo.com.au AusMedtech Melbourne Convention Centre 14-15 May 2019 Australian and international medical devices and diagnostics sector to help prepare the industry sector for its changing landscape. Australia’s premier medical technology conference for the Australian and international medical devices and diagnostics sector to discuss the major issues in global medtech success. www.ausmedtech.com.au

DesignBUILD International Convention Centre, Sydney 14-16 May 2019 The only dedicated trade show to bring together Australia’s built environment with leading product and materials suppliers from across the build process. Includes the latest construction innovations and architectural trends - catering to the whole of the build process and connecting directly with Australia’s architecture, building, construction and design communities. Includes three dedicated zones showcasing products and materials across; Construction & Building Materials, Interior Fixtures & Finishes and Software & Technology. www.designbuildexpo.com.au Austech 2019 Melbourne Convention & Exhibition Centre 14–17 May 2019 Australia’s premier advanced manufacturing and machine tool exhibition. The only show specifically targeted at the metalworking, machine tool and ancillary market in Australia.

Includes the Additive Manufacturing Pavilion and Manufacturers Pavilion and the “Inside 3D Printing” event – the largest professional 3D printing & additive manufacturing event series worldwide. www.amtil.com.au/Austech Workplace Health & Safety Show Sydney International Convention Centre 22-23 May 2019 A dedicated exhibition showcasing the latest technology, services and products to improve the workplace safety standards in Australia.

This safety event is for all safety professionals from a range of industries including manufacturing, building/construction, mining, councils/locals government, hospitals, transport and more. Focusing on Prevention, Information & Support, the event will provide suppliers and manufactures with the opportunity to connect with a wide range of decisions makers/officials from companies all over Australia. Co-located with The 2019 #SAFETYSCAPE Convention’s National Health & Safety Conference. www.safetyscape.com.au/events/ workplace-health-safety-show

Advertiser Index 600 Machine Tools 75 AGL 85 Alfex CNC 23 Amiga Engineering 49 ANCA 93 Applied Machinery 15 Autodesk 36-37 Bystronic P/L 6-7 Complete Machine Tools 21 Conflux Technology 39 Emona Instruments 89 Global Job Solutions 65 Hare & Forbes 4-5 Headland 120 IMTS 27 Industrial Laser Cover & 91 Iscar 2-3 Machinery Forum 119 Mastercam 97 Metal 3D 63 MTI Qualos 41 & 61 Okuma 9 Precise Machining & Manufacturing 11 Raymax 43 Robert Bosch 59 Ronson Gears 53 Seco Tools 17 Sutton Tools 57 Syspro 25 Thyssenkrupp 73 Treotham 103 Vaughan Construction Pty Ltd 13 William Buck 51 Amiga Engineering Insert Applied Machinery Insert Hare & Forbes Insert Headland Insert Henkel Insert Sheetmetal Machinery Insert

AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

FEBIMAR19

AUSTRALIAN

MANUFACTUR ING TECHNOLOGY YOUR INDUST RY. YOUR MAGAZ INE

OCTINOV18

AEROSPACE & DEFENCE Renewable Energy & Clean Tech

BOOK YOUR 2019 ADVERTISING NOW! AUSTRALIA’S NO. 1 ADVANCED MANUFACTURING MAGAZINE Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asamuelsson@amtil.com.au

STATE SPOTLIGHT: Tasmania Additive Manufacturing Quality & Inspection Sensors

APPROX

MEDICAL

Construction & Infrastructu re State Spotlight: Queensland

31,500

READERS

Software Cutting Tools Forming & Fabrication Material Removal

AMT DEC/JAN 2019

117

118

HISTORY

From the book “Aircraft Pioneer” by Sir Lawrence James Wackett (1896 – 1982)

PART 28

PROPELLING AUSTRALIA PART 4

Wackett’s mission – In his own words In this edition, we hand over the reigns to Sir Lawrence James Wackett, who became known as the father of the Australian aircraft industry. As mentioned in a previous edition of AMT, Wackett was selected by Laurence Hartnett to lead a three-man mission of inquiry to Europe and America, to investigate overseas aircraft and select a type suitable for Australia’s defence needs and within Australia’s capabilities to build. Below, Wackett describes the five-month mission in his own words. The group, consisting of Lawrence Wackett, H.C.Harrison, and A.W.Murphy, set sail in February 1936.

I

felt that a new era for the Australian Air Force, and for myself, had begun and I hastened to make preparations to leave on the mission - sailing on the Otranto. War was threatening in Africa, Europe and the East. And the situation in Germany had many convinced of the need to act quickly. While our ship was moving up the Red Sea at Aden, our visit coincided with a concentration of the RAF following the war in Ethiopia. We inspected the RAF’s aircraft. There could be only one conclusion: Britain was at this time thoroughly unprepared for war. Mussolini knew this and was rattling the sabre in the Mediterranean.

Our first stop was London where we reported at Austral Development to meet the Australian High Commissioner, Stanley Melbourne Bruce. Bruce could not accept seriously the proposal to build aircraft in Australia. I assured him that this was the intention of the syndicate and handed him my credentials and letters. Bruce sneered, threw them back and they fell on the floor. There was silence for a few moments while I picked them up. I was informed that such highly technical matters as aero engines could not be successfully made in Australia. It was my resolution that he should be disillusioned within a very short time. The British were hurt when I revealed that we were also going to visit Germany and the US. Surely, there was little room for doubt that British aircraft were the best? My reply was that I sincerely hoped that we would find this to be so, but we had been instructed to see what was being accomplished elsewhere.

They laughed at the suggestion that we would be permitted to see anything in Germany.

We then commenced an inspection of the British aircraft industry.

We found feverish efforts to expand the industry. The threat of Goering’s Luftwaffe (Nazi Germany) had been realized. Everywhere I went I found old-fashioned, poorly-equipped aeroplane factories.

The prototype Spitfire I saw was really the only first-class aeroplane in England at the time. Unfortunately, it was not a suitable aircraft with which to begin an aircraft and engine industry in Australia.

The next stop was Holland, where we found the Fokker plant small in comparison with the English factories. France was next - here the technical standards were very high despite the political strife (Socialism was recently introduced). After that came Czechoslovakia where we found a splendid light alloy foundry with very modern techniques.

Next stop: Berlin. There was a picture of Hitler in every shop window and here and there Brownshirts with side-arms stood silently eyeing the passers-by. The visit completely shook me. Nowhere else, in England, Holland or France, had we seen anything to approach these Establishments. They were new and modern in every way.

The engineering technique was superior to anything we had seen in England. In two of the factories which we were permitted to inspect, the aircraft in production were some of the types which swarmed over England later - during the Battle of Britain.

Last stop: The USA – and the sooner the better! We had been told that the great revival in Germany had been the result of studies in the US by German engineers, and I felt that the solution to Australia’s This is an extract from “Aircraft Pioneer” by Sir Lawrence James Wackett.

AMT DEC/JAN 2019

problems lay there also. We visited United Aircraft, the Wright Corporation, Fairchild, Martin, Grumman, Douglas, North American, Lockheed and Consolidated and many smaller plants. The enormous industry, employing millions of men, exceeded anything we had imagined.

The Americans believed in aviation and had poured capital into their industry for the previous five years. We, in Australia, had almost completely overlooked aviation. Hitler had sent envoys to the US a few years before, and, on their reports, the Junkers works and other factories had been rebuilt. We also found that Japanese engineers had been visiting American plants, and, during World War II, we discovered that Japan had developed aircraft production on American models. To us, it was soon clear that we must base our technique for the new industry in Australia on the American developments.

We selected an American design of aircraft and engine: the Pratt and Whitney Wasp H radial engine of 600 hp - a product of United Aircraft Corporation, and the North American NA 33 monoplane, a general purpose military aircraft that became the basic advanced trainer. The British Air Ministry was shocked at our consideration of US-designed aircraft.

We purchased licence agreements for both airframe and engine, and carried these back to Australia. I hurried to Melbourne to present my report. Our scheme was finally (after a struggle) accepted in its entirety though with bad grace by the British Air Ministry.

We will resume our normal instalments of Sir Laurence Hartnett’s book Big Wheels & Little Wheels in the next edition of AMT

salvagninigroup.com

Electric panel bender.

Flexibility

Universal bending tools for different materials and thicknesses.

Productivity

Patented kinematics and high dynamics.

Sustainability

Sustainable consumption and small footprint.

Simplicity

Easy programming and 3D simulation of bending process with EDITP4 2.0 software.

ONLY 3 kW

UNIVERSAL BENDING TOOLS

ZERO SET-UP TIME

Fully automated and adaptive, the P1 panel bender features automatic tool change, universal bending tools and MAC 2.0 technology. Making the impossible possible.

Machinery Forum NSW Pty Ltd 43 Brodie Street, Rydalmere NSW 2116 Phone: +61 2 9638 9600 Email: machinery@mafosyd.com.au

ZERO SCRAP

“

We’re using 21st century technology to automate our processes and manufacture high quality products.

”

- Damien Berry, R&D Manager, Norris Industries.

Image of new model shown.

Automation & Connectivity A clear advantage for Aussie Dishwasher Manufacturer Norris Established in 1954, Australian Manufacturer Norris Industries is committed to innovation.

What Norris Industries’ connected factory looks like: •

TRUMPF TruMatic 5000R with SteetMaster & GripMaster, for quality and fast machining.

•

TRUMPF TruBend 5130 for precision and folding with minimal scrap.

•

TRUMPF Bendmaster increases productivity and eliminates manual processes.

•

Hanel Lean Lift for faster pick times & cleaner storage solution.

•

SOCO Pipe Bender allows all tubes to be bent in-house.

To read more about Norris Industries story, visit www.headland.com.au/ norris-industries-case-study/

1300 592 061 sales@headland.com.au headland.com.au