AMT FEB/MAR 2019

AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

FEBIMAR19

DEFENCE & AEROSPACE Clean Tech & Renewable Energy State Spotlight: Tasmania

After introducing the World-Renowned Absolute System to Digimatic Calipers, Mitutoyo now announces a further major breakthrough in electronic Caliper Design.

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AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

FEBIMAR19

DEFENCE & AEROSPACE Clean Tech & Renewable Energy State Spotlight: Tasmania

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008

CONTENTS

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

FEATURES AEROSPACE & DEFENCE Set to soar Building our own warships crucial The competition is in the deadline Transformation in 3D for GE Aviation Innovation takes flight at Avalon 2019 Lightweight electricity solution for defence units

44 50 51 52 54 56

ADDITIVE MANUFACTURING RMIT spotlights Design for AM Birdstone delivers Schweppes redesign Leveraging full potential of heat exchanger with AM

58 60 62

FORMING & FABRICATION Bystronic – Setting the pace for factory automation

70

QUALITY & INSPECTION Hexagon CMM enhances Nupress Transforming manufacturing: Augmented reality

73 74

CLEAN TECH & RENEWABLE ENERGY Aussie invents new-breed of e-motorcycles Olympics spark success for SA clean combustion

76 78

CUTTING TOOLS Milling tools for high metal removal rates Operational excellence in the Industry 4.0 era Tools at the touch of a button

80 82 84

STATE SPOTLIGHT: TASMANIA Advancing Tasmania’s manufacturing Cobot for innovative Tasmanian manufacturer Elphinstone looks to future

86 88 89

WORKHOLDING LANG Technik – Innovation leaders

92

MATERIAL REMOVAL ANCA collaboration brings efficiency gains for Fraisa Automated die machining boosts manufacturing capacity

94 95

SOFTWARE & IT RONDO: Increased business insight & savings Small manufacturers are uniquely suited for digital era The evolution of manufacturing is driving Industry 4.0 Australian manufacturers risk lagging behind

96 98 99 100

SENSORS In one system, from a single source What if machinery components were the sensors?

102 104

REGULARS

44 Set to soar The defence industry in Australia is thriving, with major projects and government initiatives creating opportunities for Australian manufacturers both large and small.

66 One-on-One Terry Wohlers is the President of US-based consultancy Wohlers Associates. As an analyst, author, and speaker, he is an internationally-renowned expert in the field of additive manufacturing.

76 New-breed of e-motorcycles

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

36

ONE ON ONE Terry Wohlers – President, Wohlers Associates

66

COMPANY FOCUS PFG Group – Expanding across Australia

90

Dennis Savic is the inventor of a new breed of electric motorcycle which features impressively instantaneous torque and rapid acceleration and is promising to shake up the motorcycle industry.

90

AMTIL FORUMS

106

PFG Group – Expanding across Australia

AMTIL INSIDE The latest news from AMTIL

110

MANUFACTURING HISTORY – A look back in time

118

PFG is a leader in Australia’s aquaculture and commercial marine sector. Its acquisition of Keil Industries added a further production facility.

AMT FEB/MAR 2019

HIGH-SPEED, HIGH PRODUCTIVITY

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This machine’s powerful cutting capabilities and high speed automation increase productivity and reduce cycle times, while the small footprint maximises valuable shop floor space.

MODEL Travels (X-Y-Z) Table Spindle Speed Tool Storage Floor Space

MB-5000HII 760 x 760 x 810 mm 500 x 500mm 15,000min-1 (26kW) 64 tool (Disc type) 2540x 5620mm

010

FROM THE EDITOR WILLIAM POOLE

Renewing an industry There’s been a little eleventh-hour change to the features line-up for this edition of AMT. Previously billed as Renewable Energy & Clean Tech, our secondary feature this issue is now Clean Tech & Renewable Energy. A subtle but significant difference.

Ultimately, this was just down to the material at hand. At the end of the day, we simply had more interesting articles about clean technology than about renewable energy, so it seemed right to switch the emphasis. But perhaps it also says something about where the renewables sector currently stands in Australia.

That’s not to say there aren’t interesting stories being told about renewables here. We have exciting, innovative companies doing amazing work. But even though Australia enjoys natural advantages that leave it well-positioned to compete and prosper on the global renewables stage, we still haven’t come up with that indisputable breakthrough case that shows the world what we can do.

Maybe that’s down to the policy dithering and uncertainty that has stymied investment over the last decade. Maybe it’s just the usual obstacles Australia faces: the “tyranny of distance”; competition from China. But we have manufacturing companies who are admired worldwide in fields as diverse as mining, medical, even manufacturing technology.

In renewables? Not quite, not yet.

Meanwhile the economic case for this industry is getting stronger day by day. According to a new report from CSIRO and the Australian Energy Market Operator (AEMO), renewables now offfer the cheapest new-build source of power for Australia. GenCost 2018 compared the estimated cost to generate electricity from new power plants, and it found that solar and wind generation carry the lowest price tag.

The report analyses the levelised cost of electricity (LCOE), which includes operating as well as investment costs. According to the report’s authors, LCOE is the best way to compare the costs of different technologies like fossil fuel plants (which require relatively low capital costs, but higher operating expenses) and wind and solar (high capital outlays, but low operating expenses).

“Our data confirms that, while existing fossil fuel power plants are competitive due to their sunk capital costs, solar and wind generation technologies are currently the lowest-cost ways to generate electricity for Australia, compared to any other new-build technology,” says Paul Graham, Chief Energy Economist at CSIRO and the report’s lead author. “At a global level, the investment costs of a wide range of low-emission generation technologies are projected to continue to fall, and we found new-build renewable generation to be least cost, including when we add the cost of two or six hours of energy storage to wind and solar.”

This conclusion also applies whether or not estimates regarding the cost of fossil-fuel technology have been adjusted for climate policy risk. It’s higly likely that energy policy worldwide will become more focused on reducing emissions over the coming years, with significant implications for fossil fuel-based generation. Indeed, some argue that carbonintensive investments risk becoming stranded assets amid a decline in demand for fossil fuels – a claim that’s been one of the sticking points in the protracted wrangling over the proposed Adani coalmine, for example.

It’s worth noting here that CSIRO and AEMO are both government agencies. They’re not eco-activist groups, or green-aligned thinktanks. They have an obligation to get their facts straight, and face consequences for not doing so. So this report is significant. It goes without saying, of course, that manufacturing in Australia has had to contend with high energy prices for some time now, and anything that provides clarity on how best to address that is to be welcomed. But the report also reminds us again of the scale of the opportunity out there for our industry.

YOUR INDUSTRY. YOUR MAGAZINE.

AUSTRALIAN MANUFACTURING TECHNOLOGY

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

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

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

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

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

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

Contact AMTIL on 03 9800 3666 for further information.

1424AMTFEB/MAR2019

AMT FEB/MAR 2019

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012

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Austech 2019 – The main event in a big year I know it’s already February, but this is my first column of 2019 so let me start by wishing you all a very Happy New Year.

I wanted to start off with that because 2019 is going to be a big year for us here at AMTIL. Most importantly, it will be the 20th anniversary of the establishment of our Association. It seems hard to believe it’s been two decades since AMTIL was formed with the merger of the Institute of Machine Tools Australia and the Australian Machine Tool Association. The time has flown by, but the enthusiasm of the team here hasn’t faded, and we’re looking forward to many more years supporting the interests of manufacturers and manufacturing technology suppliers in Australia.

We hope to be holding a number of events to celebrate AMTIL’s 20th birthday, but the biggest of all will – of course – be Austech, which will take place at Melbourne Convention and Exhibition Centre (MCEC) from 14-17 May. As Australia’s premier showcase for advanced manufacturing technology, Austech has been a core part of our activities for almost as long as AMTIL itself has been in existence.

The show has changed a lot over the years, constantly adapting and expanding as manufacturing technology itself has evolved. We made a big change a few years ago when we decided to shift from an annual event alternating between Sydney and Melbourne, to one held every two years in Melbourne. It was a bold decision at the time and some in the industry voiced doubts about it, but I think the shows we’ve held since then have demonstated that it was the right call to make, and today Austech is going stronger than ever.

And I’m absolutely thrilled to be able to say that this year’s Austech will be the biggest show in the event’s history. Here at AMTIL we’ve been genuinely blown away by the rate at which companies have been signing on to book their stands. The space on the exhibition floor has been selling so fast that we’ve had to extend our original booking with the MCEC and take additional bays in the exhibition hall, meaning Austech 2019 will have the largest footprint on record.

There is some space still available, but it’s selling fast. So with no more bays left at the MCEC, if you’re thinking about taking a stand for your company, don’t delay in contacting us.

What I’m most excited about is the fact that so many exhibitors have opted to take larger stands than usual. To me that can only suggest that they are anticipating doing serious business and making major sales at the show – and having spoken to a few of these exhibitors in person, that does seem to be the general sentiment. I have always believed that strong levels of investment in the latest advanced manufacturing technology are one of the clearest indicators of the long-term health of our industry. So Austech 2019 suggests the outlook for Australian manufacturing is currently pretty positive.

The high number of large stands also means that the show itself will have plenty of impressive displays of big, high-end machinery. It promises to be an event that should not be missed.

Another aspect I’m looking forward to is the variety of different technologies on show. Austech has diversified over the years to reflect changes in manufacturing processes and the technologies used, and at more recent shows we’ve established dedicated areas to spotlight some of these specific categories. First was the Additive Manufacturing Pavilion, which has become an essential showcase for the latest developments in 3D printing. At the last Austech in 2017 we added the Digitalisation Pavilion, exploring the fast-evolving world of Industry 4.0 and the use of digital technology in manufacturing.

This year we’ll be introducing the Air Technology Pavilion, displaying the latest state-of-the-art compressors and air technology – an area I’ve wanted to see properly represented at Austech for a long time.

AMT FEB/MAR 2019

And then there’s the Manufacturers Pavilion, which once again will be providing a platform for some of the most innovative manufacturing companies working in Australia. Initially launched back in 2013, we’ve put a lot of work into building this section up, and today I think it’s really become an integral part of the show. We want Austech to be a true celebration of Aussie manufacturing, and seeing all those companies exhibiting in the Manufacturers Pavilion does really make that the case.

All of which means that for us at AMTIL the next few months will be a very busy few months indeed. We’re looking forward to it.

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. If you would like to attend Austech 2019, please register online at: www.amtil.com.au/austech

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014

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

The next frontier for Australia’s tech future Putting Australia at the forefront of global digital developments is at the heart of an ambitious Liberal National Government strategy paper I launched recently.

Australia’s Tech Future, Delivering a Strong, Safe and Inclusive Digital Economy provides a clear and unified plan to seize the opportunities of the digital economy. It outlines what our Government is already doing to ensure Australia is well positioned for the future, highlighting 150 existing programs and policies.

The document outlines our priorities, where we need to target investment and the impact of the digital economy on different people, groups and industry sectors. It also details how Australia can influence and help to shape the global digital economy, which is transforming the way we work, travel and communicate. Our ongoing success depends on our ability to embrace the benefits of technological advances and use them to improve existing businesses, create new products and markets, and enhance daily life.

We are already making good progress. Businesses are improving productivity by adopting and adapting new technologies, such as autonomous systems, robotics and remote sensors. New industries are being created.

Australian manufacturers are using digital technologies to modernise their systems and processes. From robotics and artificial intelligence to advanced modelling software and 3D printing, technology has become an integral part of doing business. Digital technologies will help Australian manufacturers thrive into the future.

But we need to do more, and we are. We need to maximise the opportunities of digital technology so the nation’s economy can continue to prosper. Australia’s Tech Future identifies four key areas for development where we should focus our attention, namely: • People • Services • Digital assets • The enabling environment First and foremost, the focus is on people.

The report highlights that: “More than 90% of Australians will need to use some level of digital skills at work within the next five years. All jobs will increasingly require the basic skills required to communicate and find information online.”

Individuals, businesses and governments need to work together to support a workforce with the skills in demand. All Australians have a role to play. Workers should identify opportunities to update and develop new skills, and businesses need to invest in their workforce.

We need to establish a culture of lifelong learning and make sure that all Australians who make the effort can share in the benefits of digital technology. Increasing flexibility in education will be necessary.

Non-traditional forms of education, such as “micro-credentials” are suggested in the report. These credentials recognise informal and formal learning and allow certified skills to be acquired in specific areas, as needed by the learner, rather than as part of a set course.

The Australian Qualifications Framework is being reviewed to ensure the digital skills Australia needs are being developed, now and into the future. Barriers to digital literacy and access for a range of groups, including older Australians, Indigenous people and people living in remote areas are also being addressed.

The Liberal National Government will continue to work with all stakeholders to drive change. This includes being involved in developing research infrastructure, data science, and Smart Cities plans. The Coalition invested $41m to establish the Australian Space Agency last year to maximise our opportunities in space-

AMT FEB/MAR 2019

based technologies. GPS infrastructure is dependent on space technologies. We are upgrading GPS infrastructure to provide better accuracy, building a network of ground stations in major population centres. We are investing in super computers. More than $140m has been allocated to upgrade Australia’s two Tier 1 high-performance computing facilities: the Pawsey Supercomputing Centre in Perth; and the National Computational Infrastructure National Facility in Canberra.

We are enhancing access to data and championing an open, free and secure internet. Our Government is appointing a National Data Commissioner to promote greater use of data and build trust in the way Government uses data.

People are more likely to share their data if they see a clear benefit.

Government and businesses need to build trust through increased transparency. We are pushing for consistent or equivalent data regulations and standards across the country.

Cyber security is paramount and we have announced a range of measures to enhance and develop our cyber security. We are encouraging more people to work in the cyber security field and aim to put the nation at the forefront of cyber security innovation. We want to be in a position to export cutting-edge cyber security expertise to others as part of a general push to develop cyber export industries.

Opportunities are at our doorstep. In 2017, for the first time, more than 50% of global internet users were in the Indo-Pacific. But only 46.4% of houses in the region were connected, creating a great opportunity for growth and business development.

Getting digital assets and services right allows us to connect people and places, and build from this to improve productivity, sustainability and adopt new technologies. It is vital that Australians can access government services that are simple, clear and fast. In this way Australia’s Tech Future is complemented by the Government’s Digital Transformation Strategy.

Millions of Australians are already using secure government services online each day. The Government is working hard to ensure that its services keep pace with developing technologies. For example GovPass, a new digital identity solution, will make it easy and secure to prove who you are online when using Government services.

By embracing the initiatives outlined in Australia’s Tech Future we can ensure our nation has a bright future and keeps ahead of the digital race.

Australia’s Tech Future was developed with help from businesses, industry groups, the research sector, states and territories and members of the community. The full document can be viewed at www.industry.gov.au/australiastechfuture

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016

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

“Slowth” to dominate 2019 As we do each year, towards the end of 2018 AiGroup surveyed more than 250 CEOs and senior executives in businesses from the non-farm sector, asking them to reflect on their performance of the course of the year and to forecast their prospects for the year to come.

This outlook is far from inspiring. While a healthy proportion of the anticipated slowing can be attributed to global factors including heightened trade tensions, geopolitical risks, the slowing of the European recovery and an easing of industrial activity in China, there are also a range of factors that are well within our own control that are not attracting the policy attention they deserve.

While 2018 was a better year for many Australian businesses, it was not the stellar year for which they had hoped. One-third of CEOs said that their general business conditions had improved in 2018, versus onequarter who saw a deterioration relative to the previous year.

For many of the businesses surveyed (a high proportion of which were from the manufacturing sector), higher input costs – and especially higher energy costs – ate into margins in 2018, detracting from the benefits of the increases in output and turnover that they were able to generate, and reducing their ability to invest.

Although 57% of CEOs reported an increase in turnover in 2018, non-mining profits were flat with only 41% of businesses surveyed improving their profit margins and 39% reporting a fall in margins in 2018.

For the coming year the view of the economy for 2019 could be best summed up as “slowth”. CEOs expect growth to be a touch slower for Australian businesses than was experienced in 2018. This reflects the very recent deceleration that has been evident across local and global indicators in the last few months, as well as the increasing range of risks on the horizon. This moderation in the outlook is apparent in the economic forecasts as well as in business leaders’ expectations, plans and strategies.

The survey reveals fewer business leaders are feeling optimistic about their general business conditions in 2019 than was the case one year ago. Indeed, on a net balance basis (optimists minus pessimists), fewer CEOs expect an improvement in business conditions in 2019 than in any year since 2015. This largely reflects their experiences in 2018 and especially during the second half of the year.

The report identifies a number of key risks for businesses inside Australia including: uncertainties surrounding the Federal election; concerns over the workings and direction of our workplace relations arrangements; the threat of rising barriers to global trade; the impacts of the housing market downturn; consumer caution; high energy prices; and the continuation of drought conditions in many parts of the country.

Expectations for 2019 point to moderate lifts in production, sales and employment, and for a modest pick-up in inflation and wages. The 2019 slowdown is anticipated to see activity drift downwards rather than fall precipitously.

Rather than simply drifting with the international tide, Australia should be proactively building on our relative strengths to lift our economic potential and our domestic living standards. Key policy areas ripe for action which we are calling on all political parties to support in this election year include: • Developing the skills of the current and future workforce.

• Developing a stable, effective and bipartisan approach to energy policy to secure the investment needed to reduce price pressures and uncertainties over supply.

• Removing the administrative obstructions that are preventing the approval of the enterprise bargaining agreements that were once the foundation of strong productivity and sustainable wages growth.

• Investing in developing the domestic business capabilities needed to build more world-class enterprises invested in trade, innovation and high-performance workplaces.

• Committing to improving the effectiveness, fairness and competitiveness of our national taxation arrangements.

Words like modest, soft and flat should be ringing alarm bells for policymakers. The coming election is a real opportunity for our political leaders to lay out an agenda for the future which focuses on strong growth and targeted investments that will deliver long-term benefits to our community.

The view of the economy for 2019 could be best summed up as “slowth”. CEOs expect growth to be a touch slower for Australian businesses than was experienced in 2018.

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

Broken bargaining system fails businesses AND workers On 12 May 2014, Australia’s industrial relations landscape changed forever. This was the day that Aurizon applied to the Fair Work Commission to have all of the expired Enterprise Agreements, which were governing the pay and conditions of its workforce, terminated while negotiations for new Agreements were underway.

The decision that was handed down after seven days of hearings and extensive evidence was provided allowed the terminations to proceed. This forced workers at Aurizon back onto the conditions set out under the Award system, substantially cutting their pay and stripping away hard-won conditions.

This decision marked a huge departure from the previous approach of the Commission. The Commission had previously declined applications for expired Agreements to be terminated while new Agreements were being negotiated, on the basis that it would significantly and unfairly alter the power dynamics in bargaining.

By forcing workers back onto the Award, the company incentivises workers to agree to the company’s proposed wages and conditions.

These wages and conditions may not be as good for workers as those set out in the previous Agreement, but they’re invariably significantly better than being on the Award. Every day that workers hold out for a better deal, they take home a smaller pay packet, creating a deeply unequal bargaining relationship between the workers and the employer.

Five years later, and we have seen how that shift in bargaining power plays out in workplaces across the country, across a variety of industries. We saw it first at Aurizon, and we’ve since seen it at Streets, at Griffin Coal, and at Murdoch University. The ability for an employer to unilaterally terminate an Agreement has not killed workers’ ability to bargain, but it has created a much more hostile and adversarial bargaining environment – to the detriment of workers and employers.

The compromise agreement preserved crucial family-friendly rosters at the expense of wages. The strike was costly for both workers and the company, and taking such aggressive action did not grant the company what it wanted. Ultimately they still had to come to the table and compromise with workers. This could have been achieved more quickly and in a much more collaborative fashion, had the company not chosen to pursue the nuclear option of Agreement termination.

The Streets dispute is one of the most prominent examples of how this new framework has played out. In 2015, negotiations for a new Enterprise Agreement at the Minto Streets Ice Cream factory in New South Wales broke down. The multinational company that owns Streets, Unilever, applied to terminate their existing Enterprise Agreement. Workers forced back onto the Award wage stood to lose between 25% and 50% of their annual salary.

Meanwhile, Murdoch University became the first public institution to file an application to terminate an Agreement that was granted in August 2017, threatening staff with lower wages and less secure conditions. What followed was several months of strike actions and social media campaigning, before the University and staff finally signed off on an agreement that was ratified by the Fair Work Commission in August 2018.

Rather than this leading to an immediate surrender to Unilever’s proposed new Agreement, the Streets workers fought back. On 29 November, over 140 workers voted to run a campaign calling for a public boycott of Streets ice creams, right as the country headed into the peak summer period. The campaign, run by the Australian Manufacturing Workers’ Union, went viral. The #streetsfreesummer hashtag trended. The launch of the Gaytime Sanga was hijacked.

Bad publicity was everywhere.

Once again, by choosing the most extreme route in bargaining, the University tarnished its public reputation and its standing in the community, and disillusioned many staff. The termination of Enterprise Agreements as a bargaining chip to force workers to accept sub-standard wages and conditions rarely works out as well as employers assume it will.

By late November, less than a month after the boycott campaign was launched, Streets-Unilever had come back to workers with a proposed Agreement that was acceptable to both parties. All that the termination of the existing Agreement achieved was a whole lot of bad publicity for Streets.

On the other side of the country, in the mining town of Collie, workers at Griffin Coal reacted to the termination of their Agreement by taking strike action. Workers faced a 43% pay cut when they were forced onto the Award, and lost numerous entitlements and conditions. For six months, the workers went on strike and maintained a picket line, until eventually a compromise between them and the company was reached and a new Agreement was agreed to in February 2018.

AMT FEB/MAR 2019

The bargaining system is broken. It is not delivering good outcomes for businesses or workers. The ability of companies to unilaterally terminate Agreements creates an unequal and hostile bargaining environment. Rather than promoting a collaborative environment where both parties compromise to reach a mutually agreeable solution, termination destroys trust and blows up disputes, often leading to negative media coverage and reputational damage to the company in question.

Workers do not want to render the companies employing them unviable, but they are entitled to a fair share of company profits. At a time of rising inequality and wage stagnation, the power dynamics of our bargaining system have never been more important. Employers should not be able to unilaterally cut the wages and conditions of their workers. The short-term advantage they gain almost always leads to long-term pain, and everyone loses money in the process.

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INDUSTRY NEWS

Australian CEOs optimistic on growth despite slowing economy Australian CEOs expect further growth in the coming year, but believe a slowing of activity that began late last year will continue in 2019 due to a mix of local and global factors, according to the Ai Group 2019 Business Prospects report.

The Group’s 2019 national CEO survey examines the prospects for business and the economy in the year ahead. The survey included responses from 252 CEOs of private-sector businesses in non-farm sectors from all states across Australia, with an aggregate annual turnover of around $72bn and employing 87,000 Australians.

The report identifies several key risks for businesses from inside Australia including: uncertainties surrounding the Federal election; concerns over the workings and direction of our workplace relations arrangements; the threat of rising barriers to global trade; the impacts of the housing market downturn; consumer caution; high energy prices; and the continuation of drought conditions in many parts of the country.

General business conditions are expected to be better in 2019 for one-third of CEOs, fewer than had expected an improvement for 2018 (42%). One-quarter of CEOs expect business conditions to deteriorate in 2019, the highest proportion since 2014. Business turnover is expected to increase for 58% of businesses in 2019, with 24% expecting no change and 18% expecting a decline. Profit margins are expected to grow in 46% of businesses in 2019 and fall in 24% of businesses, suggesting businesses are less optimistic about profit margins than they were for 2018.

“Expectations for 2019 point to moderate lifts in production, sales and employment and for a modest pick-up in inflation and wages,” said Ai Group Chief Executive, Innes Willox. “There are a range of factors that are well within our own control that are not attracting the policy attention they deserve.”

The CEO report identifies key policy areas ripe for action including: • Developing the skills of the current and future workforce.

• Developing a stable, effective and bipartisan approach to energy policy to secure the investment needed to reduce price pressures and uncertainties over supply.

• Removing the administrative obstructions that are preventing the approval of the enterprise bargaining agreements that were once the foundation of strong productivity and sustainable wages growth.

• Investing in developing the domestic business capabilities needed to build more world-class enterprises invested in trade, innovation and high-performance workplaces.

• Committing to improving the effectiveness, fairness and competitiveness of our national taxation arrangements.

“The survey presents an underwhelming view of our economic prospects which should be ringing alarm bells in Canberra in this election year,” Willox added. “Our political leaders should be setting ambitious goals and making targeted investments that will deliver long-term benefits to our community.

“We need more decisive action from Canberra in a range of areas including workplace relations; energy policy and delivering a better trained and aligned workforce. “Rather than simply drift with the international tide, Australia should be proactively building on our relative strengths to lift our economic potential and our domestic living standards.”

Testlab pilot program prepares for revolution The Federal Government has announced the national Industry 4.0 Testlabs network, a new program designed to prepare businesses for the Fourth Industrial Revolution that will take place in six selected Australian universities.

The University of Queensland, the University of Technology Sydney, the University of South Australia, the University of Western Australia and Swinburne University of Technology have been chosen to participate in the pilot program. They join the University of Tasmania, which has already been allocated funding.

Minister for Industry, Science and Technology Karen Andrews said the Federal Government’s pilot program would provide small to medium-sized businesses with free and open access to testlab facilities and focus on improving their skills in Industry 4.0 technologies. “The Industry 4.0 Testlabs for Australia program prepares businesses to transition to the smart factories of the future,” Minister Andrews said. “Each testlab will receive a grant of up to $1m and that funding will be matched by the participating universities, leveraging total investment of around $12m.”

In addition to their world-class research strengths, the universities have been selected to take advantage of their existing partnerships with industry. The testlabs will provide spaces for researchers and industry to work together in sectors such as advanced manufacturing, developing the skills needed to take full advantage of opportunities presented by Industry 4.0.

“Evaluation of the pilot program will provide valuable insights into the success and uptake of new Industry 4.0 technologies,” Minister

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Andrews said. “After the program is completed consideration will be given to implementing a broader initiative.”

The national Industry 4.0 Testlabs network will be led by Swinburne’s Deputy Vice-Chancellor of Research and Development, Professor Aleksandar Subic, under the auspice of the Australian Industry Group (AiG) Industry 4.0 Forum.

“Swinburne has placed Industry 4.0 at the heart of our Research and Innovation Strategy,” said Professor Subic. “We recently launched the Victorian SME Industry 4.0 Hub for manufacturing businesses, the Siemens MindSphere Demonstration and Application Centre for Australia, and the DXC Digital Transformation Centre at Swinburne. These strategic initiatives place us at the forefront of Industry 4.0 and bring our extensive expertise in industry engagement, research translation, digitalisation and technology innovation to this pilot program.

“This national network of Industry 4.0 Testlabs will facilitate collaboration across multiple sites including sharing of experiences and use cases among partner universities. We are all committed to creating a unique engagement model through this program by providing industries and businesses the support they need in order to benefit from the opportunities that the fourth industrial revolution is providing.”

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INDUSTRY NEWS

ManuFutures tenants get Government boost Deakin’s advanced manufacturing business incubator, ManuFutures, will develop an acceleration program to support emerging enterprises located within the facility, thanks to a new $500,000 Federal Government investment.

The new funding, part of the Government’s Incubator Support Initiative, means the new ManuFutures Export Acceleration Program (MEAP) will support the emerging businesses to strengthen their export focus and accelerate their entry into global markets.

Deputy Vice-Chancellor Research Professor Julie Owens joined Member for Corangamite Sarah Henderson MP to make the announcement at ManuFutures’ Waurn Ponds Campus headquarters.

Professor Owens said the MEAP would assist enterprises to grow at an accelerated rate and produce for export earlier than usual, by offering business training, skilled mentors, support through project teams of Deakin’s Work Integrated Learning students and interns, and access to researchers from across the University, as well as subsidised access to trade missions. Professor Owens said the Government’s support represented a strong endorsement of ManuFutures. The facility currently has eleven tenants, with a twelfth set to move in soon.

“ManuFutures is supporting small upand-coming advanced manufacturing enterprises fast-track new products to the global market, grow their businesses and help shape the future economy and this new support from the Federal Government recognises and is a result of just what it has already achieved in only its

first year of operations,” Professor Owens said. “Through MEAP, we will aim for our ManuFutures enterprises to achieve selfsufficiency within two years, taking a multifaceted approach to building their business expertise and capacity.”

ManuFutures tenants that have already benefited from Federal Government funding programs include Partington Advanced Engineering, HeiQ and Conflux Technology.

Textile innovator HeiQ has achieved primary production, with the initial batch having been exported into their supply chain for process testing and acceptance.

Partington Advanced Engineering, which designs and develops lightweight high-end carbonfibre bike wheels, has established a state-of-the-art manufacturing facility to support composite design and production and reached pre-production status of its first wheel product, and is set to grow its

two full-time staff to four.

“Deakin is delighted to have already seen much success from within ManuFutures’ walls in a short time, including businesses like these three, which are flourishing,” Professor Owens said. “When Partington moved into ManuFutures earlier this year, it was a small two-person enterprise and now it is preparing to double that number of staff.

It is a perfect example of how a universitybacked incubator like ManuFutures can support growth and market-enhancing knowledge through access to research, innovation and cutting edge facilities.”

The $13m ManuFutures building was officially opened last April, supported by a $3m investment from the Victorian State Government’s Regional Jobs and Infrastructure Fund, while Deakin supplied the land and $10m.

Business SA marks 180th anniversary Business SA, the oldest chamber of commerce and industry in the nation, has celebrated its 180th anniversary.

Business SA Chief Executive Nigel McBride said while the chamber had gone through several mergers since forming in 1839, it had continued to serve the South Australian business community and lobby government to provide better operating conditions.

“We are proud of the work the chamber has done over its 180 years,” said McBride. “If we can continue to help cut the costs for business as we have done for 180 years, we will ensure South Australian operators remain profitable, become more successful, and boost the local economy, which in turn benefits the entire state.”

The Adelaide Chamber Of Commerce was established two years and 12 days after South Australia was proclaimed. At the time there were only a few businesses

AMT FEB/MAR 2019

operating in the state. In 1869, the South Australian Chamber of Manufactures was formed, also the first of its kind in Australia. While the state’s foundation was built on agriculture, it quickly embraced manufacturing. One of the leaders in establishing the Chamber of Manufactures was saddler James Alexander Holden, whose grandson Sir Edward Holden went on to form General Motors Holden. In 1889 the South Australian Employers’ Federation formed.

form the South Australian Employers’ Chamber of Commerce and Industry.

In May 2000, the organisation was relaunched as Business SA, with a new image as the state’s leading business and employer group.

By 1972 it was clear the Adelaide Chamber of Commerce and the South Australian Chamber of Manufactures could better represent members’ interests by working together, and merged to form the Chamber of Commerce and Industry SA. This then merged with the South Australian Employers’ Federation in late 1993 to

“Our state has an amazing history of agricultural exports, we’ve led the nation in manufacturing and our mining industries have thrived,” McBride said. “We’re now turning to advanced biotechnology, defence and space. Our business confidence is growing and we have a bright economic future.”

These days South Australia’s major exports are wine, metals and metal manufactures, metal ores and metal scrap, wheat, meat and meat preparations, education, machinery and fruit and vegetables.

INDUSTRY NEWS

Mind the Gap train project aims to improve passenger access and safety The Rail Manufacturing Cooperative Research Centre (CRC) is funding an innovative project to improve access for passengers getting on and off trains.

Partnering with Downer Group and Monash University, this 18-month project involves manufacturing and testing a device for use between a station platform and the train door to close the gap when passengers board and alight the train.

“To address transport objectives set in Disability Standards for Accessible Public Transport, this project is driven by the need to improve travel experiences for all Australian train commuters,” said Dr Vincent Moug, the Lead Project Researcher within Monash’s Mobility Design Lab. The project will assess the design and engineering requirements for a gap filling polymer-based solution, invented

by Monash, testing its safety, durability, engineering feasibility and operational functionality. The gap filling solution will be prototyped using 3D scanning and printing.

“A key element of the project is to assess whether the solution is best attached to either the train station platform or the train itself, which will be tested in field trials across Melbourne,” said Mike Ayling, Downer’s GM Digital Technology and Innovation.

“Not only is the project identifying an innovative response to improving train station access for all users, but the team is also using key technologies when prototyping the polymer solution, so it will be exciting to watch this work progress,” said Dr Stuart Thomson, CEO of the Rail Manufacturing CRC. The project team has commenced assessing rail networks to determine the design requirements before prototyping and product testing commences. Worth $2.4m, the project is due for completion by 28 February 2020.

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Renishaw and Sandvik power the future of metal additive manufacturing To strengthen the metal additive manufacturing (AM) industry, Renishaw has initiated a collaboration with Sandvik Additive Manufacturing to supply the company with high-productivity multi-laser RenAM 500Q systems, which will substantially increase Sandvik’s printing capacity.

This is one of the largest installations to date of Renishaw’s latest AM system, the RenAM 500Q. The system features 500W quad lasers in the most commonly used platform size, enabling a radical increase in productivity, without compromising quality.

Working with ongoing support from Renishaw, the investment will complement Sandvik’s existing printing technologies and strengthen its position in the growing AM market. The two companies also intend to collaborate in areas like materials development, AM process technologies, and post-processing.

“Renishaw is a leader and innovator in metal AM and metrology, positioning it as the perfect AM partner,” explained Robin Weston, Marketing Manager of Renishaw’s Additive Manufacturing Products Division.

“Sandvik is well established throughout the AM value chain, with a leading position in fine metal powder for AM and world-leading expertise when it comes to post-processing methods like machining, heat treatment and sintering. Our collaboration will strengthen

Sandvik’s position during a period of rapid growth in the metal additive manufacturing industries.”

“Sandvik has a leading position within the AM metal powder market and has made sizeable investments in different AM printing process technologies for metal components since 2013,” added Kristian Egeberg, President of Sandvik Additive Manufacturing.

“The recent addition of multi-laser RenAM 500Q systems will complement our current printing portfolio in a very good way – and our collaboration with Renishaw will benefit both parties when it comes to capitalising on the expected rapid growth.”

Sandvik has initiated extensive investments amounting to $30m in a new plant for the manufacture of titanium and nickel powders for AM. The investment will complement Sandvik’s existing Osprey powder offering, to include virtually all alloy groups of relevance today – and further strengthen Sandvik’s leading position as a powder supplier to the AM market.

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INDUSTRY NEWS

Research project to help get new vaccine delivery technology to market A joint research project between Vaxxas, the University of Sydney (UoS) and the Innovative Manufacturing Cooperative Research Centre (IMCRC) will test the usability, manufacturability, patient acceptability and supply chain logistics of a new technology that aims to replace the traditional needle and syringe for vaccinating people against diseases.

Vaxxas is an Australian-based biotechnology company with the primary goal of commercialising an innovative, next-generation vaccine delivery platform. Vaxxas’ Micro-projection Array Patch (MAP) technology targets immunological cells below the surface of the skin. The Vaxxas MAP is applied to the skin using a disposable applicator, containing and protecting the product and ensuring repeatable delivery into the skin.

This project focuses on the manufacture and testing of a prototype commercial applicator to de-risk the device design prior to the high capital investment of a pilot scale manufacturing equipment and Australian based pilot scale manufacturing facility. UoS researchers from the Faculty of Medicine and Health, Professor Rachel Skinner, Cristyn Davies, and Professor Robert Booy, are working with Professor Behnam Fahimnia from the Business School to undertake usability and acceptability studies including an in-clinic assessment and a logistic impact/disruption assessment.

“We are at an important stage of the product development process,” said Charles Ross, Head of Clinical Operations at Vaxxas.

“However, before investing in manufacturing the applicator at pilot scale, we want to be confident that the device satisfies design, enduser and logistical requirements for its intended markets.”

In 2015 Vaxxas conducted a World Health Organization (WHO)funded study testing the usability and end-user acceptability of the Vaxxas applicator for polio vaccination in Benin, Nepal and Vietnam. According to Davies, the initial study provided valuable information and showed a lot of promise for the new vaccine delivery technology: “With Vaxxas planning to develop and commercialise the device in Australia, the focus of our research will be how the applicator is perceived by patients and administrators here.”

The application will be tested in several settings and across different age groups, in the workplace and at local GPs. The findings will then be compared against the WHO usability study to ascertain different requirements from these different markets. Vaxxas will begin a large Phase I clinical study in 2019. Alongside this, the UoS Faculty of Medicine and Health will undertake an acceptability study for Vaxxas, which will compare end-user and patient experience with the Vaxxas MAP technology compared to traditional needleand-syringe vaccinations.

The logistics study will highlight how cost-effective and environmentally sustainable the new supply chain will be compared to the traditional decentralised cold chain.

“Vaxxas has ongoing projects with the WHO and Bill & Melinda Gates Foundation developing products to eradicate diseases from developing countries,” said Angus Forster, Chief Development and Operations Officer at Vaxxas. “The data from this study will be pivotal in the roll out of these projects.”

David Chuter, CEO and Managing Director at IMCRC, said that the project is a great example of how research-led innovation in manufacturing drives better products, services and processes.

“Vaxxas is a great example of manufacturing innovation in Australia, with the technology, including both applicator and MAP, having been created and developed here,” said Chuter. “The research studies will provide Vaxxas with not only important end-user and distribution information that de-risks and accelerates the path to market, but also identify critical product and design parameters required for subsequent pilot scale manufacture in Australia.”

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There is also the opportunity to revolutionise the current vaccine supply chain by addressing future trends in product serialisation and developing methods for analysing big digital data collected from various supply chain sources. An additional benefits of the Vaxxas product is the potential elimination of the need for refrigeration during distribution and storage of most vaccines.

“This would offer a significant advantage in remote locations and developing countries where refrigeration to keep vaccines viable is a major challenge,” says Professor Fahimnia who is leading the logistics research project at the UoS.

AMT FEB/MAR 2019

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INDUSTRY NEWS

Purser passes the baton at 600 After a long stint as Asia-Pacific Managing Director for 600 Machine Tools, Cliff Purser has retired.

Purser led the 600 team in Australia since transferring in November 2004 from the position of New Zealand National Sales Manager, based in Auckland, a post he had held since 1988. A genial Englishman, Purser’s original brief was to be responsible for the supply chain, planning, and strategic direction of the business.

Under his leadership, the nationwide team successfully launched the Clausing brand in Australia, and it has become as familiar as such industry legends as Colchester and Harrison. Clausing is a major manufacturer of world-class machine tools, based in Kalamazoo, Michigan, and a member of the 600 Group since 1986. Purser is particularly proud of bringing to fruition the Group’s major objective of establishing a network of agents throughout South-East Asia.

In addition to identifying, recruiting, and training these agents, he participated in 600 Group presentations and demonstrations at the major trade fairs in the region. He also made many visits to the company’s head office in the UK, and worked with its team at many major trade shows. After serving the engineering industry for more than three decades, Purser can look back on huge changes in Australia’s workshops.

“Electronics changed the world as we know it, and such controllers as the Fanuc Oi-TF have transformed the manual lathe in the same way that the jet-engine transformed the aeroplane,” he said. “The CNC-equipped machine tools that 600 designs and builds today are extraordinarily more capable than those of the 1980s, and boast greater speed, accuracy, and durability. The ‘bang for bucks’ ratio has changed, too. When correctly configured, today’s CNC lathes will happily work through the night, unattended, transforming the economics of component production.”

Purser formally retired at Christmas and plans to return to live in New Zealand. He has been succeeded by Zelko Galic, an Australian degree-qualified engineer with an MBA and a graduate member of the Australian Institute of Directors. Galic believes that his formal qualifications, his considerable engineering and business management experience, and his strong understanding of technical products, give him a keen insight into the requirements of Australia’s engineering workshops.

“Australians are, by nature, creative,” said Galic. “The 600 Group is a trusted supplier of the tools used for the creation and production of new products. Part of my new challenge is to ensure that workshops in engineering and manufacturing have continual awareness and understanding of the rapidly-advancing technologies.

“True competitiveness springs from more than being able to produce a revolutionary mousetrap. Products have to be made faster, more accurately, and on time. Workshop managers know the key role that the latest machine tools can play in competing with imports, and in winning export markets. It will be an important part of my role as leader of the team at 600 Machine Tools to ensure that every workshop manager is kept aware of the advances in machine tool technology.

Then, to work co-operatively with individuals to identify the specific machines that will give them an edge in today’s fiercely competitive markets.”

Cliff Purser (left) with his successor at 600 Machine Tools, Zelko Galic.

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GOVERNMENT NEWS

Andrew Stevens to chair Innovation and Science Australia The Federal Government in December announced a new Board Chair and five Board members for Innovation and Science Australia (ISA), Australia’s peak innovation advisory body.

Minister for Industry, Science and Technology Karen Andrews said the appointment of Andrew Stevens as incoming Chair will provide a renewed focus for ISA in 2019.

“Mr Stevens brings a wealth of experience to the ISA Board, building on the strong foundation created under the leadership of the former Chair Mr Bill Ferris AC,” Minister Andrews said. “As former Managing Director of IBM Australia and New Zealand and Chair of the Advanced Manufacturing Growth Centre, his experience in leading large organisations with global reach will complement the skills of the other Board members.

“Mr Stevens will be well supported by Australia’s Chief Scientist, Dr Alan Finkel AO, who has been appointed for a further two years as Deputy ISA Board Chair. Dr Finkel will provide an important bridge between the work of ISA and the new National Science and Technology Council chaired by the Prime Minister.” As a key component of the Coalition’s National

Professor Raoul Mortley AO have also been newly appointed to the ISA Board.

“Professor Huntington and I are both passionate about encouraging more young women to take up science, technology, engineering and mathematics careers, and I am excited about the experience and perspective that she will bring to the ISA Board,” Minister Andrews added.

“Professor Mortley will also bring his experience of the higher education sector and knowledge in areas including the humanities and intellectual property.”

Maile Carnegie and Paul Bassat have been reappointed.

Andrew Stevens, incoming Chair of Innovation and Science Australia.

Innovation and Science Agenda, ISA provides expert advice to the Government on industry, innovation, science and research policy and investments. Professor Elanor Huntington, the first female Dean of Engineering and Computer Science at the Australian National University, and

“With the new Board membership, ISA will be able to deliver high impact, fit for purpose advice to Government to drive economic growth and help improve the lives of all Australians through innovation,” concluded Minister Andrews. “It is critical that we get this right, as innovation touches each and every one of us in our daily lives.” www.industry.gov.au/isa

Australian advanced manufacturing celebrated at Parliament House Several of the nation’s leading manufacturers were present at Parliament House on 4 December as part of the Industry Growth Centre Showcase.

The Showcase was part of the Industry Growth Centre Initiative formed by the Federal Government to drive an industryled approach toward greater innovation, productivity and competitiveness. The Advanced Manufacturing Growth Centre (AMGC), one of six growth centres, was established in 2015 to help steer Australian manufacturing in lifting its global footprint while driving the demand for high-paying jobs. ANCA, Evolve Group and Tradiebot were on hand to demonstrate how local manufacturing continues to thrive and export, along with Australia’s baby essentials company B.Box. Dr Jens Goennemann, Managing Director of the AMGC, recognised the Showcase as an important way to reinforce the positive message to Parliament on manufacturing’s bright future: “This showcase demonstrates that Australia’s manufacturing industry is producing a diverse range of unique and valuable products – from commercial robots and toddler sippy cups to virtual reality

AMT FEB/MAR 2019

Andrew Stevens, Chairman of the AMGC; Ty Hermans, CEO of Evolve Group; Monique Filer, CEO of B.Box; Carolyn Hewson AO, Independent Board Member of the Growth Centre Advisory Committee; Dr Jens Goennemann, Managing Director of the AMGC; and John Grill AO, Chair of the Growth Centre Advisory Committee.

auto repair. These manufacturing success stories have really challenged and redefined industry expectations about what is possible to produce here in Australia for the global market.”

Ty Hermans, Managing Director of Evolve Group, praised the AMGC’s support in helping support the “reshoring of manufacturing” back to Australia.

“The biggest thing AMGC has done is its proactivity and backing up what it said it would do,” said Hermans. “We went from co-funding to commercialisation within 18 months – from turning $250,000 into $25m.”

The Industry Growth Centre Showcase coincided with the announcement from the Minister for Industry, Science and Technology Karen Andrews on the formal extension of the Growth Centre Initiative.

Recognising the valuable impact and assistance Growth Centres provide industry, the Initiative maintains broad support across government. To date, the AMGC has helped hundreds of local manufacturers in their transition to become smart, export-focused businesses. www.amgc.org.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Innovation could just mean a better kind of co-operation It seems Australia’s experiment at being a world leader at “innovation” is over, with the abrupt departure of its champion, Malcolm Turnbull. By Professor Lars Coenen, with Cathy Alexander.

The then-Prime Minister made headlines with his 2015 Innovation Statement, which sought to move the Australian economy beyond dependence on natural resource extraction into an “ideas boom”.

But his replacement with Prime Minister Scott Morrison has seen innovation disappear off the Government’s radar. Even the job of Innovation Minister was scrapped – to the consternation of the tech and start-up sectors.

Photo by Jack Hunter on Unsplash.

Where does this leave us? Not poised to make the most of the 21st century, according to the Global Innovation Index, which last year ranked Australia a lowly 76th in terms of innovation efficiency.

But we cannot afford to turn our back on innovation. Our major sustainability problems – transitioning energy, future-proofing cities, reducing carbon emissions – need us to move past “business as usual”.

Rethinking innovation As my research on innovative cities and regions in Europe and Australia shows, we urgently need to rethink what innovation is and how to go about it. Too often it’s framed in purely economic or technological terms. But innovation should be much more than a buzzword or a techno-fix.

Our economy faces some intractable sustainability challenges, which must be prioritised. We’re struggling to stay within a safe climate envelope – despite (or even because of) technological advances.

Around the world, social polarisation is deepening, even in cities that rank highly on livability and innovation indices.

We need a notion of innovation based on solving problems collectively, with solutions that are relevant to society – not just to economists. What does this look like? We need to combine scientific and technological solutions with expertise from the social sciences and humanities, and to that mix we need to add real-world lessons from practice-based knowledge and experimentation.

Consider the extraordinary success of wind power in Denmark, a small country which is a world leader on renewable energy.

Denmark was an early mover in acting on the 1970s oil crisis and acknowledging – not ignoring – warnings of climate change.

The early development of wind turbines blended scientific expertise with farmers’ knowledge, with grassroots organisations involved too. New forms of partnerships were trialled between the private sector, government, universities and civil society organisations. The Danish government acted as an entrepreneurial state, which actively contributed to creating a market for wind energy.

Overall, the Danes took an approach of being resilient in a crisis and pursuing diversity of knowledge and cross-sector collaboration. It has paid off.

Innovation as collective problem-solving So we need to have a broader understanding of what innovation really is: it’s collective problem-solving, not just something that’s done by heroic entrepreneurs. Even though there is no one-size-fitsall strategy, it will always be a messy process of trial and error, and it will always take time. Beware of politicians promising swift results.

The majority of innovation projects fail. Yet it is in the failures we find the interesting stories that we can learn from, as the brilliant Museum of Failure captures. We have to accept failure and share the lessons from it. This is a challenge for politicians, who tend to be risk-averse and preoccupied with cost.

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Australia’s formal approach to innovation could use a shake-up, but since moving to Australia two years ago I’ve found plenty going on at ground level. I’ve been interested by the work of Farmers for Climate Action, who show how innovation in agriculture can be effective while largely flying under the radar.

Then there’s the Resilient Melbourne Strategy, which was endorsed two years ago and aims to help the city prepare for change and whatever the future may hold. My research into the strategy demonstrates the challenge of combining citizen engagement with large corporations, elite universities and governments (which can operate in silos) – but we need these cross-sector partnerships to make innovation work.

Meanwhile, back in my former home town of Malmö in Sweden, a former shipbuilding factory has been transformed into an experimental, sustainable “maker space” bringing together technology, crafts, art and culture.

Tailoring innovation to a specific place – whether it’s Melbourne or Malmö – reminds us why we need innovation in the first place. Getting innovation right is particularly important for places coping with the potential loss of their major industry, like Australia’s coal regions. We can’t afford to get this one wrong.

Professor Lars Coenen is the City of Melbourne Chair in Resilient Cities at the University of Melbourne. Cathy Alexander is a Research Fellow at the Melbourne Sustainable Society Institute, University of Melbourne. This is an edited extract of the MSSI Oration 2018, given by Lars Coenen at the Melbourne Sustainable Society Institute on 20 November 2018. This article was originally published by The Conversation. www.theconversation.com www.unimelb.edu.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

IP: Winning tenders and increasing your competitive advantage For many manufacturers in Australia, intellectual property (IP) can be the most valuable asset the business owns. Why? Because IP can be used in a variety of ways to support a business, writes Greg Whitehead, Principal at Shelston IP. After the best part of two decades working within the IP industry and seeing numerous missed opportunities, it remains an unfortunate reality that leaders and key decision-makers at many of Australia’s most innovative manufacturing businesses – particularly small and medium-sized enterprises (SMEs) – do not adequately understand the full range of ways in which they can capitalise on their IP. This is a common theme across Australia’s advanced manufacturing sector, including within our most innovative companies developing highly specialised products and processes in areas such as aerospace, defence, automotive, clean and renewable technology, medical technology, biopharmaceuticals, mining and agribusiness.

All too often the typical ‘understanding’ is that IP is only used “to stop others from copying us”. This results in the limited view that it is necessary to have a hard fought and costly court battle to resolve the issue at hand and gain value from an IP portfolio. Such a narrow outlook adversely limits the potential to maximise the commercial value of innovations and ultimately the value of a company – in short, it potentially reduces the return on R&D expenditure.

This is not to say that a business should or must seek to register all of its IP. Rather, it is incumbent on all business owners and managers to properly consider their company’s IP position so that they can confidently answer the question “Why have you, or why have you not, registered the company’s IP?” And for a business manager to be in a position to answer this question they must be well-informed and have a clear understanding of the potential means by which they can exploit IP rights to the benefit of the company.

By way of example, some benefits that can be realised with a structured IP strategy/portfolio include: • Recognition as market leader: Innovations can take many forms – from incremental improvements in a product to groundbreaking developments that create a new standard for a specific industry. For such innovations that become widely used and known throughout an industry, the existence of a corresponding IP portfolio can aid in further enhancing the profile and reputation of the company that produced the developments. This can lead to growth for the business, not only via increased sales but also by increasing the prospect of winning competitive tenders, particularly those having a relatively long-term supply and/or maintenance contracts.

Here the IP portfolio creates confidence and a point of difference for the company at the negotiating table.

• Collaborative partnerships: A further potential opportunity that arises from growing a company’s profile and reputation as an industry leader in providing innovative products and services relates to new opportunities to collaborate with third parties. Such collaboration can arise through new relationships as a result of the company’s enhanced reputation within the relevant industry, as well as with existing partners such as suppliers, where the IP portfolio can be leveraged to negotiate better pricing to the benefit of the company owning commercially relevant IP rights.

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• Growth and expansion without capital expenditure: Such additional revenue can be obtained through royalties paid to the IP owner by third parties who license the IP rights. In this way, the IP owner can bring in additional revenue based on the actions of a third party, thereby saving on the expense of establishing new production facilities with additional capital equipment to increase capacity. Here, it is important to recognise that registered IP rights are tied to a particular jurisdiction, which allows technology to be licensed on a state-by-state or country-by-country basis. For example, a manufacturing company operating only in the eastern states of Australia, and with no interest in expanding to the west, could license their technology to a company operating in Western Australia. The eastern-based company would benefit from increased revenue through royalty payments, thereby increasing its return on investment in the R&D that led to the relevant innovative breakthrough. A similar strategy could be employed to license technology to a company in a foreign country outside Australia, particularly where the technology is likely to be adopted widely throughout an industry.

It should therefore be appreciated that the benefits of developing an IP portfolio and associated strategy tailored to the specific needs of a company arise – more often than not – from proactive, collaborative-based actions to leverage greater value from the effort and expenditure undertaken in R&D by the company, rather than court battles. In other instances, a passive approach relying on the existence of an IP portfolio and associated profile in the market can also bring benefits, where third parties actively reach out to an IP owner to seek authorisation to use the IP under license or make an offer to purchase the technology.

In summary, the key take-home message is for business leaders to consider whether their products/processes offer a competitive advantage in the market. If so, some time should be spent considering the company’s IP position and putting in place the most appropriate, robust IP strategy – whether by applying to register certain rights (e.g. patents, trademarks) or through controlled management of confidential information and trade secrets.

Finally, it is important to remember that the potential benefits outlined above reside with the true IP owner, and there are IP ownership implications associated with all business relationships – starting from employee contracts and the actions of staff, to dealings with third-party contractors. Care must therefore be taken to ensure there is a suitable IP clause clarifying ownership in any contract before signing it. www.shelstonip.com

By registering IP rights for key innovations, a company has opportunities to obtain revenue over and above that generated from its own sales alone.

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TECH NEWS

USA: 3D printing 100 times faster with light Rather than building up plastic filaments layer by layer, a new approach to 3D printing lifts complex shapes from a vat of liquid at up to 100 times faster than conventional 3D printing processes.

The new method solidifies the liquid resin using two lights to control where the resin hardens and where it stays fluid. This enables the solidification of the resin in more complex shapes at 100 times the print speed of conventional 3D printers. This method overcomes the limitations where the resin tends to solidify on the window that the light shines through, stopping the print job. By creating a relatively large region where no solidification occurs, resin flows in thousands of times faster. Thicker resins – potentially with strengthening powder additives - can therefore be used to produce more durable objects. The method also exceeds the structural integrity of filament 3D printing, as those objects have weak points at the interfaces between layers.

claimed to be uniquely capable of mammalian and reptilian walking gaits, allowing it to move in any direction. The legs also fold up into a stowed drive-mode, where power to the joints is cut, and the use of an integrated passive suspension system maximises battery efficiency. This allows Elevate to drive at highway speeds just like any other vehicle.

The Engineer

University of Michigan

UK: Bringing rotary friction welding to the manufacturing mainstream Engineers at The University of Strathclyde’s Advanced Forming Research Centre (AFRC) are exploring the use of rotary friction welding to help reduce materials wastage and production time.

Rotary Friction Welding is currently used across a number of niche manufacturing areas, but the AFRC team hopes that its work will help open up wider applications for the process. Welding is often regarded as an easy place for a material to fail. This, however, isn’t the case for rotary friction welding, instead it generates a very strong, high integrity joint for metallic materials. “We’re working with our members and partners on an industrial research programme that will demonstrate the considerable potential of this technology.

Combining it with manufacturing techniques, such as flow forming, rotary forging and radial forging, we’re aiming to create new hybrid near net shape manufacturing processes for similar and dissimilar alloys” said Dr Laurie da Silva, Research Associate at the AFRC. The Engineer

South Korea: Hyundai unveils “walking” concept car Unveiled at the Consumer Electronics Show in January, Hyundai’s “Elevate” concept vehicle, claimed to be the first ever car with moveable legs, borrows technologies from robotics and electric vehicles to create a vehicle that can drive, walk and even climb across some of the most rugged terrain. It claims to be able to climb a 1.5m wall and step over a 1.5m gap while keeping its body and passengers completely level. The robotic leg architecture has five degrees of freedom plus wheel hub propulsion motors and is enabled by the latest in electric actuator technology. This design is

USA: More energy-efficient plastics manufacturing An innovative filtering material may soon reduce the environmental cost of manufacturing plastic. The material, a metal-organic framework (MOF) can extract ethylene, the key ingredient in the most common form of plastic, from a mixture of other chemicals -- while consuming far less energy. The research team reported that a modification to a well-studied MOF has enabled it to separate purified ethylene out of a mixture with ethane.

National Institute of Standards and Technology (NIST)

Russia: Ultrasonic, vibration & heat for composite flaw detection Researchers at Russia’s Tomsk Polytechnic University are developing an advanced composite flaw detection system that combines ultrasonic, vibration and heat testing methods.

Every year, new composite materials appear and they challenge existing methods of non-destructive testing. Joints between the materials are of particular complexity and importance. This method uses piezoelectric transducers to carry out resonant ultrasonic stimulation as well as scanning laser Doppler vibrometer and an infrared camera. The idea is that a tested object is exposed to acoustic stimulation in a wide range of frequencies. The resonant frequency of vibrations of defects’ walls differs from that of the object that can be detected with a scanning vibrometer. In addition, due to intense resonant vibrations, defect areas are locally heated.

These changes are registered with an infrared camera. The data of quality testing allow the identification of a defect itself, its location, form, and size. The approach will consume less electricity than high-power ultrasonic installations and will offer an alternative to the existing methods of non-destructive testing.

The Engineer

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TECH HEADING NEWS

Hong Kong: Strong and ductile multicomponent alloys A team has developed a novel strategy to develop new high-strength alloys which are extremely strong and yet ductile and flexible. Highentropy alloys (HEAs), are a new type of material constructed of five or more metals with potentially desirable properties for structural applications. Yet the higher the strength of an alloy, the less the ductility and toughness. Now a breakthrough solution to this daunting decades-long dilemma has been found through massive precipitation of nanoscale particles. The team reported that a new alloy has been made which is five times stronger than that of ironcobalt-nickel. High-strength alloys usually face plastic deformation instability. But the team has further found that by adding complex nanoparticles made of different element atoms, it can greatly strengthen the alloy uniformly by improving the deformation instability. The ideal formula for these complex nanoparticles consists of nickel, cobalt, iron, titanium and aluminium atoms. Each nanoparticle measures 30-50 nanometres.

City University of Hong Kong

Australia: Making building cladding fire-safe How do you make a lightweight cladding material that doesn’t catch fire? It’s a question the building industry globally is wrestling with in the wake of the 2017 Grenfell Tower blaze in London.

Cladding needs to withstand 750°C temperatures and new codes make it virtually impossible for any plastic-backed cladding to pass combustion tests, leaving the industry facing much higher cladding costs. It was noticed by a researcher that the plastic insulation around electrical cables uses tiny ceramic particles that effectively stop the material from combusting. At high temperatures, the ceramic particles activate and chemically interact with each other, forming and spreading a heat-resistant network through the material. Because building cladding needs to withstand much higher temperatures than electric copper wires, various ceramic particles were experimented with until the researcher and her partners came up with a formulated material that passed the combustion test. The product not only achieved the Australian combustibility standard, but also the more exacting ISO1182:2010 standard that is used internationally.

University of Melbourne

Japan: Non-destructively measuring salt content of concrete structures Researchers have developed a method, using the RANS compact neutron source, to non-destructively measure the salt content of structures such as bridges, tunnels, and elevated roadways, which can suffer from degradation due to exposure to salt from seawater and other sources. The collapse of a bridge in August in Genoa, Italy, leading to the deaths of 37 people, has highlighted the danger posed by aging infrastructure. Inspections are time-consuming - for example, gauging the salt content of cement structures is typically done by boring out a core. Researchers decided to use a neutron beam which they developed. They used the beam to irradiate a series of concrete

blocks with salt squeezed between them, with “prompt” gamma rays.

Different elements can be detected by looking at the energy of the gamma rays. By doing this the researchers were able to demonstrate the presence of salt even when it was surrounded by between 1218cm of concrete. Each measurement took about 10 minutes.

Riken

Australia: Drones can now flap wings, ride wind currents like birds Researchers from RMIT University and ISAE-Supaéro in Toulouse, France, have conducted experiments with drones that can sense wind gusts and thermals, then use them to gain speed or altitude, just like birds. The world-first project had exceeded expectations and represents a big leap in energy harvesting for drones. This technology not only allows a drone to gain kinetic energy to fly faster but also means less work and more efficiency for the propulsion system, potentially enabling the next generation of drones to increase their flight time on limited resources. In the latest project, gust sensors were integrated with an on-board computer to analyse gusts and command the drone to negotiate them effectively.

RMIT

USA: Measuring laser power in real time Lasers play roles in many manufacturing processes and manufacturers must ensure that their lasers fire at the correct power. But to date, there has been no way to precisely measure laser power during the manufacturing process in real time, while lasers are cutting or melting objects. Without this information, some manufacturers may have to spend more time and money assessing whether their parts meet manufacturing specifications after production. To address this, researchers have been developing a laser power sensor that could be built into manufacturing devices for real-time measurements.

The “smart mirror” is designed for lasers of hundreds of watts. It could also be integrated into machines employed in additive manufacturing.

By shining a laser beam on a reflective surface, and then measuring how much the surface moves in response to light’s pressure, researchers can both measure the laser’s force (and, therefore, its power) and also use the light that bounces off the surface directly for manufacturing work.

National Institute of Standards and Technology (NIST)

“This is an incredibly exciting and important project for us as we get a glimpse into what the future of wheel design holds … allowing us to push the boundaries of wheel design beyond anything possible with current methods,” HRE Wheels President Alan Peltier. HRE Wheels and GE Additive unveiled the first 3D printed titanium wheel, created using EBM technology (a type of 3D printing). Known as “HRE3D+”, this new prototype wheel shows what the future of wheel technology will bring and how advanced materials like titanium can be harnessed to create complex designs.

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PRODUCT NEWS

Polystar recycling technology solves insidious issue of plastic film waste With the issue of plastic recycling becoming more of a burden, companies across Australia are seeking out new ways to effectively recycle their waste, especially their plastic film waste. Waste from plastic film wrapping has been responsible for exacerbating the overflow of landfills and contributing to a looming plastic waste crisis.

Polystar presents an ideal solution to this major problem by offering a range of one-step machines that are designed for the reprocessing of polyethylene and polypropylene flexible packaging material.

Polystar machines are designed to be simple to operate and easy to maintain, all the while taking up minimal space and time. Their output comes in the form of high-quality plastic pellets that can be fed straight back into the manufacturing process, saving on raw material costs as well as on waste disposal.

This pelletising system – with its integrated cutter compactor – eliminates the need for pre-cutting in most cases, and ensures the material spends less time in the extrusion process to minimise degradation. This means that the final product will be of the highest quality and the material properties will not be affected.

In addition to the double degassing in the first extrude, the venting area – the connection between the first and second extruder serves as a third degassing section (optional) to further remove the ink and extra humidity level from the material. The unvented extruder has a very short screw L:D ratio, in which the material travels in the extruder for the shortest time and distance. This results in minimal change in material property and higher output comparing to vented extruder. Furthermore, the repositioning of filtration before degassing ensures a superior degassing effect, producing excellent quality pellets from heavily printed material.

“Manufacturers who want an easy, efficient solution to plastic film recycling now have the opportunity with Polystar recycling machines,” said Applied Machinery Managing Director, David Macdonald. “Polystar requires less space and energy consumption

whilst producing high quality plastic pellets, which are immediately reusable. The Polystar machines are a must get for companies that are serious about plastic film recycling.”

Polystar is a Taiwanese-based company that now has machines operating in 102 countries. Since its formation 30 years ago in 1988, the company has grown into a globally-respected manufacturer.

Its high-quality, reliability and state-of-the-art features have been proven in the intervening years.

“Applied Machinery is proud to have been appointed a distributor for Polystar machines. We are confident that the product will appeal to manufacturers looking to effectively recycle their plastic film waste, and provide those manufacturers with a competitive advantage in the market place,” added Macdonald.

Applied Machinery recently celebrated 25 years in business and, in addition to Polystar, represents a large range of other premium machinery manufacturers including Yawei, Genox, Hurco, Cosen, Chen Hsong, Alfarobot, Hermle, Akyapak, Pro-Plas, Hyundai-WIA and Kitamura. www.appliedmachinery.com.au

Putting you in control of difficult materials Dormer Pramet has launched several high-performance grades for milling hard materials and for precision thread turning.

The new milling grades – M4303 and M4310 – provide durability and reliability in semi-finishing and finishing.

Each is designed for high-speed milling for the die-and-mould segment, offering consistent wear and longer tool life. An ultra-thin PVD coating increases cutting edge toughness, while its substrate provides high hardness and strength of cutting edge, preventing fracture by chipping.

Created within the company’s Pramet range, the M4303 replaces the previous 7205 grade and provides superior wear resistance. It has been developed for hardened steel above 55HRC and cast iron, but can also be used for machining steels and non-ferrous metals.

The M4310 takes over from the existing 7215 grade and offers an optimum balance of toughness and wear resistance in hardened steel and cast iron. It can also be used for machining stainless steel, steels and non-ferrous metals.

Meanwhile, Dormer Pramet has announced a high wear resistant grade for thread turning. The new T8010 is ideal for continuous high precision thread turning of steels, stainless steel, cast iron and super alloys. It further extends the company’s Pramet assortment in this application area and supports the universal grade T8030. Offering excellent wear resistance while ensuring operational reliability, the T8010 has enhanced plastic deformation resistance which provides

AMT FEB/MAR 2019

a stable cutting edge and allows for increased speeds. A gold finish on the insert provides a simple wear indicator, while a hard substrate and PVD coating has been optimised to deal with interior residual stress, helping to improve tool life. www.dormerpramet.com

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PRODUCT NEWS

Securely guide hydraulic hoses with igus E2 hydraulic chain The new igus E2 energy chain from Treotham reduces maintenance intervals of machinery and mobile cranes.

With the new E2 hydraulic chain, Treotham can now offer an energy and media guide for even the smallest installation spaces on support legs. Strong, space-saving and easy to install, the igus e-chain guides two hydraulic hoses in addition to power and control cables. The E2 hydraulic chain is an ideal solution for special mechanical engineering, and its use significantly reduces the costs of maintenance and downtime.

Special challenges require innovative solutions. This is particularly true for support legs on many construction machines, such as concrete pumps or mobile cranes, which are characterised by a large variety of models, not least in the components. The safe guidance of hydraulic hoses is of crucial importance here, because they need to serve the machines constantly and reliably even under high mechanical stress and strong weather conditions. Such efficient protection is provided by the E2 hydraulic chain. It not only protects the internal cables, but also prevents torsion and bending of the hoses through the predefined minimum bend radius.

For a long time, igus has been using the principle of the “extender crossbars” when it comes to creating more interior space for the guidance of hoses. For the E2/000 series and the E4.1 and E4.1L systems, extender crossbars, in addition to normal crossbars, can be used with high holding power to accommodate additional hoses with larger diameters. Thus the entire energy and media guidance can be provided by one system.

For the new E2 hydraulic chain, the concept was applied to the installation space-specific conditions of support legs on concrete pumps and mobile cranes. A very solid one-piece extender crossbar design and a heavy-duty pin/bore connection ensure high strength, even for large unsupported lengths. The extender crossbars are injection moulded directly on the side link and thus offer optimal hose guidance and stability.

It is also possible to place two hoses safely one above the other. Since energy and hydraulics can be guided within a single hydraulic chain, the requirement for installation space is greatly reduced.

The hydraulic chain has an external width of just 41.2mm and an external height of 57.5mm. The predefined minimum bend radius is 75mm. The total required installation height for the chain is only 255mm. Thus, the E2 hydraulic chain can be integrated into almost any application, such as close to the base or on the side wall of support legs, a concrete pump or a mobile crane.

Since hydraulic hoses, which are usually operated at extremely high pressure, have to endure a lot in dynamic applications, they are very maintenance-intensive. The E2 hydraulic chain meets this challenge in two ways: the extender crossbars and e-chain are made of tribologically optimised plastic. This reduces the abrasion and protects the hoses.

In addition to this material advantage of tribo-polymers, its special design also reduces wear to a minimum. Both the extender crossbars and the interior of the chain are designed to protect the hose. Rounded contours and wide and smooth contact surfaces keep abrasion and wear of the hydraulic hoses low.

The segmentation of the cable types also reduces the strain on the cables. Electrical and hydraulic guidances are completely separated by chambers. This follows the principle that cables and hoses with very different diameters should always be run separately. This is important because power or control cables have a thickness of maximum 5mm, while hydraulic hoses can be up to 20mm. Normally a clearance space of 20% must be allowed for, since hydraulic hoses expand transversely and lengthwise when pressurised. Designed to the last detail, the E2 hydraulic chain can offer freedom from maintenance. www.treotham.com.au

CleanWeld – A new approach to fibre laser welding Coherent’s new CleanWeld technology represents an integrated approach to fibre laser welding that delivers up to 80% spatter reduction, as well as minimal cracking and porosity. In addition to improved process consistency, it allows certain welding processes to be performed with up to 40% less laser power.

Coherent’s expertise in delivering unique beam intensity profiles, including the new “ARM” fibre laser technology, is just one aspect of the CleanWeld approach. Its process-optimised delivery optics and focusing heads, extensive welding knowledge, and in-house applications development capabilities provide customers with laser welding solutions tailored to their specific requirements.

According to Gäbler, the key goal is to control and maximise the stability of the keyhole and melt pool during the welding process – that’s what produces superior results. However, actually accomplishing this can require a variety of techniques that range from changing the intensity distribution of the focused laser spot, to introducing beam motion, to other factors like controlling vapor evacuation.

“While fibre lasers have been used in welding for over a decade, many end users are still seeking to improve part quality, production throughput, and process costs,” reports Frank Gäbler, Director of Product Marketing. “Coherent provides an integrated solution that is much more than just the laser itself. This is necessary because there are numerous factors besides the laser that affect the welding process.”

“CleanWeld addresses all of these areas,” Gäbler adds. “And the benefits of this approach are already being adopted in diverse applications, including zero-gap welding of galvanised steel, automobile powertrain component welding, and aluminum and copper welding for electric car batteries.”

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www.coherent.com

PRODUCT NEWS

WeldFil – A leap in efficiency for extraction systems With its WeldFil series, Kemper is taking its portfolio of central extraction systems into the digital age, marking a leap in development for extraction and filtration systems.

The WeldFil series replaces the previous central 8000 and 9000 extraction systems. The new systems are not only internetcompatible, but are also comprehensively optimised with regard to expenditure of energy, maintenance needs and design.

“By launching the WeldFil series, we have set a new benchmark regarding efficiency and digital revolution for central extraction and filtration systems,” emphasises Björn Kemper, Managing Director of Kemper.

The WeldFil series consists of the smaller plug-and-play version WeldFil Compact as well as the full WeldFil system for larger installations. A new construction enables simple access to important components such as the fan, the filter cartridges or the compressed-air maintenance unit. This results in a reduction of maintenance costs for the system operator.

Kemper has comprehensively optimised the combination of motor and fan. Its new and more efficient interaction has allowed the system constructor to reduce the motor power in some cases up to 40%, from 37kW down to just 22kW. The new systems are thus particularly energy-efficient.

These optimisations streamline the extraction system portfolio overall and assistance for specialist dealers will become significantly easier. The WeldFil series also meets all company requirements regarding volume flow and filter area. With their low noise emission of maximum 65dB(A), Kemper installations remain the quietest on the market, just like their predecessor models.

The new WeldFil series has made the leap into the Industry 4.0 age with its new sensor technology and a cloud-based internetcompatible control module. Important information such as differential pressure, temperature or residual dust monitoring are easily retrievable over the Internet.

“In this way, we make automated, rule-based processes possible for central extraction systems,” Kemper explains. “Predictive maintenance becomes reality for extraction technology.”

Kemper notes the generation change in central extraction and filtration systems by introducing a modern system design. This makes maintenance of the installations easier, too. A new base frame offers better corrosion protection, particularly when installed outside.

It is more than 25 years since, with its 8000 System, Kemper brought the first fully integrated filtration system for welding fumes extraction onto the market. After its introduction in 1992, its systems technology was successively further developed. With its larger 9000 sister plant, the portfolio for central extraction systems was expanded for greater quantities of fumes and dust.

Kemper’s systems technology is widely regarded as the industry standard to this day, due to the horizontal mounting of its filters.

Now, Kemper is repositioning its portfolio. WeldFil achieves a direct link to the core application area – welding fumes extraction. www.kemper.eu

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

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PRODUCT NEWS

Premium-quality compressed air for trades and workshop applications Anyone looking for a super-quiet, efficient and cost-effective supply of quality compressed air for their workshop requires a user-oriented solution. With the space-saving i.Comp 8 and 9, Kaeser Compressors has introduced a completely new compressed air supply concept that has been specifically developed with this field of use in mind.

The i.Comp units are tough, powerful, compact, efficient and easy to maintain. At the heart of the new i.Comp family is a new drive concept, which provides a multitude of advantages. It delivers the necessary power to cover the required compressed air demand with infinitely variable control. The reciprocating compressor itself is made in Germany and is manufactured to the highest industrial standards.

Moreover, the i.Comp family of reciprocating compressors are able to operate with 100% duty cycles. Intelligent solutions – such as drawing the air for compression in through the piston head – ensure exceptional filling performance and, as a result, outstanding efficiency.

With a volumetric flow rate of 412 to 580 litres per minute, the i.Comp Towers can be used for a wide range of workshop and trades applications and assure a constant pressure of up to 11 bar with absolute operational reliability. Made from roto-moulded polyethylene to enable optimum corrosion- and impact-resistance, the attractive sound enclosure not only hides an advanced all-in-one compressed air station comprising a compressor and a refrigeration dryer, but also keeps sound levels to a minimum and helps retain system value.

Kaeser’s field-proven Sigma Control 2 controller allows pressure preselection and infinitely variable speed operation, as well as connection to a master controller such as the Sigma Air Manager 4.0.

Since i.Comp Tower systems deliver oil-free compressed air, no oil enters the compressed air supply itself. This in turn eliminates the potential for accumulation of oil-contaminated condensate that

would otherwise have to be carefully disposed of. In addition, there is no need for oil changes or oil inspection, which of course further reduces overall service costs. i.Comp Tower systems are particularly well suited to workshop and trades environments, such as in car repair shops, where a dependable supply of quality compressed air is required. www.kaeser.com.au

Konica Minolta partners with Mobile Industrial Robots in Australia Konica Minolta has partnered with Mobile Industrial Robots (MiR), a leading manufacturer of collaborative mobile robots, to bring a greater level of automation to its clients in Australia.

MiR manufactures robots that help companies increase the efficiency of their operations. These robots are used by companies to transport trolleys and goods in the manufacturing sector and move pallets in the distribution industry. Built-in sensors and cameras combine with market-leading technology so the mobile robot can collaborate safely with humans. No cages or designated human or robot areas are required.

The partnership was made official on a recent visit by Keetels to MiR’s Headquarters in Odense, Denmark. MiR CEO Thomas Visti hosted Keetels throughout a two-day visit to the innovative facility.

“Innovation and automation have a significant role to play in manufacturing and distribution environments in Australia,” said Martin Keetels, National Manager of Robotics & Innovation at Konica Minolta. “Konica Minolta is excited to bring another level of automation to its customers.

“Konica Minolta is committed to continued investment in this space through partnerships and by developing internal resources to deliver the best outcomes for its customers. Konica Minolta’s role is to work with robotics companies to support their growth by harnessing its capabilities of distribution, services, and maintenance while our partners continue designing, manufacturing, and supplying the robots.

“With Australian businesses requiring greater efficiency to remain competitive in the region, and globally clients are beginning to demand robotic technology. Robotics will be a growth and productivity engine of Australia’s future economy. With more than 150 service engineers in-house and the equivalent number in the channel that can potentially service robots, Konica Minolta is in a unique position to prepare our clients for the workplace of the future.”

AMT FEB/MAR 2019

“I was incredibly impressed by the calibre of MiR’s management team and the market-leading robots,” Keetels said. “It’s a great combination to find in a partner and we are excited by what the future holds.

“Konica Minolta’s robotics capability is just beginning with MiR with many opportunities to extend across different industries and applications in the future.” www.konicaminolta.com.au www.mobile-industrialrobots.com

PRODUCT NEWS

Tritan-Drill – Drilling with three edges for all materials, applications Tritan drills from Mapal have established themselves across the board due to their economic advantages. Four new designs have now completed the range.

Mapal is offering the four new models – the Tritan-Drill-Uni-Plus for universal use, as well as the application-specific designs –TritanDrill-Alu, Tritan-Drill-Iron and Tritan-Step-Drill-Steel. The TritanDrill-Uni for machining steels, stainless alloys and cast materials has been further developed and improved with regard to its tool geometry. The new Tritan-Drill-Uni-Plus has a clear advantage over the previous drill for universal use: finished groove profiles improve chip removal, while a wear-resistant coating increases the tool life by up to three times. In shank form HA, the Tritan-Drill-Uni-Plus is available in the diameter range of 4mm to 20mm and in lengths 5xD and 8xD as standard.

5-AXIS MACHINING IS

NO LONGER OUT OF REACH!

For use in aluminium and cast materials, Mapal presents the Tritan-Drill-Alu and the Tritan-Drill-Iron. Thanks to innovative tool geometries, the drills also achieve significant increases in feed rates and thus in performance in these material groups. The Tritan-DrillAlu has a polished groove profile matched to aluminium materials.

Large chip spaces and a special, sharp cutting edge preparation ensure optimum chip formation and reliable chip removal.

In cast machining, the Tritan-Drill-Iron impresses with its corner radius design that stands for greater stability and wear resistance of the cutting edge. In conjunction with a wear-resistant coating, cast materials can be optimally machined with the Tritan-Drill-Iron.

Both designs are included in the range of products as applicationspecific special solutions.

Finally, the Tritan-Step-Drill-Steel was developed for stepped bores in tapped drill holes. Until now, only double-edge drills were available for these machining operations. Due to their flat chisel edge in the centre, these tools oscillate up and down along the chisel edge, which leads to a high load on the cutting edges and guiding chamfers and thus to poor results with regard to circularity and cylindrical form. Based on the Tritan-Drill-Steel, the triple-edge technology has now been adapted for stepped bores.

The new Tritan-Step-Drill-Steel has an innovative point thinning and finely ground chip flutes, so the chips are rolled tightly and broken.

The chips are reliably removed through the relatively small chip flute.

The crowned cutting edge with a pulling cut from the centre to the stable cutting edge reduces the load and makes the drill robust. In conjunction with a wear-resistant coating, the machining results of the Tritan-Step-Drill-Steel are excellent: compared with conventional double-edge step drills, Tritan drills can achieve double the feed rates –while simultaneously increasing tool lives. www.mapal.com

Universal Series Multi-axis machining used to require exotic machines, expensive options, and complex configurations – until now. Haas Universal Machining Centers simplify the process, providing a cost-effective solution for reducing setups and increasing accuracy on multi-sided and complex parts.

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All of the COASTONE machines are built in Finland, home to Europe’s higher quality machine exports. They are all electric, servo-driven and built to run for decades in most demanding environments.

Haeger, a PennEngineering company, is a world leader in the development of innovative fastener installation technology solutions.

Haeger – PEMSERTER, offers the most comprehensive line of automatic and manual machines designed to safely, reliably, accurately, and quickly install the complete range of fasteners.

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DEFENCE & AEROSPACE

SET SOAR TO

The defence industry in Australia is thriving, with major projects and government initiatives creating opportunities for Australian manufacturers both large and small.

By William Poole.

FA-18 Hornets fly in formation with one of a pair of F-35A Joint Strike Fighters Š Commonwealth of Australia, Department of Defence.

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On 10 December, two F-35A Joint Strike Fighters (JSF) landed at RAAF Base Williamtown in New South Wales (NSW), the first deliveries in what will eventually see at least 72 F-35 aircraft based in Australia.

Built by Lockheed Martin in the US, with support from subcontractors from all over the world, the JSF is the largest acquisition in the history of the Royal Australian Air Force (RAAF), and the arrival of the first two planes represented a landmark not just for defence and aerospace in this country, but also for Australian manufacturing.

“Australian industry is manufacturing parts that will be fitted to every F-35 in production globally, and more than 50 Australian companies have directly shared in $1.2bn in production contracts to date,” said Steven Ciobo, the Federal Minister for Defence Industry. “Up to 1,500 contractors have worked on the construction of the facilities to accommodate the F-35A at RAAF Base Williamtown, representing approximately $1bn of investment in the Hunter region alone.”

In the same week that the two aircraft touched down, an event was held at Osborne Naval Shipyard in South Australia to mark the beginning of works on the construction yard for Australia’s Future Submarine fleet, accompanied by the announcement that the submarines would be known as the Attack class. A day later, steel was raised at Osborne for the construction of the Royal Australian Navy (RAN)’s new Hunter Class frigates.

These developments rounded out what had been an eventful 2018 for the defence sector in Australia, which got underway on 29 January with the release of the Federal Government’s Defence Export Strategy. This ambitious plan aims to see Steven Ciobo, Federal Minister Australia become one of the top for Defence Industry. ten global defence exporters within the next decade. With the Government investing $200bn over the next decade to modernise Australia’s defence capability, the Defence Export Strategy includes a raft of measures intended to boost Australian industry, increase investment, and create jobs.

The Strategy was followed by a host of related announcements over the course of 2018. One significant initiative arrived in November, as Ciobo unveiled the Sovereign Industrial Capability Priority Grants program. This will provide grants of up to $17m per year to help eligible small and medium-sized enterprises (SMEs) meet up to 50% percent of eligible project costs, including capital equipment, specialist software and security infrastructure, non-recurring engineering costs, design activities, or training and accreditation.

“The more Australian industry can contribute to meeting the ADF’s capability needs, the greater prosperity and security we will all enjoy,” said Ciobo. “Involving Australia’s SMEs in this major renewal of Australia’s defence capability will grow our industry and economy, helping create new jobs.”

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DEFENCE & AEROSPACE Continued from previous page

BAE Systems Australia – Business is good The flood of positive announcements from Canberra have helped to create a buoyant mood among companies involved in the defence industry in Australia, and that upbeat mood was in evidence at ‘Defence Industries: Unlocking global markets’, an event held by the Committee for Economic Development of Australia (CEDA) in Melbourne in October. Gabby Costigan, Chief Executive Officer of BAE Systems Australia, provided the keynote address, and she began by summing up the current state of optimism across the industry.

Another major defence project for BAE Systems Australia is the Hunter Class Frigate Program. On 14 December its subsidiary ASC Shipbuilding was awarded a contract by the Government providing the framework for the design and build of nine of these antisubmarine warfare ships for the RAN. With prototyping projected to commence in 2020 before steel is cut on the first ship in 2022, the Hunter program is expected to create more than 5,000 jobs across the Australian defence supply chain.

Gabby Costigan, Chief Executive Officer of BAE Systems Australia.

“This brilliant job that I have is insanely busy, but busy I like to think is good,” said Costigan. “Busy means progress, busy means exports, and busy usually means business is good and profitable. In our case at BAE Systems, busy does mean business is good! But it is not just our business that is in a good place right now, the broader defence sector is as well. The Federal Government has made Australian defence capability a priority in its procurement processes and recognised the importance of removing the boom-and-bust cycles that can result from the beginning and ending of major acquisition programs. Exports play an important role in supporting this.”

One of the world’s largest defence companies, BAE Systems is a major partner in the F-35 program, and its Australian subsidiary is one of several manufacturing companies in this country supplying the JSF. BAE Systems Australia has invested more than $15m in facilities and equipment to establish a titanium machining facility in Edinburgh Parks, SA, to manufacture vertical tail components for the aircraft. Assembly of those parts is subcontracted to Marand Precision Engineering, a family-owned manufacturing business based in Moorrabin, Victoria.

“Our initial investment has led to more supply opportunities on the F-35 program, including titanium components for electronic warfare (EW) systems, navigation and identification modules and also a corrosion prognostic health management system,” said Costigan.

“We are just one of the companies in Australia supporting this important global program.”

Above: BAE Systems Australia has been awarded a contract for the design and build of nine new Hunter Class frigates for the Royal Australian Navy (RAN).

AMT FEB/MAR 2019

“The program has incredible potential to support Australian exports,” said Costigan. “BAE Systems will require hundreds of Australian SMEs to support this exciting 35-plus year endeavour. Five Australian companies are already exporting into the Type 26 frigate program in the UK, from which our Hunter Class frigate has evolved. As the program matures in Australia so will the opportunities for Australian companies.”

While fighter jets and warships hog the headlines, BAE Systems Australia’s most successful defence export – and its largest in revenue terms – is less well known: a missile decoy system known as Nulka. Australian designed and developed, Nulka comprises a rocket packed with highly sophisticated electronics, which can be launched from a naval vessel and then hovers in mid-air to draw incoming missiles away from their targets. Currently deployed aboard more than 150 Australian, US and Canadian warships, Nulka is now Australia’s largest defence export, having generated more than $1bn in revenue.

“Nulka is a unique national defence capability, which was developed by the defence sector right here in Australia, and my employees played a key role along with DST Group,” Costigan explained. “I think it is important everyone understands that it is not just BAE Systems that benefits from the export revenue something like Nulka achieves.

Approximately 50% of Australia’s manufacturing workshare on this decoy is distributed to local subcontractors. By exporting Nulka, we have been able to create further opportunities for Australia, invest further in research & development (R&D), create new jobs, and further expand our Australian supply chain. I think that is something we as Australians can certainly be proud of.”

For Costigan, projects such as Nulka, the F-35 and the HunterClass frigate highlight the impressive capabilities and technology that Australia’s defence industry has at its disposal. And there is great potential for this industry to grow further.

“If defence was characterised as a standalone industry, it ranks fifthhighest in Australia,” said Costigan. “It is a highly skilled and productive

Right: A Nulka Active Missile Decoy being launched from HMAS Darwin.

Nulka is BAE Systems Australia’s most successful defence export. © Commonwealth of Australia.

DEFENCE & AEROSPACE

workforce and can support a more balanced and sustainable economy. And with such unique products, we are very well placed to compete in the export market, where innovation and technology deliver an important market edge. With Australia currently achieving in the order of $1.5bn to $2.5bn per year in defence exports, there is clearly an economic opportunity for Australia to grasp.”

Costigan believes the Government’s Defence Exports Strategy is a good step in releasing that potential: “This Strategy has the potential to incentivise investments that support sustainable sovereign industry capabilities and will also help to develop the export potential of Australian developed technologies. The Strategy helps to ensure the sector gets the focus it warrants, not just from government but also the wider business community. Strengthening defence trade to our priority markets makes sense, and my company would welcome any initiatives that further strengthen these existing trade relationships with Australia’s key partners.”

However, Costigan stressed there was another important reason to support defence exports: in order to ensure Australia’s sovereign defence capability.

“It is in our national interest to have a strong defence industry that is able to meet our sovereign capability needs,” she said. “It allows Australia to have greater self-sufficiency and maximise the economic benefits of large capability investment. It ensures we have greater control in meeting our security needs, and it helps us control our destiny and to protect us and our national interests. As a country, we need to continually innovate to ensure that Australia has the best possible equipment and support for our Defence Force. Scale is needed to achieve this, and defence exports certainly help with this objective.”

Above all, Costigan believes the defence industry can be the basis on which to build a stronger, more sustainable and more sophisticated economic outlook for Australia in the future.

“We know the Australian economy is changing,” she concluded.

“While in the past we may not have been particularly good at turning R&D into commercial IP, I think defence has demonstrated it can be done and now is the time to seize the opportunities in the defence sector. Australia’s exports don’t have to be restricted to things dug out of the ground or grown. The opportunities are enormous and the benefits to our community are significant.”

Australian Precision Technologies – Transforming its business While BAE is a well established, globally recognised name, Australian Precision Technologies (APT) is, in contrast, still building a foothold in the defence industry.

Nonetheless, the company, based in Berwick, Victoria, is making impressive progress in seizing the opportunities described by Costigan.

Founded in 1992 by Richard Weinzierl, who remains at the reins today as Managing Director, APT has adapted and evolved continually over the years. In the late 1990s the company was a preferred supplier to Robert Bosch, which at one point accounted for 86% of its business, and for some time it

was – like many Australian manufacturers – heavily exposed to the automotive sector. More recently, APT has diversified into advanced manufacturing, building a strong reputation in this field.

Over the last few years the company has actively targeted the defence sector, and the transformation has been radical, to say the least. As of December, defence accounted for 75% of the company’s business, with Weinzierl predicting that number could reach 95% by March.

“It’s been very quick,” he says. “And we’ve grown from 18 staff two years ago to 30 now.”

Today APT’s list of key customers reads like a roll-call of some of Australia’s most prestigious defence projects. The company is involved in supplying components for the JSF program. It works with Thales Group, providing munitions and components for the F90 Steyr rifle and the Bushmaster and Hawkei armoured vehicles.

And it produces components and assemblies that go into radar systems, remote weapon stations, and submarines. In securing these contracts, APT’s ability to deliver high-quality, complex components in full and on time has given it a distinct edge.

“We just made this submarine part; that is one complex part that not many people can make,” says Weinzierl. “There’s not many people like us that can make those quality parts and on-time.”

APT has in fact been working in the defence sector since its very early days. In 1993, the first component it supplied was a small pin for a a submarine launch flare, and the company has continued to find work in defence and aerospace from then on.

“It just kept growing and growing and it just seems to be where the growth is,” says Weinzierl. “For us, making high-end, quality precision parts is where defence is. We don’t compete with your backyarders, we don’t make bushes and sleeves; we do high-end complex machining.”

The company’s transition into defence gained significant momentum at the 2016 Land Forces exhibition in Adelaide, where Varley Group, one of Australia’s oldest, most advanced manufacturing companies, recommended that APT engage with the Centre for Defence Industry Capability (CDIC). APT joined the CDIC’s Supplier Continuous Improvement Program (SCIP). The company has been on the program for two years now with a further 12 months to go, and Weinzierl is candid in describing the impact this has had in transforming his business.

“The business coaching which the CDIC has funded has turned APT around,” says Weinzierl. “The main thing was they gave us a whole strategic plan to work to. First of all we did an employee survey, and we revisited that survey recently, and the company’s turned around, it’s not the same company. Everyone’s engaged, everyone’s onboard. And it’s getting staff on-board that’s really making a difference.

We’ve never seen anything like this. It’s fantastic.”

To facilitate this transition, APT has dedicated significant resources to overhauling its processes and operations. The stringent requirements of defence industry clients have seen the company work towards gaining AS9100 accreditation, the defence industry quality specification, by June 2019. It has also had to put a cyber-security plan in place, as well as a plan to ensure compliance with the US’s International Traffic in Arms Regulations (ITAR) regulatory regime.

The company has also paid considerable attention to improving the way it works to maximise efficiency. It recently invested in M1 enterprise resource planning (ERP) software to streamline operations. Data from across the business is studiously recorded, charted and evaluated. The team meets regularly to review KPIs, or to track DIFOT (delivery in full on time) performance. Again, Weinzierl acknowledges the CDIC’s role in bringing about these changes.

Richard Weinzierl, Founder and Managing Director of Australian Precision Technologies (APT).

Continued next page

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DEFENCE & AEROSPACE Contined from previous page

“Their help has been crucial. They’re really interested in improving your business” he says. “APT’s been able to get better organised, which has then made us more competitive. And we’re monitoring outcomes, we’re implementing Industry 4.0 to collect data, and improve on that through Lean manufacturing. That’s where we’re at.”

These changes have been accompanied by a simultaneous shift in the workplace culture, with a growing focus on staff’s health and well-being. Like many manufacturing SMEs of its size, APT used to depend heavily on its employees taking on overtime when the workload demanded it. That all changed when the CDIC got involved.

“They couldn’t believe how much overtime the guys were doing here,” recalls Weinzierl. “When the CDIC did the operational and business excellence review, they said that’s just not normal, it’s not a healthy company to work at, where you’re expected to do overtime.

“So now, if the guys are studying and they’ve got to do an assignment, I say ‘How about you work from home today?’ You know how happy that makes them? We offer flexibility and I think that’s important. If you’re looking after them, they’ll look after you.”

Given the speed with which it has transitioned into defence, you might be inclined to assume this has been an easy process for APT. However, defence clients are exceptionally demanding, both in terms of the precision and quality they expect, but also in terms of the timeframe in which they expect to see their orders fullfilled.

“Capacity’s a massive problem,” says Weinzierl. “Anyone can have heaps of machines, but if you don’t have the operational excellence behind that, you’re not going to make quality parts and on-time.

That’s the difference. And with AS9100 and our MRP system there’s a process that you have to follow. One of the biggest challenges has been sticking to and adhering to that process. So now we have regular DIFOT meetings which track it. Why are we behind? We analyse why we didn’t hit the targets.”

Having the machinery and processes in place is one problem. Even harder, according to Weinzierl, has been ensuring personnel are also ready and willing to come on that journey of transition.

“Getting all the staff trained and on-board; that’s been the biggest challenge. One thing I’ve learned is that you’ve got to engage your staff, you’ve got to meet with them and find out if they have any issues. It has to start off at the ground floor.”

Despite these challenges, there’s a palpable sense of excitement building around APT and its future. And word is getting out, with the company lately receiving some illustrious visitors: local MP Jason Woods recently paid a visit, and in November the Federal Treasurer Josh Frydenberg took a tour of the Berwick plant. Meanwhile, APT is continuing to pick up new business, while consolidating its position with existing customers.

“What we’re finding now is a lot of smaller companies are closing and bigger companies like us are absorbing their work,” Weinzierl explains. “Because we can offer delivery and quality, we’ll pick up more and more work. We often go back to companies now after the transition from automotive and say ‘Okay, the pricing we had for the last 10 years is not going to cut it now. But what we can deliver is quality in time and in full.’ Those companies tend to come back and

APT’s state-of-the-art manufacturing facility in Berwick, Victoria.

say ‘Okay we’ll pay more.’

“And obviously the Defence Force needs people like us. Because without people like us, they will not be able to buy a component that’s accurate and be delivered on time when they need it.”

In addition, APT is pushing ahead with even more ambitious plans.

The company’s manufacturing operations are currently spread over two separate industrial units, directly facing each other across the road. However, over the next couple of years it plans to build a brand new advanced manufacturing facility on the other side of Berwick.

Located on on a greenfield site, the new factory will be a state-ofthe-art facility with a strong emphasis on its clean, green credentials: solar energy throughout, sustainable water supplies, and recycling of all waste.

“The new site’s going to be huge,” says Weinzierl. “It’s fully automated, it’s going to be unreal. There’s a lot of planning that goes into this. It’s a challenge, but we’re up to it.”

With so many exciting developments going on, it might be easy to forget that APT remains very much a small family business whose founder is still very much at the helm. And Weinzierl is adamant in stressing who has been the real driving force behind the company’s transformation: “It’s all thanks to my wife Nicola; she’s the one who puts all this together.”

Moreover, if Weinzierl gets his wish, the business could soon become even more of a family-operated enterprise: “How lucky am I, that my daughter graduated from university last week and with a high distinction in project management? So I’m trying to get her to come to APT. She says ‘No way in the world can I work with you Dad.’ But she’ll come. It’s only a matter of time before she comes.”

Whenever that time comes, APT is continuing to steadily outperform the targets it has set for itself, and Weinzierl is optimistic about the future.

“Look at our sales budget,” he says. “We’re tracking above budget, and if we keep continuing in defence the way we’re going we could smash the budget. And we’ve only got 30 employees. Who knows what we can achieve next year?” www.defence.gov.au www.business.gov.au/cdic www.baesystems.com www.aptengineering.com

Defence components manufactured by APT.

AMT FEB/MAR 2019

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DEFENCE & AEROSPACE

Building our own warships is Australia’s path to the next industrial revolution Despite some criticisms, the Government’s plans to invest in local naval shipbuilding present a significant economic opportunity for Australia, and lays the ground for a transition to advanced manufacturing, writes Giselle Rampersad.

Naval defence procurement is very big business. Nine Hunter-class frigates will cost Australian taxpayers $35bn; the 12 submarines to replace the existing Collinsclass submarines at least $50bn. Although both the frigates and submarines will be built by foreign companies – the frigates by Britain’s BAE, the subs by France’s Naval Group – part of the deal is that they build locally.

The Federal Government isn’t shy about spruiking the local economic benefits.

“We make no apologies for deciding to invest in Australian-built ships, creating Australian jobs and using Australian steel,” said Christopher Pyne, then the Defence Industry Minster and now the Defence Minister, in May. There are critics. The Australian National Audit Office, for instance, has flagged the risks of cost blowouts in a local build. These risks will need to be proactively managed.

But the local shipbuilding program does present a tremendous economic opportunity.

It provides a platform to invigorate advanced manufacturing and ride the wave of the next industrial revolution. We need to focus on how to maximise the benefits by leveraging the program to create competitive new industries and jobs.

Mapping the manufacturing ecosystem Transitioning the Australian economy towards advanced manufacturing is not easy. It is tempting to simply import cheaper products. A good example can found in the renewable energy sector. With a few exceptions, the majority of solar panels and wind farm components are imported. This is a missed opportunity.

We can avoid making the same mistake in shipbuilding. Our research shows that building ships locally has huge flow-on effects, and can help underpin other advanced manufacturing. To facilitate this process, we have developed a map of the advanced manufacturing ecosystem in Australia (http://tinyurl.com/y6ugbyxy). The aim is to help boost the visibility of Australian organisations capable of supplying components or services to these projects.

This will assist in initiating partnerships.

Several Australian businesses and universities have already begun to secure relationships with the international shipbuilders. More are in the pipeline.

AMT FEB/MAR 2019

Industry opportunities Building ships presents many opportunities for Australian organisations.

In Australia, X-ray and imaging products are examples of complex products we have been able to competitively export. This technology is obviously relevant to medical imaging devices. It can also be applied to surveillance systems for the defence sector.

Conversely local manufacturers that develop capabilities in defence shipbuilding can leverage their expertise to supply to non-defence-related supply chains and for export. Relevant technologies include autonomous vehicles and systems, energy management, cyber-security, robust and maintainable materials, acoustics and digital technologies. These technologies can have flow-on effects for advanced manufacturing in transport, renewables, health, space and information technology. In these sectors, making complex products is vital for competitiveness.

Anchoring Industry 4.0 It is wrong to think advanced manufacturing is not viable in Australia. Britain and Germany are two economies with high labour costs, yet both have been able to sustain manufacturing sectors. The success of advanced manufacturers in Europe is based on an approach called Industry 4.0.

The “4” refers to the advent of the fourth Industrial Revolution since the 18th century – integrating information and communication technology in industrial production. During a visit to European manufacturing sites we saw how this involved the use of robots, cobots (or collaborative robots), digital twins and driverless vehicles.

Automation means that shipbuilding will not provide the sorts of jobs it did in the past. In Germany’s automotive industry, for example, human labour that cost 40 euros an hour has been replaced by robots that cost 5-8 euros an hour to operate – even cheaper than a Chinese worker. But other jobs have been created, particularly in computing and engineering. There are now 100,000 more jobs in Germany’s auto industry than in 2010.

Another feature of Industry 4.0 is digitisation of the supply chain. Information about parts can be captured and used in new ways. The point when a component will need to be serviced or replaced can now be predicted with high accuracy. This is important in any large ship, built to be operational for decades and using vast numbers of components from thousands of suppliers.

It’s even more important in a naval ships, where a breakdown could be catastrophic.

Digital transformation will make our factories more competitive. Additionally, economic gains will come from defence procurement that encourages the local development of complex and competitive products. If done well, defence investment will make as powerful a contribution to the nation’s economic prosperity as its military security.

Giselle Rampersad is an Associate Professor in Innovation at Flinders University. This article was originally published by The Conversation. www.theconversation.com www.flinders.edu.au

DEFENCE & AEROSPACE

The competition is in the deadline The industrial machinery and equipment manufacturing, metal fabrication and electronics industries are very competitive at the best of times, and there is a critical requirement for manufacturers to evolve to remain competitive.

One of the most important considerations in remaining competitive in the aerospace and defence industry is the ability to deliver to customers on time and in full. By Jakes Mantle.

Australia has a proven history of aerospace manufacturing and continues to provide world-class products to both the local and the global aerospace sector, based on an understanding of unique considerations such as the need for particular expertise, and dedicated resources. According to the Aerospace Manufacturing Services Report published by the Australian Trade Commission, the aerospace industry has to deal in specialty alloys and materials for their products, and also has multiple regulations and certifications to consider during the overall manufacturing process and in meeting the all-important deadline.

In order to accomplish this, certain matters must be taken into consideration. Time and quality management are crucial and can be the key differentiators. It is then critical that the right enterprise resource planning (ERP) system is in place. This will help to ensure a complete manufacturing lifecycle management system that enables planning, scheduling, publishing, collecting, tracking and analysing, to optimise and improve end-to-end manufacturing operations. As manufacturers look to effectively manage their processes, greater value will be placed in allocating budget to ERP systems, and not just to machines for the factory floor.

Streamlining operations With specific focus on the aerospace and defence industry, the right ERP solution can ensure that you streamline your transactions with industrial alliance partners, deliver on complex products faster with tight regulatory and engineering controls, cost efficiency, advanced planning, strategic decision-making, and compliance with both domestic and international regulations. All these factors make employing the right ERP solution fundamental to the overall success of your manufacturing operation in this sector.

There are specific solutions that can drive efficiency, such as scheduling, traceability and visual APS (advanced planning and scheduling). Being able to schedule quickly and accurately will reduce downtime and enable manufacturers to maximise order fulfilment and resource utilisation, collect data from the shop floor, and track employees, equipment and orders in real time. This will lead to a reduction in resource losses, and subsequently cost reduction, and will drive continuous improvement.

Enhanced ERP systems, which allow you to automatically connect your machines in order to read data, without manual inputs, will also help aerospace manufacturers to digitise their factories, and provide insights from the in-depth analysis of the performance data. These insights will clarify, among others, why actual run rates differ from planned run rates, where performance loss is occurring in relation to operator inefficiencies, and how the business’s bottom line is being affected by equipment wear and tear, and minor stops from component jams.

Regulatory compliance ERP systems with enhanced functionality should offer a unique level of compliance to domestic and international regulations.

In the aerospace and defence sectors, manufacturers must be compliant with several regulations and certifications. One of the most important is Nadcap (National Aerospace and Defence Contractors Accreditation Program), and given that approval from Nadcap is based upon industry consensus – something that sets it apart from other third-party programs – adhering to it can be complicated.

The second main certification is the AS9100, which provides suppliers with a comprehensive quality system, making sure that products are safe and reliable and addresses civil and military aviation requirements. With the right functionality in your ERP system, compliance to these and other regulations becomes second nature.

Monitor and track your supply chain A state-of-the-art ERP system would be able to monitor and track how your supply chain and your own production line is tracking against the regulations that are required. In this regard your supply chain is almost as important as your own business.

Ensuring all levels of compliance is critical to success in this sector. This is where strategic sourcing policies for procurement come into play. By partnering with the right suppliers, you secure the best-quality materials at the lowest cost, thereby giving yourself a competitive advantage.

This industry is one typically characterised by long set-up times, detailed testing, ordering of specialist raw materials, and difficulties in sourcing. All these factors can result in long delays for deliveries to customers. And delays mean slow payments, which can hurt the bottom line and the reputation of your business. With the right systems in place, these factors can be improved upon to ensure that projects are completed in full and on time.

While manufacturers in the aerospace and defence sector are continuously balancing improving operational efficiency and keeping pace with the ever-changing industry, maintaining control over the management of the end-to-end manufacturing process can ensure the viability of your business for many years to come.

Jakes Mantle is a Product Manager at SYSPRO Australasia. www.syspro.com

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Transformation in 3D: How a walnut-sized part changed how GE Aviation builds jet engines A jet engine fuel nozzle doesn’t look like much. Shaped like a water tap perched atop two stubby legs, it resembles a piece of plumbing equipment small enough to hold in your palm. Few would guess this unimposing object is among the most disruptive pieces of technology in GE history – one that gave rise to the world’s best-selling commercial jet engines, ignited a new GE business unit, and showed the world just what 3D printing can do. By Amy Kover.

In just a few years, 3D printing, also known as additive manufacturing, has evolved from an alien-like technology confined mainly to labs to a bona fide manufacturing method ready for prime time. GE has already started using it to mass-produce parts for jet engines. In October, GE Aviation’s 3D-printing facility in Auburn, Alabama, produced its 30,000th fuel nozzle tip.

It all started a decade ago, when CFM International, a 50-50 joint venture between GE Aviation and France’s Safran Aircraft Engines, was developing the LEAP engine, a new commercial jet engine that promised to burn less fuel than existing engines and release fewer emissions. As ambitious plans for the engine unfolded, Mohammad Ehteshami, the head of engineering at GE Aviation at the time, quickly recognised its success rested in many respects on the labyrinthine passages inside the tip of the fuel nozzle, which is designed to mix jet fuel with air in the most efficient manner.

To get the job done right, Ehteshami assembled a top-notch team of engineers, including an amateur pilot named Josh Mook, then just 28 years old, whose work with turbine blades had caught Ehteshami’s attention. Before long, Mook and his colleagues came up with their dream variant, a walnut-sized object that housed 14 elaborate fluid passages.

But as elegant as it was, the part arrived with a flaw: the tip’s interior geometry was too intricate. It was almost impossible to make.

“We tried to cast it eight times, and we failed every time,” Ehteshami recalls.

Traditional methods wouldn’t cut it, but 3D printing just might. A 3D printer functions like a laser pen, following a computer drawing and fusing layer upon layer of fine metal powder into the final shape.

Josh Mook stands next to a LEAP engine.

Images credit: GE Aviation.

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3D printers can build complex, dense parts like the fuel nozzle while generating a fraction of the waste produced by conventional manufacturing. The catch: at the time, GE Aviation used additive manufacturing only for prototypes. It had never printed anything for commercial use, much less for an entire fleet of passenger airplanes.

For Mook, who obsessively tinkered with machines as a boy, this was the dream job. Working closely with 3D-printing pioneer Greg Morris — whose company GE eventually acquired — Mook helped re-engineer off-the-shelf 3D printers to meet the fuel nozzle’s specifications.

Rather than 20 pieces welded together, the new tip was a single elegant piece that weighed 25% less than its predecessor, and was five times more durable and 30% more cost-efficient.

But the team was far from finished. They had to work fast to meet the LEAP program schedule and make sure that the US Federal Aviation Administration certified the part. And with orders for the LEAP engine pouring in, GE Aviation needed to figure out how to get its 3D-printing operations ready for mass production.

“People think 3D printing is as simple as operating an ink printer, but it’s not,” says Chris Schuppe, who runs GE Additive’s AddWorks team, a group of almost 200 engineering consultants dedicated to accelerating additive adoption for GE’s customers. “The fuel nozzle requires orchestrating over 3,000 layers of powdered metal that are about the thickness of a human hair.”

GE Aviation assembled a new team of roughly 100 employees, ranging from aviation experts to metallurgists, to hammer out these complex processes. That included making sure each machine was properly calibrated to handle the given product’s material properties — an arduous procedure that must be repeated every time a manufacturer adds a new machine to the production line.

DEFENCE & AEROSPACE A 3D printer functions like a laser pen, following a computer drawing and fusing layer upon layer of fine metal powder into the final shape. Image credit: Avio Aero.

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Rather than 20 pieces welded together, the new tip (inside the punctured ring section on the right) was a single elegant piece that weighed 25% less than its predecessor, and was five times more durable and 30% more cost-efficient.

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And in 2015, it built the fuel nozzle a 3D-printing facility of its own, in Auburn. With more than 40 3D printers at the ready and a deep pool of talent from Auburn University, the plant delivered a total of 8,000 fuel nozzles in 2017. As of now, the total tally stands at over 33,000 3D-printed fuel nozzle tips.

There’s much to celebrate with this milestone. The factory supplies fuel nozzles for engines that power both the Airbus A320neo and Boeing 737 MAX jets, with total orders for the LEAP engine exceeding 16,000 - valued at more than US$236bn.

Beyond the LEAP engine, GE Aviation uses additive manufacturing to make sensors, blades, heat exchangers and other parts for engines like the GE9X, the world’s largest jet engine, developed for Boeing’s new 777X wide-body plane. The technology even broke into the small-aircraft industry with Catalyst, GE’s new turboprop engine. Engineers used 3D printing to replace 855 components with just a dozen.

However, aviation is only the beginning. Today the automotive, energy, healthcare and other industries are embracing 3D printing.

GE estimates that by 2020, its GE Additive unit will continue to increase its revenue from equipment, materials and services.

Amazing what can grow out of one little walnut. www.ge.com

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

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Innovation takes flight at Avalon 2019 Key players in the international aerospace and defence industries are gearing up for Avalon 2019, the Australian International Airshow and Aerospace and Defence Exposition. Held biennially, Avalon 2019 will run from 26 February to 3 March at Avalon Airport, near Geelong.

While the air displays act as a big draw for the general public who attend Avalon, the real business is done in the exhibition.

Avalon is a global business event that attracts senior civil aviation, air transport, aerospace and defence industry, military and government decision‐makers from around the world. In 2017 the last event featured 664 companies from 25 countries, 158 delegations and more than 33,000 accredited trade attendances, with a total event attendance of 210,664.

As part of the build-up to the event, its organisers have released the shortlist for the $60,000 Avalon 2019 Innovation Awards. Twenty three SMEs, research institutions and individuals from six Australian states and territories have made the shortlist, submitting innovations across a range of fields from aerial sensors to helicopter training, a system to monitor space assets and a water‐powered rocket school teaching aid. Judged by an expert panel, the Avalon 2019 Innovation Awards attracted a record 68 submissions from 33 entrants, presented in six categories.

The awards are open to Australian companies and Australian subsidiaries of overseas parent companies. The innovation can be a new product or service to a new approach to business, with entries judged on originality and utility in aerospace, space and defence. Past winners have included TAE Aerospace for its Fountx wearable engineering technology, BAE Systems for its EDMAP corrosion management system and Thomas Global Systems for its “plug and play” LCD replacement for legacy cathode ray tube aircraft instruments.

The Avalon Innovation Awards are part of a program also involving Maritime, Land and Civil Security Industry Innovation Awards, presented biennially at the Pacific International Maritime Expo in Sydney, the CivSec Civil Security Congress and Exposition in Melbourne and the Land Forces exposition, which has been held in Brisbane and Adelaide. The program has awarded $305,000 in Innovation grants and awards since it began in 2013.

The Avalon 2019 Innovation Awards were developed by Avalon 2019 organiser and national not-for-profit foundation Aerospace Australia Limited as part of its mission to promote the development of Australian industrial, manufacturing and information/communications technology resources.

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The shortlisted Avalon 2019 Innovators are: • Cassowary Machining & Fabrication, Queensland – Chinook Helicopter SOS seat • Cryoclock, South Australia – Sapphire high-precision timing clock • Deakin University, Victoria – Haptically enabled Universal Motion Simulator • Defence Innovations, Victoria – NonIntrusive Flight Test Instrumentation System • DST Group, Victoria – Hornet Outer Wing Static Test System • Immersaview, Queensland – VADAAR LVC digital streaming system

• InnovAero, Western Australia – Big Eye aerial camera system • Inovor Technologies, South Australia – Space Situational Awareness System • It’s Rocket Science Adventures, Queensland – Water rocket teaching aid • Millswood Engineering, South Australia – Failsafe Flight Safety Device • Nova Systems Australia, South Australia – Requirements Assurance and Validation Suite • Opaque Media, Victoria – AIVA training assessment platform • RMIT University, Victoria – Black Kite UAV

DEFENCE & AEROSPACE

• Seeing Machines, ACT – Pilot eye scanning technology • Toll Helicopters, NSW – ACE Training Centre • Varley Group, NSW – Mudbucket avionics integration solution The shortlisted candidates for the Avalon 2019 Young Innovator Award are : • Graham Bell, Victoria – Monash University and NextAero • Steen Bisgaard, Queensland – GaardTech • Jordan Forsyth, NSW – JAR Aerospace • William Henderson, Victoria – Nova Systems Australia • Jimmy Toton, Victoria – RMIT University and DMTC • Achim Washington, Victoria – RMIT University • Joshua Wilson, Queensland – Skyborne Technologies “The key criteria in the Avalon 2019 Innovation Awards is that the innovation must not only be groundbreaking, but must also provide a tangible benefit in defence or industry,” said Avalon 2019 CEO Ian

Honnery. “The awards are not about innovation for its own sake, but about creating products and services that solve problems, create opportunities and make a difference in the real world. The fact that this year’s innovation awards attracted a record number of entrants is a tribute to the level of innovation and creativity in the Australian aerospace and defence community.” www.airshow.com.au

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Lightweight electricity solution emerges for deployed defence units A micro gas turbine designed to provide electricity to defence units in the field has been demonstrated to leading industry players in Australia.

South Australian company ecoJet Engineering demonstrated its 20kW gas turbine in Canberra in late November. The prototype engine system is only about 10% of the weight of a comparable internal combustion diesel engine and can be configured to run on a range of liquid and gaseous fuels, including propane, natural gas and diesel.

ecoJet Co-director James Kim with the 20kW micro gas turbine.

ecoJet Engineering received funding at the beginning of this year from the South Australian government and the RAAF Air Warfare Centre Innovation Hub to progress its concept design for a 20kW micro gas turbine into a viable prototype unit. The demonstration unit is the first stage in developing the next generation in deployable power generators for the military.

The demonstration unit generator weighs just 48kg, excluding the control system and the fuel tank, compared to 433kg for a current military diesel generator. It is also about two-thirds the size of the diesel engine, measuring about 600mm long and 250mm wide ecoJet Co-director Alexander Wright says the mobility of the unit, the versatility of the fuel source, and its potential for more efficient electricity production are among the advantages of the system compared with traditional diesel generators. Moreover, according to Wright, the demonstration unit already had flow rates comparable with current diesel generators.

“And that’s comparing a prototype unit with a commercially mature product,” says Wright. “We have a lot of scope for improving our efficiencies above that with things like heat recuperation, bearing advancements, the use of advanced materials such as ceramics and graphenes, and multi-stage turbo machinery, which is uncommon for turbines of this scale.

“It is quite efficient and it’s not restrictive of other technologies. It can work quite well in parallel with solar and battery storage, so it’s not a competitor to other products exclusively – it can complement other systems.”

The micro turbine works in basically the same way as a typical jet engine where a compressor draws in air and passes it into a combustion chamber where fuel is injected and ignited as it passes through a turbine, creating rotation.

“What we’ve got as part of our novel solution is an integrated shaft assembly where the shaft that connects the turbine and the rotor has an integrated generator attached to it,” says Wright. “The generator spins with the turbine to create electrical energy from the rotational energy extracted from those combusted gases.”

The origins of the formation of ecoJet Engineering began in 2015 with an Honours project at the University of Adelaide. The project – a collaboration involving Wright, James Kim and Warren Day – achieved one of the world’s smallest ultra-micro gas turbines.

Through further studies at the University of South Australia, the collaboration won a Venture Capitalist grant in 2016, which helped launch the company. ecoJet Engineering also pitched its ultra-micro gas turbine design at this year’s Land Forces event in Adelaide where it was named best innovation.

Major players in the global micro gas turbine industry include Capstone Turbine Corporation (US) and Bladon Micro Turbines (UK), but Wright says their focus is more on industrial applications in the 30kW and greater range. He says the ecoJet micro gas turbine also had potential as a domestic product to complement

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renewable technologies such as solar and help households become independent from the electricity grid.

“A military product is a commercial product with a bunch of extra stuff on top so we can easily tweak it to suit both markets because we are very much looking to break into both areas,” Wright says.

“We’re planning a fairly rapid development timeline and as part of this demonstration we’re looking for further investment from defence and government grants.”

The Canberra demonstration included five sessions throughout the day with various stakeholders including senior representatives from all three Australian armed services, the Air Warfare Centre and the Defence Innovation Hub. “It was a really good opportunity for us to understand from the defence side where they would use this particular application, what requirements they value more highly, such as size over weight or fuel efficiency over fuel versatility,” Wright says. “So it was really helpful in terms of the next stage of development. It was received well and we had some good conversations around some of the funding opportunities for the next stage of developing the technology and the specific capabilities.” www.ecojetengineering.com.au

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RMIT spotlights Design for Additive Manufacturing RMIT’s Advanced Manufacturing Precinct was the venue on 6 December 2018 for a breakfast seminar exploring ‘Global Trends and Opportunities in Additive Manufacturing’, including a presentation from Terry Wohlers, the globally renowned expert on additive manufacturing (AM).

The seminar was part of a special three-day course on Design for Additive Manufacturing (DfAM), run by RMIT in partnership with Wohlers’s consultancy Wohlers Associates.

The course addressed issues including DfAM guidelines and best practices, explored AM’s capacity to consolidate many parts into one, and focused on methods to reduce material and weight. Targeted at designers, engineers, and managers, the course offered participants handson experience in designing real parts and building them on industrial AM equipment.

“Design for Additive Manufacturing is design for manufacturability as applied to AM,” explained Professor Milan Brandt, Technical Director of RMIT’s Advanced Manufacturing Precinct. “It is a design methodology that captures the benefits of additive manufacturing technology when considering product characteristics such as its manufacturability, reliability, and cost.

“The RMIT course addressed this through a number of sessions, which included examining the complete AM process chain, from CAD part creation, to part production, and specific issues and guidelines around designing for metal AM, including topology optimisation, lattice structures, anisotropy, process constraints, post-processing and material properties. Also covered was where AM and design software tools were headed in the future, and the implications they will have on DfAM.” The breakfast seminar was held in collaboration with the Innovative Manufacturing CRC (IMCRC) and the Additive Manufacturing Hub (AM Hub) administered by AMTIL. David Chuter, CEO and Managing Director of the IMCRC, got proceedings underway with the opening address.

“Additive manufacturing is not a new technology,” said Chuter. “However it’s never been more readily accessible for commercialisation, and the technology is moving at an incredibly fast rate. We’re seeing changes that are enabling making mass production possible. We’re seeing this technology emerging across a whole range of industries, from medical to aerospace to defence. And we’re also seeing some fantastic companies being born out of Australia that are becoming relevant and competitive across the world.”

In his keynote presentation Wohlers offered detailed insights into the current state of play for AM worldwide, and the trends that

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The breakfast seminar was held at RMIT’s Advanced Manufacturing Precinct in Melbourne.

will shape its development going forward.

He focused in particular on the growing array of industrial applications of AM, the ongoing surge in take-up for technology for the production of parts in metal, and the increasing profusion of support systems and software. Wohlers also provided a wealth of interesting case studies; one notable example involved the manufacture of a hydraulic manifold for Atlas Copco mining equipment, where the use of AM cut the part’s weight by 91% and consolidated 13 parts into one.

like his faces in embracing a breakthrough technology such as AM.

“There’s a lot of strong growth, especially in metals,” said Wohlers. “A lot of systems and applications are developing. The future possibilities are almost endless. What we know is really exciting, but I think what we don’t know is even more exciting. For the younger generation and people of all ages to come up with new ideas and try new ways to apply the technology. We have a great technology, bridging that gap into new market opportunities is so exciting.”

Responding to a question from the audience, Brown stressed that manufacturers contemplating bringing AM into their operations needed to have a clear understanding of the technology and what they intend to do with it before committing

“Supply chain management, IP protection, cyber-security: these things are particularly important with regard to AM because of the lack of tooling, which was an inherent barrier to theft,” said Fuller. “These machines don’t have any tooling implications, so the data security is particularly important, and how that data is exchanged and how value is exchanged. This is a really fascinating frontier and it’s going to be interesting to see how it plays out.”

After his presentation, Wohlers was joined for a panel discussion by three local experts in AM: Mike Brown, Managing Director of Renishaw Oceania; Michael Fuller, CEO of Conflux Technology; and Alex Kingsbury, AM Hub consultant. They engaged in a wideranging discussion on AM, the opportunities the technology presents, and the challenges associated with its adoption.

Based in Geelong, Conflux is an AM applications company specialising in thermal and fluid engineering. Fuller spoke about some of the issues that a business

Terry Wohlers giving the keynote presentation.

ADDITIVE MANUFACTURING

3D Printing Functional

Terry Wohlers, President of Wohlers Associates; Shane Infanti, CEO of AMTIL; David Chuter, CEO and Managing Director of the IMCRC; Alex Kingsbury, AM Hub consultant; Professor Milan Brandt, Technical Director of RMIT’s Advanced Manufacturing Precinct; Mike Brown, Managing Director of Renishaw Oceania; and Michael Fuller, CEO of Conflux Technology.

The panel discussion involved: Mike Brown, Managing Director of Renishaw Oceania; Michael Fuller, CEO of Conflux Technology; Alex Kingsbury, AM Hub consultant; and Terry Wohlers of Wohlers Associates.

to what can be a significant investment. “If you were a manufacturer of a traditional part, if you want to do a traditional part in a traditional way, or have a part that resembles the outcome of a traditional process, I wouldn’t recommend 3D printing,” said Brown. “I wouldn’t recommend additive methods. The point being though, if you can take your part and modify it, change the design… If you can give that part functionality that you can’t get from anywhere else, people will pay for it, and you’ll have a market. So it’s not a question of saying ‘Do I do it additively or in a traditional way?’ Take the part, figure out where you can make it better, and then use 3D printing to produce that better-performing part, and then you’ll have a revenue.”

Wohlers picked up on this point, stressing the array of opportunities that exist around AM for offsetting the risk by establishing collaborative relationships with external partners.

“One solution is that you can do everything you want to do but not own the equipment,” said Wohlers. “Outsource it. Form a partnership with someone else. And then as these other machines develop, maybe then you can consider investing. That would be a way forward; let someone else take the risk.

There are a growing number of companies that are willing as a service provider or a contract manufacturer to have you as a partner.”

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Finally Kingsbury shed some light on the current patterns in the adoption of AM technology, both globally and here in Australia.

“Anyone who’s seen me talk before knows that I go on a lot about adoption of technology and the different types of adopters we have through the adoption cycle,” said Kingsbury. “What we know is that we had that tipping point in 2012 for AM globally when things really started to take off. That tipping point tends to occur when we have that the transition through the early adopters into the early majority. And that’s when you start to have an inflection point where your adoption starts to slope up and the train just starts taking off. Here in Australia we are about six years behind; my reading of the landscape is that we’re at the tip of the early adopters and just starting to cross into the early-majority stage.” www.rmit.edu.au www.wohlersassociates.com www.imcrc.org www.confluxtechnology.com www.renishaw.com www.amhub.net.au

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Birdstone delivers Schweppes redesign with 3D Systems prototyping services Packaging agency Birdstone selected 3D Systems’ On Demand Manufacturing team for the delivery of true-to-life prototypes for glass and PET bottles.

As new private label products continue to proliferate in the beverages category, established brands like Schweppes are under increasing pressure to stay current in the eyes of the market. To refresh its image as an upper-mainstream option for mixers and sparkling beverages, Schweppes enlisted Birdstone, a Melbourne-based packaging agency to design a contemporary look for its sparkling waters and carbonated soft drinks.

Schweppes products are offered in both glass and PET (polyethylene terephthalate) plastic bottles. For a comprehensive redesign and evaluation, Birdstone was tasked with generating design proposals and prototypes for each material option. To ensure both sets of prototypes convincingly represented their real-world counterparts, Birdstone collaborated with 3D Systems On Demand Manufacturing throughout the redesign, taking advantage of the service bureau’s deep manufacturing expertise and broad technology portfolio to quickly deliver high-quality, true-to-life prototypes to its client.

Designing contemporary packaging across materials A packaging redesign is no small undertaking. Not only is a production overhaul typically required, and expensive, but it puts a brand’s visual identity on the line. Both Schweppes and Birdstone were highly invested in getting the redesign right, implementing several design check-ins and evaluations throughout the process to ensure they were on the right track.

According to Grant Davies, Director – Design & Strategy at Birdstone, “Our biggest challenge running such a large project for Schweppes was designing a family appearance for multiple materials.”

Fortunately, a history of successful collaborations with 3D Systems’ On Demand Manufacturing team had proven to Birdstone that it could focus its energy on design and confidently outsource model production to 3D Systems’ manufacturing experts. 3D Systems’ consultative and collaborative approach hinges on establishing a clear mutual understanding of both visual and functional project requirements to facilitate quick, accurate quoting and fulfillment.

With 3D Systems briefed and on board, Birdstone began its work to contemporise key Schweppes brand elements without abandoning the company’s rich history. Once a design direction had been selected, the project’s complexity grew. To ensure the final family design could be replicated in both glass and PET, design work for each material was undertaken simultaneously. Birdstone worked closely with Schweppes to develop multiple designs that were refined to three distinct concepts, each meeting key objectives including: an increased label area; a sleeker, more premium shape; and a volume reduction for the PET bottle to 1.1 litres.

Multiple checkpoints to validate the design In creating a new packaging design, there are multiple review checkpoints to ensure all stakeholders agree with the direction and impact of a proposed concept. As a design concept earns more confidence, the sophistication of its representation evolves, typically from a 2D and 3D concept model, to a visualisation and animation, and finally to a physical prototype for in-hand evaluation. Accordingly, to provide Schweppes with early prototypes to assess the new

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bottles’ hand feel and proportions, Birdstone ordered 3D-printed models in multiple sizes from 3D Systems. These early stereolithography (SLA) prototypes were central to a concept development workshop, in which stakeholders from marketing to operations reviewed them and provided feedback. Prototyping at this early stage allowed all decision makers to reach a consensus around format and direction before further investments were made in any one design.

Achieving true-to-life bottle prototypes Once Schweppes was satisfied with the designs internally, it was time to test them with customers. For this stage of the design evaluation it was important for the prototypes to be as realistic to the final product as possible to enable an authentic interaction with, and reaction to, the new designs. Again working with 3D Systems, Birdstone outlined the prototype requirements. The glass and PET versions would each need to convincingly replicate the specific appearance, weight and visual properties of the final two materials.

The variable material properties of glass and PET required different prototyping approaches. Through a combination of creative thinking and an in-depth understanding of different manufacturing technologies and materials, 3D Systems’ On Demand Manufacturing experts advised on the best processes to achieve the desired results.

For the 750ml glass design, 3D Systems CNC machined acrylic (PMMA) with a high polish finish, while to achieve the thinness and flexibility of the PET design, 3D Systems again opted for SLA 3D printing using Accura ClearVue with premium finishing. 3D Systems Accura ClearVue is a rigid, tough, clear 3D-printing material offering the highest clarity and transparency on the market. According to Birdstone, both prototyping processes produced outstanding replicas of the production materials.

Birdstone completed the prototypes with self-adhesive graphic labels to give the bottles their research-ready appearance. A total of six bottles were made across three design concepts, which were then subjected to a week of hands-on consumer research. The final design was selected based on these results, giving Schweppes and Birdstone reinforced confidence in the new chosen direction.

As the project continued through to design engineering, Birdstone continued working with 3D Systems as it refined the final bottle concepts with each of the packaging suppliers, and requested two additional sets of prototypes made to the final product specifications.

New design gains traction Following the initial market release of the refreshed Schweppes range, the beverage company has continued to extend the new design family across additional bottle sizes. The bottle redesign has helped reposition the brand as a high-quality, high-value offering in the face of private label competition.

According to Birdstone Director Iain Blair, “The market success and Schweppes’ confidence in the design can be directly attributed to the meaningful research that was conducted, and which was made possible by the high-quality prototypes by 3D Systems.” au.3dsystems.com www.birdstone.com.au www.schweppesaustralia.com.au

ADDITIVE MANUFACTURING

Henkel launches new materials and adhesive solutions for 3D printing Henkel has released a range of next-generation materials designed to enable and optimise 3D printing and manufacturing processes according to required functionalities and designs.

The materials were launched at Formnext 2018, the leading trade show for additive manufacturing technologies, in Frankfurt in November. Henkel was appearing at Formnext for the first time ever, presenting a variety of differentiated new engineering resin platforms: General Purpose, Flexible, High Temperature, Durable High Impact, Ultra Clear and Silicone Elastomeric.

AEROSPACE

AUTOMOTIVE

DEFENCE

MEDICAL

INDUSTRIAL PARTS At Formnext Henkel also introduced its new Loctite 3D Printer.

The company showcased its growing solution portfolio for end-toend-processes. As an enabler for the resins, Henkel also introduced its new Loctite 3D Printer and equipment for functional prototyping applications at an entry-level. For small-run production and industrial manufacturing of final parts the company is collaborating with technology leaders such as HP and others.

Henkel also launched its first General Bonding Kit for 3D Printing applications. The kit consists of Loctite 3D Printing Universal Bonder and the Loctite 3D Printing Instant Bonder, as well as activators, primers and cleaning products. The kit aims to easily support customers in bonding prototyping parts for the most-known 3D printing technologies. Henkel also offers bonding solutions for the industrial series production of 3D-printed parts. The company also plans to set-up bonding trainings for industrial users via tutorials and webinars soon.

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“Formnext is an ideal platform to strengthen our positioning as partner for end-to-end 3D printing processes – for prototyping as well as for applications in the production of final parts”, explained Philipp Loosen, Head of 3D Printing at Henkel. www.henkel.com.au Henkel’s nextgeneration materials are designed to enable and optimise 3D printing and manufacturing processes according to required functionalities and designs

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Leveraging the full potential of a heat exchanger with additive manufacturing Conflux Technology, a Geelong-based additive manufacturing (AM) applications company, has patented a highly efficient, compact heat exchanger design that derives its performance from a geometry that can only be made using AM. High surface area density, combined with optimised fluid pathways and 3D surface features, results in a high thermal exchange, low-weight, low pressuredrop heat exchanger. The performance advantages were achieved within a rapid development timeline that was underpinned by computational fluid dynamics (CFD) modeling and Design for AM expertise.

With no tooling implications to consider, multiple variants can be manufactured simultaneously.

Heat transfer is a ubiquitous challenge that is at the heart of the First Law of Thermodynamics. A heat exchanger, simply speaking, is a device that effectively transfers heat between two or more fluids, typically liquid-liquid, liquid-gas, gas-gas or multiple fluids. You can find them in products like air conditioners and car engines. One practical benefit of such devices is energy recovery. There are numerous others — it is a complex technology with broad applications. Heat exchanger designs and manufacturing methods have evolved with the prevailing technologies available and, consequently, have been limited by those technologies.

Conflux’s Founder and CEO, Michael Fuller, spent more than a decade as an engineer in the automotive racing industry.

Here, heat exchangers have to perform in harsh environments, meaning that smaller, more efficient components are constantly sought, but substractive manufacturig methods had reached their limits.

Fuller saw the rapid, transfomative benefits of 3D printing and ultimately identified AM as an enabling technology for the next generation of heat exchangers.

Highly complex geometries with hitherto unachievable surface area densities could be achieved, resulting in a compelling thermal exchange performance, all packaged in efficient volumes.

Such components could have a dramatic effect on future developments, such as lighter racing cars and aircrafts. These fundamental opportunities are extended when functions are integrated and multivariant simultaneous production is realised.

Fuller set out to take this idea from concept to design to prototype to product, using industrial 3D printing.

Conflux analysed the industrial AM landscape and, after a technical due diligence process, concluded that EOS

AMT FEB/MAR 2019

A cross-section of the Conflux Core 3D-printed heat exchanger (Source: EOS).

was the only partner with the technical and commercial capabilities to fulfill its ambitions. The Conflux Core design was patented after a rapid proof-of-concept development program. Within just six months, six prototypes were built and a final product could be developed.

During the development program, several tools were utilised: CFD complemented the heat exchanger design iterations with flow visualisation and, after correlation, performance predictions.

Non-linear thermomechanical finite element modeling was used to analyse the resultant displacements and stresses to ensure structural integrity was maintained.

EOS equipment possesses a suite of specific AM software tools for data preparation, process optimisation and quality assurance. These were all used during the development of the Conflux Core heat exchanger, which now has applications across multiple industries such as aerospace, automotive, oil & gas, chemical processing and micro-processor cooling.

The Conflux Core heat exchanger was compared to a Formula 1 benchmark.

Young Calibrations, a UKAS-certified laboratory in the UK, provided accredited calibration services and thermal fluid and component testing services, and tested Conflux’s product. The results underlined the radical improvement Conflux has achieved with its 3D-printed heat exchanger.

AM allowed Conflux to design internal geometries that radically increased the

The Conflux Core 3D-printed heat exchanger mounted to an engine.

surface area in a given volume. This tripled the thermal heat rejection. At the same time, the pressure drop is reduced by two-thirds.

Additionally, AM enabled a compact new design for the heat exchanger, reducing its length by 55mm compared with a F1 benchmark. This ultimately also eliminated 22% of the weight. The design flexibility AM offers allows for optimum placement inside a vehicle and also enables the merging of components, reducing the overall number of parts. Integration of subcomponents into a single part removes assembly time and reduces failure points from joints and seams.

The Conflux Core heat exchanger is the foundation upon which Conflux has developed into an AM applications company focused on thermal and fluid challenges.

Customers and development partners from diverse markets have provided Conflux with equally diverse challenges. With an R&D pipeline driving expansion of intellectual property, the company’s technological success stems from its in-house expertise in Design for AM, computational modeling and a deep engagement with EOS. Conflux can work with customers and development partners to create compelling thermal and fluid solutions that will assist in realising the potential of AM within their enterprise.

“Our customers have acceptance criteria that matches exacting quality and repeatable performance,” says Fuller. “EOS systems are the only AM platforms that can produce our challenging geometries whilst exceeding our customers’ requirements.” www.eos.info www.confluxtechnology.com

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ADDITIVE MANUFACTURING

Airbus Helicopters saves development costs with German RepRap x400 Production using additive manufacturing in the aerospace industry brings many advantages. Airbus Helicopters uses its German RepRap x400 3D printer in the development field to ensure deadlines, cost and quality goals. In a recent case, it has been utilised in validating the design of an integral new step.

Frank Singer, Head of Department Vehicle System Installation at Airbus Helicopters in Germany explains: “It happens again and again that a crew member of a helicopter stands outside on the runners during the flight due to operational reasons under certain circumstances, such as during operation of the rescue winch. The relatively small footprint on the runners could be optimised by using a step.”

Firstly, the nearly three-metre-long model is subdivided into individual printable parts.

Afterwards, individual plug-in connections are constructed, in a design reminiscent of a jigsaw puzzle.

“In the past, we have had to divide larger prototypes into separate parts because of the print bed size,” says Singer. “These were often glued together. However, this was always associated with further processing steps, which we can now save – if the application allows it. The quickly printed parts require no further processing steps or curing time of the adhesive anymore. With this method, we have found an ingenious application for this design, to have a large component quickly and cost-effectively available with the print bed size that is available.”

Part of the redesigned step inside the German RepRap x400 3D printer.

For Airbus Helicopters, the new plug-in connection, for appropriate applications, is an optimal solution because it requires no glue, no screw connection or tools. The plug connection can be used at least 50 times without any signs of wear.

The model is much more stable than it would be in a glueing process. It withstands its own weight of 3.9kg without any problems and can be mounted on the helicopter for illustrative purposes without wobbling or even loosening or falling off. PLA was used because the material can be easily and quickly processed and there were no further requirements for the component.

Airbus Helicopters uses the German RepRap x400 especially for the so-called “FIT Check”. All designed parts are printed as prototypes. With these parts, installability and fitting for the helicopter are checked.

Possible changes and adjustments can be easily transferred to the series parts with little effort. The machine was purchased in 2015 to make it easier for engineers, in particular, to make prototypes faster and easier to test.

Over the years, the company has acquired more and more knowledge and no longer wants to work without the 3D printer.

“The x400 is in use every day and often runs on weekends,” Singer adds. “The use of the readily available prototypes or demonstrators has become firmly established in our development process.

We see this clearly in the future, especially in the development area. The use of the 3D printer makes it easier for the company to work, especially in the area of prototype construction and in automated production.

You can see that clearly in the numbers. In 2017, almost 50 print jobs were carried out, often including several parts. In the first half of 2018 we already had 51 print jobs.” www.germanreprap.com

Air Liquide, Additive Industries announce industrial 3DP partnership Air Liquide and Additive Industries have intensified a long-term relationship and entered into a formal partnership to facilitate industrial 3D printing.

“On our continuous quest to improve the performance of our systems while offering our users a fully integrated solution, we have identified the gas infrastructure for argon and nitrogen as an often overlooked but important piece of the puzzle,” added Daan Kersten, CEO of Additive Industries.

“Because of our partnership with Air Liquide, we now can offer a blueprint to our customers to guarantee a reliable gas storage and supply as well as a higher level of safety, our number one priority.”

Air Liquide will provide its solutions in the supply and storage of shielding gasses to Additive Industries’ proposition in the field of industrial additive manufacturing.

A dedicated infrastructure blueprint for Additive Industries’ MetalFAB1 system will enable Additive Industries’ customers in demanding markets such as aerospace, automotive, medical and high-tech equipment to increase both the quality and safety of the 3D printing process as well as post-processing.

“We are proud to team up with Additive Industries to provide the optimum solution at a customer site to create the perfect environment for their production

AMT FEB/MAR 2019

processes”, said Diederick Luijten, Managing Director IM Benelux of Air Liquide.

www.additiveindustries.com www.airliquide.com.au

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ONE-ON-ONE

Terry Wohlers is the President of US-based consultancy Wohlers Associates. As an analyst, author and speaker, he is an internationallyrenowned expert in the field of additive manufacturing. He spoke to William Poole.

AMT: Tell us firstly about Wohlers Associates and what the company does.

Terry Wohlers: Wohlers Associates turned 32 years of age last November. Most of the three decades-plus have been focused on additive manufacturing and 3D printing – terms that are used interchangeably. In the last couple of decades, our focus has been almost 100% on additive, as well as complementary technologies, such as design tools, 3D scanning, and post-processing – things linked in some way to additive manufacturing.

The core business is consulting. We work with client companies of all types and sizes. Among them are RØDE Microphones of Sydney, America Makes, Airbus, Honeywell, and many other organisations in 26 countries.

An important part of our business is the Wohlers Report, an annual review of the state of the additive manufacturing industry. We’ve been publishing it for 23 years and we’ll be starting our next edition early next year. As many as 80 people in 32 countries help with the report, so it’s truly a global effort.

The third leg of our business is speaking engagements and design for additive manufacturing (DfAM) hands-on courses. In fact, we conducted a three-day DfAM course at RMIT University in early December. The course covers design considerations that need to taken into account. Those who take the course run software tools, work in small teams, and have parts built overnight. The DfAM courses are an important and growing part of our business and are a reflection of the maturing AM industry.

AMT: What was your professional background and how did you end up so closely involved in additive manufacturing?

TW: I started the company in 1986 after grad school, where I was focussed on manufacturing and product development (and as an undergraduate as well). Wohlers Associates was a consulting firm focused on product development and CAD/CAM tools and applications from the very beginning. It was before additive manufacturing was introduced and commericalised, so nobody knew about it. 3D Systems showed its first beta systems in 1987, and that was when I was introduced to it, about a year after we started Wohlers Associates. And the rest is history.

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We got very excited about it, thinking this could be very powerful, as useful as CAD solid modelling. When you’re young and you’re not real sure where you want to go, but you think you want to take a company in a certain direction, you build some flexibility into it. And when you uncover something that’s new and exciting, the light bulb in your head illuminates and you say “This could be big some day.”

We were maybe a few years ahead of our time, but we could see it was going to grow over time. Over the next few years, we were invited to speak and write articles on the subject and we accepted consulting projects.

Our really big break was working for a company which was at the time – and still is today – the largest manufacturer of custom-fit, in-the-ear, hearing aids. Back in 1988-89 they wanted to produce parts using additive manufacturing, so we helped them develop the process by scanning the ear impression, developing software to process the data and send that data to the additive manufacturing machines for production. The project went for four years. The company had us going around the world, learning as much as we could, and reporting progress to the management. It was a little early back in those days; everything worked, but not very well. Materials were poor and the software wasn’t good, and the machines were slow and expensive, so the project was put on the backburner.

Several years later, Phonak and Siemens got together and were the first to commercialise it, so they got the credit. Today, more than 90% of custom hearing aid shells are manufactured this way.

AMT: I think a lot of the general public might be surprised to learn that additive manufacturing has been in use as far back as the 1980s.

TW: That’s correct. Additive manufactured parts were installed on the International Space Station and flying on the entire fleet of the Space Shuttle nearly 20 years ago. Rocketdyne, which was owned by Boeing at the time, was building parts by laser sintering for installation on the Shuttle fleet in 2000. Additive manufacturing has been used in many rigorous applications since then.

AMT: We saw a lot of hype about 3D printing about five years ago, but things seem to have settled down in the public perception more recently. Would you say there is a clearer understanding about the potential of the technology these days?

HEADING

TW: Yes. Most people now are more realistic as to what can and can’t be done. There’s always going to be hype about anything, but you’re right: it peaked around the 2012-13 timeframe and since then, reality has set in, which is good. People have understood that 3D printing isn’t magic. We’re still hearing some hype around 3D-printed buildings. I believe there’s an application for concrete printers, but building entire homes, at least the way it’s been shown to date, does not have merit.

For product development and manufacturing, a growing number of people appreciate more fully what it takes to build a good-quality part. It’s not always easy to build good-quality parts, whether it’s CNC milling, injection moulding, or additive manufacturing. You’ve got to know what you’re doing.

AMT: What do you think are the most significant trends in additive manufacturing at the moment?

TW: One trend is that customers are now learning that it’s more than just buying additive manufacturing machines. Once you have the machines, the effort is largely about having software tools and a system in place to review where capacity is available, and tracking jobs. We’re seeing development at the front end, but even more going on at the back end related to post-processing. A part of this overall trend is the growing number of machines and tools available to help automate and streamline powder removal, partfinishing, and inspection. At last November’s Formnext in Frankfurt, Germany, we saw many machines and processes that surround and support additive manufacturing. We also saw a lot of software tools for distortion analysis and design optimisation.

Contiuned next page

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ONE-ON-ONE

Continued fromprevious page

AMT: That’s interesting. Is that shift in emphasis, from the printers themselves towards this complementary technology, indicative of a move towards actual production rather than just prototyping?

TW: The additive manufacturing industry has had 30 years to figure out how to use these devices for prototyping and tooling.

Companies have figured it out. Taking it into manufacturing is an order of magnitude more difficult to achieve, so a lot of effort is going into it, from the likes of Airbus, GE, HP, Honeywell Aerospace, Striker, and many others. Companies are using robots and other forms of automation to drive down costs. Each part is on a caseby-case basis, on whether it makes sense to produce by additive manufacturing. It’s typically done carefully on a very controlled basis because the parts can still be quite expensive.

AMT: What about printing in metals? That seems to be a big area of progress at the moment.

TW: What’s interesting about metals, compared to the polymers, is that most of the metals are very similar or identical to those for conventional manufacturing processes. As a result, additive manufacturing machines are producing parts that are better than cast parts and sometimes on par with wrought properties. With casting, molten metal is poured into into a mould, and solidification occurs at different rates and in different places, resulting in weld lines. Even so, castings are used for a very wide range of parts and products. In the case of additive manufacturing, the microstructure of the metal is are more consistent and better than most castings.

From nearly the beginning of metal additive manufacturing, organisations have viewed it as a solution for real manufacturing.

Companies will do some early parts for prototyping and design validation, but ultimately it’s for manufacturing. What’s more, most of the systems have been open in the sense that you can buy materials from third-party companies at competitive prices, which helps support the interest in using them for actual manufacturing.

Organisations are indeed manufacturing with these machines.They include orthopaedic implant manufacturers, dental companies, and those producing parts for aircraft. I mentioned Honeywell Aerospace. It claims to be producing more metal parts for flight than any other company in the world. Airbus is also certifying metal parts for flight, which is exciting.

But there’s also some more obscure, less well-known companies.

Croft Filters in the UK is 3D printing metal filters for food processing, chemical processing, and many other applications. They’re a relatively small company, but they’re growing. I just talked with someone today who’s building bicycle parts, building the lugs to connect carbon fibre tubes on the frame. And they’re doing custom parts for different riders. I spoke with someone from another very small company today that are producing human jaw (mandible) implants for human patients. A surgeon is the founder of the company and they recently purchased a metal additive manufacturing machine. It’s good to see small companies adopt the technology and drive it.

AMT: It seems like it’s not about using this technology to make things that are the same as traditionally manufactured parts. It’s about using it to do things that don’t exist yet, things that are completely new.

TW: Correct. If you’re trying to use it as a replacement technology, in some cases it will work. If your volumes are low enough, it could be a good alternative to how you’re doing it now. The much bigger opportunities are in applying additive manufacturing to new ideas and niche markets.

AMT FEB/MAR 2019

Wohlers was in Australia in December as part of a special three-day course on Design for Additive Manufacturing (DfAM) at RMIT’s Advanced Manufacturing Precinct in Melbourne.

AMT: Where do you see the technology in 10 years time? What will the newspaper headlines be saying about additive manufacturing?

TW: I’d like to believe that material prices for additive manufacturing will be dramatically lower than they are today. They’re still much too expensive. Currently, it is limiting the industrial adoption for production applications. We will see many more end-to-end solutions, from start to finish, so that customers don’t have to figure it out on their own. Today they do. It’s like a “roll-your-own” type of approach. In the foreseeable future, the company will create process and workflows that are far more developed and mature.

To date, it has largely been left up to the customer to figure it out.

Fortunately, companies like Stratasys, EOS and 3D Systems now have consulting groups that are helping customers figure some of it out. They’re not just selling machines, but also offering services to help you, with applications-development type programs. They help increase the chances of success for the customers. That’s something we will see in ten years time: mature end-to-end solutions.

AMT: Finally what’s your view of the take-up of additive manufacturing in Australia?

TW: This my tenth visit to Australia, so I have picked up a few things about the country. It is certainly a remote part of the world, yet it has adopted additive manufacturing technology in interesting, and in some cases, impressive ways. It’s great to see the ongoing work in academia and the research community in Australia. The next challenge and opportunity is for industry to embrace the technology at the same level, but Australia is not alone. Many other countries are facing the same thing.

Australia has the chance to take additive manufacturing to the next level. The country has many interesting programs underway, such as the Additive Manufacturing Hub and the Innovative Manufacturing CRC (IM CRC). Other additive manufacturing programs and facilities have been launched and rival the best of the best worldwide.

Some examples include the Advanced Manufacturing Precinct at RMIT University, ProtoSpace at the University of Technology Sydney, Monash Centre for Additive Manufacturing, and CSIRO’s Lab 22. World-class companies, such as RØDE Microphones, are evaluating ways they can apply additive manufacturing to the production of complex parts. Australia has countless bright and creative people, so little is preventing the country from advancing its adoption of additive manufacturing in big ways. www.wohlersassociates.com

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Bystronic – Setting the pace for factory automation Bystronic Australia opened up its showroom in Cranbourne West, Victoria, on 29-30 November to demonstrate some of the latest state-of-the-art technology in sheet metal laser cutting, bending and automation.

The Bystronic Automation Day was an opportunity for the company to catch up with its existing customers as well as to connect with potential new clients, while presenting some of the highlights from its product range. Already world-renowned as a leader in the fields of sheet metal cutting and fabrication systems, the event was also an opportunity for Bystronic to showcase its latest innovations in automation technology.

Automation represents a key area of focus for Bystronic worldwide, and 2018 saw the Swiss-headquartered company taking a number of significant strides in this area. In March it completed the takeover of TTM Laser, Italian specialists in laser-based tube and profile processing, enhancing Bystronic’s existing technology offerings along the cutting, bending, and automation process chain. This was followed in June with the acquisition of a majority interest in Antil, a highly innovative company specialising in automation solutions for sheet metal processing, headquartered in Milan, Italy. Both TTM and Antil had their own dedicated exhibits at the Bystronic Automation Day. Alongside these new acquisitions, September saw Bystronic hold a groundbreaking ceremony just outside Chicago at the site of its new Experience Centre. With the construction phase now well underway, this state-of-the-art facility is on track to be completed by mid-2019. Once opened, it will offer visitors the chance to to experience a “smart factory” for sheet metal processing. Built on a site occupying more than 15,000sqm, the Experience Centre will include an advanced showroom where Bystronic will be able to demonstrate how sheet metal products can be manufactured in an age of automation, digital networking, and intelligent services.

Demonstrations of the latest technology were also the main attraction at the Bystronic Automation Day, with a rolling program of displays going on throughout the two-day event. First on the agenda was a Laser & Automation Demonstration, comprising the ByStar Fiber laser with 10KW laser power, coupled with a ByTrans Extended automatic loading and unloading system, and a ByTower flexible storage tower. This impressive set-up is capable of handling sheet metal up to 25mm thick, up to a weight of 33 tons(11 cassettes/3 tons), enabling extended automated processing for full lights-out operations.

Next up was a demonstration of the Xpert Tool Changer 150, Bystronic’s compact automation solution for fast bending tool changing. This machine combines the Xpert 150, Bystronic’s topof the-range pressbrake, supplemented by a robot arm to enable automated changing of upper and lower tools. Allowing users to reduce set-up times while increasing bending quality, the Xpert Tool Changer 150 brings the potential benefits of automation to even the smallest SMEs. For manufacturers seeking a more compact solution, the Xpert 40 pressbrake was the focus of the third demonstration. Combining a small footprint with very low power consumption, this machine is the fastest pressbrake in Bystronic’s line-up, offering maximum process speed thanks to the high acceleration of its upper beam and back gauge. With an ergonomic design and individual customisable work environment supporting high ease of use, the Xpert 40 is an impressively flexible machine that can be also operational as a Mobile Bending Cell with a robot attached in less than five minutes.

Finally, tying all the machinery displays together, the last demonstration focused on BySoft 7, Bystronic’s latest software solution for bending, folding and cutting. BySoft 7 enables users to design parts, program cutting plans, create bending sequences, and

AMT FEB/MAR 2019

monitor processes, facilitating a digitally networked manufacturing environment that guides users from the incoming order to the finished part, in a fast and efficient workflow.

Drawing a strong turnout over the course of the event, the Bystronic Automation Day was attended by clients from Queensland and New South Wales as well as Victoria – and even as far afield as New Zealand. With a barbecue lunch, refreshments and networking breaks throughout, and a special gathering for families on the afternoon of the second day, the event was a forum for Bystronic’s Australian team and their customers across ANZ to get together and catch up in a relaxed formal setting. But above all it was a chance to see some of the most advanced manufacturing technologies of their kind on the market today, providing ample proof that Bystronic is among the real pace-setters for manufacturing in the future. www.bystronic.net.au

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FORMING & FABRICATION

Headland helps 3Metals provide right service at right price Starting out with six employees, 3Metals has been in business for five years and has grown steadily since, now employing 32-plus members of staff at its facility in Yatala, Queensland.

Primarily servicing the construction industry, 3Metals specialises in commercial buildings and domestic buildings, along with manufacturing and mining. The company offers a range of laser cutting, CNC pressing, robotic welding and fabrication services.

Director Michael Fletcher explains that 3Metals places prime importance on keeping abreast of new technology, because advanced machinery enables the company to remain efficient, providing the best customer experience possible in terms of turnaround time, product and service. While price is always a big driver in customer decision-making, the team at 3Metals don’t believe in being the cheapest.

“We believe in giving the right service at the right price,” says Fletcher. “Our service encompasses a decent turnaround time and our products are manufactured to excellent quality. We don’t sacrifice quality for price, nor do we use cheap materials.”

Along with the TruBend 5130, 3Metals also purchased a KUKA robotic welder for higher-volume welding assemblies, and a TRUMPF 5030 6kW laser, which allows it to offer top-quality parts in stainless steel and aluminium. Having used TRUMPF machinery for more than 20 years, Fletcher expolains why he favours this brand over the competition.

3Metals prides itself on supporting Aussies, using local supplies and materials. As Fletcher says: “It’s important to us that we support the Aussie economy and source all materials locally, as we believe that it enhances our product offering and services to our customers.”

“It’s the best you can buy,” he says. “It’s the most reliable brand out there, plus it’s backed up by Headland service. We chose KUKA because it’s the best robotic brand available – we’ve used others in the past but German technology is unbeatable.”

Laser is the core of the business, according to Fletcher, the first process the company employs before any other value is added to a component. Therefore it’s crucial that 3Metals use the best quality machinery possible.

This combination of machinery also offers 3Metals the possibility of significant further expansion, as its TRUMPF 5030 laser can be run 24/7, enabling the company more capacity to sell. Requiring less manual operation, errors are eliminated, which means less downtime. Meanwhile a reliable press brake doesn’t produce rejects and doesn’t require multiple processes to be carried out, resulting in a quick, efficient factory.

“If the laser breaks down, it affects downstream value-added processes,” says Fletcher. “We need reliable machinery at the source, which makes a fabricator’s job much easier down the line.”

3Metals also offers solutions to customers in design, with a great deal of recent investment in the design team. With a recent purchase of a TRUMPF TruBend 5130 press brake, the sheet metal experts can now focus on designs for customers, adding more folds and presses to reach the same goal at a cheaper price. The press brake also offers more accurate folding and designing of complex parts.

“Headland’s service team in Queensland are outstanding,” adds Fletcher. “Focused, willing to help, and informative, I would recommend them to anyone. Their reliable service and support means that we can continue to provide the best customer experience possible.” www.headland.com.au www.3metals.com.au

Hypertherm expands availability of X-Definition class plasma with XPR170 Hypertherm unveiled the XPR170 X-Definition class plasma, at the EuroBLECH exhibition in Germany in October.

The new 170-Amp system joins the XPR300 as the only two X-Definition-capable systems in the world. A combination of engineering advances and refined high-definition plasma processes help X-Definition-class plasma deliver unmatched plasma cut quality on mild steel, stainless steel, and aluminium. Laboratory testing shows ISO-9013 Range 2 cut quality on thin mild steel and extended ISO Range 3 cuts on thicker metals.

Consumable life and cut quality over the life of the consumables get a dramatic boost from advances such as Cool nozzle and Arc response technology, the latter of which protects consumables from the negative impact of ramp down errors, a regular occurrence in real-life cutting. By reducing the impact of ramp-down errors, XPR consumables can last up to last three times longer than on competitive, older generation systems.

Like the XPR300 before it, the new XPR170 contains several new patent-pending processes like Vented Water Injection (VWI), plasma dampening, and vent-to-shield technologies for squarer cut edges, markedly less angularity, and excellent surface finish on non-ferrous metals like aluminium and stainless steel. It is ideally suited for cutting thin-to-mid-range thickness metals. At the same time, the system cuts faster and uses power more efficiently than earlier Hypertherm systems like the HyPerformance HPR130XD.

“We’ve enjoyed changing peoples’ perceptions of plasma since the introduction of the XPR300 with X-Definition plasma a year and a half ago,” says Phil Parker, Product Manager for Hypertherm’s XPR line of plasma systems. “Even experienced fabricators are surprised by the precision they are seeing, and excited by the prospect of using plasma — with its lower initial investment cost — in lieu of laser.” www.hypertherm.com

AMT FEB/MAR 2019

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QUALITY & INSPECTION

Hexagon CMM enhances capabilities for Nupress Established in 1972, Nupress Tools is an advanced manufacturer of precision machined components and assemblies based in Cardiff, outside Newcastle.

Competing in an increasingly competitive international marketplace, Nupress focuses on working smarter not harder. Its innovative manufacturing approach positions it well for the manufacture of unique, complex parts, while also being able to excel in highquantity batch manufacturing.

This commitment to innovation and quality led to Nupress’ Managing Director Murray Claire and its CEO Craig McWilliam embarking on an analysis of suitable co-ordinate measuring machine (CMM) technologies to complement and enhance their other leading edge technologies.

Among other parameters, the key criteria established by Claire and McWilliam were threefold : 1. The system should enhance the company’s process control capabilities and had to include continuous analogue scanning.

2. The selected unit should be suitable for use in both a production and a quality assurance role.

3. To get the best out of any system that Nupress chose, extensive ongoing local support would be critical.

After evaluating three potential suppliers, Nupress decided on a Hexagon Global Classic SR 09.12.08 CMM with PC-DMIS software and analogue scanning. The Global Classic is an affordable all-purpose CMM for the dimensional inspection of a variety of components. It can be equipped with touch-trigger probes or optional scanning probes. Global Classic CMMs are used in a number of industries for first and final part inspection, fixture qualification and more.

In late 2016 Hi-Tech Metrology installed and calibrated the machine, and then provided the operator training necessary to ensure that Nupress gained maximum benefit from their investment. Now, a short two years since it was installed, Claire is happy to report some of the tangible benefits achieved by Nupress as a result of the new CMM. “A lot of customer drawings have dimensions to intersection points in space or tight tolerance diameters at a gauge plane dimension along a taper,” he explains.

“In the past we would manufacture gauges and checking jigs that would take not only manufacturing resources but also engineering resources with considerable cost associated. Now we can eliminate that part of the cost equation.

As well as these gains, the new CMM has meant that Nupress can utilise its staff in more productive ways. “There has not been any direct labour savings; I mean we have not reduced the workforce at all,” says Claire. “However, we have been able to use the labour we have more efficiently for a large percentage of the time.”

Claire went on to emphasise the ongoing benefits of sourcing the technology from Hi-Tech Metrology: “Local support.

The equipment itself is only one part of the total value proposition. It is when the machine is not running or when we need to have more people trained that puts the Hi-Tech solution to the top of the list. The local support and rapid responses to questions made the whole transition very smooth.” www.nupress.com.au www.hitechmetrology.com.au

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Transforming manufacturing through augmented reality Augmented reality is quickly emerging as a transformative technology that may revolutionise manufacturing processes, particularly in the area of factory metrology. By Quah Beng Chieh.

In the information-driven, cyber-physical environment of Industry 4.0, the digital transformation of the manufacturing industry has brought on an interconnection between data, people, processes, services, systems, and production assets. With this, the volume, velocity, and variety of data that companies manage has increased exponentially. Known as ‘Big Data’, this information is crucial for companies looking to implement datadriven strategies to optimise performance and efficiency, or increase competitiveness.

Amidst the excitement and anticipation of potential opportunities that these changes bring, augmented reality (AR) has emerged as a transformative technology that is set to revolutionise manufacturing processes.

Valued at U$2.39bn in 2016, the AR market is expected to reach US$61.39bn by 2023, and the applications of AR has evolved significantly since its introduction.

Transformative technology for the everyday AR has many applications in today’s society, whether through the use of smart glasses, video and laser projectors, or the overlaying of additional information. AR users can experience a new and improved natural environment, where virtual information is used as a tool to provide assistance in everyday activities. This functional aspect of AR, together with improvements in the technology, are key factors that have transformed its uses.

In 1992, the first functioning AR system was introduced and used by the US Air Force as a new method for training pilots.

Subsequent commercial AR applications were largely concentrated in the entertainment and gaming businesses, but with technological advancements in the last decade, other industries are also developing a keen interest in the possibilities of applying AR in their fields. Education, for instance, is an industry where few would expect to see AR employed, but the technology has made learning more exciting for students as they access content by scanning or viewing an image with a mobile device. Another example is an AR helmet for construction workers that displays information about the construction sites.

Augmented reality for manufacturing Globalisation has made it possible for worldwide exchange of new technologies,

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Left: With the integrated camera on the mobile device, an overlay of the as-built object with virtual 3D data, including all process and workflow information, can be realised in real time.

finished goods, and even new ideas. It has also allowed manufacturers the option of expanding their production facilities across borders. To ensure consistent quality across the global process chain, companies need an effective solution that offers them visibility and flexible control over their processes, without incurring too great a cost in terms of personnel, time, and travel.

Within this context, AR can provide considerable added value to manufacturers by enabling direct, intuitive access to information and fast variance inspection, at any time and from anywhere. Processes can also be supported continuously and without disruption throughout the entire process chain.

In fact, the industry has caught on to the use of mobile devices with an integrated camera.

An image captured by the camera can be enhanced with additional information of the operator’s choice as it is being displayed on the device. A key reason for this method’s popularity is in the efficiency it provides — the accuracy of the overlay achieved here reduces the time and cost of inspecting components, tools, and production facilities.

In this case, AR is the extension of a model in the production space, connecting virtual reality with the actual product. The exact match between the real and virtual world is ensured with the use of markers. An overlay is created by connecting 3D points on a computer-aided design (CAD) model with 2D points in one corresponding image.

Previously, complex CAD data was not always available across the various functions of a company, and it was challenging to migrate large amounts of industrial data.

With the support of AR technologies, it is now possible to share such information with just a tap on a mobile device. The

data can also be seamlessly transferred from the device and utilised, streamlining the production process. AR can be used in the inspection of parts, dies, and moulds to detect and document errors; in CAD-topart comparisons to see real-time deviations from nominal data; as well as in component alignment and assembly to see how complex parts should be assembled. In addition, it can be used for quality assurance to inspect incoming parts directly at the delivery point or at the supplier site before delivery.

Application: Complex assembly Modern manufacturing involves assembling hundreds or thousands of elements in an accurate order, as quickly as possible.

This is true regardless of the product type — whether automotive, aerospace, heavy equipment, or shipbuilding — and every new product calls for a new set of assembly instructions.

Manufacturers rely on assembly drawings as a main means for assembly guidance.

An assembly drawing delivers the holistic constructional knowledge of a machine and its separated components, and it is an essential technological file for the technicians to carry out the assembly task and evaluate the end product.

Confined to a 2D drawing, a large amount of information on product components can be quite excessive and cumbersome – making it challenging for engineers to quickly understand the complex assembly relations. The application of AR in complex assembly processes enables technicians to access accurate and up-to-date information for component alignment and assembly swiftly, to see how complex parts should be assembled — without the need for complicated 2D drawings.

Application – Quality assurance Metrology in general, and quality assurance (QA) more specifically, also offer numerous potential applications for AR. AR can be used for final inspection in the production space. Any error in the manufacturing process becomes apparent by directly overlaying the CAD data to the as-built part or assembly that is being inspected. This application is extremely versatile, and it

QUALITY & INSPECTION

FARO’s Visual Inspect offers intelligent functions where the user is able to interact with the 3D data to inspect details of interest against 3D data.

can be used to check that brake lines and flexible parts have been installed correctly, or that single parts have been positioned according to design. It can also be used to verify the completeness of assemblies.

The technicians in charge of quality inspection can take photos of the parts or assemblies on the product, and compare them with supplier-provided or CAD images via an AR overlay. Technicians can easily spot features that are out of specifications from the overlay, allowing them to identify any issues quickly and intuitively.

Reaping the benefits of AR Unquestionably, AR promises major benefits for manufacturers. With the integration of AR, processes can be more co-ordinated, and production can be operated in a Lean, structured manner.

AR can provide immersive instructions for technicians in the production space, leading to significant time-savings through improved performance, and cost reduction through the use of lesser resources. AR enables users to visualise product components and allows for quality improvement in training, with a more authentic and sustainable learning experience. Some AR solutions also provide manufacturers with greater mobility and flexibility by introducing mobile solutions, which offers mobile visualisation and comparison to real-world conditions.

This presents the potential for quality improvement, with earlier error detection in the production or design processes.

Concerns over the cost of adopting AR solutions may keep manufacturers from reaping the benefits it brings. However, some degree of investment is necessary to ensure greater product quality. Top manufacturers place great importance on producing quality products in the most efficient manner, and it is entirely possible to make an informed choice to ensure a positive return on their investment in improving quality.

Manufacturers should decide on a solution that would work best for them by determining the key function for AR integration, before exploring the solutions available. For example, if the main objective is to provide AR for quality inspection while eradicating the need for paperwork, an integrated solution like FARO Visual Inspect provides convenience and speed for the user, as it offers a large amount storage on a single mobile device, with all the files required easily within reach.

The innovative platform offers complex 3D data and augmented reality in all working environments, regardless of time and location, and is also a cost-effective alternative to expensive AR solutions.

Complex CAD data that was previously unavailable throughout a company or on a production line can now be utilised anywhere due to Visual Inspect’s powerful translator, which compresses the CAD data to a format suitable for use on the iPad. This enables Visual Inspect to be used for comparison and inspection, allowing users to spot discrepancies between the CAD model and the physical product — through taking a photograph and overlaying the CAD data, or by using the AR functionality and making comparisons in real time for deviations. In addition, the data collected can also be used, shared, and analysed across departments, offering companies opportunities for better collaborations and improved productivity.

Worthwhile investments pay for themselves when it comes to time- and cost-savings in the long run. With Visual Inspect, FARO offers a whole new solution that meets the needs of a globalized, flexible manufacturing process, and it helps manufacturers streamline their processes to be more flexible and nimble, while taking into account increasing cost pressures.

Quah Beng Chieh is the Head of Marketing (Asia Pacific) at FARO Technologies. www.faro.com

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CLEAN TECH & RENEWABLE ENERGY

26-year-old Aussie invents new-breed of e-motorcycles Dennis Savic is the 26-year-old inventor and founder behind a new breed of electric motorcycle, developed under the brand Savic Motorcycles, which is promising to shake up the motorcycle industry.

The young Australian entrepreneur has been dreaming about designing a vehicle ever since he was six, when he made his first sketch of the new and very different engine configuration. At the age of 14, Dennis shifted his interest to motorcycles. Since then, he has been working on a new concept for an electric motorcycle, which features impressively instantaneous torque and rapid acceleration, all with a vastly reduced environmental impact. This will be the first electric motorcycle company in Australia, manufacturing internationally and assembling bikes locally in Melbourne.

Dennis Savic, the 26-year-old inventor behind Savic Motorcycles.

Savic Motorcycles, a young start-up, is currently in the design phase and will build their production prototypes in 2019, followed by their first production run in 2020. The company has already received seed investment and is preparing for a Part Series A capital raise. The plan is to focus on sales and production first in Australia, then take the offering to international markets. Driven by his passion to do to motorcycles what entrepreneurs such as Elon Musk and Mate Rimac have done for cars, Dennis had completed a Bachelor of Mechanical Engineering and an MBA by the age of 25, while he was building motorcycles at night. He worked for three years in the oil & gas industry, and after some inspiration from Horacio Pagani, the founder of Pagani Automobili, Dennis decided to work in the automotive industry, while developing Savic Motorcycles in his spare time.

Meeting the challenge The challenge was to develop Australia’s first range of electric motorcycles in order to address pollution issues that the world is facing and to capitalise on the exponential growth of electric vehicles at a global scale. Dennis aimed to develop a market-leading brand with unique and noticeable styling features, and electric motor technology that will set Savic Motorcycles apart from 95% of other motorcycles on the market.

To obtain access to the most sophisticated engineering software available to prototype and build his vision, Dennis applied for Altair’s Global Startup Program and was successful at gaining access to leading simulation design tools and computer aided engineering software used by the likes of Ford, Airbus and Samsung. Access to Altair’s technology has enabled the Savic Motorcycles team to reduce development times and lower costs through the entire product lifecycle from design to in-service operation.

“Altair has enabled us to get quickly trained in the platform within just a couple days,” says Dennis. “We’re using the software to develop CAE analysis, simulation, stress testing, topology optimisations and load testing.

“We want to offer our customers the most advanced technology in our products, because that is our point of differentiation. We will be the first Australian motorcycle manufacturer to feature a metal 3D-printed component. In 2019, we will progress several research projects with various universities to further develop our technological advantage. As an early-stage company, we’re agile and can quickly pivot and position ourselves and our products to ensure customer satisfaction and retention.”

for that product across its entire life cycle.”

In the realm of virtual product development and simulation, there are several technology tools that can be used to develop a market-ready product. Using Altair’s HyperWorks and Altair SmartWorks software, the team at Savic Motorcycles used Altair’s software to create a digital twin that is very close to reality, thanks to coupling the physical with the virtual world. “Creating a digital twin means we can gain valuable insights and make powerful predictions about failure risk, functional safety, and durability,” Dennis explains. “The virtual prototype knows the ideal state of the product and therefore becomes a prediction tool

Compared to the traditional internal combustion engine, the Savic Motorcycles technology drastically reduces operational costs. For example, a single charge of 9kWh would cost the rider only $3 and will take the rider 200km, as opposed to the equivalent internal combustion engine costing approximately $15. Being electric, the Savic Motorcycles powertrain delivers near instantaneous torque, with the bikes able to accelerate from zero to 100km per hour in four seconds (and even quicker if a customised gearing ratio is requested).

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Dennis and the team have created a unique design featuring a perfectly rolled backbone frame, and developed their own electric motor and energy storage system. Multiple capacities will be available for all their models to ensure a personalised solution for every rider.

CLEAN TECH & RENEWABLE ENERGY Savic Motorcycles used software from Altair in developing the design of its new motorcycle.

The team unveiled their first product line at Moto Expo in Melbourne on 23 November 2018.

Ready for launch The first product line that Savic Motorcycles will take to market is the C-Series, a CafĂŠ Racer-inspired design, which was launched at Moto Expo in Melbourne in November. On show at the Expo was the C-40, the concept prototype for the vehicles they intend on taking through to production. Savic Motorcycles also took pre-production orders at the event.

Customers can choose from four models, including the C-FE (founder edition), the Alpha (60kW, from $20,000), the Delta (40kW, from $15,000), and the Omega (LAMS, 25kW, from $12,000). C-FE models are limited to ten orders, and will be delivered in 2019, while the Alpha, Delta, and Omega orders will be delivered in 2020.

Each model comes with several battery pack options. Larger pack size will provide a range of 170-200km, while the smallest will have a range of 50km. Customised styling will be key, with each vehicle coming in a range of options for brakes, suspensions, wheels and tires, and a choice of three colours – Spectre, Stealth, and Rustic.

Aftermarket upgrades will also be offered.

Savic Motorcycles intends to take the product global by 2022, but the team is currently focusing on becoming the leader in electric motorcycles in Australia. The aim is to close their Series A round by the end of February, collect 50-100 production orders by the end 2019, and begin production in 2020. www.altair.com

www.savicmotorcycles.com

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CLEAN TECH & RENEWABLE ENERGY

Olympics spark success for SA clean combustion specialists A South Australian company that shot to international prominence after designing the flames for the Sydney Olympics has become a leading supplier of clean-tech and alternative fuel solutions for the cement industry.

Adelaide-based FCT International had a small customer base in the cement industry when its current ownership group took over the company in 1999. But instead of simply continuing to design and build industrial burner systems, FCT won the right to design the burner system for the Olympic torches and the entire cauldron at the 2000 Sydney Olympics. That success led them to design and manufacture 14,000 torches for the Athens Games in 2004, as well as the cauldron and the Olympic rings of fire featured in the opening ceremony. FCT quickly became the global leader in ornamental flames, and revenues from the major events market reached up to 70% of the company’s total.

“We quickly became the market leader in that space and became involved in more and more major events around the world,” says FCT Managing Director Con Manias. “The thing with the flames business is it’s hit a ceiling – it’s got no more market share to grab as there are only so many major ceremonies and event spaces being built.”

Nonetheless, international success gave FCT renewed confidence within the more traditional industrial combustion side of the business, which delivers burner systems for high-temperature processing factories including cement, lime, alumina, nickel and iron ore pellets plants. Key to this was establishing sales and engineering bases closer to key markets, prompting FCT to launch hubs in Florida, Turkey, Brazil and Austria in the past five years, doubling its workforce from 25 to 45.

“We realised a few years ago that working only out of Adelaide when you are targeting the world market for industrial combustion was not that great because we’re so far away from our markets,” says Manias.

“The technology development and overall strategy and marketing are still centralised in Adelaide while the satellite offices are developing their own relationships, getting to know their markets intimately and FCT International helped deliver the flames for the 2010 Vancouver Winter Olympics.

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capturing market share in these regions, which is impossible working solely out of Australia. As a result of taking the company closer to the markets, our orders have increased quite spectacularly; it’s actually been more successful than we imagined.”

FCT International is now made up of three companies: FCT Flames, FCT Combustion and FCT ACTech, an online instrumentation business. FCT Flames continues to lead the ornamental flame industry and has supplied equipment to dozens of major global events, including every summer Olympics since 2000. However, the rise of FCT Combustion has been the latest success story.

FCT Combustion is experiencing dramatic growth with its burner technology for the iron ore pelletizing industry, fitting out more than a dozen plants with burner equipment in countries such as Sweden, Algeria, China, Brazil and the US. It is also having success globally converting cement plants with systems that run more efficiently and can burn a variety of alternative fuels, including rice husks, sewage, used engine oil and municipal waste. The success of FCT Combustion has meant the industrial side of the business provides about 80% of total revenue while the flames business brings in about 20%.

FCT has worked with the University of Adelaide to develop leading gas burner technology, which is helping it win work in the US as cement plants convert from coal to natural gas.

“The cement industry tends to use solid fuels mostly but in North America, with cheaper gas available as a result of fracking, it’s going back to using natural gas as a fuel,” says Manias. “Our burner is a very low-emissions, high-efficiency technology based on different principles to every other burner, and it’s giving us a particular advantage in doing gas conversions in North America – it’s the best gas burner technology available for a cement kiln.

CLEAN TECH & RENEWABLE ENERGY An iron ore pellet kiln burner being built at FCT International.

“Italy and Belgium burn municipal waste, in Thailand it’s biogas, California wood chips. Pretty much anything that burns can be used in a cement plant to produce heat to make cement clinker.”

FCT International won two major export awards in Australia in late 2018 on the back of its strong global growth. It was named Export Business of the Year at the Optus My Business Awards held in Sydney in November; and it won the Minerals, Energy and Related Services Award at the Business SA 2018 Export Awards in October.

While its burner technology in the cement industry has been a significant achievement, growth in the iron ore pelletising industry has driven FCT’s more recent success.

“We have done quite a number of those projects in the US in cement, lime and ore pelletizing as well, and there is still a lot of opportunity as more plants switch to natural gas.”

Fuel represents up to half the cost of producing cement. According to Manias, in Europe there is a strong focus on using waste as alternative fuels, and other parts of the world are also slowly catching on. FCT custom designs every project to cater for the specific fuels being burnt by each customer.

“Typically a plant will burn two or three conventional fuels as well as have the ability for two or three alternative fuels as well,” Manias says.

“In Malaysia we are commissioning a burner for rice husks, in Turkey we’ve supplied burners that use sewerage sludge, waste oil from shipping and municipal waste containing paper, plastic and green waste that has been shredded.

“We were able to win significant projects – these things tend to grow with your reputation – and the last couple of years it’s been our major revenue earner for the entire FCT group,” says Manias.

“We’ve supplied more burner equipment than any other company that operates in that iron ore space in the past two or three years. At the moment our big projects are in China and Brazil – Vale in Brazil and SinoSteel in China.”

Manias says FCT International is looking to further grow its business by providing other equipment such as furnaces and kilns for each new project. There are also many parts of the world and industries that the company has yet to target.

“There are other industries, other geographies, and we have a few strategies depending on which markets we move into next, and some of those involve new products,” Manias says. “The growth prospects are fairly well unlimited – it’s really around how we can bring that about.” www.fctinternational.com

UNSW student solar car sets new efficiency world record A team of students from the University of New South Wales (UNSW) set a world record in early December after driving across Australia in an electric car.

The UNSW Sunswift solar car team arrived at Sydney’s McMahon’s Point on & December having driven from Perth, setting a Guinness World Record for the lowest energy consumption while driving across Australia in an electric car. It was a determined return to form for the UNSW students. Despite a number of setbacks over the past year, including a rear suspension failure during the 2017 Bridgestone World Solar Challenge and a battery fire in October, the team of 14 students completed the 4,100km journey without a hitch and two days ahead of schedule.

“I’m so excited we made it,” said Courtney Morris, 20, a mechanical engineering student. “It’s always so nerve-wracking to see the car that you built with your own hands on the road; I’m always afraid that something could change at any moment, but it all went pretty well and the team dynamic was great.”

The car, named Violet, is the sixth-generation solar car built by Sunswift, a student-led initiative at UNSW, now in its 22nd year. To set the record, the team had to keep the car’s energy consumption to under 5.5kWh/100km. Actual energy consumption throughout the journey was an average of 3.25kWh/100km, which is about 17 times less than an average Australian car. Travelling an average of 600km a day, Violet used about the same energy per day as that of a standard household (20-24kWh). The cost to run the car from Perth to Sydney was also economical, at well under $50.

UNSW Dean of Engineering Professor Mark Hoffman greeted the team at the finish line.

“These students have pushed the boundaries of modern engineering and proven that solar powered cars are likely to be a big part of Australia’s motoring future,” said Hoffman. “They worked extremely hard to prepare for this journey and despite setbacks, they’ve shown resilience, bounced back like professionals and got on with the job.

This is what a university degree should entail – actual, hands-on

experience and overcoming real-world challenges. I am incredibly proud of the calibre of young adults we have studying here at UNSW. A wholehearted congratulations to every one of you.”

Driving into Sydney was the best part of the trip, according to Hayden Smith, a 25-year-old computer science honours student.

“That’s when it finally clicked that we had crossed the country in just six days – that’s 4,100km. In a car built by students,” he said. “Violet is lively on the road a lot, it’s not a production car and you have to kind of handle it like a horse in order to manage it on public roads.

But we did it.”

The Sunswift team returned to their families for the holidays before returning in the New Year to begin preparations for the 2019 Bridgestone World Solar Challenge in October. www.unsw.edu.au

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CUTTING TOOLS

Faster than fast – Milling tools for high metal removal rates The method of rough machining with significantly increased feed per tooth – known as fast-feed milling or high-feed milling – found its industrial application in the 1990s. Die and mould making was one of the first industries to adopt high-feed milling, following a massive increase in customer demand for reduced manufacturing time for dies and moulds. High-feed milling answered this need while also providing an effective tool for boosting productivity.

The high-feed milling method is based primarily on two principles: the geometry of a milling cutter; and the high-speed feed drive of a machine tool. A typical fast-feed milling tool features a small cutting edge angle, normally 9-17 degrees. This design characteristic results in three important outcomes.

The first is the possibility of considerably increasing feed per tooth due to a chip thinning effect. For example, in the face milling of lowalloy steel, 0.2mm per tooth is a near-maximum value feed, but highfeed milling the same material with a 2mm per tooth feed is normal.

The second is a shallow depth of cut that ensures this geometry for the tool. Milling with reduced depth of cut diminishes cutting force and power consumption. Finally, the third point relates to minimising the radial component of the cutting force combined with maximising its axial component, which acts toward the axis of the machine tool spindle – i.e. the direction of the maximum machine tool rigidity. This improves machining stability. Increasing feed per tooth means greater feed speed that requires the appropriate feed drive of the machine tool. In the above example of high-feed milling low-alloy steel, the feed peed may be 7,000-9,000mm per min – the next-higher order versus conventional values.

Recognising the market’s needs, machine tool manufacturers developed a variety of machines intended specifically for high-feed milling. These relatively low-power machines have “triple high” characteristics: high torque: a high-thrust spindle; and a high-speed feed drive. The machines feature advanced computer numerical control (CNC) hardware and software. Introducing high-feed milling substantially changed the concept of rough milling. Instead of intensive material removal at large depths and width of cut by using high-power machines, the method proposed extremely productive milling at shallow depths by low-power machines fitted with a cutting tool that runs very fast.

The fast-feed milling method has since undergone some interesting changes. Originally considered as an effective way for rough machining cavities and pockets that was typical for die and mould making, high-feed milling soon proved advantageous in face milling (“fast-feed facing” or “triple F”). The diameter range of the fast-feed milling cutters was increased, and the group of engineering materials suitable for cutting by the high-feed milling method expanded.

Fast-feed milling quickly penetrated to many industrial branches.

It began to be more than an effective technique for the applicative niche of die and mould making, embracing all metal cutting areas as a generally recognised productive method. Steel and cast iron may be known as the main “consumers” of fast-feed milling, but stainless steel, titanium, and even high-temperature superalloys can be successfully machined by the method as well. This in turn led tool manufacturers to introduce a variety of fast-feed milling cutters in different forms. Indexable or solid in concept, they can have shank- or arbor-type design configurations, integral or modular body structures, and cutting geometry that varies according to the machined material group.

Iscar leads the way Iscar’s line of high-feed milling cutters illustrates this diversity, with almost dozens of fast-feed mill families; today the company is unique in this field, with an extensive range of options. By the late 1990s,

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Icscar had already introduced a family of indexable tools with onesided inserts for fast-feed milling, and continued to expand its line by adding more indexable milling families, with designs that provided added value to customers.

In one case, the tools carried cost-beneficial double-sided inserts; in another, an advanced cutting geometry considerably improved rampdown abilities for better performance in milling by helical interpolation.

For applications requiring small-size cutters, the company developed fast-feed solid carbide endmills and replaceable milling heads for the company’s “Multi-Master” products. Efficient use of high-feed milling tools in face-milling operations generated new demands, and Iscar not only introduced appropriate cutter families but also suggested an original additional solution: the specially designed insert. These inserts, intended for mounting in general-purpose cutters in the standard milling line, transform the latter to fast-feed milling tools.

The solution won the recognition in particular of small and mediumsized manufacturers, as it allowed more effective usage of alreadypurchased tools.

In its latest LogIQ campaign, Iscar has introduced four new fast-feed milling tool families as well as upgrading several existing lines. What was the motivation behind these developments? Iscar is renowned for its commitment to innovations, driven by research & development (R&D) advances and manufacturers’ needs.

The first noticeable feature of the new families is a substantial decrease in the size of indexable fast-feed milling cutters. For example, the diameter range of Iscar’s FFT3-02 Nan3Feed endmills is 8-10mm – “classical” dimensions for solid carbide tools. The company is confident that the indexable concept represents a competitive solution.

These endmills are characterised by the original clamping method of miniature carbide inserts. The inserts do not have a traditional central through-hole that weakens the insert structure. A screw head, which acts as a wedge, secures the insert, allowing insert indexing to be quick and simple. As the insert is very small in size, it is placed in the pocket via a key with a magnetic boss on the key handle. The proposed design ensures a multi-tooth tool configuration – two and

CUTTING HEADING TOOLS

Nan3Feed endmills are characterised by the original clamping method of miniature carbide inserts.

Tang4Feed fast-feed shell mills are designed mostly for rough machining medium and large cavities and pockets.

three teeth for diameters of 8mm and 10mm respectively – and three indexable cutting edges of the insert provide cost-effective using cemented carbide.

The variety of high-feed milling tool family options inevitably raises the question: how should one choose the most suitable tool? In addition to Iscar’s ITA (Iscar Tool Advisor) software, the company has developed a quick tool selector guide, providing a compass for manufacturers to find the most effective solution for fast-feed milling.

Another example is Tang4Feed, a family of fast-feed shell mills carrying tangentially clamped rhombic inserts. The mills are designed mostly for rough machining medium- and large-size cavities and pockets.

The tangential clamping principle, combined with a dovetail profile of matching surfaces for secure insert mounting, ensures a durable mill structure. The insert’s rhombic shape significantly improves mill performance in ramping-down and side-plunging operations. The Tang4Feed inserts are double-sided, resulting in four cutting edges.

The inserts of both the Nan3Feed and Tang4Feed families are provided in several cutting geometries for optimal milling of different engineering materials.

The case of Iscar’s high-feed milling line is good evidence that developing fast-feed milling cutters is still far from its high point.

The newly introduced tool families offer logical answers to real manufacturer demands. High-feed milling, as a productive method of rough machining, has optimistic prospects, and the metalworking industry will continue to require faster and faster milling cutters for high metal removal rates. www.iscar.com.au

The Surftest SJ-210 is a user-friendly surface roughness measurement instrument designed as a handheld tool that can be carried with you and used on-site

Easy to use • 2.4-inch colour graphic LCD with backlight • Simple key layout The Surftest SJ-210 can be operated easily using the keys on the front of the unit and under the sliding cover.

Highly functional • Advanced data storage capabilities • Optional memory card • Password protection • Multilingual support • Stylus alarm An alarm warns you when the cumulative measurement distance exceeds a preset limit.

Contact MTI Qualos today to learn more about the SJ-210 Series.

Extensive analysis and display features • Complies with many industry standards The Surftest SJ-210 complies with the following standards: JIS (JISB0601- 2001, JIS-B0601-1994, JIS B0601-1982), VDA, ISO-1997, and ANSI. • Displays assessed profiles and graphical data In addition to calculation results, the Surftest SJ-210 can display sectional calculation results and assessed profiles, load curves, and amplitude distribution curves.

M.T.I. Qualos Pty. Ltd. 1300 135 539 or email sales@mtiqualos.com.au

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Group Technology: Operational excellence in the Industry 4.0 era From before the Industrial Revolution until the present day, manufacturers have shared common goals: producing a certain number of parts, in a certain amount of time, at a certain cost. Despite the advent of Industry 4.0, operational excellence remains the core driver of productivity and efficiency. By Patrick de Vos, Corporate Technical Education Manager at Seco Tools.

Manufacturing processes have evolved from craft-made single-item methods to mass production lines and output of increasingly greater numbers of identical parts: a high-volume/low product mix (HVLM) scenario. Most recently, digital technology in programming, machine tool controls and workpiece handling systems are facilitating a manufacturing environment known as Industry 4.0 that enables costefficient manufacture of highly diverse parts in small batches: high-mix/low-volume (HMLV) production.In the era of Industry 4.0 it is fashionable to highlight the newest production techniques and digitalisation technologies.

However, maximum productivity and costefficiency still are based on a foundation of operational excellence. In the present economic environment, manufacturers generally consider speed to be a key indicator of operational excellence. A drawing comes into a facility and eventually a completed workpiece leaves the plant; manufacturers want the time between the two events to be as short as possible.

Efforts to boost speed typically focus on strategies such as e.g. lean manufacturing or Six Sigma.

However, those strategies generally relate to HVLM production and are not always effective when applied in HMLV scenarios.

An important contributor to streamlined HMLV output is the Group Technology approach, in which classifying and coding parts into machinable families enable a shop to achieve the highest level of operational excellence.

Group Technology Group Technology is a manufacturing organisational strategy in which parts with certain similarities such as geometry, material, manufacturing process or quality standards are classified into groups or families and manufactured under a common production method. Operations are planned for the part family rather than individual workpieces.

Very often when production is organised to handle part families, the arrangement is described as cellular manufacturing.

Cellular manufacturing came to prominence in the 1980s, roughly when the era of HMLV production began. Manufacturers

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recognised that batch sizes were shrinking while the variety of workpieces and new workpiece materials were growing. Shops were confronted with a high diversity of different workpieces, produced in comparatively small batches. Time spent preparing for production rose exponentially, and manufacturers sought to control it.

The creation of part families in Group Technology is based on part codification and classification. Each part is assigned a code consisting of letters or figures or

combinations thereof, and each individual letter or figure represents a certain feature of the workpiece or a production technique that is required to produce the workpiece. In the diagram below, the sixth digit in the part code represents workpiece dimensions, the seventh digit the raw material, the eightth digit the original shape of the workpiece material, and the ninth digit the level of quality required. Digits 3 through 5 describe the operations required to machine the part.

The part codes are used to plan production

CUTTING TOOLS The faster, more accurate quoting process had two benefits. There were fewer incidents of erroneous underbidding that negatively affected profit margins, and there were fewer quotes that were inaccurately high and discouraged customer acceptance.

Implementation of Group Technology concepts gave the manufacturer more control over what was being done and how much it cost, and reduced the incidence of inaccurate quotes.

and make price quotes by referring to an imaginary or non-existent part called a complex workpiece. Complex in this case does not mean difficult; it describes a generic workpiece that illustrates all the features that a company is able to create, such as high- and low-accuracy holes, deep and shallow pockets, side milled features, etc. Summing up the costs of producing the required features produces a representative total cost and simplifies estimation of pricing.

It is not necessary to analyse the costs on an individual part-by-part basis.

Production planners and estimators work with a drawing of a workpiece and develop a price quote by matching features on the workpiece with those on the complex workpiece and also determine other production elements such as the machine tool required, whether coolant will be needed, and so on. In addition, executing the Group Technology technique with the help of a sophisticated CAM system further reduces pre-machining engineering time requirements. Additional benefits include improved communication between departments in a facility as they all work from the same complex workpiece model.

The Group Technology approach was initially based on experience as personnel developing it interviewed process engineers, programmers and planners to gather information regarding the cost of various production operations. Although the development occurred in the 1980s, compiling individual experiences and data and organising them into a system was a process that resembles today’s initiatives in artificial intelligence.

In some cases, Group Technology prompts reorganisation of the shop floor. Parts often take a circuitous path through a shop that is organised in a traditional layout based on machine functions such as turning, milling or grinding. However, when workpieces are grouped and processed as families in a cellular layout, machine tools can be arranged to streamline manufacturing flow and minimise part movement within the shop. Each different workpiece family is machined in the most efficient way without unnecessary transport within the shop.

Significant reduction of the time required to produce the parts is the result.

As always, the adoption of new concepts offers both benefits and challenges. The Group Technology approach offers benefits in engineering, process planning and manufacturing time savings, but possible challenges exist as well. First, to some extent the Group Technology approach reduces flexibility. The traditional shop setup is more flexible if there is a significant increase in demand for a certain workpiece configuration that creates a production bottleneck. In the traditional layout other

machines in the department can be used to produce the parts. Secondly, managing machine downtime can also be a challenge.

If one part family experiences a temporary decline in demand, the machines in the cellular layout will be idled.

Another possible difficulty arising from implementation of Group Technology concepts is a tendency to spend an excessive amount of time comparing one coding system to others. More important than the specific coding system itself, however, is that a company should thoroughly know its equipment and resources and the results desired. In that case, a custom coding system created in-house can be a simple and efficient approach. Possibly rearranging the shop floor to machine part families more efficiently is another facility-specific decision.

It may be easier for larger companies to realign their machinery while smaller companies may face economic constraints and other factors.

Faster, more accurate quotes The Group Technology approach to creating part quotations can increase both revenue and profitability. An example comes from an aerospace subcontractor in an HMLV production environment, with batch sizes from one to five workpieces, that receives about 4,000 price requests per year.

Insufficient time to analyse and quote each part separately slowed the pricing process and the shop could make serious quotes for only 1,500 of the 4,000 possible jobs. About 2,600 orders were received. Then, using analysis supported by Group Technology initiatives and quoting parts using complex workpiece information, the subcontractor found it could make 3,000 serious quotes per year. More serious quotes attracted more orders, to the level of 3,200 annually.

Most importantly, the bids, based on cost plus profit, averaged more than 30% lower than the bids made before the application of Group Technology concepts.

Group Technology dictates that instead of thinking through every individual workpiece and its production parameters, parts with similar characteristics are grouped and machined together. In a clear example of this approach, a shop was producing pulleys for a belt-style transmission. For use with different belt sizes, the diameters, widths, and profiles of the belt groove differed from pulley to pulley. The changeover time between machining of different configurations was about an hour and a half.

Analysis of the process showed that for each changeover between pulleys the machine was completely dismantled, and all the tools were taken out and cleaned and stored. To machine the next pulley, most of the same tools were put back in the machine. Under the Group Technology approach, similar but not identical wheels were grouped as a family. Changeover then involved changing the NC program, altering some machining parameters and sometimes changing the tool that machined the groove profile.

Depending on the workpiece, changeover time dropped from one and a half hours to ten minutes. The key challenge was convincing shop personnel that the parts they were making belonged to the same family and could be machined much more quickly.

The Group Technology manufacturing organisational strategy (on which Dave Morr from SECO in Australia have done extensive development work) helps manufacturers efficiently handle the challenges of HMLV production. Traditional productivity-boosting strategies such as Lean manufacturing and Six Sigma provide proven benefits, especially in HVLM production where operations can be fine-tuned over long runs of identical parts. However, highly diverse, small batch manufacturing continues to grow in prominence, aided by advances in machining technology and digital product design and management. By classifying parts into families and consolidating pricing activities and machining operations, the Group Technology approach provides manufacturers with an efficient way to manage the challenges of the Industry 4.0 era. www.secotools.com

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Tools at the touch of a button By focusing on the needs of customers, machining specialist Walter seeks to set itself apart, including when it comes to providing digital product data. Walter supports its customers with high-quality product data, which is available from tool data management systems and online libraries such as MachiningCloud.

Konstantinos Bountolas, Product Data Solutions Manager at Walter, summarises the company’s data philosophy as follows: “Product data that is ready to use enables our users to find, choose and assemble tools more quickly when it comes to designing, planning, NC programming and purchasing, as well as on the shop floor.”

Walter’s strategy of focusing on its customers is also geared towards the customers’ procurement preferences.

“We leave it to our customers to choose where they would like to access the product data for our tools,” Bountolas explains.

“Everyone has their own preferred channels for obtaining this data. All that matters is making sure that we provide our data exactly where our customers are looking for it.”

Walter mainly relies on the “channels” of MachiningCloud, the e-catalogue for TDM, and Tools United.

Walter on MachiningCloud Customers around the world can access more than 40,000 Walter tool elements on MachiningCloud.

“MachiningCloud is perfect for us,” underlines Bountolas. “There, we present our tools in virtually the same way as in our catalogue. Thanks to Walter’s standardised product designations, the way in which the products are presented and the logos that customers are familiar with, users will find our products without fail on MachiningCloud.”

Walter e-catalogue for TDM MachiningCloud and the Walter e-catalogue for TDM have similar functions, such as product specification lists (cutting diameter, projection length, length of cutting edge, the direction of rotation, and so on), 2D drawings, 3D models, photos and descriptions. However, the Walter e-catalogue for TDM goes into even greater detail. With an average of 20 parameters, it contains all the information that is required by a CAD/CAM system. The e-catalogue can also be linked to ERP software via TDM. “It’s not good when customers have to manually re-measure missing properties, such as lengths and diameters and have to manually enter parameters,” says Bountolas.

“Customers want product data at the touch of a button.”

Tools United More than 900,000 tool components from 36 different manufacturers, including Walter,

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are stored on the Tools United tool platform.

The platform provides NC programmers, buyers, tool managers, project managers and design engineers with product data based on their requirements in standardised formats and common export interfaces for tool management systems and CAM systems.

Optimising processes with apps Optimally prepared digital product data, which the company provides to its customers across different platforms, is just one part of the digital product range. Walter offers a whole host of apps for various applications in the machining process. These include apps for wear optimisation, for ascertaining the ideal indexable inserts, for calculating starting values, and for configuring special tools.

• Walter eLibrary – The Walter eLibrary app provides access to all printed catalogues and brochures in 17 languages. PDFs can be printed out as individual pages. The app is optimised for use on all devices.

• Walter GPS – The Walter GPS machining navigation system is another way of finding the right tool without fail. It supplies tool and cutting data recommendations perfectly adapted to the machining task at hand, along with information on the machining strategy, cost-efficiency calculations and more.

Bountolas is certain that “with Walter GPS, we definitely have one of the best applications for tool recommendations currently available on the market.”

• Walter Machining Calculator – The Walter Machining Calculator supplies cutting data for milling, drilling and turning machining operations.

For example, torque, drive power and machining volume, as well as the main operating time, main cutting force and chip thickness. In addition, a simple cost comparison of two tool solutions is possible with the integrated profitability calculator.

• Wear Optimisation – Walter’s Wear Optimisation app helps increase the tool life by visualising forms of wear and illustrating the causes of wear.

• Walter Insert Converter - The Insert Converter app specifies exactly which Walter indexable insert is compatible with the solution that is currently in use.

• Feeds & Speeds – The Walter Feeds & Speeds app calculates starting values and the cutting speed and feed for turning, drilling, threading and milling.

• Walter Xpress – Walter Xpress configures special tools using an interactive online form and is available for around 10,000 defined variants.

Bountolas summarises: “At Walter, we are convinced that high-quality data is the basis for optimising customers’ processes. With our digital solutions, we are paving the way towards Industry 4.0 for our customers.” www.walter-tools.com

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STATE SPOTLIGHT

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Advancing Tasmania’s manufacturing

Tasmania’s advanced manufacturing sector has experienced a major turnaround over the past two years, with niche specialist companies leading the way.

Storemasta is a perfect example of an innovative local company that has found great success with out-of-the-box thinking. It has carved out a space as Australia’s leading manufacturer of dangerous-goods storage, supplying its product to a raft of our biggest business names from Coca Cola Amatil and Visy, to Rio Tinto. The company is also actively growing its export market.

“We build products that reduce risk and improve efficiencies in the storage and management of dangerous goods,” explains Storemasta Marketing Manager, Walter Ingles. “We are the only Australian company involved in the manufacture of customised dangerous goods storage products. Our business is highly automated and highly specialised.”

According to the lobby group, the Advanced Manufacturing Advisory Committee (AMAC), Stormasta is exactly the sort of niche operator that has helped spearhead the sector turnaround.

The business is also spread across a number of sectors, all with their own highly specified needs. Food & beverage producers – for instance, Coca Cola Amatil, Nestle and Mars Snack Foods – may require specialist storage for highly flammable flavourings such as peppermint. Manufacturing plants, like Visy, Nustar and Caterpillar, have more extensive requirements, including large storage for gas cylinders, machine lubricants and flammable liquids. Laboratories require small, indoor safety cabinets, where the segregation of chemicals is of prime concern. The mining industry needs large outdoor dangerous goods storage for petrol, fuels and lubricants.

They also need dispensing stations where large quantities of liquids – including lubricants – can be safely pumped in a contamination-free environment.

“This is an incredibly exciting time for Tasmania’s advanced manufacturing sector,” says AMAC Deputy Chairman Kent Wyllie.

“Not so long ago, there was little positivity around manufacturing, however my observation is that now we are in a period where we are seeing incredible opportunity. Two years ago we were worried about workers getting jobs. Today we are seeing a skills shortage.”

The AMAC is charged with guiding the future growth of this sector and is keen to capitalise on Tasmania’s unique advantage as an island state.

“We should not think of Bass Strait as a hindrance,” Wyllie adds.

“On the contrary, our unique island mentality is one of our greatest assets. Our ability to fix problems in an ingenious and unique way is our greatest asset.”

While Wyllie admits some traditional manufacturing industries are having trouble, he says the focus needs to be on specialist, valueadded products, and embracing new technology. That is exactly the philosophy that guides companies like Storemasta.

With a manufacturing plant in Burnie, on the north-west coast, and teams of dangerous goods experts based in Sydney and Melbourne, Storemasta employs a workforce of 48 people. This low-key Tasmanian success story also only sells a fraction of its product – 2 to3% – within its home state. The bulk is sold interstate, with a growing export market to Asia and New Zealand.

Storemasta provides an ‘end to end’ service, designing and manufacturing a range of tailored solutions for dangerous goods storage, including flammable liquids, corrosive substances, chemicals and explosives. It specialises in hazardous storage cabinets, flammable storage cabinets and spill management.

Storemasta has come a long way over 25 years, from its humble beginnings when sheet metal specialist David Urquhart built small safety cabinets as a sideline business. Today is it continually evolving and embracing new design and technology.

Much like Tasmania itself.

“We need to constantly add a level of digital expertise to be able to compete on the global stage in the advanced manufacturing sector,” Wyllie says. “Tasmania should not be scared of taking on new challenges.”

Best defence Momentum is building to have Prince of Wales Bay officially recognised as a defence precinct, reflecting Tasmania’s growing reputation as a leading sector supplier. Covering just over 100 hectares in Hobart’s north, Prince of Wales Bay has long been the Tasmanian hub of maritime and advanced manufacturing.

Long recognised as the home of global success story Incat Catamarans, in recent years Prince of Wales Bay has also been garnering a reputation as a leading defence hub, and the pressure is

Liferaft Systems Australia (LSA), one of the earliest Tasmanian companies to move into defence, supplies marine evacuation systems, including 100-person liferafts, to the US, UK, New Zealand and Dutch navies.

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TASMANIA on to make that official. The Tasmania Maritime Network (TMN) – the peak maritime industry lobby group – is leading the push to have the area officially named as a defence precinct.

“The importance of having this precinct officially recognised as the Prince of Wales Bay Maritime Defence Precinct is that it underpins the positive image and profile of Tasmania’s defence capability,” explains TMN Chairman Rob Miley. “Most other states and territories have similar focused hubs of activity, and it is important that we have that kind of recognition as well.”

How do you structure your business for growth and profitability?

Tasmania’s defence industry is big business, and rapidly getting bigger. The sector now injects $340m into the state economy each year, as well as providing 2,000 direct jobs. Some 30 key Tasmanian companies currently supply defence contracts. Of these, one-third are based at Prince of Wales Bay. “I think it [Prince of Wales Bay] is unique. There are not many places in Australia with that level of commitment and diversity in the defence industry in one area,” Miley adds. “Prince of Wales Bay Maritime Defence Precinct is an outstanding hub of export, innovation and advanced manufacturing, not only in Tasmania, but representing the nation.

“Furthermore, the potential here is huge – really huge. We are really only just coming of age now with our nine key companies here out of 30, but they are getting really good opportunities and contracts and I think it is important that we realise it is export dollars that they are generating.”

The roll-call of companies involved with defence at Prince of Wales Bay is impressive. To mention just three: Incat has supplied military use catamarans for both the Commonwealth and overseas; CBG equips naval vessels with fire barriers; and Taylor Bros fit out naval ships.

Another is Liferaft Systems Australia (LSA), one of the earliest Tasmanian companies to move into the lucrative defence sphere.

Since 2004, LSA has been supplying its marine evacuation systems, including 100-person liferafts, to the US, UK, New Zealand and Dutch navies. The company also scored a $10m contract to supply marine evacuation systems for Australia’s newest battleships: nine Hunter Class global combat ships under a supply agreement with British manufacturer BAE Systems.

“I think there is a lot of potential in terms of niche manufacturing products that the Navy can’t necessarily source from other states in Australia, and we tend to do the specialist manufacturing in defence very very well in this state,” says LSA Managing Director Michael Grainger. “A lot of development is going on within companies in the TMN, and these companies – like ourselves – who have been dealing with defence for some time now, are continuing to evolve and become more defence-savvy and ready to supply our defence forces.”

As the Commonwealth embarks on its $195bn defence spend – touted as Australia’s largest ever economic stimulus – Tasmania is perfectly poised to carve out a lucrative slice of this pie. With a large portion of that slice coming from the Prince of Wales Maritime Defence Precinct.

“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

“There is nothing we can’t do here in this state. As an island nation we have proven our innovation and our willingness to come up with a solution and that’s what defence is looking for,” Miley explains.

“We have got to still continue to push that hard through Canberra and other areas to make sure we get the right product out there for defence in the future.”

Reprinted courtesy of Brand Tasmania. www.brandtasmania.com www.tasmanianmanufacturing.com.au www.storemasta.com.au www.tmn.org.au www.lsames.com

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STATE SPOTLIGHT

TASMANIA

Collaborative robot saves time, money for innovative manufacturer in Tasmania Huntingfield-based manufacturer Lightning Protection International (LPI) has been making lightning protection equipment in Tasmania since 2002.

The company makes a highly-customised range of direct-strike lightning protection products, along with grounding equipment and transient protection goods, for customers all over the world. Due to an increased demand for LPI’s know-how, both in Australia and overseas, the company engaged ABB Robotics to supply it with a YuMi Collaborative Robot – a dual-arm, industrial robot that offers high scalability for short and variable production runs.

In a few short months, the robot – supplied by ABB in Melbourne – has not only reduced costs and production lead times, but has also maximised quality within LPI’s production facility, in Hobart’s southern suburbs.

Customer demands LPI’s customers are predominantly infrastructure-based, with many of these operating in the telecommunications and utilities sectors.

Due to the changing nature of telecommunications industries around the world, the team at LPI has its work cut out for it to ensure customer installations remain up-to-date, and safe from power surges – often with short lead times.

“Recently in Australia we’ve been involved with upgrades to 4G networks for all carriers,” says Paul Hollingsworth, LPI’s CEO. “The National Broadband Network (NBN) network has benefitted from a lot of our expertise. Similarly in other countries, deployment of telecommunications and upgrades of telecommunications networks is one of our major customer segments. Others are utilities including power and water, as well as commercial construction.”

LPI’s products help these customers improve the reliability of their infrastructure. In the case of telecommunications clients, LPI ensures events such as lightning don’t cause damage or downtime to their installations.

LPI had previously used robotic work cells with traditional fencing.

However according to Hollingsworth, this set-up reduced the flexibility of their robotics.

“The collaborative feature that has been helpful in this respect is the ability to work with human beings – with less interlocking, safety fencing, and so forth. YuMi as a collaborative robot has been an excellent fit in that respect.”

Support, service and useability

“Across much of Australia we probably wouldn’t perceive that as a big issue, but in lots of our customer base in South-East Asia and other parts of the equatorial belt, lightning events are the sorts of things that happen perhaps realistically every second day throughout the year,” says Hollingsworth. “So if you have such high lightning incidents, damage or downtime becomes a very routine event.”

Hollingsworth and the team at LPI have been ‘very impressed’ with the service and support from ABB since installing the YuMi robot.

Flexible manufacturing

YuMi has enabled the team to move from testing and configuring one product to a completely different product in only half an hour.

With LPI’s short and small production runs – and lots of variety from one product to the next – traditional robotic work cells were not ideally suited to the changing nature of the company’s manufacturing. It needed an equally-malleable robot. The team began by researching ‘flexible robotics’, and came across the concept of collaborative robots. It wasn’t long before they happened upon ABB’s YuMi. “YuMi was probably the best fit for what we required as a company.

I hadn’t been to trade shows or seen YuMi in action at this stage, but from what we saw on the web, we decided pretty early on that it was the best fit for our needs,” Hollingsworth explains. “The fact that YuMi has two co-ordinated arms working together – so let’s say, simulating a human being – was a very attractive feature.

“And with options for integrated video, as well as vacuum and servo-grippers, YuMi gives us a lot of flexibility – not only of what we can manufacture, but of how we can handle and manipulate different parts, and how we can identify them. Essentially, YuMi gave us an entire box of tools in one robot – and that has ended up giving us quite a lot of flexibility for different tasks, as well.”

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“Geographically, Australia is a large place, with lots of distance between us – as a customer – and ABB,” says Hollingsworth. “But regardless, I’ve found that when we have issues, we’ve been able to get those resolved fairly quickly, in our case through ABB in Melbourne. We’ve found their service and support very good.”

“Of course that’s required a little bit of thought and planning in terms of how we interface to YuMi with test jigs and so forth, but we’ve been able to show that we can swap from one type of product to another quite quickly,” Hollingsworth adds. ““Changing from one task to another – for example, from testing to assembling a product – takes a little bit longer, but we’re still only talking a matter of hours, not days.”

In a matter of only months, using YuMi in test and inspection, and product assembly, the team at LPI has noticed a positive change in their production.

“In the first few months of using YuMi in real production, we’ve already increased productivity, while at the same time giving our people more interesting work and less repetitive tasks,” Hollingsworth concludes. “And that’s really only with the first product release that we’ve pushed through YuMi. We’re optimistic that productivity gains from fully deploying YuMi will lead to a payback of less than a year.” www.abb.com/au www.lpi.com.au

TASMANIA

Elphinstone looks to future with new investment Elphinstone Engineering has invested in a new Okuma CNC vertical machining centre with OSP Control to strengthen output at its Triabunna plant on Tasmania’s East Coast, and secure additional work in-house with new capabilities.

“The speed of the new machine is unbelievable with a time reduction of 1.5 hours on one complex part alone to just nine minutes fully finished,” said Jason Cameron, Production Manager at Elphinstone. “The new machine complements another recent Okuma machine, a CNC lathe model LB3000EX, also with Okuma’s own CNC OSP Control, allowing us to meet strong demand and drastically reduce production delays, and at the same time bringing work back in-house. The latest machine will also be used for fast prototyping and product development.”

Machining operations in progress on Elphinstone’s new Okuma vertical machining centre.

The Elphinstone story is a long one, commencing with Graeme Elphinstone moving from Burnie to Triabunna in 1971.

Graeme had been a logger and started welding and chainsaw repairs before purchasing a two-hectare block of land in Triabunna and establishing Elphinstone Saw Centre.

Graeme’s specialist knowledge of the logging industry led the company to import Australia’s first on-board weighing system fitted to a logging truck. Further developments followed, with a special folding pole tandem jinker; an automatic weighing platform for axle groups; Australia’s first ‘Stretch’ mudguard system; folding triaxle jinkers, and many more. In 1985, the company won the BHP Steel Award for innovation and design of the ‘Tri-Beam’ suspension, and this was followed by the world’s first folding skeletal trailer, the Fold-A Skel.

In 1994 this innovative company’s expertise in logging also extended to highly specialised equipment that was required for Antarctica. Design and development was a natural fit for the company in items such as special-purpose trailers for general haulage and the transportation of large tanks in ice conditions. Visiting Antarctica for the first time in 2000, Graeme saw the company’s special equipment in person, driving a snow train some 1,100km to Dome C, and he has since made two further trips to the ice continent. Special heavy-haulage trailers with skis, modular building support systems, walkways, platforms have all been developed through the first-hand Antarctic experience of Elphinstone personnel.

Developments also continued in the logging area with the Elphinstone Auto Tensioning System, self-loading Tri-Tri B-Double Trailers, the development of electronic scales, the first hydraulic folding skel, and the introduction of air suspension to the company’s trailers. Elphinstone has been

Braiden Garbowski of Elphinstone at work on the new Okuma machine.

a winner of numerous awards, such as the Australian Freight Industry ‘Australian Trailer of the Year’ for its ‘Easyloader’.

For the small community of Triabunna, with a population of some 1,000, Elphinstone provides highly valued employment opportunities for young people. With its strong commitment to training, a number of Year Ten students are provided the opportunity of work experience within the various departments of the business. Today there are four apprentices at various stages under training in the machine shop, and an additional five training as fabricators, thus ensuring the future of the industry and employment for locals.

Cameron himself originally joined Elphinstone as a storeman in 2004 but took the

opportunity of a mature age apprenticeship which has since led him to his current position as Production Manager for the machining, steel management and quality control of finished trailers and equipment.

Following the company’s latest acquisition, he is complimentary about Okuma’s support during and after the installation.

“Okuma’s after-sales service and training back-up are impeccable and a stand out in the industry, which is a strong reason for this investment due to our somewhat remote location of the business,” he says. “We couldn’t be happier with the commissioning of this machine and the back-up we have received.” www.okumaaustralia.com.au www.elph.com.au

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COMPANY FOCUS

PFG Group – Expanding across Australia Tasmanian manufacturer PFG Group’s acquisition in October of Keil Industries in the Gippsland region of Victoria saw it add a further production facility to its existing operations in Tasmania and South Australia (SA). By Carole Goldsmith.

PFG supplies aquaculture products to customers across the globe.

“The combination of PFG and Keil merges two industry-leading capabilities, PFG’s polymer fabrication expertise and Keil Industries’ exceptional rotational moulding skill,” says Michael Sylvester, CEO of PFG Group. “Both teams have a passion for tackling those challenges which others might consider too hard to solve, creating durable products for harsh environments and a long history of success in doing this for our customers.”

PFG Group’s main headquarters in Goodwood, Tasmania.

The company’s 71 employees are located across two Tasmanian sites, two SA sites and the Victorian site. The three manufacturing sites are at Goodwood, near Hobart; Port Lincoln in South Australia; and Morwell in Victoria, all in regional areas.

“All Keil Industries employees have been retained and we are in employment mode right across the group,” Sylvester adds. “We are very conscious as a business that we are a responsible regional employer in three states. So, we have a lot of social responsibility for both the local community and for our employees to provide a sustainable business and good career prospects.”

PFG is a leader in Australia’s aquaculture and commercial marine sector, underpinned by a broader industrial services capability.

The Tasmanian advanced manufacturer has close to 40 years’ experience in the design, manufacture and sales of engineered polymer products to the aquaculture, security, mining, civil construction and agricultural sectors. The Keil acquisition now enables PFG to expand its industry sectors further to transport, food-handling and fast-moving consumer goods (FMCG).

PFG has passed through several owners since its commencement four decades ago. In 2007, the company was acquired by a Tasmanian family trust and more recently has attracted investment from a second family trust. There are a range of different companies in the PFG Group, all of which are run under the PFG brand.

Diverse exports The company supplies its products to customers across the globe, Sylvester explains. “We have strategic partners in New Zealand, Asia and Europe and they are effectively distributing our products across those regions. PFG exports right across Asia, into Japan, China and other parts of the region. As examples of our products being exported, we mainly sell aquaculture products into Japan, such as net cages for growing fin fish and oyster baskets for oyster cultivation. Our specialist mooring systems are distributed into the

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United Arab Emirates (UAE) and our vacuum-based net cleaners are sold into Norway.”

Sylvester explains how PFG’s net cleaners work: “If you can imagine a net full of fish in sea water, the net material collects a lot of fouling (of unwanted materials). PFG’s net cleaners are the only ones in the world that vacuum the net’s fouling through a filter. Then the fouling is collected as dry waste and returns clean water to the ocean. We have a global patent for our net cleaner and we won an innovation award for it at the world’s largest aquaculture event – Aqua Nor in 2011.”

PFG has won a number of other industry awards since then, including the 2016 Australian International Marine Export Group (AIMEX), Best Commercial Innovation and the 2016 Ausmarine, Best Aquaculture Support Vessel for its Aquatruck boat range.

Sylvester says Aquatruck is one of PFG’s most attractive products.

The boats are reliable and built to last. Manufactured with highdensity polyethylene and made for extreme sea conditions, the boats, which range from 3-12m in length, provide a ride secondto-none.

“We’ve produced 100 Aquatrucks over the past 25 years and all are still in full commercial operation,” Sylvester adds. “They are used by public safety agencies such as police, defence, fisheries & parks, commercial marinas, port authorities and private users. There’s a level of pride in providing a safe and reliable platform for agencies protecting our country. PFG is targeting marketing to secure a prime defence contract.”

TASMANIA HEADING

PFG has produced 100 of its Aquatruck vessels over the past 25 years.

Aquatruck boats are built using traditional boat building techniques, but using polymer instead of metal

PFG’s sea cages are its most popular product sellers, built for the mariculture industry. This is a specialised branch of aquaculture, which involves marine cultivation for food and other products in the ocean. The company has built around 2,000 of these cages to date for Australian and global distribution. Sylvester notes: “Through the Keil Industries acquisition, we are also making around 40% of the McDonalds’ playgrounds for Australia, NZ and the Pacific Islands and we are a leading supplier of plastic pellets.”

Sylvester speaks excitedly about projects currently happening at PFG: “Our employees’ inventiveness and creativeness shines through in many of our projects. We have partnered with the Institute of Marine and Antarctic Studies (IMAS – a University of Tasmania subsidiary) for the past eight years to crack the science behind hatchery rearing of tropical lobsters at a commercial scale.

That just means growing a lobster from an egg. No-one in the world has been able to do this at a commercial scale yet. The Institute’s team of scientists have now mastered that amazing feat.

Innovation and sustainability.

Sylvester is an international expert in sustainable business management. He’s been at PFG’s helm for the last three years and has 20 years’ experience in leadership roles. Trained as a civil engineer, he also holds a Master’s degree in technology with majors in project management and innovation. He’s been engaged in the public, private and not-for-profit sectors as an owner, contractor and consultant across manufacturing, infrastructure, engineering, project management and organisational capacity development.

Recruited to deliver positive changes at PFG, Sylvester has worked with employees to develop innovative and creative manufacturing practices. Among these are Lean production initiatives to provide extra value to customers and substantially cut waste.

“Lean has shown up in several areas, including waste identification, waste elimination and continuous improvement,” he explains. “One of our Aquatruck boat models is called Ocean 8.8, that we used to manufacture in 1,800 hours. Since implementing Lean practices, we are now making the boat in 1,200 hours, thus maintaining profitability and market share by reducing our labour.”

PFG has also substantially reduced plastic materials waste at its sites. Any polymer off-cuts are recovered and recycled by grinding it into powder for reuse, where it’s acceptable to use secondgrade powder. Polymer sheet greater than 300mm is recorded in the company’s database. PFG uses optimisation software, which selects the most suitable sized off-cut required for a particular job, thus minimising waste.

According to Sylvester, advanced manufacturing takes several forms at PFG: “Aquatruck boats are built using traditional boat building techniques, except they are made out of polymer instead of metal. When we started building them 25 years ago there were no applicable polymer welding standards. So, we partnered with the University of Tasmania and developed a range of tests for polymer welding and then wrote our own standards. This standard has since been adopted by the Australian Maritime Safety Authority and all of our factory employees have been trained to this standard.”

PFG also uses 3D printing for developing prototypes for new products and a range of CNC controlled cutters, routers and moulding machines for a variety of production jobs.

“Our employees have now designed and developed the culture systems or the physical apparatus that the scientists need to grow the lobsters in. If you can imagine a goldfish aquarium on your desk in a tank, which has lights and a filtration system. For research cultivation, you need six to eight 10,000-litre tanks each holding 10,000 baby lobsters. The growing lobsters need to float around in the tanks to maturity without touching each other for over 100 days.

To make this work at a commercial scale, you need in excess of 30 tanks and significant redundancy in the system design. “ PFG is now working with an investor to build the world’s first commercial rock lobster hatchery in Tasmania. Another exciting project that PFG currently has under construction is the building of a new 8m-long Aquatruck boat prototype, designed for high-end security border force, defence and police services.

“It will be longer than the ones we have provided for the police before and we are using a new design and welding technology,” says Sylvester. “This is beneficial for high-end security use because the vibration level is much lower than metal alternatives and this reduces fatigue and other human risk factors.”

On the marketing side, PFG uses external providers for its website development and its LinkedIn communications.

“LinkedIn is very effective for the company’s business promotions and B2B communications, but we have not found Twitter or Facebook very valuable for marketing,” says Sylvester. “Last year we attended a defence expo in Washington and Aqua Nor in Norway the previous year. We also attend many Australian boat shows and manufacturing expos like Austech, which we will be going to in May.” The future for PFG is an aggressive growth target to move from a medium-sized business to a large one.

“There is a potential to float or become an attractive acquisition,” Sylvester says proudly. “We are not driven by the fact that we want to sell out, but moreover that we want to run our business in a way that it is attractive to other people. PFG plans to retain its level as a leading Tasmanian aquaculture provider, but we also want to grow the business across mainland Australia and continue to be an employer of choice.” www.pfg-group.com.au

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WORKHOLDING

LANG Technik – Innovation leaders in workholding & automation Tobias Farr, Export Sales Manager for LANG Technik, was over in Melbourne in November 2018, visiting the workholding and automation specialist’s agents for Australia and New Zealand, Dimac Tooling, and catching up with clients here.

LANG Technik was founded by Josef Lang in 1982 in the German town of Neuhazen, initially operating as a sub-contractor for the mould-making industry and a manufacturer of general mechanical components. After Josef passed away, his son Guenter Lang stepped in as CEO in 1985. Taking the reins at the age of just 23, it was Guenter who would come to set Lang’s longterm direction, overseeing the company’s transition from contract manufacturing to developing its own products, beginning with the Vario-Tec pin-jaw clamping system in 1997. And Guenter remains very much at the heart of the company’s operations today.

“My boss is a typical German inventor,” says Tobias Farr. “He always has some idea of how to optimise processes and manufacturing cycles, and he came up with more and more ideas.”

Guenter also took a keen interest in the people side of the business. When Farr joined LANG as a driver in 2003, he

was planning to join the German Army.

However, Guenter found out about this, and he was quick to intervene, making Farr an alternative offer.

“He said: ‘No don’t do that. We have a job here,’” Farr recalls. “And that was my career. I did my apprenticeship at LANG, and then my Bachelor’s degree study. Now I’m looking for sales partners.”

Farr was in Melbourne for four days, running training sessions on LANG’s products at Dimac’s offices in Dandenong, as well as getting out and visiting some of LANG’s Australian customers. This followed a stopoff for the METALEX exhibition in Thailand, with Taiwan next on the itinerary before heading back home to Germany. It’s a lot of travel, but LANG – like Farr – has come a long way.

“When I joined in 2003 we were 15 employees,” says Farr. “Now 15 years later we are 115 people. There’s been enormous growth.”

Today LANG specialises in two areas: workholding, and automation.

Its automated loading systems employ existing industrial robots from the likes of Fanuc as part of an integrated solution for the handling of vices, pallets and fixtures, and can be retrofitted to almost all machine tools. Meanwhile, LANG has acquired a well-earned reputation as a global leader in workholding, specialising in particular in products for milling machines. Its core growth areas are in high-end applications in advanced manufacturing sectors such as aerospace or medical.

“Our products are especially important everywhere you process expensive material,” says Farr. “That’s the case with medical or aerospace (titanium, aluminium, stainless steel). The purpose of our products is that it can save expensive material and guarantees the utmost process reliability for sophisticated machining tasks.”

Tobias Farr, Export Sales Manager for LANG Technik, with Dimac Managing Director Paul Fowler.

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WORKHOLDING LANG Technik’s MakroGrip stamping technology

Clean-Tec – Automatic cleaning of workpieces One of the most unique products LANG Technik developed in its early years was the Clean-Tec Cleaning Fan. Clean-Tec automatically cleans the machine table, pallet and/or workpieces after the machining process is complete.

Traditionally the workholding segment has not been especially innovative, with the fundamental design for many vices relatively unchanged in 100 years or more.

However, the last 20 years or so have seen considerable change, and LANG has been a key player in this. As Farr puts it: “We want to be an innovation driver in this industry.”

One example of this is Quick Point, LANG’s patented zero-point workholding technology. Zero-point systems are not unique these days, with many suppliers offering products in this area. What distinguishes Quick Point is the way it combines impressive flexibility with high levels of rigidity.

“In Germany we have a saying: ‘Nothing is as expensive as a machine tool standing still,’” says Farr. “So the main target is always to keep the machine tool running.

If you change from one job to another, the set-up time should be as short as possible.

With zero-point clamping systems a onetime installation is required. Once the base plate is mounted and aligned to the machine tool table and the zero-point is defined, you can build up anything – workpieces, flanges, vices, fixture – quickly and accurately. The changeover time is reduced to maybe five minutes maximum.

In the past, if you had aligned everything, it took up to one or two hours to change the job.”

Five-axis machining is currently the most significant trend in CNC milling in terms of defining how LANG is directing its ongoing research & development (R&D) efforts. The growth in five-axis machining is driving demand for workholding products that are much smaller and more compact.

“In Germany and Europe, I think there is not one company that does not have a five-axis machine tool, even the one-man job shop,” Farr says. “For five-axis machining it only

makes sense if you can finish the part in one or a maximum of two set-ups. Therefore we have to have small, lightweight vices to have the access from all around, all five faces, the top side and four lateral faces.”

LANG’s innovation strategy is built on a constant focus on R&D. It releases a new catalogue every two years, and always strives to include new products each time.

The company also maintains an active policy of co-operation with its clients in driving the evolution of its products.

“For us it’s very important to be in constant communication with our customers,” says Farr. “They are very inventive when it comes to application possibilities, which often initates a product development process at LANG. We get feedback from customers what can be done better and we continuously apply modifications, improvements.

The fan can be stored like a common tool and selected automatically via a CNC program. It can be clamped in every common shank with a diameter of 20mm. The fan is activated by the revolving of the machine spindle, whereupon the wings will unfold to commence the cleaning task. The fan is available in different diameter sizes of 160mm, 260mm, and 330mm.

“Clean-Tec is the practical time saving solution for removing chips and coolant from the machine table, fixtures and workpieces prior to unloading,” says Dimac Managing Director Paul Fowler.

This approach also serves as a way for LANG to strengthen its customer relationships and bolster brand loyalty.

“Since we collaborate so closely with our customers, they are quite loyal to us because we are facing them on the same level. We really have a good relationship with our customers.”

Germany remains LANG’s biggest market, accounting for 40% of its turnover, followed by the USA, France, the UK and Italy.

Japan is its biggest market in Asia, while Farr is also quietly impressed with what he has seen of manufacturing in Australia.

“It’s the first year we are co-operating with Dimac in the Australian market,” he notes.

“Compared to other markets, it’s picking up quite quickly here. In other markets in South-East Asia for example, it took much longer until we had good results. But even though the market here is quite limited, it has developed quite quickly.” www.dimac.com.au www.lang-technik.de

“Because all LANG Technik’s extensive products come from the one place, they are perfectly matched and interfacing problems with other systems do not exist. The modular building system and the multitude of combinations and capabilities are the reason that their workholding systems can be used in almost any machining centre.

“Like all the products we sell, Clean-Tec along with the rest of the LANG Technik range will have the full back up and support of Dimac technical personnel to ensure the products are installed correctly and operate at optimum performance.”

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MATERIAL REMOVAL

ANCA collaboration brings efficiency gains for Fraisa A collaboration with ANCA helped Swiss tool maker Fraisa reduce production costs by 50% through a customised automation solution.

Fraisa is a family-owned business that offers its customers a complete range of solid round tools with endmills, drills and taps, with a full service offering encompassing logistics, customised tooling, regrinding and recycling of tools. Headquartered in Switzerland, Fraisa has a strong position in Europe and has entered the US and Chinese markets in the last ten years as it capitalises on a tap market predicted to reach $699m globally by 2020.

“I think opportunities in the tool and cutter market are significant,” says Josef Maushart, CEO and President of Fraisa.

“I expect a further growth of 2-3% a year and see especially high growth in solid round tools. To meet this demand, we are moving into a complete renewal of our tap production.

“We knew that providing taps was a unique selling proposition for us as most of our competitors only manufacture endmills and drills. However, with high labour costs in Switzerland we needed to incorporate automation into the manufacturing process and that took us to the edge of technology as far as cutting tool production is concerned, especially with a complex tool like a tap.”

The classic way to grind a tap is to first grind the flute and then on a separate machine, grind the thread. The ANCA TapXcell combines these operations on a single machine, creating an opportunity to automate the entire process. Fraisa also wanted the flexibility to change the product without people being involved in the fabrication for small and large lot orders.

Amelinda Ilardi, Engineering Project Manager at ANCA, facilitated the collaboration with Fraisa.

“To remain competitive in high cost labour markets like Switzerland, Fraisa wanted a machine that could grind multiple tap types unmanned for 50 hours,” says Ilardi. “There was no solution on the market, and Fraisa approached us to develop the technology they needed.

“To enable the machine to run unmanned, we needed an in-process measurement capability to ensure grinding stability. To do this we designed a new application where the thread pitch diameter is measured by a Renishaw MP250 touch probe. Measuring to ±0.002mm accuracy, this feature is crucial as it ensures every batch of taps are of consistently high quality.”

Not only can the machine run unmanned for 50 hours, it is fully connected to Fraisa’s

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factory ERP system for further efficiency and reliable production data gains. The machine can be remotely monitored using ANCA’s RedaX product and automatically sends notifications to keep remote staff aware of the machines progress and also any issues or faults that need to be addressed. RedaX can also be used to track the productivity and up-time of multiple ANCA machines.

“ANCA’s commitment to innovation is by being able to deliver custom solutions as an enhancement to our standard product,” adds Ilardi. “This requires agile response and capacity in our engineering to deliver what can be quite a complex set of customer requirements.”

Unique to the market, the TapXcell is a complete production package for tap manufacturers. The grinder itself includes a 37kW grinding spindle that enables grinding of even taps above M32, as well us dual wheel dressers and between-centre workholding. Industry leading iTap software makes setting up all machine operations easy, even for the more complex tool geometries. Grinding capability is complemented by the TXcell’s robot loader, which manages autochanging of up to 24-wheel packs and tool changing. For Fraisa, ANCA introduced an extended-capacity turntable to the current TapXcell design to meet additional capacity requirements.

“ANCA has the capability and will to answer our specific requirements and collaborate with our teams to customise a solution fairly quickly,” says Maushart. “From previous projects I knew they had an experienced

engineering team with the capabilities and capacity to take on complex challenges such as automating tap grinding.

“As a CEO I am often asked how a country with high labour costs like Switzerland can have such a thriving manufacturing sector. The answer is easy, Switzerland is one of the most innovative countries in the world. At Fraisa, innovation means we have a steady product renewal process and renew on average 800 of our 8,000 articles each year. This is the evolutionary aspect of our business, with daily improvements.

But to really succeed, from time to time it is important to have a revolutionary innovation.

According to Maushart, the change from a manned three-shift operation for five days a week to an unmanned sevendays operation, Fraisa has cut costs by half. Productive hours have risen from an average of 105 per machine per week, to 150 hours, with serious efficiency benefits.

Fraisa does not see unmanned production as a negative for its employees, Maushart adds: “There are several advantages for our workers. We made the decision to retain their salary if they invested more time in upskilling themselves in other manufacturing processes. This benefits us as we have a more engaged and skilled workforce who can focus on more valueadded work rather than just monitoring machines. It also offers them a better work-life balance by not having to work on weekends or shift work.” www.anca.com www.fraisa.com

MATERIAL REMOVAL

Automated die machining boosts manufacturing capacity German cookware manufacturer WMF Group introduced a standardisation strategy that helped it streamline production processes at its tool and mould making division, thereby creating the scope for services for external customers, assisted by a C 22 UP machining centre from Hermle.

WMF was founded in 1853 as Metallwarenfabrik Straub & Schweizer, and has been part of the French SEB Group since 2016. More than 2,200 employees at the Geislingen headquarters and the nearby Hayingen plant alone are engaged in the development and production of high-quality cookware and cooking knives. Many of these products are still manufactured through the primary and secondary forming of sheet metal blanks, with most of the required tools produced in-house at its tool shop in Geislingen.

“For about 30 different knife models alone, we use between 100 and 150 die tools, each consisting of an upper and a lower tool made of hardened hot-forming steel,” explains Hans Brühl, Part Production and Tooling Technician at WMF. To guarantee consistent product quality, the mould makers have to rework the tools after roughly 3,000 strokes. This involves precisely milling and removing approximately 0.5mm of material, a process that is possible up to 15 times with the dies.

“In the past, we performed all these milling and finishing operations on an HSC milling machine,” says Bruhl. “However, this machine could only accommodate two dies at a time, which then had to be processed successively and in several time-consuming setups. As knife production in Hayingen increased, more dies were obviously needed and this led to capacity shortages.”

An evaluation process, which included tests to assess contour accuracy, precision and surface quality and to

determine whether machining time for refinishing had been significantly reduced, saw the C 22 UP five-axis machining centre from Hermle come out on top. A machining process developed together with Hermle led to extraordinary results: not only was the desired reproducibility of contour accuracy and surface quality achieved, the machining time was also reduced considerably.

ULTIMATE PRODUCTIVITY

With the C 22 UP machining centre, which features an 11-fold PW 150 pallet changer, it is now also possible to rework dies automatically – during the night and at weekends. This means additional capacity is now available for processing internal and external orders.

The fact that WMF’s tool and mould making division was able to achieve new levels of productivity is due, on the one hand, to standardisation of the dies. On the other hand, a self-developed pallet and workpiece clamping system with four-fold bolting directly to the pallet and the automation provided by the PW 150 pallet changer have allowed machining to become significantly more efficient.

“We were able to reduce the machining time by 50% and more when refinishing the dies,” says Axel Spadinger, Head of Tool Engineering & Making at WMF. “Since this work is generally carried out at night and over the weekend, we can therefore use the C 22 UP machining centre very flexibly during the day for all other machining operations. Combined with our knowhow in tool and mould-making, we are thus in a position to meet external customer needs on time.” www.hermle.de www.wmf.com

Ti Endmills

• Increased tool life • Improved cutting times • Higher productivity

Raw Material

Finished Product

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Call 1800 335 350 or visit

The working area of the C 22 UP machining centre.

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SOFTWARE & IT

RONDO rolls out increased business insight, productivity and savings RONDO North America, founded in 1964, is a wholly-owned subsidiary of Swiss-based RONDO Group, developers and manufacturers of high-quality machines and systems for the production of pastry, bread and all types of baked goods.

Thousands of customers – from small artisanal bakeries right through to large-scale industrial applications, rely on RONDO “dough-how”, the company’s unique combination of expert knowledge and experience in dough and technology. RONDO North America is responsible for sales and after sales support across the US and Canada. As RONDO North America grew, it became clear that its 18-year-old, UNIX-based enterprise resource planning (ERP) system was struggling to cope with business demands.

Jerry Murphy, President of RONDO North America explains: “We had significant problems reconciling sales, managing inventory and creating accurate reports. The user experience was also very poor and employees were frustrated by the limitations of the systems. In many instances hours of additional work had to be done to get the information we needed – so it began impacting our productivity.”

After a competitive bid process, the organisation chose Pronto Xi. “One of the key features of Pronto Xi for us, was the ability to organise and track every sale and each transaction using Pronto’s Project module. This enables optimal business planning,” says Murphy.

RONDO North America uses the Sales Order functionality to order and track parts. Some sales however, are more complex. They may have progress payments or, span a period of several months– from the initial order, to the machinery being built and then installed.

“We typically have more than 100 different types of projects – or sales processes – on the go in any month,” adds Murphy. “Pronto Xi’s Project module enables us to track each individual project, right from if we’ve ordered the equipment to receipt of payment and when we expect the shipments to arrive. This real-time information that Pronto Xi provides about the status of each individual sale or project enables us to confidently make better business decisions.

“It ensures RONDO North America maintains the outstanding service standards we are recognised for in this industry. The previous aging ERP system we had just did not offer any of this functionality. Pronto Xi is clearly a significant contributor to our business success.”

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Layering reporting with powerful analytics RONDO also makes use of CRM functionality to track customer interactions across their whole life cycle, from prospect to customer or accounts receivable stage.

“We conduct business for North America as a whole,” says Murphy.

“Our administrator, who is located in Canada, must also be able to process an order for any customer and everything needs to be captured in the one system so that anyone in any office can complete the next steps. Pronto Xi allows us to do this seamlessly.”

Zeffriena Milton, Financial Controller at RONDO North America, adds: “We also use the service module to manage our preventive maintenance contracts, capturing the time spent at a location by our service agents and which parts were purchased through the Pronto Xi inventory module. This ensures we have complete records and bill accurately. We gained a time savings of up to 50% in inventory management through correct inventory reconciliation and in the year-end stocktaking processes with Pronto Xi.” The greatest transformation for RONDO North America since moving to Pronto Xi has been the efficiencies introduced in business reporting and financial analysis.

“We need to provide specific reports to our Swiss head office and these reports are now easily created with Pronto’s reporting and business intelligence module,” explains Milton. “One of the key reports created is a trial balance, which then provides us with a balance sheet, profit and loss statement. Pronto has enabled an estimated 26% reduction in the time we spent reconciling end of financial quarter and end of year reporting.

“We’ve completely eliminated a lot of time-consuming manual tasks, such as foreign exchange revaluation which was especially tedious. This has enabled a 10% increase in the time I can invest in business analysis that provides incredibly valuable insight about how we can improve the profitability of our business.”

SOFTWARE & IT

To satisfy its uptime and service requirements, RONDO chose to move to Pronto Cloud Managed Services. Murphy said that the motivation for going to cloud hosting was the need for comprehensive disaster recovery, as well as unparalleled uptime.

“Given our geographic dispersed operations, having ‘anywhereanytime’ access was critical. Now with Pronto Cloud even if we have a power outage onsite, our other office still has access,” he explains.

Milton adds: “Further, when we factored in the cost of hardware, and the cost of maintaining Pronto ourselves, it was apparent that cloud was the only way for us to go. For all the right reasons, the time was right for us to migrate to the cloud.”

Blending in cloud perfection Like many other sales and support teams, the business experiences staff turnover and Pronto’s intuitive design is a big advantage – making it possible to train new staff quickly.

“With our old system we did not have discipline,” says Murphy.

“Staff could do things their own way, and so there was significant variety in the way transactions were processed. Pronto has enabled us to enforce a standardised approach which delivers substantial efficiency improvements. This discipline also ensures reporting accuracy which is really vital.”

In 2014, RONDO updated to a later version of Pronto Xi and the process was seamless.

“We were pleased to see that some of the customisations we had are now available ‘out-of-the box’, as additional functionality,” says Murphy. “This is great because it makes supporting us easier. Our relationship with Pronto is best described as collaborative. The team is knowledgeable and in the rare instances when we have encountered a persistent problem they have worked with us to resolve it – despite us being half a world away. I would suggest Pronto to any organisation looking to manage a growing business built on accurate reporting and insight.” www.rondo-online.com www.pronto.net

Pronto Software releases Pronto Xi 750 Pronto Software has unveiled Pronto Xi 750, the latest version of its flagship ERP business management software. With a broad range of new capabilities and enhancements, Pronto Xi offers businesses simple and secure authentication, improved real-time insights and better operational efficiency.

“A central theme for Pronto Software this year was to help organisations connect siloed business processes, through automation and innovation,” says Chad Gates, Managing Director at Pronto. “Pronto Xi 750 delivers on this by integrating all aspects of an organisation, from financial and operational functionality to cloud technologies, data analytics and digital commerce. This makes it easier for Australian businesses of all sizes to take advantage of a powerful business management solution that drives profitability.”

With more than 120,000 hours of development and drawing on customer feedback, Pronto Xi 750 incorporates hundreds of enhancements and has been built to help answer the most difficult business questions.

“The common advantage of all the introduced capabilities within Pronto Xi 750 is that all users, no matter their business, industry sector or organisational size, stand to benefit from a significant gain in a precious resource for us all – time,” says Gates.

“Through automation of functionality and information, as well as easy access to real-time insights, businesses will enhance their productivity, accuracy and efficiency across the full operational journey, from staff management, to the supply chain, sales and service management.”

Pronto Xi 750 delivers sales optimisation and improved planning capabilities by integrating artificial intelligence (AI) into CRM for mobile devices. The adaptive and predictive technology empowers sales teams to more effectively engage customers with the right information, at the right time, through the channel

most relevant to them. A new integration with Google Maps enables businesses to manage their field-based staff more effectively, allowing emergency jobs to be allocated based on real-time locations. Pronto Xi 750 users will also benefit from the new IBM Cognos Analytics platform, which offers a more intuitive interface and allows organisations to harness accurate, actionable business insights.

The latest release of Pronto Xi revolutionises the authentication experience for users, combining bleeding-edge security and simplicity. Pronto Xi 750 fully integrates with Cipherise, a highly secure yet simplified smartphone-based authentication solution from Melbourne-based cyber security innovator, Forticode.

For businesses to protect their data from cybercrime they need to ensure providers encrypt all connections – from their in-office client applications and remote workers, to their ERP server.

To protect their revenue and reputation, technology-enabled businesses also need to be better prepared for unplanned IT downtime, caused by cybercrime for example. When an ERP solution runs major functions of a business, resilience can be built into the technology by using a disaster recovery solution such as Pronto Cloud EverSync. This helps minimise corporate risk by continuously protecting business data and enabling critical applications to recover to a point in time closest to the outage – minimising any data loss and maximising recovery speed.

Australian businesses need their critical day-to-day applications to talk to one another, no matter the software provider. Responding to the market need for flexibility in this area, Pronto Software has launched a Solution Partner Network to facilitate the integration of third party solutions through native plugins or API connections.

No matter the industry or use case, applications such as the Pronto POS App, Mobile CRM and Mobile Field Service are offering businesses a new way to use ERP.

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Why small manufacturers are uniquely suited for the digital era It is a great time to be a small business in manufacturing. Today’s digital disruption is about ideas, not major capital investments or facilities with sprawling footprints. By Helen Masters.

Although it’s true that larger companies possess more resources, with the right technology, small companies can behave like large ones – while still retaining the agility that makes them perfectly suited to the digital era. Here’s a closer look at four reasons why small-to-midsized enterprises (SMEs) are ideally poised to win big in the 21st Century, and how technology can provide the capabilities needed to do so.

Innovation and investment This is the era of innovation—and not just in product design, but also in operational technologies. The Internet of Things (IoT) is driving much of this innovation. Sensor-generated data are paving the way for new offerings that are born from collected and analysed data points. Innovation is also taking the form of new business models, partnerships and co-manufacturing. SMEs are well suited for this type of out-of-the-box thinking.

Crowd-sourcing and venture capitalists are helping start-ups execute the next great idea. Technology also plays a part as e-commerce, supply chain visibility, and predictive analytics all help online storefronts to manage large volumes of commerce with minimal overhead.

Barriers to entry For decades in manufacturing’s history, starting a new operation meant inheriting, buying, or building a factory—and then filling it with expensive machinery and equipment. During the last decade, investing in robotics became a necessity for automating processes and keeping pace with the competition. This has all changed, seemingly overnight.

Today, capital investment in machinery is still a budget necessity for many SMEs, but now companies often specialise as tier-two suppliers, fabricators, or subcontractors. This means they can focus on investing in one type of machinery rather than a wide spectrum. Other prerequisites that were barriers to entry in the past have also faded. Proximity was once a major concern: Suppliers had to be located near original equipment manufacturers (OEMs), and distribution warehouses had to be near population centers and transportation and logistics hubs. The advent of the global supply chain, expedient delivery, affordable transportation costs, and reliability of worldwide suppliers makes the old notions about proximity obsolete.

Technology supports this fundamental change by giving SMEs access to buyers, as well as visibility into product availability and supply chain resources. If the small company has a professional website, reliable e-commerce, and international pricing and shipping abilities, it can sell its goods to anyone who has a smartphone and the necessary funds.

Service-centric The customer relationship is more important than ever in manufacturing. To overcome the risk of commoditisation, manufacturers are turning to service-centric business models. The customer experience is a good way to differentiate from similar competitors. Plus, excellent service does not require massive capital investment or a large workforce. SMEs, therefore, have a good opportunity to fill a service need, such as aftermarket service, maintenance contracts, or managing warranties.

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Focusing on service is a growing trend. Manufacturers are starting to offer services or outcome-based offerings, rather than just products. IoT technology makes this type of business model possible – and profitable. Data collected from smart sensors help companies provide services that are highly efficient and productive.

IoT data can also be leveraged to help R&D teams sense what customers are wanting and where product design is working – and identify room for improvements. Small companies, as well as large ones, can analyse data from sensors to make highly informed decisions and enable automated responses. Systems are set up so that sensors, artificial intelligence, algorithms, and automation perform the heavy lifting.

Agility With the speed of change today, manufacturers must be agile in responding to new demands from customers, emerging opportunities, and changing threats from the competition. SMEs are masters of agility. Unlike large enterprises, which go through layers of decision-makers and rigid approval structures, SMEs can identify an opportunity or challenge and take swift steps to respond. SMEs still need to be confident in their decision-making ability, relying on data-points, projections, and reliable business intelligence.

Once again, technology provides the necessary arsenal. Advanced business intelligence solutions give SMEs the same abilities as an enterprise with a large staff of market researchers and data analysts. Business intelligence software can, in fact, provide an added advantage, allowing the company to easily predict future opportunities, be proactive, and be the first to offer new product innovations.

Parting thoughts Small manufacturers play a critical role in the industry, acting as suppliers, subcontractors, fabricators, and catalysts for the entire industry to work harder, innovate more, and push the creative envelope. Small businesses enjoy many advantages, such as agility and their ability to seize new opportunities without the hassles of multi-level approvals. They also face more than their fair share of hurdles because they have limited staffing resources and often limited capital to invest.

By investing in the right technology, small manufacturers can gain many of the abilities of their larger competitors. From business intelligence tools and e-commerce, to service solutions and IoT, small businesses can enjoy the same game-changing capabilities as their larger counterparts.

Helen Masters is Senior Vice-President and General Manager – Asia Pacific at Infor. www.infor.com

SOFTWARE & IT

The evolution of manufacturing is driving Industry 4.0 An increasingly competitive market will drive manufacturers to fully embrace digital transformation and pay attention to the trends leading the Fourth Industrial Revolution – Industry 4.0 – if they want to remain competitive. By Mike Russell.

The manufacturing industry is undergoing dramatic changes.

Companies face growing demand to deliver quality products with minimum go-to-market time. A recent survey from Statista reveals that by 2020, the industrial manufacturing industry is forecast to invest more than US$175bn in Industry 4.0 endeavours. Therefore, the onus is on the businesses to embrace the required technological advancements in order to become more efficient and build a competitive advantage.

The Fourth Industrial Revolution encompasses a range of concepts, including the Internet of Things (IoT), Big Data, humanmachine interaction through augmented reality and digital-tophysical transfers, and technologies such as 3D printing. The industrial IoT will further enable interconnectivity of technologies to create seamless manufacturing processes. According to PWC, 86% of 2,000 manufacturers are expecting to see cost reductions and revenue gains from their digitisation efforts over the next five years. With investments in digitisation expected to reduce costs by 3.6%, manufacturing will evolve into smart factories with increased productivity and accelerated on-time delivery of products.

Game-changers in Industry 4.0 Big data is the emerging player in the manufacturing industry. The ability to collect, store and analyse data through cloud services and analytics solutions will enable businesses to successfully streamline information, subsequently increasing efficiency and accuracy, as well as providing better services and products. Retrieving actionable insights will become a growing source of economic value for businesses, no matter their size.

Additionally, using machine learning analysis to perform quick product enhancements and changes will become crucial to preserve high-priced assets and machinery. Leveraging the IoT to undertake predictive maintenance can accurately predict failure and reduce downtime for maintenance. With benefits such as decreased malfunctions, improved safety and increased efficiency, predictive maintenance will prove to be a game changer for manufacturers competing to stay relevant in the technology revolution.

Embracing the transformation According to a Deloitte report, only 2% of Australian business leaders are highly confident that they are ready for the changes associated with Industry 4.0, in comparison to 14% of their global counterparts. On the other hand, 71% of Australian executives (compared with 40%percent globally) say they have people in place with the right skills to maximise their potential – the highest percentage of any country surveyed.

Within the manufacturing industry, skill proficiency in the likes of computer-aided design (CAD) and building information modelling (BIM) is critical in ensuring a business is responding to the changing demands of the industry by allowing complex products to be designed and manufactured faster than ever before. In the current digitised world, customer experience needs to be revisited as consumers are constantly connected to the industry.

Solutions like CAD and BIM are becoming a strategic imperative to increase customisation capabilities and improve production of bespoke goods at small volumes. By embracing next-generation manufacturing, businesses can leverage from the efficiencies of new processes to allow for mass customisation of unique products.

Customers are now looking for companies with high-quality products and quick turnaround time; consequently, the manufacturers who prioritise production lifecycle with customisation will stay ahead.

Transforming your workforce Industry 4.0 will change how manufacturing works and as a result; it will also change who is needed to work within the industry.

Traditional skills like machining and tooling will remain valuable, but manufacturers will require employees with proficiency in fields like augmented reality, big data and robotics to get the most out of the new technology. To keep up with digitisation, current employees will need to prepare for more value-added responsibilities, as businesses must invest in up-skilling their facilities to be able to leverage the new technology and adapt to its implications.

Moreover, giving direct access to the information that the employees need the most will make them feel more connected and empowered. Training through collaboration platforms and tools will make it easy for employees to access data remotely and will also enable organisations to attract potential global talent in the future.

As Industry 4.0 emerges as the key digitalisation trend and continues to make a major paradigm shift in the manufacturing industry, it also offers opportunities for companies to optimise the production cycle and be efficient. For manufacturers, keeping up with the pace of digital transformation is critical for success. Industry 4.0 will continue to create changes, whether it’s through the use of machine learning analysis or big data extraction, and manufacturers must make sure that both their processes and workforce are evolving to meet these growing demands.

Mike Russell is the Chief Operating Officer at Central Innovation. www.centralinnovation.com

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Australian manufacturers risk lagging behind without IoT and AI to drive innovation Emerging technologies such as the Internet of Things, machine learning and articial intelligence are having a profound impact on manufacturing worldwide. However, the industry in Australia has been comparatively slow to embrace these innovations and risks missing out on the opportunities they represent. By Scott Hubbard.

By now, you have probably heard numerous predictions for 2020, refering to billions of devices connected to the Internet of Things (IoT) and the masses of data that will be generated. There’s no doubt that the big data created by IoT devices is increasingly driving manufacturing intelligence to generate greater operational efficiencies across the assembly line. It is helping manufacturers to target specific pain points, such as improving machine productivity and maintenance, as well as to predict supply shortages and equipment maintenance needs and failures.

Already, 40% of the world’s IoT devices are now used in business and manufacturing.

However, the Australian manufacturing industry has been relatively slow to adopt smart technologies, with recent reports estimating we’re sitting at about half the global rate.

So why haven’t Australian manufacturers jumped on board the IoT bandwagon?

High energy costs and strong overseas competition have created some reluctance to invest in new technologies. However, the IoT will be the golden ticket to Australia’s continued economic success and will deliver a massive injection to further boost steady manufacturing sector growth.

The role of machine learning in leveraging IoT data Technologies such as machine learning (ML) and artificial intelligence (AI) that can help analyse the masses of IoT data being created are transforming the industry, helping manufacturers to increase their yields and better manage plant operations. In fact, according to PriceWaterhouseCoopers, manufacturers’ adoption of machine learning and analytics to improve predictive maintenance is expected to increase by 38% in the next five years.

AI and ML can help manufacturers better predict supply shortages and/or demand spikes to help them make more intelligent business decisions regarding production output in real time. By predicting demand shortages through the use of advanced ML and AI, manufacturers also have the ability to better plan maintenance activities and prepare for downtime periods of lowcustomer demand — which will, in turn, optimise margins. By leveraging machine learning capabilities, manufacturing

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equipment is projected to be 10% cheaper in annual maintenance costs, reduce downtime by 20% and reduce inspection costs by 25%.

Supply chains also reap significant benefits from the deployment of machine learning.

McKinsey & Company predicts machine learning will reduce supply chain forecasting errors by 50% and reduce lost sales by 65% with better product availability.

Additionally, analytic and machine learning capabilities provide architects the opportunity to experiment with in-place analytics. Machine learning models can also be deployed on target cloud environments without architects having to copy data in separate locations for advanced analytics.

The importance of data consolidation To transform the chaos of raw data into constructive action, manufacturing operations heads, CIOs or plant managers should be seeking a versatile, consolidated data platform, which enables sophisticated analytics and machine learning capabilities.

Through data consolidation, manufacturers can effectively drive better real-time and historical data analysis and modelling, and open the door of opportunity for better automation and machine learning.

However, when data is scattered and siloed, the integration and analysis of data becomes a tedious and resource-intensive manual process. The longer the time taken

to analyse data, the more it decreases in value.

Solution architects must select the right platform that can handle the scale of Industrial Internet of Things (IIoT) data, along with the capability to process the data where it is generated. This will enable plant managers to create real-time data analytics to make informed, strategic realtime decisions.

Manufacturers must also decide which platform is the best suited to them, whether it is a single, multi or hybrid cloud, on premise or at the edge; the options are extensive.

Otherwise, data can be processed on the edge near the equipment. This decision will depend on the amount of data required to take accurate action and the level of urgency of converting insights into real-time action. To maximise equipment uptime, while ensuring the reduction of regular maintenance costs, manufacturers can build a connected factory solution by applying IoT methods to their equipment and developing predictive maintenance schedules with failure analysis models.

For Australian manufacturers of today to maintain an advantage in a highly competitive sector, the use of IoT data and AI and ML technologies are critical to achieving greater efficiencies and enabling better business decisions and outcomes.

Scott Hubbard is the Managing Director – Australia & New Zealand at MapR Technologies. www.mapr.com

Explore your unlimited possibilities additively The Additive Manufacturing Hub is a $1.85m program that will grow and develop additive manufacturing capability and investment in Victoria. The vision of the AM Hub is to provide an industry-driven network of users, suppliers and supporters that will foster and grow the use of Additive Manufacturing technology in Australia. + Promote and market additive manufacturing sector capabilities. + Expand the knowledge base of additive manufacturing technologies. + A grant program for Victorian businesses to encourage adoption of additive manufacturing technologies. + Support the creation of high quality additive manufacturing jobs. + Be a voice to Government on additive manufacturing sector development.

Companies looking to explore the potential of additive manufacturing, or further expand their use of the technology should register interest via email at amhub@amtil.com.au

www.amhub.net.au 1407AMHUB

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In one system, from a single source At Burkhardt+Weber (B+W), no-one needs to explain the benefits of the bi-directional communication interface IO-Link.

Based in Reutlingen in south-west Germany, this manufacturer of high-precision machining centres and even more of their customers have already learned to appreciate the many advantages when it comes to installation, configuration, diagnostics and service. In B+W’s new MCC series, the company has used Safety over IO-Link from Balluff to integrate safety into the overall concept of IO-Link.

This makes the processes simpler, more efficient, cost-effective and of course safer.

Measuring 8m x 3m and 3.5m high, the MCC 630 exudes elegance and power, radiating a feeling of solid performance, precision and reliability within its compact dimensions. Not visible is the fact that this is a new series production machine with a complete set of possible uses. Nor is it obvious that behind the blue, grey and black facade of this machining centre is a modern control and safety concept from Balluff based on the digital IO-Link standard.

With Safety over IO-Link from Balluff, the system has the world’s first simple-to-install and easy-to-retrofit IO-Link safety system onboard. The advantage: both Balluff safety components as well as safety devices from other manufacturers can be easily connected to the newly developed Balluff safe I/O module using M12 standard cable. Even standard components such as binary sensors can be bundled via the new safety I/O module.

This also eliminates the need for a separate hub. Now the prerequisites for fully transparent configuration and diagnostics solutions, flexible and safe machine operation, as well as innovative Industry 4.0 concepts are provided.

Since 2012, B+W has been part of Indústrias Romi, the largest machine tool builder in Brazil. With around 250 employees, B+W is today an international manufacturer of machining centres for complex steel, cast and titanium parts of the highest quality. Notable among its customers are many key players in the aerospace and diesel motor industries, as well as in the machine tool sector. Whether as a standalone machine or part of an interlinked production system, the MCC 630 and MCC 800 series of flexible, fully digitised fiveaxis machining centres process workpieces efficiently and ready-

to-install with just a few set-ups. In general it is the large motor or transmission parts that demand a number of various milling, drilling, turning and measurement cycles.

Balluff has been a technology provider and consultant to B+W for over 20 years.

“The co-operation over all the years has been outstanding, and we consider Balluff a reliable, creative and innovative partner,” says Benjamin Rother, Manager of Electronic Design at B+W. Rother recounts when six years ago Nico Schmid, Sales Engineer at Balluff, first presented the intelligent IO-Link interface: “At that time we wanted to wait and see how this new standard would develop.

But since 2014 we have been consistently and committedly using IO-Link in our machining centers.”

Until then B+W still used the traditional fieldbus-based wiring systems as the standard. Systematically separated from the standard signals, the safety-relevant signals were gathered in the field via ProfiNet. Cumbersome, complicated wiring was the order of the day, as were a variety of different cable types, sensors, actuators as well as tedious set-up procedures. Beyond the actual switching signal there was only little usable and processable information available from the process or sensor level.

When conceiving the new MCC series, the engineers at B+W pursued a clear objective. In addition to characteristic B+W features such as force, precision and availability, performance features were required that should benefit the manufacturer and operator equally: reducing the complexity in cabling; plug-in cables instead of discrete wiring; shortening the installation and commissioning phase; more transparency and information about what is happening in-place; and support through simple-to-use configuration, diagnostic and service concepts. Requirements that could be meet with amazing ease using the bi-directional communication interface IO-Link.

Codified in IEC 61131-9, this versatile point-to-point connection below the bus level has found broad acceptance among machine and systems builders. It clears the way for unhindered data exchange between the process location and the bus and control

The MCC 630 series from Burkhardt+Weber in an interlinked configuration.

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SENSORS The MCC 630 machining table and spindles.

level, while providing a never-before-available amount of information to the user. Continuous monitoring, detection and visualisation of current machine states, individual warning levels, quality assurance and more can all be realised and documented with ease using IO-Link.

The new MCC machining centres are impressive power packs based on torsionally stiff cast components. With two independently operated plate changers, clamping a new workpiece is possible while the other one is being processed by a tilting spindle behind a safe chip protection door along five axes. The connected magazine holds more than 100 tools and can be easily expanded up to 320 slots.

The tools are automatically fed and are equipped with Balluff industrial RFID systems. Processing capacity up to 1.5 tons (or 2.5 tons for the MCC 800), axis drives with 17.5kN feed, and motor spindles with speeds up to 12,000rpm demonstrate that safety for man and machine is a central topic here. Each machining centre comes with multiple interlocks and light curtains – all drives, suspended loads such as the opened chip protection door, as well as the obligatory E-Stop buttons, are monitored.

“There was just no competition for Safety over IO-Link!” says Rother. “In interlinked production and assembly operations efficiency is especially important if high-performance systems are to have an optimal price-performance ratio. IO-Link offers us as the systems builder, and even more so our customers, a plethora of advantages.“ Safety over IO-Link from Balluff is the logical extension of the IOLink philosophy and uses the advantages of IO-Link and PROFIsafe for safety-relevant signals as well. Like IO-Link, Safety over IO-Link also features simple system construction, time- and cost-saving wiring, minimal control cabinet space requirements and Lean system concepts. Safety always ends up on stop, as Safety over IO-Link applications can be adapted quickly and simply to changing requirements.

Every machining centre in the MCC series comes with a broad spectrum of Balluff products and systems: ten IO-Link sensor hubs

Uniform, decluttered, transparent: the IO-Link connector arrangement.

with eight inputs and outputs each collect the signals from the distributed sensors and actuators, including numerous inductive and optical sensors from Balluff. The sensor hubs are configured as needed for the requirement – in other words, 16 signals can be freely assigned, all of which can be connected as is typical for IO-Link using standardised three-conductor cable with M12 connectors.

The sensor hubs channel to six installed ProfiNet IO-Link masters.

Three Balluff safety hubs serve as safety gates. In addition to the industrial RFID systems, optional inductive couples from Balluff can be used: these transmit power and signals without contact over an air gap of up to 5mm. They are generally used where fixed wiring of sensors and actuators gets in the way, for example on rotary index tables and tool changers. As with the MCC series, when tools are placed in the machine, the controller does not release the gantry axes of the loading system until the clamping devices has reported perfect seating of the part to be processed via the opposite coupler modules.

Safety-relevant data is handled both safely and simply, as Safety over IO-Link uses elements of PROFIsafe. The IO-Link master itself remains a non-safety standard device and is considered a ‘black channel’: the transported data is tunneled through the master to the control level safely and untouched, and only there is it unpacked.

The final programming is done using drag-and-drop from the programming interface of the controller.

Automation and safety technology in one results in more economical and more productive system concepts.

“The entire pallet of virtues that IO-Link brings with it, the simple integration of safety in the same system, provided the impetus for relying on the integrated Balluff Safety over IO-Link concept in the new MCC series,” Rother concludes. “We give our customers high-performance machining centres at an outstanding priceperformance ratio that sets new standards when it comes to configuration, flexibility and service, and which are Industry 4.0 ready in every respect.” www.balluff.com

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What if machinery components were the sensors?

Sensors are a key method of data collection in manufacturing processses. Sensotect is a revolutionary coating from world bearings and digital technology leader Schaeffler, that allows components to become sensors in their own right.

By Mark Ciechanowicz.

In all industrial machinery, components add value to the system, and the lifecycle of the system creates an entire value. Digital technologies typically play an important role in analysing data from components and sending this back to the cloud, to what we call a ‘digital twin’.

This data can be used to optimise maintenance schedules or improve the performance of the system by changing the way that it is used.

Mark Ciechanowicz, Manager – Industrial Services at Schaeffler Australia

Sensors are one of the main methods of data collection, and are commonly placed on parts such as bearings, shafts, axles, bending beams and other moving parts. But they can’t always measure component parts, because of limited space or a lack of availability.

To solve this accessibility problem, and revolutionise the way we think about sensors, Schaeffler has developed new technology that allows the industrial or automotive component to be the sensor. Schaeffler’s Sensotect coating system is a directly coated sensor layer that can sit over the top of components such as bearings to measure forces in previously unavailable places within machinery, which can help achieve fuel and energy savings. With the aid of modern thin film technology, the component becomes a sensor and the sensor becomes a component.

Sensotect is a globally significant technology that has enormous potential in Australasia for use as intelligent sensors, offering data transmission in real time. With Sensotect, the forces and torques that act on a component can also be rapidly recorded in places where existing sensors cannot be used.

Sensotect is engineered to have a number of advantages, including no adhesives, a high strain sensitivity, no aging drift and no temperature creeping. The innovative coating system opens up strain and force measurement possibilities that have always been impossible with adhesive strain gauges, due to their limited operating life.

This innovative measuring technology means that it is also possible to precisely determine the torque acting on drive shafts and vehicle transmissions, and to adjust the engine’s output to exactly match the occurring load. Sensotect therefore makes an important contribution to achieving energy and fuel savings, and helps to reduce CO2 emissions as well.

Coating performs measuring tasks With Sensotect, the actual measuring function is performed by a thin PVD (physical vapour deposition) coating that is sensitive to expansion. After the component has been coated, this layer is then created using a micromachining process. The structures that are thus created undergo the same degree of distortion as the carrier component, which makes it possible for the distortion to be measured. Schaeffler has already successfully demonstrated the function of this type of sensor system in its demonstration vehicles.

One of the greatest challenges posed by this type of sensor coating system is the manufacturing process itself. By using very highperformance coating sources and adhering to particularly high requirements with regard to cleanliness in the manufacturing process, Schaeffler can achieve a level of quality previously only found on planar substrates in semiconductor technology, even in components with narrow radii.

Sensotect allows multi-functional surfaces that are characterised in particular by their sensor properties to be created without affecting the design envelope – in other words, components that are coated with it become sensors in their own right.

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Development of the technology for applications in Australia and New Zealand is supported by Schaeffler’s local manufacturing and research facilities, backed by the extensive international research facilities of the Schaeffer Group, which employs more than 90,000 people at 170 locations in over 50 countries.

Sensotect benefits • Very precise measurement of force and torque on functional components where the possibilities associated with conventional methods are limited • Sensor layer is deposited directly on the substrate surface • Measurement possible on 2D and 3D geometries • Sensor technology with neutral effect on design envelope • No use of adhesives or transfer polymers • Continuous measurement of force and torque during operation • High sensitivity with very little deviation in hysteresis and linearity • No temperature deviations • No ageing effects • Wireless transfer of data and energy (telemetry).

Schaeffler’s digitalisation offensive Advantages such as those offered by Sensotect are integral to Schaeffler’s global initiatives at the forefront of Industry 4.0 automation and data exchange technologies. Smart technologies highly relevant in Australia and New Zealand include the latest evolutions of Schaeffler’s SmartQB and SmartCheck condition monitoring systems, along with a host of digitalisation and cloudbased technologies that harness the advantages of Industry 4.0, such as Schaeffler’s BEARINX software.

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Schaeffler’s latest predictive maintenance solutions enable machinery operators to look ever more clearly into the future – they provide machine operators with vital information about the future condition of their machines. Predictive maintenance allows not only the capacity utilisation of factories, mines, utilities and processing plants to be optimised, but also makes it possible to plan maintenance intervals at precisely the right time for optimised “Total Cost of Ownership” calculations.

An important prerequisite for predictive maintenance is automated rolling bearing diagnostics, a function that is used in motor gearbox units, for example. These units are used not only in machine tools but also in belt conveyors, presses, and steel mill rollers, for example.

Schaeffler BEARINX software is one of the leading programs for performing rolling bearing calculations. It enables rolling bearing supports to be analysed in detail – from single bearings to complex gear systems and linear guide systems. All calculations are performed in a consistent calculation model. Even for complex gears, the contact pressure on each rolling element is considered in the calculation.

Because machine drives are operated virtually without interruption, they require intensive maintenance in order to prevent production downtimes. This is why it is so important for operators to know the condition of the drive components at all times, and why the bearings are becoming particularly important as a central machine element.

The latest generation of the FAG SmartCheck diagnostic system now represents a further step forward for Schaeffler in these areas.

In addition to identifying the threat of bearing damage, wear, and irregularities such as imbalance and misalignments based on vibration

pattern changes, this system also features a cloud connection. The system creates an automated diagnosis in the cloud from the raw data supplied by the FAG SmartCheck and from additional data, e.g. from the machine control system.

Applications for which this technology applies include bulk handling and conveyor applications, mining and energy; building, construction and access equipment installations, such as forklifts and logistics; food and beverage and agribusiness processes, including paper and packaging; manufacturing, metals and process engineering, transport and industrial motor and transmission applications, including pumping and HVAC installations and utilities including electricity, water and waste water.

Mark Ciechanowicz is Manager – Industrial Services at Schaeffler Australia. www.schaeffler.com.au

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Parallel importing just got easier There has been a significant amendment to the Trade Marks Act 1995 (Act) which further entrenches the legality of parallel imports in Australia. Julia Cameron and Andrew Hudson explain.

Until recently, s123 of the Act provided a defence to parties (including importers) using a trade mark to sell or import goods where the trade mark had been applied with the consent of the trade mark owner.

This defence was relied on by parties importing into and selling genuine branded goods in Australia through channels other than the trade mark owner’s authorised distribution channel. This practice is frustrating for brand owners who have invested significant resources in their licensed and/or contracted distribution channel, who are often required to discount stock to stay competitive. Branded goods which are imported into, or sold in, Australia are known as “grey goods” or “parallel imports”, and they are not illegal in Australia. A series of cases sought to clarify the defence in s123, for the benefit of brand owners, the most definitive of which was Paul’s Retail Pty Ltd v Lonsdale Australia Limited [2012] FCAFC 130. In this case, Paul’s Retail was unable to rely on the defence in s123 because, in part, the foreign licensee that applied the mark to the relevant goods was not a member of the same corporate group as the local brand owner. As a result, the local brand owner had not ‘consented’ to the application of the mark as required by s123.

• lodging or maintaining Notices of Objection (Notices) with the Australian Border Force (ABF); • limiting warranty and service obligations for parallel goods, where permitted under the Australian Consumer Law; and • keeping a tight rein on your global supply chain and distributor contracts.

Some overseas manufacturers established conditional assignment agreements with their Australian distributors which assigned foreign trade marks to Australian subsidiaries, or permitted the Australian distributor to register the trade mark in Australia, on the condition that the mark was assigned back to the overseas manufacturer when the distribution agreement terminates. Until recently, these arrangements were likely to have circumvented the defence in s123, making it harder for parallel importers.

What does this mean for those in the supply chain?

Section 123 is repealed

• ensure that relevant staff and customers are aware of the changes to the law;

On 24 August 2018, section 123(1) was repealed and replaced with a new s122A. Section 122A sets out when use of a trade mark will not be considered an infringement and includes an expanded list of circumstances where consent will be considered to have been given.

If the parallel importer can establish that a reasonable person, after making inquiries, would have concluded that the trade mark had been applied by, or with the consent of, the registered owner or authorised user of the trade mark, a person permitted to use the trade mark by either party or any of their associated entities (among other related parties), there will be no trade mark infringement:

What is the effect of the s 122A? Put simply, if the goods are genuine (not counterfeit) and the mark has been applied with the consent of the local or foreign trade mark owner, or entity associated with either party or permitted to use the mark, the importer (and any subsequent seller) is likely be able to rely on the defence in s122A.

Is there anything brand owners can do to stop parallel importers?

The changes to the Act have the potential to open up the market to grey goods and create price wars between local subsidiaries/ distributors and parallel importers and unauthorised dealers.

However, there are courses available to brand owners to maintain control over their brand in Australia and limit the proliferation of parallel imports of its goods, including by: • prosecuting and maintaining trade mark registrations in Australia;

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Service providers in the supply chain such as licensed custom brokers (LCB) and freight forwarders (FF) often suffer “collateral damage” in these disputes over parallel imports. The LCB and FF need to deal with clients on the claim being made. The LCB and FFs are exposed to claims for detention if containers are held pending resolution of any dispute These events are difficult for the LCB and FF to manage and we would suggest the following general steps to be taken:

• do not offer gratuitous advice to importers as to their right to import “parallel” goods; • refer the importers to secure their own advice; • remain aware of who have lodged Notices so that the issue can be raised before import if it appears that the goods may be subject to Notices; and • ensure that terms and conditions of trade include a warranty that the customer has the right to import the goods and an indemnity against liabilities associated with action taken to hold the goods pending any dispute.

Ultimately, the service providers will still be directly affected.

If you are a brand owner or an importer or distributor of parallel imports, Rigby Cooke Lawyers can offer you advice about how these changes affect your business.

Julia Cameron is a Partner in our Commercial and Intellectual Property Groups and Manufacturing Industry Group Lead.

Julia has extensive experience in advising brand owners, manufacturers and distributors in their distribution and IP protection, including trade marks. T: +61 3 9321 7807; E: JCameron@rigbycooke.com.au Andrew Hudson is a Partner in our Litigation and International Trade and Customs Groups. With significant expertise across international trade law and customs, Andrew is a trusted and highly-regarded industry adviser to businesses, industry associations, other peak bodies and Government. T: +61 3 9321 7851; E: AHudson@rigbycooke.com.au www.rigbycooke.com.au

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Get onboard: what you probably don’t know about IMDG but should If you or your organisation is involved in any capacity with the transportation by sea of dangerous goods then you need to know the what, why and how of the International Maritime Dangerous Goods (IMDG) Code. Brendan Torazzi elaborates.

The best way to get on board for the safe sea-transportation of dangerous goods is to undertake International Maritime Dangerous Goods (IMDG) training. And if you think it’s just for the seafaring types, then think again. Training is also compulsory for shore-based personnel. So whether you are on the high seas or a land-lubber, IMDG training is the only way to make sure dangerous goods get from A to B safely and securely.

Just to recap, the IMDG Code lays out the rules for safe transportation of dangerous goods by sea. Its main objectives are to: • protect human life • prevent marine pollution • facilitate the safe movement of dangerous goods The IMDG Code applies to all ships which are subject to the following two conventions: 1. International Convention for the Safety of Life at Sea, 1974 (SOLAS 1974) – this covers the safety implications of dangerous goods onboard ships.

2. International Convention for the Prevention of Pollution from Ships (MARPOL) – which covers the pollution aspects for ships carrying dangerous goods.

The IMDG Code lays out what constitutes dangerous goods and regulates how they are to be transported. The IMDG Code requires that such goods are correctly and safely: • classified and identified • packed • marked and labelled • documented • stowed on board the vessel • segregated from other goods with which they might react dangerously Emergency response actions must be comprehensively documented and easily available and the Code also contains security requirements to minimise the risk of terrorists accessing and misusing dangerous goods.

The transport of dangerous goods is, unsurprisingly, a dangerous business and there are multitude of ways in which terrible accidents can happen. Dangerous goods constitute about 10% of all containerised shipments worldwide and have caused around 30% of all shipping incidents. Maintaining the integrity of dangerous goods in shipments is therefore crucial to keeping all stakeholders – and the marine environment – safe.

In order to stay up to date with the rapid changes in the maritime industry, the International Maritime Organisation periodically publishes changes to the IMDG Code.

Changes can include, but are not limited to, issues such as: • • • • •

important amendments to terminology amendments to certain dangerous goods classifications updates to stowage and packing instructions new segregation groups updates to the list of dangerous good categories

The most recent changes incorporate the 2018 edition (featuring Amendment 39-18). The changes are optional for the 2019 calendar

year but become mandatory on 1 January 2020 for two years.

Likewise, the 38th amendment became mandatory on 1 January 2018 and include changes regarding the packing of Cargo Transport Units (CTUs). The amendment is extensive and will require training in order that employees are in full compliance with the Code’s requirements.

According to shipping company Hapag Lloyd, non-compliance in the transportation of dangerous goods and restricted commodities is estimated to be the root cause of a major shipboard fire every 60 days. Chapter 1.2 of the amended code clearly references the CTU Code with exporters of dangerous goods now under mandatory obligation to secure their products inside the shipping container in a way that conforms to the CTU Code.

It is essential that organisations use the correct version of the Code and have their staff fully trained and competent in the requirements of the code. Referring to an outdated code can have dangerous consequences, especially given the rapid changes that can take place in the industry. With lives and the environment at stake, IMDG Code training should be a no-brainer. The loading of goods in maritime environments is fraught at the best of times but add dangerous goods or hazardous commodities to the picture and the risk increases hugely. Reduce that risk with effective training. The Alertforce IMDG Code general awareness training includes but is not limited to: • • • • •

descriptions of all classes of dangerous goods labelling, marking and placarding requirements packing, stowage, segregation and compatibility provisions purpose and content of dangerous goods transport documents emergency response documents

In Australia, this mandatory training is regulated by AMSA, the Australian Maritime Safety Authority. Companies failing to comply with these new regulations risk delays, rejected consignments, fines and/or a damaged reputation. If your company fails to adhere to these new rules then it could create delays, fines, or rejected consignments. Any of these can result in a damaged reputation.

The AlertForce IMDG Code dangerous goods training program is accepted by AMSA and delivers cost-effective compliance for all shore-side sectors including: • shippers and freight forwarders • container packers and consolidators • shipping line operations and booking staff • stevedores • port staff • cargo surveyors Brendan Torazzi is CEO of AlertForce - a registered training organisation specialising in Health and Safety. There are three types of IMDG courses offered (General Awareness; Function-Specific and Full In-Depth). The training will provide increased operational flexibility and a reduced cost to companies. It’s an open-book course that allows students to reference the IMDG Code throughout the training. Brendan 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

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Five keys of process sustainability Process sustainability, why does it matter? After all, once a company deploys a programme, achieves its goals and has reaped the benefits, there is nothing more to do, right? Wrong! Rod Hozack explains.

Process sustainability is a crucial element in any Australian business success story. In ANZ growth rates have turned around, but that is no guarantee of business success; those companies who do the fundamentals extraordinarily well are the ones who will come out on top regardless of the overall health of the economy .

The five keys of sustainability form a self-perpetuating cycle to maintain results, and continually build improvement through the a disciplined approach. However, in many Australasian businesses, we often see the misperception that the formality and discipline required for sustainability can stifle creativity and flexibility. This is in fact the opposite – it liberates creativity because there are boundaries to work within. The primary impact of process sustainability mechanics is to ensure that ‘the routine things are done routinely’, which in turn frees people to work on strategy and innovation.

1. Education and training Education and training should be ongoing to encourage personal development and the motivation to improve. There is a subtle, but important difference between “Education” and “Training”. Education is the “why” we do things the way we do, and the training is the “how” we do things. Let’s start with the induction, which generally consists of company policy, product range, who the major customers are, and an organisation chart. Although these have merit, the purpose of induction education should also be to formally introduce and explain the key processes in the business, as well as people’s roles and responsibilities. This education should not be limited to just an induction, with annual ‘refresher’ sessions a golden opportunity to re-energise people, look at what has been done and obtain feedback on improvements. This can also be timed to coincide with annual document reviews and updates to policies and procedures.

A common mistake for Australasian organisations is to either provide superficial training, such as a PowerPoint presentation with just screenshots, or to give access to the tools with no guidance at all. True integration should start with people and behaviour ensuring knowledge transfer has occurred and buy-in to appropriate behaviours has been gained. At Oliver Wight we would follow this by guiding a company in designing processes that align with the business’ strategy, and in turn, align the tools (computer systems) to business processes. All too often, however, this is done in reverse, and is rarely successful. Two companies in particular we have worked with in NZ and Australia are so passionate about their processes, that there are no exceptions to induction education and training, even for new CEOs and Lead Team members. Knowledge fades over time, so top-up sessions always help to keep things fresh, and it is essential that when tools are installed, they are used and used optimally.

2. Communication and feedback When Oliver Wight introduces programmes of work, there is always a communication plan to ensure timely information is shared. At the end of the programme this plan should be ongoing with a budget allocated, its strategic intent documented, and a detailed activity plan created – and then it should be measured for impact and relevance.

Feedback thus becomes fundamental in establishing a culture of two-way communication and continuously improving how we work together. A good example of this is of an IBP leader from a NZ client company who has built up a reputation as something of a legend within his own organisation, but also with many outside providers and customers, for his informative and entertaining weekly blog posts.

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3. Formality and discipline For sustainability to happen, policies (the rules) and procedures (the steps) are fundamental and essential disciplines for embedding ways of working – you just need to keep it in control. If policies are the rules, they therefore need to be signed off by the CEO and Lead Team, and they must also include and clearly define people’s roles, responsibilities, and accountabilities. Supporting policies at a more detailed level, procedures should describe how the process flows from beginning to end. The test of a good policy and procedure is whether someone new to the business can follow the steps and engage in the process with minimum assistance. Several companies across Australasia even use the policy and procedure documents “as is” in their induction education and training.

4. Role descriptions Many companies in Australasia either don’t pay attention to role descriptions (RDs) once they are written, or don’t use them at all.

RDs however, ‘join the dots’ from the roles defined in Policy, to what is identified in the role description. This assists in performance appraisals against specific roles (what a person does) responsibilities (how the person performs their role) and accountabilities (how the role is measured).

5. Appraisals, and the recognition and reward approach Given the choice, people will always choose the path which will earn them the most recognition and reward. It is vital to align expectations, through role descriptions, so that people can be judged fairly during performance appraisals. Recent neuroscience studies have shown that ‘fairness’ is one of the top motivators for people. If RDs aren’t aligned, then there is a strong risk that people will be assessed subjectively, leading to frustration and de-motivation.

To summarise, Albert Einstein said, “Education is not the learning of facts, but the training of the mind to think,” which is why Oliver Wight focuses on the transfer of knowledge. Commitment without understanding is chaos – there needs to be an underlying understanding and belief in the process to enable it to run efficiently and effectively. Once this becomes the way the business works, the ‘loop is closed’ on the fundamentals of process sustainability and the appraisal system will highlight what education and training is needed.

And the cycle starts again.

Continual improvement is what divides the great from the good in business, and the organisations which understand that ‘improvement’ is an on-going journey, are the ones that will achieve the greatest success.

This article has been taken from a white paper by Oliver Wight entitled Process Sustainability: the test of all good transformation programmes. www.oliverwight.com Oliver Wight is a consultancy firm and pioneer of Sales and Operations Planning, the originator of the fundamentals behind supply chain planning and is the acknowledged leader for Integrated Business Planning (IBP). www.oliverwightasiapacific.com Rod Hozack is Partner at Oliver Wight Asia Pacific information@oliverwight.com

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FINANCE

How to build your business value in trying times Liz Smith offers helpful economic advice to manufacturers who may potentially encounter challenging market conditions this year.

There is a lot of talk about how difficult market conditions are going to be this year: many retailers are continuing to struggle; housing prices have softened; and it is likely that bank loans will be harder to get in light of the Royal Commission. These factors, amongst others, are going to contribute to tough conditions for many manufacturers.

So what can you do to make sure that you maximise the value of your business during these potentially troublesome times?

1. Revisit your strategy Ben Franklin’s motto “out of adversity comes opportunity” will ring true in the upcoming economic climate. Many of the companies that we have worked with over the years have not identified a great new opportunity for their business until they have been forced to revisit their strategy due to declining sales. For example, I have seen manufacturers that were servicing the automotive industry diversify into new product offerings for the mining, defense and infrastructure sectors. Why wait until your sales are declining - take your management team off site and brainstorm innovative channels to market for new or existing products.

2. Don’t focus on sales growth at the expense of value creation When devising your strategy, it is important to consider more than revenue growth. Unfortunately, we have seen businesses go into administration because they have chased revenue growth without giving sufficient consideration to the return generated from the capital invested. Growth creates a significant drain on cash flow due to the additional working capital and expenditure required.

Prior to making any significant investment decision, it is vital that detailed cash flow forecasts are prepared to ensure that any new investment decisions are value accretive.

3. Make sure you have the right information to make the right decision Too few businesses we look at have quality management systems in place to enable issues to be identified and responded to on a timely basis. In difficult times, it becomes even more critical for management to be able to identify and respond to issues in their businesses and/or industry. Ideally, there should be systems in place to readily determine revenue and gross margin by customer and product and, where possible, you should also be benchmarking revenues, gross margin and operating expenses against your peers to ensure that your business is remaining competitive.

4. Prepare a budget It never ceases to provide amazement as to how few small and medium businesses prepare budgets and monitor their performance against budget. If properly prepared and used, budgets are an extremely important tool in driving sales, controlling costs, improving employee accountability and performance, identifying funding issues well in advance and reducing the risk of fraud and error. In summary, it just makes good business sense to use and monitor budgets.

5. Drive financial performance My grandfather used to tell me that if you look after the pennies, the pounds will look after themselves. This is also sound advice for business owners. Looking after the small things can often add

materially to the bottom line. How is your business going with: increasing prices on each product to the maximum extent your customers will allow? Eliminating bottlenecks in the manufacturing processes? Controlling inventory levels? Reviewing costs and analysing supply contracts to ensure you are getting the best terms? Invoicing customers on a regular basis and following up on debtors? Making sure the credit process includes a review of PPSR? Implementing controls to reduce unwanted employing turnover? These are just some of the small factors that can have a significant effect on the business.

6. Check your structures Some accountants set up business structures with the sole purpose of helping the business owners to reduce their short-term tax liabilities. Whilst this is an important factor, there are other important issues that need to be considered. For example: Does the current structure adequately protect your personal and business assets in the event of an adverse event? Do you have the right structure in place to access government grants that may be applicable? Will the structure enable you to raise capital in the future to support your growth initiatives? Will it help reduce the tax liability on the eventual sale of the business?

7. Maintain the relationship with your bankers It is generally expected that it will be harder for manufacturing businesses to maintain and access debt in the coming years.

Businesses will need to develop and maintain quality two-way relationships with their bankers by keeping them informed, providing them with accurate and reliable information, being responsive to their questions and concerns and planning well in advance for new debt or debt-rollovers.

Are you unsure how to grow your business through the current market challenges? William Buck has significant experience working with manufacturing businesses. We are proud to be AMTIL partners with expertise to review your existing strategies and highlight areas of focus to enhance the value of your business. If you are interested in improving your business contact Liz Smith (Director, Corporate Advisory) to arrange your consultation liz.smith@williambuck.com or ph: 03 8823 6810. www.williambuck.com

“It’s likely that bank loans will be harder to get in light of the Royal Commission.”

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Our Institute loses a friend Life membership of any organisation is a big deal. To be awarded life membership means more than just time, effort and longevity in an industry. Many of us have that. It’s awarded to those people who have a deep commitment, a real passion, who go above and beyond to serve, not for themselves, but for the industry they care for. Bob Corbett was one of those people.

Bob passed away recently at 92 years of age. He was our first life member, given that honour in 1999; a husband, businessman, father, mentor, gentleman, larrikin and lovable rogue. I attended his wake and there were many stories to back up all of those attributes.

One of my favorite memories of Bob goes back to 1995, my first involvement with the then-Institute of Machine Tools Australia (IMTA). Bob was Treasurer in those days and we were truly a volunteer-based nonprofit organisation, so at our regular meetings we all waited for the Treasurer’s report and for Bob to announce whether the funds allowed us to have port with our coffee. It became a ritual – “Yes, we can have port with our coffee tonight boys” – and we would all rejoice. On occasions, I have stolen this line to use at more recent meetings, just to keep the tradition going! I asked Bob’s son Gary to pen a few words so I could include them in this article.

Robert ‘Bob’ Corbett, one of the driving forces behind the establishment of the Institute of Machine Tools – the forerunner of AMTIL – passed away recently following a short illness at the age of 92. The Institute’s founding treasurer, Mr Corbett, was made a life member of the association in December 1999.

The Managing Director of Corbett Saw and Tool Company, Mr Corbett played an integral part in the establishment of AMTIL and up until his death he keenly followed the fortunes of the association with much pride. After starting his working career as a Sales Engineer at Rockley Machinery Company in South Yarra, Mr Corbett quickly rose through the ranks to become the company’s General Manager before branching out in the mid-1970s to start his own business.

As a result of ongoing frustration at the lack of recognition for the manufacturing industry in Australia, Mr Corbett enthusiastically lobbied for the establishment of a peak industry body to oversee the industry’s fortunes. Up until his retirement at the age of 82 in 2009 he continued to attend AMTIL meetings as often as possible and took an active interest in industry developments.

Mr Corbett is survived by his wife, Norma and his children Gary and Julie and their respective families.

On behalf of our Board and Management, I pass on our condolences to Norma, Gary and Julie and their families. Bob was a true stalwart of our community and a much admired and respected person.

Bob, I’ll have a glass of port tonight and remind myself of the legacy you helped start all those years ago. We are indebted to you. I hope you enjoy the tennis and merlot – wherever you are.

Shane Infanti, CEO AMTIL

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AMTIL HEADING INSIDE

John Croft appointed to head up AM Hub AMTIL has announced the appointment of John Croft as the new Manager of the Additive Manufacturing Hub (AM Hub). John joins AMTIL on the back of a wide-ranging career in Australian manufacturing, having most recently served as Business Development Manager for Automation & Robotics at Robert Bosch Australia.

Led by AMTIL and generously supported by the Victorian Government, the AM Hub has been established to grow and develop additive manufacturing (AM) capability. Its goals are to: promote and market AM capabilities; support the creation of highquality AM jobs; provide a forum for dialogue and communication for the AM industry; encourage R&D, innovation and collaboration; and provide a strong, cohesive voice on AM sector development.

John is uniquely well placed to oversee the direction of the AM Hub, having been at the forefront of the adoption of AM technology in Australia for more than two decades. In the early 1990s he launched Interact Plastic Services, the first private company in this country to move into AM, having purchased a Stratasys FDM 2000 3D printer. For John, part of the appeal of his new role with AMTIL has been the opportunity to re-engage with AM and its continuing development.

“I have had to ask myself who in their lifetime gets an opportunity to complete something they started 23 years ago?” he said. “I am very excited to have the opportunity to work with AMTIL in one of the major technologies that will eventually become the norm for future manufacturing.”

John started his career from humble beginnings, initially working as an apprentice fitter and turner, before moving quickly into the plastics industry, where he accrued many years of experience in plastics toolmaking. His career has seen him closely involved in every aspect of product development from concept to manufacturing – including design for manufacture – as well as running consultancies on a range of global platforms and industries.

Commercially astute and strategically focused, John has extensive experience of providing solutions to major players in the manufacturing, defence, automotive, medical, pharmaceutical, FMCG, food and agricultural sectors. At Bosch he had an excellent

success rate in identifying commercial opportunities, establishing a new division that would become the preferred supplier of medical device assembly equipment for Cook Medical, Fisher & Paykel, ResMed and Cochlear, as well as supplying a range of other industry sectors.

With exemplary technical and cultural expertise in manufacturing, John has a proven track record in driving growth in sales, revenue and customer base, working with stakeholders from across the globe. His ability to build strong relationships at all levels and to work with key business decision-makers will make him a valuable asset to AMTIL and the AM Hub. “I look forward to working with the AMTIL staff - our members in making the AM Hub the centre of additive manufacturing in the ASEAN Region,” John added. www.amhub.net.au 1382AMTIL

AMTIL gratefully acknowledges the support of its Corporate Partners.

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

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AUSTECH 2019 – Registrations open now Online registrations have now opened for Austech 2019, set to take place at Melbourne Convention and Exhibition Centre (MCEC) from 14-17 May. Austech is Australia’s premier advanced manufacturing and machine tool exhibition, showcasing the very latest in state-of-theart manufacturing tecnology. The opening of registrations marks a significant milestone in the build-up to this year’s exhibition, which is set to be the biggest in the event’s history. Preparations for Austech 2019 have been marked by unprecedented levels of early interest.

Floor space for the exhibition has been booked significantly faster than it was for Austech 2017, which went on to become one of the most successful shows to date.

For this year’s event more than 5,600 square metres of space have already been sold. To accommodate such strong demand, AMTIL took the decision late last year to expand its booking with the MCEC, making this year’s Austech the largest in terms of floor space to date.

However, despite the addition of further bays within the exhibition hall, demand has remained very strong, with most of the exhibition area now fully booked.

Notably, early floor space sales have been dominated by a comparatively small number of exhibiting companies, as many manufacturing technology suppliers have opted to book much larger stands at Austech 2019. According to Banks, the tendency among exhibiters to book early reserve larger stands is indicative of a positive mood among Australian manufacturers and technology suppliers that has not been the case for a number of years.

“We’ve been quite blown away by bookings this time round,” says Kim Banks, AMTIL’s Events Manager. “Three months out from the start of the show, there’s still some stands left, but we fully expect Austech 2019 to be a full house. And the fact that exhibitors seems to booking early and taking larger stands suggests people in the industry are expecting to see significant sales taking place at this year’s show.”

REGISTRATION NOW OPEN!

AMT FEB/MAR 2019

Co-located with National Manufacturing Week (NMW), Austech 2019 is expected to attract more than 10,000 key decision-makers from across the industry. They will be able to see a diverse array of machinery exhibits from companies such as Bystronic, Dimac Tooling, Hare & Forbes Machinery House, Industrial Laser, Okuma,Raymax Applications, Robert Bosch, and Sutton Tools.

As well as Austech’s traditional showcase of machine tools and ancillary equipment, interest has also been strong in the Manufacturers Pavilion, an area devoted to highlighting some the most innovative manufacturing companies working in Australia today. First launched at Austech 2013, The Manufacturers Pavilion has enjoyed consistent growth in the number of companies exhibiting, and this year that trend is expected to contune, with a number of manufacturing businesses already confirmed to take part. The exhibition will also feature a variety of dedicated technology areas. The Additive Manufacturing Pavilion will once again explore the latest developments in 3D printing, while the Digitalisation Pavilion – returning after a highly successful debut in 2017 – will shine a light on current trends in the application of digital technology in manufacturing processes. The newest addition is the Air Technology Pavilion, an area displaying the latest state-of-the-art compressors and air technology.

Along with to the exhibition itself, Austech will 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.

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. If you would like to attend Austech 2019, please register online at: www.amtil.com.au/austech

Hotspots is proudly owned and managed

by AMTIL

Press our buttons and we’ll be there to help you •

You need a specific component made, but don’t have the capabilities in house.

•

Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

•

Your business is diversifying into an area where the expertise available within the company is not sufficient.

HotSpots is a service designed to connect AMTIL members with opportunities to help their businesses grow. That piece of work that you need done might be just the sort of opportunity they’re looking for. And by featuring that opportunity as a HotSpot, you gain access to a wealth of Australian manufacturing capability and expertise.

Our regular AMTIL HotSpots email goes out to over 1,000 people every month, making HotSpots an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector.

Provided your opportunity meets our criteria for listing, inclusion in AMTIL HotSpots is free. If you have something you feel will meet our criteria, please forward it to AMTIL for assessment by emailing info@amtil.com.au with the subject line HOTSPOT. www.amtil.com.au/Membership/Hotspots

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AMTIL members see in the Festive Season AMTIL held a series of Christmas events for its members around the country throughout November and December.

Celebrations were held in Adelaide, Perth, Melbourne, Sydney and Brisane. The biggest event was at Carlton Brewhouse in Melbourne on 5 December, where more than 130 guests enjoyed a threecourse meal, drinks and entertainment. However, all the events were well attended and feedback from the members who came along was very good.

Perth

AMTIL staff were racking up the air-miles jetting around Australia to represent the association at each event. For AMTIL CEO Shane Infanti, who attended all of the events, it was an excellent opportunity to catch up with some of the members and thank them for their support throughout 2018.

“This Christmas we had our biggest line-up of festive celebrations to date, and it’s been great to be able to have almost every state in the country covered in terms of local events,” said Shane. “For me it’s been really good to get out and see a lot of our members and chat about what’s going on in their businesses, as well as discussing our plans for 2019.”

Brisbane

Adelaide

Melbourne

Sydney

AMT FEB/MAR 2019

Real Business Real People Real Members New Touch Laser Cutting have been members of AMTIL since 2001.

This membership has resulted in many benefits from access to experienced professionals who I often seek second opinions and advise from, to helping us grow our business via networking events, advertising in AMT and appearing at Austech, by far the best manufacturing magazine and exhibition in Australia. AMTIL have put us in contact with many business specialist in all fields who have offered invaluable support and assistance over many years. On behalf of myself and the whole team at New Touch Laser Cutting I would like to thank AMTIL for many great years of service, assistance, help and friendship.

Brad Drury, New Touch Laser Cutting

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

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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 TURNING DAYS Germany, Friedrichshafen 19-22 February 2019 www.turning-days.de/en

Machineering Belgium, Brussels 27-29 March 2019 www.machineering.eu/en/concept

MachAutoExpo India, Punjab 22-25 February 2019 www.machautoexpo.in

MECSPE Italy, Parma 28-30 March 2019 www.mecspe.com/en

China Machine Tool Exhibition China, Shanghai 26 February – 1 March 2019 www.cme-shanghai.com

SIMM China, Shenzhen 28-31 March 2019 www.simmtime.com/simm_en.htm

TIMTOS Taiwan, Taipei 4-9 March 2019 www.timtos.com.tw

Advanced Factories Spain, Barcelona 9-11 April 2019 www.advancedfactories.com/en

TECMA Mexico 5-8 March 2019 www.tecma.org.mx

Powder Metallurgy Belarus, Minsk 9-12 April 2019 www.minskexpo.com/poroshkovayametallurgiya

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 St. Petersburg Technical Fair Russia, St. Petersburg 12-14 March 2019 en.ptfair.ru INTERMOLD KOREA South Korea, Goyang 12-16 March 2019 www.intermoldkorea.com/2019/en Metal + Metallurgy China China, Shanghai 13-16 March 2019 www.mm-china.com/En WIN EURASIA Turkey, Istanbul 14-17 March 2019 www.win-eurasia.com/en Mashex Siberia Russia, Novosibirsk 26-28 March 2019 www.mashex-siberia.ru/en-GB

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DST Südwest Germany, Villingen-Schwenningen 10-12 April 2019 Turning and machining technology. www.dstsuedwest.de MachTech & InnoTech Expo Bulgaria, Sofia 15-18 April 2019 www.machtech.bg/index.php/en CIMT China, Beijing 15-20 April 2019 China International Machine Tool Show www.cimtshow.com INTERMOLD Japan Metal Stamping Die & Mould Asia Japan, Tokyo:- 17-20 April 2019 Japan, Nagoya: June 19-22 2019 www.intermold.jp/english BLECH India India, Mumbai 25-27 April 2019 www.blechindia.com/2019/english/ EXPOMAFE Brazil, Sao Paulo 7-11 May 2019 www.expomafe.com.br INTERMACH Thailand, Bangkok 8-11 May 2019 Co-located with Subcon Thailand and MTA2019 . www.intermachshow.com/en-us Saw Expo Germany, Augsburg 14-17 May 2019 www.saw-expo.com/en

Made in Steel Italy, Milan 14-16 May 2019 www.madeinsteel.it/en SWISSTECH Switzerland, Basel 14-17 May 2019 www.swisstech-messe.ch Metal Show & TIB 14-17 May 2019 Romania, Bucharest www.metalshow-tib.ro LAMIERA Italy, Milan 15-18 May 2019 www.lamiera.net/en/home METAL OSAKA Japan, Osaka 22-24 May 2019 www.metal-kansai.jp/en Moulding Expo Germany, Stuttgart 21-24 May 2019 www.messe-stuttgart.de/moulding-expo BUTECH South Korea, Busan 22-25 May 2019 www.butech.or.kr METALLOOBRABOTKA Russia, Moscow 27-31 May 2019 www.metobr-expo.ru/en Subcon UK, Birmingham 4-6 June 2019 www.subconshow.co.uk Inside 3D Printing Brazil: 10-11 June 2019 South Korea: 26-28 June 2019 Largest professional 3D printing & additive manufacturing event series worldwide. www.inside3dprinting.com AmeriMold USA, Chicago 12-13 June 2019 www.amerimoldexpo.com IMTOS India, New Delhi 14-17 June 2019 www.kdclglobal.com/imtos 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 Special insights into space exploration and man’s foray into this “final frontier”. World’s leading innovators displaying their latest aerospace, aviation and defence products. 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 Showcasing the latest products and technological breakthroughs for the Australian oil and gas industry. Includes 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 An annual conference held by AusBiotech, 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 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 special technology areas dedicated to Additive Manufacturing, Digitalisation and Air Technology, as well as the Manufacturers Pavilion, showcasing some of Australia’s most innovative manufacturing business. www.amtil.com.au/Austech Workplace Health & Safety Show Sydney International Convention Centre 22-23 May 2019 Safety event for all safety professionals 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 AGL 77 Air Liquide Australia 69 Alfex CNC 41 Amiga Engineering 53 Applied Machinery 15 Autodesk 11 Bestech 23 Bystronic 13 Complete Machine Tools 31 Complete Machine Tools Services 42-43 Emona Instruments P/L 59 Hare & Forbes 4-5 Headland 120 Hi-Tech Metrology 25 IMTS 37 Industrial Laser 33 Iscar 2-3 Machinery Forum 119 Metal 3D 61 Met Optix 75 Modern Tools 24 MTI Qualos Cover, 39, 81 Okuma 9 Punchtech Australia p/L 6-7 Reed Exhibitions (NMW) 21 Renault 65 Renishaw 63 Ronson Gears 55 Sandvik 57 Seco Tools 17 Sheetmetal Machinery 71 Sutton Tools 95 Syspro 26-27 Thyssenkrupp 49 William Buck 87 Complete Machine Tools Insert Modern Tools Insert MTI Qualos Insert Sheetmetal Machinery Insert

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AMT FEB/MAR 2019

117

118

HISTORY

Big wheels & little wheels – the story of UK-born Australian Sir Laurence John Hartnett (1898 – 1986) Australia’s “Father of the Holden” and much more

PART 29

PROPELLING AUSTRALIA PART 5 Moving quickly

The overseas mission of 1936 to investigate overseas aircraft for production in Australia had concluded and recommendations made … there was no time to lose!

A

request had come from the Government that we should most seriously address ourselves to the national problem of manufacturing aircraft in Australia primarily as an essential ingredient of defence. After receiving the report and advice from Lawrence Wackett and our overseas mission in 1936, we decided to move forward with all possible speed.

Many in the industry initially recommended a British design: But nothing they had seen in Britain, either in design or production methods, compared with the suitability of the American product as a basis on which to pitch the Australian aircraft industry. Many in the industry shared a sense of urgency: In 1936, though the world was at peace, many of us had the forebodings of war – from the experience of our recent travels overseas and from moves in the technical sphere. Each of us felt we had no time to waste.

The decision to stimulate manufacture of aircraft in Australia by Australian firms was made for three major reasons: Deliveries of RAAF aircraft from England, ordered by the Government, had been delayed consistently for as long as three years in spite of every pressure the Government could exert. This situation made it clear to the defence leaders that in time of war Australia would be lucky to get any aircraft at all from England. If Britain couldn’t deliver in peace, how much more critical would things be in war! If Australia was cut off from Britain by blockade in time of war, or if England were overrun by an invader, we would have to fend for ourselves.

The Commonwealth Aircraft Corporation (CAC) was formed in October 1936, having a nominal capital of £1,000,000, with £600,000 subscribed, the subscribers being B.H.P., Broken Hill Associated Smelters, I.C.I, the Orient Steam-ship Co. and GMHolden’s. Lawrence Wackett was appointed general manager.

Next on our agenda was to select a suitable factory site with enough land adjacent to it for an airstrip for the test-flying of the aircraft. I argued in favour of Melbourne as the logical centre for aircraft manufacture. For one thing it was farther from any possible enemy than the other capitals. Some members of the syndicate were in favour of a site near Newcastle, but my argument won out. The group elected me as a sub-committee of one to find a suitable site for the factory and an accompanying airstrip.

At that time GM-H had just successfully negotiated with the Victorian Government for the purchase of fifty acres of Crown land at Fishermen’s Bend for our new Holden plant. I considered Fishermen’s Bend was also an ideal site for the aircraft plant. It had plenty of space and was close to the city. Albert Dunstan, the Premier of Victoria, helped us to get a grant of thirty acres of Crown land which went through almost immediately.

Wackett was instructed to move fast and negotiate manufacturing licences with the North American Aircraft Corporation and Pratt & Whitney, and Wackett and I worked fast and determined a layout for the new factory. I was again appointed by the board as a subcommittee of one to get the factory built. The building of the C.A.C factory was the smoothest and quickest thing probably ever achieved … Australia produced her own aircraft and aero engines in a worldrecord time from scratch. The first Australian plane and engine was

The Commonwealth Aircraft Corporation of Australia was incorporated in October 1936 and by September 1937 a factory had been constructed at Fishermen’s Bend in Port Melbourne to produce military aircraft and engines. Pictured here is a Wirraway (an Aboriginal word meaning “challenge”) flying over Melbourne circa Feb 1940. This was a training and general purpose military aircraft manufactured in Australia between 1939 and 1946. This airplane commenced the aircraft industry in Australia.

flying within a year of the start of work on the factory plant.

I did a tremendous amount of work for C.A.C., both in Australia and on overseas trips.These tasks, voluntarily undertaken, without any reward, fee, expenses – not even a tuppenny postage stamp involved me in conferences here and in the U.S. and Britain, in trips, at my own expense, to distant parts of each country. In England I went on a high pressure “sell-Australia” campaign of my own, in which I convinced the British - who were at first very touchy about Australia linking with the Americans for aircraft manufacture - that it was the best thing for Australia and the Empire for us to make our own planes and engines.

This led directly to the joint UK-Australia Air Mission a couple of years later, when the British began to ask Australia to make certain British aircraft. Joe Lyons (PM of Australia) asked me if I’d become chairman of the mission, and I accepted. Anything to help!

The Air Mission recommended the manufacture of the newly developed Beaufort bomber in Australia. This was done, though not exactly in the way recommended. But the Beaufort production got under way and turned out great numbers of these very good aircraft for the RAAF during the war. The original North American NA16, with improvements, became known in Australia as the Wirraway which was not intended for combat, but for advanced training. It served its purpose - to give experience and modern knowhow to our engineers and semi-skilled people - wonderfully well. We could not have tackled with confidence projects like the Beaufort, the Beaufighter, and the Mosquito had we not had the Wirraway experience behind us.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT FEB/MAR 2019

To be continued…

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