AMT APR/MAY 2020

APR MAY 2020

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008

CONTENTS

Volume 20 Number 02 APR/MAY 2020 ISSN 1832-6080

FEATURES RENEWABLE ENERGY & CLEAN TECH Powering Up – Australia’s green manufacturing future How heavy industry can transition to sustainability Batteries made with sulphur Seabin – Bringing manufacturing onshore

48 54 56 58

CUTTING TOOLS Cutting out vibrations in machining Keeping local manufacturers at the cutting-edge Expert grooving for small part production Tool holders provide vital link to productivity

60 63 64 66

ROBOTICS & AUTOMATION Why automate your paint line?

“Sensorised” skin helps soft robots find their bearings

68 70

MATERIAL REMOVAL ANCA develops hybrid additive-subtractive platform Cutting-edge machine tools & CAM help slash cycle time

72 74

FORMING & FABRICATION Tube bending with robots

78

COMPRESSORS & AIR TECHNOLOGY Saving energy costs with complete blower packages Taking the pain out of your compressed air system

82 84

STATE SPOTLIGHT: SOUTH AUSTRALIA Digital manufacturing in the Hunter Frigate program End of Holden is not the end of manufacturing in SA First Australian-built electric aircraft prepare for take off Bygen – Adelaide start-up in activated carbon breakthrough

88 89 90 92

MATERIALS HANDLING Adaptalift: New cost-effective ranges Enmin’s Industrial vibrators keep profits flowing

94 95

BUSINESS MANAGEMENT The keys to successful Lean material management Design thinking… or design doing?

From offshoring to rightshoring Why we must get behind Australian manufacturing

96 98 100 102

MOTORS & DRIVES SEW Eurodrive – The taste of sweet success

104

48 Powering Up - Australia’s green manufacturing future Despite the drop in confidence in green-energy investment, there are still Australian companies developing innovative new clean technologies and embracing the opportunities these create for the manufacturing industry in this country.

76 Company Focus - Catten Industries Innovation in design and diversification are helping Australian precision sheet metal manufacturer Catten Industries succeed in a traditionally tough sector.

86

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

10 12 14 16 18

INDUSTRY NEWS Current news from the Industry

20

VOICEBOX Opinions from across the manufacturing industry

32

PRODUCT NEWS Our selection of new and interesting products

38

COMPANY FOCUS Innovation and diversity – Driving Catten Industries forward

76

ONE ON ONE Colin Thomas

86

AMTIL FORUMS

106

AMTIL INSIDE – The latest news from AMTIL

110

MANUFACTURING HISTORY – A look back in time

118

AMT APR/MAY 2020

One-on-One Colin Thomas is the Manager of the Tonsley Manufacturing Innovation Hub within the Tonsley Innovation Precinct in Adelaide. He speaks to AMT about the Hub, its objectives and its notable projects.

92 Bygen Adelaide-based company Bygen has developed a breakthrough new technology that can produce activated carbon from plastics and agricultural waste, raising the potential of a new sustainable option in the multi-billion-dollar industry.

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Using a hypoid gear drive, the GENOS M460V-5AX features trunnion construction that offers exceptional accuracy, rigidity and table rotation speed.

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010

FROM THE EDITOR WILLIAM POOLE

Moment by moment At time of writing, the coronavirus pandemic has reached the status of a global emergency.

Countries are shutting down borders and locking down populations, governments are scrambling to manage developments, businesses are bracing for profound economic consequences. Above all, the healthcare sector is dealing with a crisis the likes of which we’ve arguably never seen before, with a terrible human cost escalating worldwide.

From the perspective of putting together this edition of AMT, what’s been striking has been the rapidly evolving nature of the crisis, its impacts and the measures to counter it has been changing. Between this edition going to print and it finally reaching readers, a period of almost two weeks will have elapsed, by which time it seems certain a lot will have changed, so it’s been hard to gauge how best to approach our coverage of the pandemic.

But of course, the challenges of finding the right content and tone for a magazine are vanishingly inconsequential in comparison to the immense burdens so many people are shouldering right now.

So in this issue, you can find information (page 111) on where we believe you should go for the most up-to-date information and advice about the pandemic - for individuals, for workers and for employers, for people who had planned travel, and for businesses on some of the support that is available.

The Australian Industry Group has provided an excellent set of recommendations on workplace health & safety (WHS) for those many businesses that will be continuing to operate during the crisis, and that need to keep their people safe (page 16). And our corporate partner William Buck has provided some invaluable insights on some of the support measures the Federal Government has announced for businesses under its first stimulus package (page 112).

However, there’s no escaping the fact that much of the information in this edition will already have been superseded by the time this magazine has emerged from the printers and arrived with the readers. Indeed, as I write this, the Federal Government has just unveiled a second tranche of stimulus measures, including extensive support for businesses. There’s every possibility additional measures will have been announced by the time you read this.

Above all, readers are strongly advised to stay abreast of developments by monitoring official sources for updates, such as those listed on page 111 of this magazine.

Nonetheless, we will be doing all we can over the coming weeks to keep our readers informed. Keep an eye on the AMTIL website (www.amtil.com.au) for regular updates.

We’ll also be pushing as much information as we can to our social media channels, so if you haven’t signed on to follow them yet, you can find links at the foot of the AMTIL website.

As well as updates on what the Government is doing to help, we’ll also be trying to flag up ways that you can help. Already we’re seeing manufacturers in Australia rallying to contribute to what is fast becoming a national - indeed global - mobilisation to combat the coronavirus outbreak. From surgical masks to medical ventilators, manufacturers are redirecting their operations to provide help where it is needed most.

We’ll be sharing any requests for assistance in this regard as soon as we receive them and of course, please do share any of them as widely as you can.

Meanwhile, stay safe.

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 Editorial Assistant Sarah Cayless 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 PEFC™ Programme for the Endorsement of Forestry Certification Chain of Custody certified from sustainable forests 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 bi-monthly.

Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $175 (ex GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

1498AMTAPR/MAY2020

AMT APR/MAY 2020

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012

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Manufacturing in a time of crisis These are undoubtedly challenging times. The coronavirus (COVID-19) pandemic is having an impact on every aspect of how we all live our lives. As I write this, it’s impossible to predict how the situation will have evolved by the time this magazine reaches its readers.

Above all, this is an unprecedented health crisis, and our thoughts are first and foremost with those people who have been directly affected by the virus, their families and friends. Our thoughts also go out to the doctors, the nurses, and all workers in the healthcare sector, as they strive to combat the outbreak. And our thoughts go out to all the key workers in so many areas as we face the weeks and months ahead.

Alongside the immediate threat posed by COVID-19, there are also the inevitable consequences for our economy, and for our industry.

Several AMTIL members who I or my staff have spoken to have already reported significant disruption to their normal business operations. As this crisis continues, the impact will surely deepen.

AMTIL welcomes the measures put in place by Government, both at Federal and State level, to support businesses during these times, and hope to see further assistance over the coming weeks.

There have also been a number of major industry events cancelled or rescheduled, including Maxitrans, the Workplace Health and Safety Show, and the Advanced Manufacturing Expo, the latter of which AMTIL was planning to participate in. AMTIL has also had to postpone a number of its own events, with further schedule changes highly likely. We decided to reschedule these events with great regret, but we did so knowing it was the right thing to do, both for the health and welfare of those who were planning to attend, and for the wider community.

At times like these, everyone has a part to play in keeping each other safe. For most of us, that simply means maintaining vigilant personal hygiene, social distancing, self-isolation and avoiding public gatherings. Others are playing a much larger role, and I must admit to feeling a degree of pride to be associated with the manufacturing industry as it rises to the challenge posed by the outbreak.

You may have seen news stories about Med-Con Pty Ltd, based in Shepparton, Victoria, which is ramping up production of medical protective equipment such as surgical face masks, sanitizer, goggles and gowns our doctors and nurses so badly need.

Alongside Med-Con, manufacturers such as Ego Pharmaceuticals and Manildra Group are working round the clock to increase supplies of hand sanitiser. As I write this, I’ve just seen news that Holden Special Vehicles has offered to help health authorities in Australia manufacture makeshift emergency medical equipment to treat coronavirus patients. And gin distilleries across the country are repurposing their production lines to help with the production of hand sanitiser. AMTIL’s own Additive Manufacturing Hub is currently exploring ways that its members can help by providing 3D-printed parts at short notice for fast turnaround.

Stories like these, of manufacturers helping to shoulder the burden we face, can provide much-needed respite from the anxieties we’re all feeling at a time like this. So aside from those companies tackling the pandemic, I thought it might be worthwhile to draw attention to some of the other inspiring stories from around the industry, which might otherwise get overlooked amid all this doom and gloom.

Flicking through the pages of this magazine, for example, I see that ANCA is now working on developing a new hybrid platform combining both additive and subtractive manufacturing. ANCA has long been a prime example of a great Australian company at the cutting edge of advanced manufacturing, and I don’t doubt this new project will deliver remarkable outcomes.

AMT APR/MAY 2020

In the field of additive manufacturing there are all sorts of exciting developments going on. One long-time AMTIL member, Amaero, has just expanded operations with the opening of a new facility in Adelaide. Another, RUAG International, has hit a major milestone with its completion of the first component repairs on the Royal Australian Air Force (RAAF) F/A-18F Super Hornets, a first for the company here in Australia. Meanwhile Titomic, based in Notting Hill, Victoria (and yes, another AMTIL member), has been busily signing a series of contracts with leading global defence & aerospace suppliers - Thales, Composite Technology and Ascent Aerospace for its groundbreaking industrial-scale additive manufacturing.

Back in the realm of more traditional manufacturing, Brisbaneheadquartered Austin Engineering has just entered into a partnership with South Africa’s ETT to its mining products throughout Africa. And one of my favourite stories: up in Preston, in Melbourne’s northern suburbs, Harrop Engineering is celebrating 65 years in business.

Harrop is a great example of an Australian manufacturing company that has lasted by moving with the times, diversifying into new markets, and constantly adapting and upgrading its capabilities, and I am confident they’ll continue to do so for a long time yet. Here’s to another 65 years!

All these examples and more just go to show the vitality and ingenuity that Australian manufacturing has to offer. We’re seeing our industry doing its bit to get us through this current crisis, and once it’s passed, our industry has all the attributes to help make Australia bounce back and become stronger than ever.

014

FROM THE MINISTRY ANTHONY MURFETT – Deputy Head, Australian Space Agency

Advancing space capability in the manufacturing sector People have been fascinated by the idea of space and space travel. As Australia’s space industry transforms and grows, there are increasing opportunities for businesses across the country to make the idea of space a commercial reality.

The reason Australia’s space industry is expected to grow at an annualised rate of up to three times that of GDP over the decade to 2023-24 is because the space sector is no longer restricted to governments. It is becoming a fast-growing and fiercely commercial sector, driven by falling costs of launch and rapid technology development. This means the time is right for Australian industry to leverage its competitive advantages that can support the growing space economy, including in advanced manufacturing, automation and robotics, and next generation communications.

We have amazing companies, from those working in robotics that can support activities in space, Artificial Intelligence that will assist satellite activities, and new rocket technology. However, there are also companies working in a range of manufacturing fields that could apply their trade to space. For example, companies specialising in the 3D printing of metals that could withstand the extreme conditions of space. We’ve seen start-up spinoffs from the research sector that have 3D printed an entire rocket engine. There are also companies using silicone injection moulding technologies to manufacture devices that are used in harsh conditions, and companies developing machined components and gears that could be transferrable to spacecraft. I could go on – the point is we’ve got industry capability in spades.

The Australian Government aims to significantly grow Australia’s space market segment from around 10,000 jobs and a market size of $3.9bn up to another 20,000 jobs and $12bn by 2030, with further jobs and economic growth from spillover effects.

At the heart of this mission is Australia’s Moon to Mars initiative.

Late last year the Australian Government launched a new partnership on future space co-operation between the Australian Space Agency and NASA. This partnership consists of a $150m investment in Australian businesses and researchers to join NASA’s inspirational plan to return to the Moon and travel on to Mars – our own Moon to Mars initiative. It’s an investment here in Australia to grow our industry.

The Moon to Mars initiative is a five-year program that will support the transformation of industries across the economy and accelerate the growth of the space sector through three integrated programs: Supply Chain, Demonstrator and Trailblazer.

Opening in the second half of 2020, the Supply Chain program will focus on building national capability and capacity to enable Australian space and non-space industries to supply products and services to international space supply chains. Another focus area of this program is to open doors for Australian firms and support those firms to meet the conditions to engage and provide products and services in the space industry. This extends from ensuring businesses meet specific standards and qualifications, like cyber security, to demonstrating capability to support the development of space technology and products, for example showing a machined component can be used in space. Ultimately, the Moon to Mars initiative provides opportunities to develop Australian capabilities in a wide range of industrial areas that have space applications.

For example, Australians have already demonstrated worldrenowned ingenuity in remote and extreme environments, an excellent testing ground for technology that has applications in

AMT APR/MAY 2020

space. In Western Australia’s Pilbara region there are mine sites being operated remotely from Perth, 1,600km away. There are also companies controlling robots with satellite communications to service pipelines underwater. With space only 100km above our heads, the potential for the use of this technology in space is an enormous opportunity.

Australia also has immense experience in terrestrial resource infrastructure and extraction, meaning we are well positioned to investigate resource extraction and processing in space, as well as become a leader in advanced in-space manufacturing, such as additive manufacturing. As it becomes more accessible, space will become another place to operate and opportunities around these areas will grow.

Our role at the Australian Space Agency is to help open doors nationally and internationally, to stimulate commercial investment in partnership with industry as outlined in the Australian Civil Space Strategy 2019-2028.

To that end, the Agency has signed joint statements of strategic intent and cooperation with industry to highlight areas of investment and growth for Australia and build upon our unique potential. These companies include small and medium businesses like XTEK, which uses advanced manufacturing techniques to create lightweight, composite materials and equipment for space applications.

There are also larger industry primes including Airbus, which is progressing space-related high-tech manufacturing, and the likes of Boeing, Lockheed Martin and Thales, which are expanding Australia’s advanced manufacturing in space through industry and research partnerships.

The Australian Space Agency can change how Australia defines itself in space by working as a co-ordinating body to open doors internationally, managing the regulations and legislation, and kickstarting the space economy so that commercial enterprises can focus on their missions.

I encourage you to talk to us and keep an eye to the Moon to Mars initiative, which will open soon. The ultimate focus of the program is capability development so companies across industry, including advanced manufacturing, can contribute to the rapidly growing space sector.

Watch this space.

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016

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Controlling WHS risk: When working from home doesn’t work Australia’s manufacturing and distribution networks are crucial to enable everyone to obtain the essentials for daily life. Amid the COVID-19 crisis, we are all being asked to exercise social distancing and enhance cleaning and hygiene protocols. Much of the advice is about “working from home” where possible. But that’s not going to get crucial goods made and distributed.

The Ai Group has put together a list of possible control measures from our general knowledge of manufacturing and from examples members have provided to us. It’s important to note that knowledge and official advice is evolving rapidly, so please monitor regularly for updates to this advice, available via Ai Group’s dedicated COVID-19 webpage (www.aigroup.com.au/business-services/covid19coronavirus).

Identify and control your specific risks Identify what work activities create a risk of close contact or communal use of equipment. Implement control measures according to the legally required hierarchy.

Increase cleaning and hygiene protocols Make sure you have in place heightened cleaning and hygiene protocols. All staff should maximise hand washing in the way recommended by health authorities (for a poster that could be displayed in workplaces, visit https://bit.ly/2UpsUfc).

Below are some specific extra considerations for the workplace: • If you are providing handwipes and sanitisers they are most effective if they are alcohol based – generally in the range of 60% to 80% alcohol.

• If multiple workers are using equipment, provide appropriate cleaning materials for handles and operational controls, and ensure that they are used whenever the operator changes.

• Ensure cleaning staff use appropriate gloves and any other appropriate personal protective equipment when undertaking all cleaning work.

• Have extra cleaning in place for high-traffic touchpoints during break times.

• Introduce a daily cleaning regime and/or consider betweenshift changeovers.

• Review other facilities that are provided. Is the equipment used to supply drinking water, such as bubblers, a transmission risk?

Should communal equipment (such as sandwich makers and cutlery) be removed?

Decrease interaction between workers and workgroups when possible • No unnecessary contact between workgroups within the workplace.

• Consider splitting up your support teams so that you have back-up resources if one person becomes unable to work (e.g. have members of the accounting team work in separate offices).

• Use skype or similar to interact when necessary, even with those in the same building.

• Identify whether some work can be undertaken in different locations, or at different times, to reduce the physical contact between workers.

AMT APR/MAY 2020

• If meetings must take place in person, use larger rooms to allow the recommended social distancing between people – currently a minimum of 1.5m but the more the better.

• Consider holding meetings outside in the fresh air, whilst maintaining social distancing.

• Split up office areas to reduce contact between people.

• Stagger breaks to reduce the number of people congregating in meal rooms.

• Keep teams separated from each other during breaks.

Changing work hours to reduce contact between workers Any changes to shift arrangements or start and finish times must be undertaken in consultation with workers and may require agreement. It is important to consider the personal circumstances of individual workers who may not have the flexibility to change work arrangements.

Nevertheless, if you identify an opportunity to reduce risk, you should not be reluctant to pursue quick change.

Ai Group’s Workplace Advice Line can assist you to understand and apply the requirements of the relevant industrial instruments (Fair Work Act, Awards and Enterprise Agreements) and they can also help you to respond to specific concerns raised by workers.

Even if you are not considering making changes now, it helps to be prepared by understanding what options might be available: • Consider changing work arrangements so that one group of workers starts and finishes early and another group starts and finishes later to minimise time together.

• Consider introducing new shift arrangements. A current example from a member is the introduction of 3 x 12.5-hour shifts across a six-day week; this may also assist if employees are faced with school closures at some time in the future as it may be easier to manage childcare across fewer working days.

Limit direct contact with external organisations and people If contact is necessary, consider seeking assurances about the control measures that the organisation or individual has in place.

Ensure there is access to personal hygiene items (soap and water or alcohol-based sanitisers) at all entrances.

P R OC ES

DI N G V TAN AL

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• Introduce separation protocols for deliveries – no physical contact (like signing documents, consider emailing receipt confirmation).

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• Install signage on all access points advising of required protocols and the importance of not entering if unwell and to seek medical advice.

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• Separate entries and facilities for each shift; some organisations have hired additional portable facilities to allow this to happen.

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• Do you have key person weaknesses? Train at least two people to do every critical job but keep them apart.

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• Can you split your core production team into two groups who do not interact?

• Ensure your delivery drivers are engaging in good personal hygiene practices and have processes in place for cleaning the cab of the truck.

• Contractors only coming onsite when absolutely necessary.

• Restrict visitors to essential requirements.

Travelling to and from work Travelling on public transport may be confronting during these times.

Consider what arrangements could be made to provide parking onsite or nearby for workers who normally use public transport.

Remind workers about the importance of their external activities Workers and their families exercising good hygiene and social distancing away from work is just as critical as what happens at work. These protocols are there for their protection to keep their workplace and income going.

Provide information and support for workers It is a difficult time for everyone. As more people start to work from home and workplaces begin to close, people who are continuing to work may begin to feel more anxious about their exposures. There may also be financial concerns if partners or family members are facing unpaid leave, even if your workers are not at direct risk of financial impact.

This anxiety may show itself in increased tension in the workplace or through general changes in the behaviour of people. It is essential that managers and supervisors are supported to provide individual support and that those supervisors and managers also have access to support.

It is very important for leaders to help everyone understand how their individual contribution is assisting the organisation to generate incomes and keep key supply chains working for the community.

If you have a current Employee Assistance Program (EAP), make sure it is widely promoted and the specific services are identified.

Many people think of EAP as purely a counselling service, but many EAPs also provide direct access to financial advice. If you don’t have an EAP, promote the free services that are available to access.

Beyond Blue: www.beyondblue.org.au/get-support/nationalhelp-lines-and-websites.

National Debt Helpline: www.ndh.org.au www.aigroup.com.au/business-services/covid19-coronavirus

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

Government attack on R&D tax credits sends the wrong message Everyone in our industry knows that investment in research & development is crucial if we want to build a worldleading manufacturing sector. Investment in R&D returns many times its investment through improvements in productivity and other beneficial spill-over effects, not just for the business but for our economy.

In an increasingly interconnected world, even small comparative advantages can be the difference between entering a global supply chain and missing out. We must take every opportunity to give our local businesses a leg-up and ensure that we can export our goods to the world.

This makes the recently introduced Treasury Laws Amendment (Research and Development Tax Incentive) Bill 2019 even more confusing. The Bill will discourage investment in R&D in Australia, leading to some companies shifting these highly skilled, highly paid positions overseas, or abandoning them entirely. We are already less generous with our support for R&D than many of our international competitors, and these changes will make that even worse.

Failing to invest in R&D leads to lower productivity growth, a less competitive Australian manufacturing industry, less investment in new and upgraded capital, and in the long run, fewer jobs and poorer wages for Australian workers.

The Government’s attempt to save money by reducing the effective rate of the R&D tax credit for most Australian businesses has no basis in sound policy. Australia was recently ranked 93rd in the world in Harvard University’s Atlas of Economic Complexity, despite being the 14th largest economy.

This is an indictment on decades of industry and trade policy which have emphasised the export of minerals and agricultural goods at the expense of developing a sophisticated manufacturing sector.

These changes will only further cement our place at the bottom of the economic complexity ladder, leaving our economy vulnerable to a future in which our primary products are not as valuable on the global market.

Intensity test punishes local manufacturers Even worse, the Bill punishes companies that have a large local operation, by discounting their R&D tax credit because they are not seen as sufficiently “research intense”.

This will place Australian manufacturing jobs in jeopardy because this test actively encourages local businesses to move their manufacturing operations offshore.

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This means that businesses that undertake R&D in Australia and then turn that investment in new technologies, processes or products into Australian jobs will receive less support than companies that undertake R&D here but produce their goods overseas.

This change would send the opposite signal to small firms developing cutting-edge technology. We want to encourage them to keep those great ideas in Australia and to create Australian jobs. These changes will punish them if they decide to scale up their local operations, by reducing their tax credit as their R&D section shrinks as a portion of their total business.

This is bad for local businesses and bad for local manufacturing jobs.

A new way forward?

The Bill is currently being reviewed by a Senate Committee, which has previously rejected a very similar Bill in the previous Parliament. The last time the Government proposed this legislation, companies such as CSL and Cochlear made submissions raising concerns about the negative impact the changes would have on Australian manufacturers. That last time the Government agreed to go away and review the technical elements of the Bill.

The Bill is largely unchanged from a similar version presented to the last Parliament, which the Committee recommended that the Bill be deferred for further consideration.

It is our view that the new version of the Bill still contains many of the same defects as

the previous version. While there is merit to the suggestion that the R&D tax credit system needs to be reformed to ensure that it remains targeted and effective, this Bill does not deliver that.

So long as the Government sees the R&D tax credit as an expense on the budget and not an investment in our future, our industry will be forced to continually fight back against these sorts of attacks. The AMWU encourages the Government to withdraw the legislation and engage in genuine consultation with employers, employees and their representatives about the best way to ensure a strong, diverse, cuttingedge manufacturing sector now and into the future.

Australia is well placed to secure the manufacturing jobs of the future. We have a strong university sector, an established industry that employs hundreds of thousands of skilled workers, we’re situated between two of the largest emerging markets in the world, and we’re blessed with many natural benefits that will be the drivers of growth in the carbon-constrained economy.

But without a Government willing to adopt a new approach to industry policy and do its part by supporting investment, innovation and skills, those high-skill, high-pay jobs many never eventuate.

The first step towards a better future for our industry is telling the Government to go back to the drawing board with the R&D tax credit changes.

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INDUSTRY NEWS

Australian manufacturing hits worst slump in 20 years Australian business conditions in the manufacturing sector were hit by the largest single quarter decline in 20 years, the latest Australian Chamber-Westpac Survey of Industrial Trends has found.

The survey, undertaken between 10 February and 3 March, found the Actual Composite index fell to 45.0 in the March quarter, from 56.1 in December and down from 61.7 during the same period in 2019. A similar drop was last observed in December 2000 when the index fell 12.5 points and, during the global financial crisis, when a 15-point decline was observed over two quarters.

The survey’s Labour Market Composite also points to a further slowing of jobs growth across the economy, declining to 44.7, down from 53.7 a year earlier, its lowest level since 2014.

“The survey shows a steady decrease in business conditions and confidence because of uncertainty around the impact of the coronavirus,” ACCI CEO James Pearson said. “A number of key markers are down, including employment conditions. While the

Federal Government’s initial economic stimulus package will go some way to restoring confidence in the manufacturing industry, we need to deal with supply chain disruptions that manufacturers are particularly exposed to. Further stimulus would help support SMEs and jobs at risk.”

depreciation for 50% of the value of other eligible assets.” Westpac Senior Economist Andrew Hanlan said the softer reading on actual conditions was evident across all the sub-components, from employment, new orders, output, backlog and overtime.

Person said the survey indicated that businesses were still open to invest: “There was little change in investment intentions, as businesses appear to take a longer-term view on investment.

The business investment measures included in the stimulus package, along with the very low interest rates, will potentially stimulate considerable investment in plant and equipment for the next three months.

“The weak start to the year is largely a product of transitory disruptions to demand and the supply chain, including the bushfires, the drought and the COVID-19 outbreak, as well as the ongoing downturn in home building,” Hanlan said. “Sentiment amongst manufacturers understandably has been dented by the disjointed start to the year.

A net 9% of respondents expect the general business situation to deteriorate over the next six months. Whereas, at the end of 2019, the mood was positive – a net 5% of firms expected business conditions to improve.”

“Small-to-medium businesses planning to upgrade or purchase new equipment over the next 12 to 18 months are likely to bring forward this investment to take advantage of the very generous $150,000 instant assets write-off and accelerated

AMGC hits 1,000-member milestone The Advanced Manufacturing Growth Centre (AMGC) has reached a landmark milestone, adding its 1000th member – Incat Crowther – to the organisation’s Australian manufacturer network.

Incat Crowther is an Australian company specialising in the manufacture of ships across commercial, military and private yacht sectors both locally and abroad.

Incat Crowther currently has 82 ships under construction in 17 countries, ranging in length from 20 to 125 metres.

AMGC is a not-for-profit, industry-led organisation established by the Federal Government to support the development and growth of advanced manufacturing in Australia. Upon joining AMGC’s network, Incat Crowther’s Technical Director, Dr Andrew Tuite, said: “Incat Crowther is pleased to join AMGC at a time when manufacturing across the globe is evolving to become more advanced and nowhere is this more evident than in Australia.

“AMGC enables us to connect with other Australian manufacturers via its networking events, access the latest research, highlights grant and funding opportunities and allows us to participate in peer learning via the Manufacturing Academy – and it’s all complimentary.

“AMGC is assisting us as we transform the traditional shipbuilding industry into a smart-ship manufacturing sector to meet the challenges of developing bespoke ships

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for unique operating environments,” Dr Tuite added. Advanced ship manufacturing is a flexible, agile business model that meets the demands of market fluctuations, new technology and innovation, regulatory changes and the requirement by the ship operator, for quality control processes and build cost efficiencies Dr Jens Goennemann, Managing Director of AMGC, said: “Since our foundation, AMGC has been able to build an enviable network of Australian manufacturers who are actively engaged in advancing their industry and workforce skills, and we

welcome Incat Crowther to our membership base. “Over the past four years, AMGC has had the privilege of working across a multitude of sectors. When it comes to advanced manufacturing, AMGC uncovers and fosters great examples of Australian manufacturing capabilities to rival any country. “While all the right signals are there, Australian manufacturers can do more to embrace advanced manufacturing principles. We aim to build an Australian manufacturing industry that is highly skilled and resilient, that competes on value, not cost and that manufactures some of the world’s best products.”

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INDUSTRY NEWS

CEOs anticipate deteriorating conditions in 2020 The Australian Industry Group’s latest CEO survey has predicted deteriorating economic conditions for 2020, heightening the need for action to stimulate the broader economy and for a determined effort to lift productivity.

Released at the end of January, Ai Group’s annual Business Prospects report for 2020 is based on a survey of 252 CEOs conducted in late 2019. The results show that even before the summer’s devastating bushfires and the ongoing coronavirus pandemic, Australia’s CEOs were pessimistic about business conditions for 2020.

on a ‘net balance’ for 2020 than for any year since 2015 (that is, more businesses are expecting no improvement in these indicators in 2020). More positively, employment growth is expected to edge higher in 2020, with a greater proportion of businesses planning to increase their workforce over the coming year.

• 27% plan to increase spending on physical capital (CAPEX) in 2020 (lowest ‘net balance’ since 2015).

More CEOs are expecting a deterioration in their trading conditions in 2020 (relative to 2019) than an improvement, with 40% of CEOs expecting no material change in their business conditions in 2020 and 34% expecting a deterioration, but only 26% expect conditions to improve. This indicates 2020 will be the first ‘net negative’ year for Australian business expectations since 2015, on a ‘net balance’ basis (that is, more CEOs expecting a fall than a rise in general business conditions).

In response to the disappointing trading conditions experienced in 2019 and the modest growth outlook for 2020, fewer CEOs plan to increase expenditure on various types of investment in 2020:

Ai Group Chief Executive, Innes Willox, said: “While Ai Group’s latest survey reaffirms an immediate outlook for the economy that is flat at best, we can secure our future economic prosperity with timely and multifaceted action to address substantial headwinds. It’s a challenge for governments, for businesses and for the broader community, but it’s one we should rise to with confidence that we will emerge stronger.”

Business expectations for turnover, profit margins and productivity are all lower

• 40% plan to increase spending on staff training in 2020 (lowest ‘net balance’ since 2017).

• 43% plan to increase spending on new technologies (lowest ‘net balance’ since 2015).

Some 60% of businesses reported they had revised their plans and strategies in 2019 in response to changes (including deteriorations) in conditions, up from the previous three years.

• 23% plan to increase spending on R&D (lowest ‘net balance’ since 2015).

RUAG achieves first component repairs on RAAF F/A 18F Super Hornet RUAG Australia has completed the first component repairs on the Royal Australian Air Force (RAAF) F/A-18F Super Hornets.

RUAG Australia’s Airport West facility performed extensive testing, fault diagnosis, and expert repair on the aircraft’s Auxiliary Power Unit (APU) while the company’s Hydraulic Center of Excellence at Bayswater and Amberley carried out hydraulic component repairs on MLG Brake Assemblies and Hydraulic Swivel Joints, all for the first time. These repairs have all led to the return to service of the F/A-18F Super Hornet in a timely and costeffective manner.

RUAG fulfilled the repairs to the F/A-18 F Super Hornet, achieving high quality standards and short lead-times, using current capabilities. The aircraft life cycle support provider’s maintenance, repair and overhaul (MRO) teams throughout its Australian facilities have gained technical expertise from their comprehensive work on the F/A-18 A/B Hornet. The knowledge and skills acquired have enabled RUAG to carry out the Super Hornet repairs reliably and accurately, thus enabling the RAAF to benefit from sustainable aircraft availability.

“Our extensive work on the Hydraulic, APU and Undercarriage Systems of a variety of RAAF platforms including the F/A-18 A/B

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Hornet, C-130 Hercules, E-7A Wedgetail, C-27J Spartan, AP-3C Orion and the C-17A Globemaster III has made our MRO teams indispensable,” said Terry Miles, General Manager, RUAG Australia. “We are proud that the RAAF has entrusted us to add component repair for one of their premier combat jets, the F/A-18F Super Hornet, to our portfolio of aircraft for incountry MRO.”

“The unique capabilities at the RUAG Australia Hydraulic Centre of Excellence prove a significant contribution and ensure our solutions continue to meet the demands of the RAAF and their aircraft well into the future,” added Stephan Jezler, Senior Vice President Aviation International, RUAG MRO International “We are very proud to contribute to a high fleet availability of the RAAF.”

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INDUSTRY NEWS

Australian Space Agency opens in Adelaide Prime Minister Scott Morrison on 19 February officially opened the Australian Space Agency’s new home in Adelaide.

“The Australian Space Agency is central to my Government’s vision to secure more jobs and a larger share of the growing space economy – forecast to be over $1 trillion in size around the globe by 2040,” said Morrison. “Space captures the imagination and inspires us all. It develops new technologies that improve life on Earth and it offers huge economic and job opportunities.”

From left: Dr Megan Clark AC, Head of the Australian Space Agency; Minister for Industry, Science and Technology Karen Andrews; Prime Minister Scott Morrison; and South Australia Premier Steven Marshall.

The ASA’s headquarters are based at the Lot Fourteen innovation neighbourhood.

The opening of the new offices is an important next step in the development of the Agency, who are working to triple the size of the Australian space industry and create 20,000 new jobs by 2030.

Minister for Industry, Science and Technology Karen Andrews said the opening was another chance to highlight the great opportunities space presents to everyday Australians.

“Australia’s space sector has gone from strength to strength since we established the Agency and I’m confident we will continue to build on that momentum,” Minister Andrews said.

Head of the Australian Space Agency, Dr Megan Clark AC said the national headquarters is a strong base for the Agency to grow and transform the Australian space industry: “We’re delighted to have a new home in the centre of Adelaide, and we look forward to developing the Australian Space Discovery Centre and Mission Control, which will open next year,” said Dr Clark.

South Australia Premier Steven Marshall said: “We are now, without a doubt, the space capital of the nation. Young people from across

the state have the opportunity to seize incredible jobs across the sector, right here in South Australia. Young South Australians can look up at the stars and genuinely find opportunities right here in this state to pursue their dreams.”

Relief needed for manufacturers battling high gas prices The high cost of gas poses an imminent threat to east coast manufacturers, making them internationally uncompetitive and increasing the likelihood they will wind up or relocate their operations, according to the Australian Competition & Consumer Commission (ACCC).

In a speech to the Australian Domestic Gas Outlook conference in Sydney on 5 March, ACCC Chair Rod Sims urged gas suppliers to immediately consider how they could avoid driving manufacturers and other domestic gas users out of the market.

“Gas suppliers would be well advised to consider what they can do to provide immediate price relief to the manufacturing sector,” Sims said. “We must all remember that, when the LNG projects in Queensland were being commissioned, the suppliers promised that this crisis wouldn’t happen.”

Sims said producers must accelerate investment in gas exploration and development, and governments must, in turn, allow access to gas resources and encourage development of gas infrastructure.

“To avert the current crisis, these actions were required a number of years ago,” Sims said. “What is puzzling is why we are not seeing more investment in new gas supplies now.”

Sims said that the ACCC would be closely monitoring decisions made by gas producers to develop their reserves and resources.

He added that governments must actively monitor gas producers’ compliance with their licence requirements and ensure large gas producers do not withhold gas from development and production to suit their own commercial priorities.

“The east coast of Australia is just about the only region in the world that has both gas exports and a liberalised gas market,” Sims told the conference. “It should be a privilege for gas

AMT APR/MAY 2020

producers to operate in a country that embraces a free market, but that privilege should not be taken for granted.”

Sims noted that RemaPak, a producer of polystyrene coffee cups in Sydney, recently went into administration citing high gas prices.

This followed Coogee Chemicals closing down its Laverton plant in 2016.

“Many others are on the verge of making critical investment decisions and if they chose to relocate or exit, they will not come back,” Sims added.

The ACCC’s gas inquiry, which commenced in April 2017, highlighted that in the first half of 2017 domestic gas users were paying more for gas produced in Australia than overseas buyers.

Gas prices reduced and stabilised after a Heads of Agreement between the Commonwealth Government and gas producers in late 2017. However, current wholesale gas prices remain two to three times higher than historical prices.

The ACCC’s fortnightly LNG netback price estimate, first published in October 2018 with the aim of boosting transparency in the market, shows that after peaking at about $12.50/GJ in September 2018, the 2019 average of expected LNG netback prices fell to about $8.55/GJ by the end of February 2019.

“We will be closely watching to see whether offers made by gas suppliers continue to track LNG netback prices on the way down, as they did on the way up,” Sims said.

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INDUSTRY NEWS

RMIT: Local manufacturers risk missing i4.0 express train A new report on Australian industry’s digital future reveals widespread hesitation to embrace game-changing technologies for fear of cost.

The Demystifying Industry 4.0: Helping SMEs lay the tracks for Australia’s digitalisation express train white paper follows in-depth interviews with over a dozen company executives and ongoing engagement with the local advanced manufacturing sector. Industry 4.0 (i4.0), the fourth industrial revolution, uses technologies such as artificial intelligence (AI), big data and cloud computing to provide up-to-date information for better decision making.

RMIT University’s Dr Ben Cheng, who led the project, said fear of cost and feeling overwhelmed with the complexity of linking older and newer technologies into a single data stream was still holding many local SMEs back, despite the massive potential to be realised.

“The businesses we talked to mostly assumed Industry 4.0 implementation was inherently costly and therefore only within reach of large, cashed-up corporations,” Cheng said. “Contrary to these perceptions, transitioning to i4.0 technologies doesn’t necessarily require major investment – there are more affordable technologies, such as data analytics, that can return significant value when expertly deployed within a manufacturing enterprise.”

The white paper suggests that getting started in transitioning to i4.0 technologies, even at an entry-level, can yield direct bottom-line benefits and pave the way for higher returns as a business’ level of data maturity grows. The further along the i4.0 journey a business travels, the greater the value generated: from just seeing more data, all the way to systems self-optimising.

“For low-profit margin manufacturing operations, in particular, staying agile and being ahead of the game is crucial,” added Cheng.

“The potential impacts of incrementally increasing the efficiency of mechanical and human resources, cutting costs and reducing waste cannot be understated.” The key requisites for success in transitioning to i4.0 technology, as outlined in the white paper, were a commitment of top management, a deep understanding of one’s own business and the potential and desired level of transformation; and having a clear implementation strategy. Cheng said many companies were struggling to get their heads around what the most relevant data was and extracting value from it.

“That deep understanding of your own business includes understanding what data you currently produce, or potentially could produce,” he said. “Before investing in i4.0 solutions, a business needs to develop a specific understanding of which data is most essential to capture, who within their organisation will use it, and how that data can be presented to these people in meaningful ways that meet their needs.”

Developing an i4.0-savvy workforce is an important step in making the right decisions at this stage. The white paper outlines the value of partnering with universities to get PhD researchers working on projects, or hiring recent university graduates, as ways to tap into the next generation of digitally savvy engineers.

Cheng said taking a business towards i4.0 doesn’t have to happen overnight, that it was more of a journey.

“However, there is still a need for timely action, particularly if competitors are already gearing up and introducing i4.0 technologies,” he said. “The i4.0 express train is leaving the platform and playing catch up if left behind could be costly. It is important to be on that train and to keep moving forward as quickly and strategically as possible.”

Lack of seed-stage venture capital holding Australia back Increasing foreign investment in venture capital, particularly at the early and seed stages, could give industry and innovation the critical boost it needs, generating greater economic benefits to Australia including higher employment and more patents, according fund manager Atlas Advisors Australia.

Guy Hedley, Executive Chairman of Atlas Advisors, called on the Federal Government to give priority to venture capital under its Significant Investor Visa (SIV) program. Hedley’s comments formed part of Atlas Advisors’ recent submission in support of the Government’s review of the Business Innovation and Investment Program. He said while there had been significant growth in venture capital investment to $1bn in annual commitments, investment in early-stage venture capital and seed funding declined by as much as 46% in the past four years.

“It is estimated that investment in early stages has been about $75m spread across 138 deals in fiscal 2019. This is down significantly from $180m across 270 deals in 2016,” Hedley said. “This could be significantly increased by boosting the

AMT APR/MAY 2020

asset allocation towards early stage investments under the SIV’s complying investment framework,” he said.

Australia reported very low venture capital per capita of between $15 and $30, amounting to less than half the OECD average, and significantly lower than Sweden at $122, the UK at $114, France and Germany at $60.

According to AusIndustry data, 40% of the 84 registered venture capital funds didn’t make a single investment in fiscal 2019 and only 14% made 10 or more investments. It was important to consider that the economic benefits, including employment and patents, were driven much higher by allocating to venture capital than to secondary public market equities, said Hedley.

INDUSTRY NEWS

Harrop Engineering celebrates 65 years With a rich heritage in manufacturing, Harrop Engineering is celebrating its 65th anniversary.

Based in Preston, Victoria, Harrop Engineering has accrued a strong reputation for proprietary innovative design and precision manufacturing, supporting programs for iconic motorsport teams, automotive OEMs, as well as diverse aftermarket and industrial customers globally. Founded in 1955 by Len Harrop in the inner Melbourne suburb of Brunswick, Harrop Engineering originated in specialist general engineering for the textile and general trucking/ haulage industries. As the business grew, Len and Elsa’s son Ron joined after completing his boilermaker apprenticeship. Ron had a strong interest in modifying cars and motorsports, so with Len’s technical knowledge and Ron’s motorsport passion the business evolved, opening them to the world of automotive performance parts.

The production of performance parts continued to gain momentum through Ron’s car racing, with the iconic Harrop Howler through to touring cars (HDT) and then engineering Holden Racing Team Commodores. Harrop Engineering enjoyed enormous on-track success, playing a decisive role in the precision design of performance products for racing teams over the past 30 years.

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In 2008, Harrop Engineering was acquired by Adrad Group, a familyowned conglomerate of companies from Adelaide, South Australia.

Today the business offers several core product groups – supercharging and induction, braking, driveline and cooling over several different market segments, alongside its industrial manufacturing capabilities.

“We’re very proud of our rich heritage and talented team who design, develop and deliver our world class products,” says Heath Moore, General Manager at Harrop Engineering. “It’s a significant milestone for Harrop to reach 65 years manufacturing in Melbourne, with an increasingly diversified global focus today which is exciting for all of our stakeholders”. Harrop Engineering recognises its ability to remain agile and capitalise on new product opportunities both locally and in export markets as fundamental to its ability to remain a leader in the automotive aftermarket industry. As a result, Harrop Engineering USA was recently established in Dayton, Ohio, to support the brands growth in the US market, and the company has invested in an Agile Robotic System and Mazak Multi-Pallet Variaxis to remain at the forefront of manufacturing technologies to support its production efficiency and capacity.

Harrop Engineering was also recently certified by SAI Global to the internationally recognised AS9100D standard, gaining accreditation to precision manufacture components for Aerospace and Defence applications. “We are very proud to be celebrating our 65th year as an Australian manufacturer,” says Operations Manager Tim Harrop.

“It is with a salute to our staff who create and our customers that partner with us, that enables us to deliver precision engineered solutions. We embrace the challenge of continuing to innovate our products, processes and engineering service offerings for our broad customer base.”

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AMT APR/MAY 2020

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INDUSTRY NEWS

Austin inks partnership agreement with ETT AMTIL member Austin Engineering has signed a partnership agreement with South Africa’s ETT to market and support their combined mining-oriented product ranges throughout Africa.

Following almost 12 months of management meetings on either side of the Indian Ocean, the new agreement will bring together two of the Southern Hemisphere’s largest mining equipment design and manufacturing entities. Austin Engineering, an award-winning ASX-listed company with headquarters in Brisbane, has more than 50 years’ global experience in engineering and manufacturing equipment for the mining industry with operations in Australia, Asia, North and South America, and now South Africa.

“We are looking forward to growing this partnership,” said Austin Engineering Managing Director Peter Forsyth. “It gives both companies a solid and reliable platform from which to offer customers throughout the continent, proven world-class products backed up by world-class service.” ETT, a privately-owned South African company based in Richards Bay, with products already distributed in more than 20 countries around the world, celebrates 25 years of engineering excellence this year.

ETT managing director Andre McDuling said: “ETT’s manufacturing and innovative record, as well as our strong presence and product supply into Africa, is one of the key reasons why this partnership

Peter Forsyth, Managing Director of Austin Engineering, with ETT Managing Director Andre McDuling.

was formed. We are confident that the industry is ready for a partnership like this that will provide the widest range of mining attachments and support products in the world.” Both companies are well established and acknowledged globally for

their unique, engineered mining equipment.

The combined product range of the new partnership will include customised dump truck bodies, water trucks, diesel lube trucks, gooseneck-equipped recovery vehicles, tyre handlers, lowbed off-road trailers and excavator buckets.

Manufacturing employees expect action on social issues New research has revealed Australian employees want businesses to play a stronger leadership role on key societal issues, such as the environment, healthcare and cost of living.

The study, commissioned by Atlassian Corporation and conducted by PwC, found businesses are more likely to lose employees if they don’t take a stand on important issues. The Return on Action report surveyed more than 1,200 Australian employees and provides an up-to-date snapshot of the growing expectations on businesses to lead on the issues important to society. The report marks the first cross-generational research on the new expectations, accountability and moral obligations of business.

Key employee findings include: • 69% agree businesses should be just as concerned with their societal impact as they are with their financial performance.

• 78% agree businesses need to take full responsibility for their environmental impact.

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• Just one in three is satisfied with the level of action their employer takes to address key issues.

• 67% agree businesses should publicly encourage governments to act on societal issues which are important to the community.

• Only 34% are satisfied with the level of action their own employer takes on key societal issues such as climate change, data privacy, unemployment and the cost of living.

Across all demographics, environmental issues emerged as a key area for change.

The research revealed that the majority of employees want businesses to use their resources to drive meaningful change in waste and pollution. Additionally, as Australia rebuilds from a summer marked by severe weather, drought and access to water was rated as one of the top three

issues of most importance to Australian employees. Among Generation Z, 72% said they value businesses speaking out on issues important to them and 75% agree employees should be allowed to voice their opinions on political and societal issues they care about. However, only a third of employees (34%) are satisfied with the level of action their employer takes on key societal issues.

The opportunity for improvement is clear.

Mike Cannon-Brookes, Co-Founder and Co-CEO of Atlassian, said Australian businesses have reached a tipping point: “As business leaders, we have an awesome responsibility. Employees want us to ensure we are making the planet better, not worse. Faced with government inaction on some of our biggest problems, it’s the business community that can step up and drive meaningful change”.

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GOVERNMENT NEWS

Australian Made logo grant to help our exporters The Federal Government is helping Aussie exporters take on the world, grow their businesses and create new jobs, with a $5m grant to extend the international reach of the Australian Made logo.

Karen Andrews, the Minister for Industry, Science and Technology, said the gold kangaroo on a green triangle was an instantly recognised and trusted symbol of quality.

“The Australian Made logo is used by more than 2,800 businesses, is universally recognised by Australian consumers and is a central element of the Government’s mandatory food labelling laws,” Minister Andrews said. “We want to increase the impact of this trusted symbol overseas so Australian exporters can grow and employ more Australians.

“This grant will allow the trademark to be registered and promoted in key export markets like the European Union, the United Kingdom and Canada. There will also be an effort to crack down on misuse of the logo by strengthening its legal position in key export markets.”

The money will be provided over four years to the Australian Made Campaign Limited (AMCL), which administers the logo. The funding delivers on a election commitment by Prime Minister Scott Morrison’s Government.

AMCL Chief Executive Ben Lazzaro welcomed the level of commitment through this grant to Australian manufacturers and growers. “The Australian Made logo has a proven 34year track record in making the ‘Australian connection’ here and overseas, so it makes real sense to enhance its effectiveness as export markets continue to open up for Aussie manufacturers,” Lazarro said. “We look forward to working with the Government to help deliver this initiative and further extend the reach of the Australian Made logo and that of Aussie manufacturers and exporters.”

The logo is a registered trademark in the US, China, South Korea and Singapore and proceedings are underway to register it in Hong Kong, India, Indonesia, Japan, Malaysia, Taiwan, Thailand and Vietnam. The Australian Made, Australian Grown logo is Australia’s only registered country of origin certification trademark and can be used on all classes of goods. www.australianmade.com.au

Queensland hails Women in Manufacturing More than 170 manufacturing professionals, innovators and students came together on 10 March for the first 2020 Women in Manufacturing industry breakfast at Customs House in Brisbane.

Speaking at the event, Minister for State Development, Manufacturing, Infrastructure and Planning Cameron Dick said inspiring women to take up a career in manufacturing is a key priority for the Queensland Government.

“These networking events are a key part of our Advanced Manufacturing 10-Year Roadmap and Action Plan,” Dick said.

“Already we have seen 14 state-wide Women in Manufacturing industry events rolled out in partnership with the Australian Industry Group. We are excited to partner with them again this year to deliver nine more events across the state in 2020.”

Dick said that the event was particularly special as it was held as the State was celebrating Queensland Women’s Week.

“This week we are reminded that diversity and gender equality are essential for economies and healthy communities to thrive,” Dick said. “Already in Queensland we have amazing women in manufacturing who are designing and producing their products locally and enabling manufacturing jobs in Queensland. I am also proud to say that my Manufacturing Ministerial Council comprises over 50% female representation”.

Australian Industry Group’s Queensland Head Rebecca Andrews said they were honoured to continue with the Women in Manufacturing series again this year: “Each year, we shine a light on inspirational women that are leading the way in the manufacturing sector. We are also very pleased to see an increased participation of students and teachers from around the state in this event. We all need to continue the message that manufacturing is a viable career path for our future workforce.”

Tubeworx’s Sales Manager Shantelle Loyden said she loved what manufacturing offers young women: “I have been able to enjoy a wide range of roles working in the family business.

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New technology in manufacturing has opened up so many more opportunities for young people and having a great attitude toward learning new skills is imperative.”

Dick said manufacturing contributes around $20bn each year to the Queensland economy and is a major employer, with around one in four being women: “We want to continue to build on this and encourage females to pursue careers in manufacturing, because attracting and retaining more women is important to a stronger manufacturing sector.”

Brisbane speakers included manufacturing trailblazers Dr Cori Stewart from the Advanced Robotics in Manufacturing (ARM) Hub, Amelia Luu from Design Robotics, Heather Sinclair from Volvo Group Australia, Shantelle Loyden from Tubeworx, and Tim Morgan from Arnott’s Biscuits.

For more information about the 2020 Women in Manufacturing series go to: www.dsdmip.qld.gov.au/womeninmanufacturing

Every business has different needs.

Incubator Support The Entrepreneurs’ Programme (EP) is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. The Incubator Support initiative is part of a suite of services offered through the EP and will provide funding to incubators to deliver support services to Australian start-ups with an international focus. Funding will be available to support the establishment of new incubators in regions or sectors with high innovation potential, and for existing incubators looking to expand their services. Funded incubators will deliver a range of activities designed to improve the prospects of commercial success of innovative start-ups, allowing them to realise their economic potential faster than they otherwise would.

Support for New and Existing Incubators: •

To help develop new incubators in regions or sectors with high potential for success in international trade.

•

To boost the effectiveness of high-performing incubators, including funding support to expand their product or service.

Support for Expert-in-Residence: • To provide access to top-quality research, managerial and technical talent through secondments of national or international expert advisers who will improve their chance of commercial success in international markets.

To find out what the Entrepreneurs’ Programme can do for you, contact Greg Chalker 03 9800 3666 or email gchalker@amtil.com.au

www.amtil.com.au Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

1465AMTILEPRM

Rob Murphy (Dip.Eng (mech), B.Com, M.Bus(manuf), Cert.Eng, MIIE, GAICD) Entrepreneurs’ Programme Business Adviser

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Five STEM education trends for 2020 According to the Federal Government, workers with an education in science, technology, engineering and mathematics (STEM) fields are deemed to be “critically important for our current and future productivity”. It has already allocated over $64m in funding for early learning and school STEM initiatives, a move to encourage further study in these fields.

In the coming decade, we will see a change in STEM careers and, consequently, the ways in which graduates will be prepared for them will need an overhaul. Based on an NAE survey of global technology leaders and scholars, STEM careers of the future will be faced with solving four “grand challenges” comprising major technology issues in the areas of sustainability, health, security, and the joy of living.

What are some of the areas that teachers, students and parents should track to help create a workforce that is ready to take on the challenges of the coming decade? Below are five of the major trends that we will see affect how university students and independent learners are taught to meet the challenges of the decade ahead.

1. Authentic learning is bolstered by authentic assessment: We are seeing the rise of authentic assessment, with teachers moving their attention to assessing and supporting students individually as students engage in authentic learning practices.

The ability to accurately track students’ progress is helped by interactive tools and technology that increase student engagement to improve learning outcomes. Professors are starting to explore and integrate tools into their curriculum that allow them to provide students with immediate feedback and automatically grade student work to help assess individual student performance.

2. Shift from “Learning to Code” to “Coding to Learn”: Computational thinking enables solving problems, designing systems, and understanding human behaviour analytically.

Bringing computational thinking to the classroom will help create professionals who can break down large and complex problems into a series of small, manageable problems that can often be solved algorithmically. This approach enables scientists and engineers to solve extremely complex problems with large data sets effectively and efficiently.

3. Tools enabling global education collaboration: Over the last decade, we have seen more students learning and collaborating online using workflows and technologies that are used in industry. Looking ahead, we will continue to see a growing number of countries moving to technology and internet supported learning, as they shift from paper and blackboard-based teaching and learning. Students from different geographies who are learning on online platforms, are also enabled to address real-world local and global problems through collaboration with peers from all over the world. Teachers can engage with global communities, and have access to common, cloud-based storage locations like GitHub. Teachers from around the globe are now accessing, sharing and versioning code gathered from the global community to create real and effective teaching strategies and course work.

4. Growing demand for “Bi-Lingual” engineers = computer science + X expertise: Developments in techniques for datainformed inference and decision-making have blended artificial intelligence (AI) and data science from the fields of statistics and computer science with other domain expertise. Academia is responding to such needs for individuals with both domain and AI expertise by creating programs that educate “bilingual” engineers and scientists. For example, individuals in fields of chemistry and signal processing who also possess

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modern computing skills like AI. Since these areas are also seeing rapid growth in industry, universities and industries are partnering to provide such “bi-lingual” educational opportunities. Students who are equipped with both domain and computing knowledge, will have the advantage of knowing how to use such tools and techniques and, more importantly, when to and when not to apply them.

5. Growth of self-paced and personalised learning: For motivated independent learners, there are multiple ways to build and brush up on skills using self-paced online courses and certifications available from MOOC providers like Coursera and EdX. In addition to building knowledge, these courses demystify AI and allow engineers to see AI as an extension of their toolkit to solve problems and be innovative. As students, it is easy to become overwhelmed by buzzwords like AI. However, such courses give students opportunities to focus on how they can gain competencies in actual techniques that give them a professional edge such as data analytics and reinforcement learning.

Today, there is growing acknowledgement that we need to change the way we teach and learn if we want to improve the quality of life for the next generation. To do this effectively, we need STEM students to be comfortable and skilful in collaborating and working within multi-disciplinary environments. It has become even more imperative today to engage in lifelong learning and stay current with new concepts, systems, and approaches while in school and beyond. To help facilitate this, we are seeing a seismic shift from traditional approaches of teaching and evaluating students’ grasp of curriculum, to understanding each individual student’s readiness to use and apply tools and technology, to solve real-world challenges.

In 2020 and beyond, we will see industry and academia develop deeper relationships, where industry will support instructors as they teach and mentor the next generation of STEM students prepared to tackle the grand challenges that await them.

Stephane Marouani is the ANZ Country Manager at MathWorks au.mathworks.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Holden’s dead-end shows government policy should have taken a different road GM’s retirement of its Holden brand reflects the tough competitive conditions in today’s automotive industry. In continual need of growing economic support, Holden found it almost impossible to compete in global markets. By Roy Green.

The only surprise about the termination of the Holden brand in Australia was that it caused such surprise. This was the final nail in an already empty coffin, given local assembly manufacturing ended more than two years ago.

In 2017, when Holden stopped making cars in Australia but committed to keeping the brand with local engineering and design facilities, I wondered how long it could last. We now know. There was, in reality, no commercial justification for a US-based global corporate to continue to invest in switching imported cars to right-hand drive, for 3% of 1% of the world’s car market. Holden’s dominant local market share was well and truly a thing of the past, no matter what was being rebadged under its name.

The huge nostalgia for the loss of an iconic Australian brand is perfectly understandable. But the naiveté shown by successive governments in dealing with the owners of this brand is not.

Particularly when this has meant accepting commitments supposedly made in good faith in return for billions of dollars of taxpayers’ money.

Let’s remind ourselves of the three factors that doomed Australian car assembly.

Tariff protection The first factor was removing tariff protection. Domestic car manufacturing flourished behind high tariff walls for more than half a century, but like many other areas of manufacturing, it was not keeping up with the rest of the world. It was hoped removing tariffs in the 1980s and exposing the industry to international competition would transform it for the better.

Alongside tariff reform were “industry plans” to manage the transition, in particular focusing on export markets where economies of scale could be achieved. At the same time, workers were given training and financial support to move from companies that couldn’t survive this harsher environment, to those that could.

Such success was patchy but, with substantial government subsidies and a number of manufacturers withdrawing from the local market, the Australian car industry continued to be viable.

However, as the local makers introduced new models on a dripfeed of investment from their global parents, they lost market share to imports. This could not be offset by increased exports as the same global parents limited Australia’s role in overseas growth markets.

Rise of the dollar The second factor affecting domestic car manufacturing, and indeed Australian manufacturing more widely, was the rise in the value of the Australian dollar associated with the mining boom beginning in the early 2000s. Local manufacturers found it more difficult, if not impossible, to compete with imports. By 2016, the number of jobs in manufacturing had fallen to less than 684,000, down from more than 903,000 in 2011 (and a peak of 1.35m in the early 1970s). The “death of manufacturing” became a popular headline.

Some manufacturing has subsequently revived, but not in the same form as in the past. Large mass-production facilities were increasingly superseded by small to medium manufacturers pursuing “smart specialisation” in global markets and value chains.

This worldwide trend included many companies in Australia’s highcalibre auto-components sector, but less so the car-assembly industry.

Flawed business model This brings us to the third and decisive factor in the decline of car manufacturing in Australia: a flawed business model. An industry designed for success in a protected domestic market had to innovate and scale up radically, in an intensely competitive global market once protection was removed. This simply didn’t happen.

In retrospect, we can sympathise with governments not wishing to pull the plug on a major industry employing many thousands of workers. Not many countries can sustain an integrated car manufacturing industry. Most don’t even try. Those that succeed do so because they can control their own destiny, including investing in future technologies, skills and market development. The only part of the Australian car industry that could control its own destiny was the auto components sector, which was world-competitive.

Which brings us to the inevitable counterfactual. What if, instead of directing public support to global car giants that had no intention of transforming local assembly, governments had focused on accelerating the growth of the auto components sector?

The problem in Australia has not been the use of public funds to support manufacturing, but rather to prioritise what might have worked in the past over what we know will be required in the future.

Such as electric vehicles.

It is worth taking the opportunity to reflect on the fact this observation applies as much to other challenges – such as climate change – as it does to the car industry.

Roy Green is an Emeritus Professor & UTS innovation adviser, University of Technology Sydney. This article was originally published by The Conversation. www.theconversation.com www.uts.edu.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Quality over quantity – Making the most of big data Gathering data is something all manufacturing facilities do, but making the most of this information and transforming it into actionable insights is what gives data its purpose. John Young explains how manufacturers can make the most out of big data to achieve business value.

Roughly 80% of the mass that makes up our universe is material that scientists cannot directly observe — known as dark matter. While we are unable to see dark matter, physicists are confident it exists because of its gravitational effects. For many organisations, dark data is of a similar character. But what use is unseen, unused data?

Gartner defines dark data as “the information assets organisations collect, process and store during regular business activities, but generally fail to use for other purposes”. Just like dark matter in space, dark data comprises most businesses’ universes of information assets. Also like dark matter, many know little of its existence. So, what qualifies as useful data, and how can manufacturers make sure they’re getting the most out of it?

Volume Doug Laney, a Gartner analyst, defined big data using three words — volume, velocity and variety. Big data is, unsurprisingly, large in volume. It relies on massive datasets in volumes as large as petabytes and zetabytes. While such a scale may seem unmanageable, these large datasets aren’t as difficult to collect as you may imagine.

Technology is increasing the size of datasets that every device and system generates — and it’s growing at an exponential rate.

Manufacturing facilities are being overloaded with data, with every machine on the shop floor generating information that has the potential to create business value.

The increase in smart technology, including the use of sensors, means that a manufacturing plant is capable of capturing data from almost any type of machinery. Variables such as temperature, vibration and changes in operations can be used to monitor individual parts, such as motors or gaskets, to predict equipment failure.

Using data analytics to predict when a piece of equipment is likely to break down means that any maintenance or re-ordering of a part can be planned well in advance, minimising costly downtime.

Velocity Velocity refers to the speed at which data is being generated and the time it takes for this data to become ready for use.

The faster the data is analysed, the quicker it can be transformed into actions. But with today’s data deluge, keeping pace with this speed can be difficult.

Let’s go back to thinking about motors. An accelerometer is responsible for collecting vibration data by generating a voltage signal that corresponds to the amount and frequency of vibration the motor is producing. However, improved sensor technology now also allows for non-contact, high-speed laser sensors that can detect issues accelerometers cannot. With laser sensors able to identify everything an accelerometer can, in addition to characteristics such as joint domain and modal analysis, condition monitoring gets a lot more complex.

Ultimately, a big data infrastructure that is capable of processing all this data, and fast, is crucial.

Variety Variety refers to the diversity of big data, both structured and unstructured. Equipment condition, consumer habits, inventory and product lifecycle management are just some of the touchpoints in a manufacturing facility that build up a complex web of data.

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Managing this information requires several different systems. These systems cannot remain in siloes — they must be integrated for an all-encompassing view of the facility. For example, condition monitoring data could identify when an industrial part is showing signs of failure, then automatically cross-reference this data to see if the part is in stock. If a replacement is unavailable, repurchasing from a trusted automation parts supplier can be completed using an enterprise resource system (ERP).

Value The growing volume, velocity and variety of data are all rendered useless without one other ‘V’ — value. Gathering masses of diverse data is useful, but it must be analysed and transformed into actionable insights for it to be of any worth to the business.

The speed at which data is being produced, and the sheer number of variables that can be tracked, can lead to masses of data that are left unused and unseen. However, making the most of big data is a case of quality over quantity. By taking a wider look at a facility’s business segments and evaluating how data can link them together, big data can help create enormous business value.

John Young is Sales Director – APAC at automation parts supplier EU Automation. www.euautomation.com/au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Australia is in good hands If you have ever spared a thought for the future of engineering-manufacturing in Australia… have no fear – the next generation coming through is at the top of their game and they’re making the rest of the world sit up and take notice!

By Craig Hingston.

The National Finals of the F1 in Schools STEM Challenge, held in Melbourne in March, was a demonstration of passionate boys and girls pushing themselves to new limits to master industry-standard software, equipment and processes and use them to innovate at an astonishing level.

Organised by the Re-Engineering Australia (REA) Foundation, F1 in Schools is not only the biggest Science-Technology-EngineeringMathematics competition in Australia, but also in the world. It challenges students to form teams akin to Formula One, with a manager, design engineer, and a person in charge of manufacturing and resources. They have to design, make, test and race a miniature powered F1-style racer with an aerodynamic body and wings. It accelerates from 0 to 80 km/hour in less than two seconds!

It was amazing to see teenagers engaged in animated discussions with the judges about machining techniques, 3D printing, drag coefficients, and using various materials. Something you would expect to see in a professional design office or machine shop.

The students were encouraged to collaborate with industry and understand the design-to-manufacture process, and exploded views of their cars on the multi-media pit displays showed just how much work had gone into them. Special wheels, hub assemblies and multi-layer aerofoils… made from the lightest possible materials.

Employers would be pleased to know that not only is this an engineering-manufacturing project, it includes sought after “soft skills” including teamwork, problem solving, time management and communication. In fact, the students were judged on their presentation and ability to work together.

The National Finals were staged at the Australian headquarters of Robert Bosch for the second year in a row and the global manufacturer excelled itself at encouraging the youngsters to consider a career in manufacturing. Staff members ran a series of breakout sessions which included augmented reality and autonomous technology.

Following several days of intense competition, with race times separated by hundreds or thousands of a second, the 36 teams attended the awards ceremony. The VIP list was a reminder of how highly respected the program is, including figures from across industry, academia and politics.

The recipients of the 40-plus awards came from across Australia showing that STEM is being promoted and led by a large contingent of educators. As expected, STEM strongholds Perth and Melbourne starred, along with Tasmania. The Gold Coast was a delightful newcomer.

A team of students from Wesley College in Perth earned the title of National Champions in the Professional class. The Nebula team won awards for Best Engineering CAD, Best Engineered Car, Best Manufactured Car, Best Team Marketing and Best Team Pit Display. They will now prepare for the next World Finals, which will be held in conjunction with a round of the Formula One championship.

This is where they will face teams from 50 nations … and all eyes will be on them, because since F1 in Schools began in 2004, Australia has had a stranglehold on it, with six world championships, five runners-up spots, three third places, the reigning world speed record (0.916 seconds), eight Best Engineered Car Awards and six Fastest Car Awards!

The Nebula team from Wesley College in Perth earned the title of National Champions in the Professional class.

Victorian schools continued their dominance once again, proving that Victoria is a STEM powerhouse on a global scale. Seido, from Trinity Grammar School, Kew, claimed the title of National Champions of the Development (entry level) class. The school’s other team, Hydron, finished third in the Professional class. Between them they won seven awards.

Trinity’s team at the World Finals will also be under the microscope because the school has won the World Championships of F1 in Schools twice – a feat only equalled by one other school in the world (in Adelaide). They have also finished in the Top Ten twice.

This makes them a leading STEM school at an international level. In recognition of this feat, their teacher Peter Clinton, who introduced F1 in Schools to the school 15 years ago, was presented with the prestigious John Button Award For Outstanding Contribution to STEM Education. It is remarkable that for a decade and a half Peter has continued to raise the bar. Schools like his are providing our nation with such high-quality designers and technicians.

Tasmania always ranks well at National Finals and their teams picked up awards for Best Engineered, Best Manufactured Car, Best Managed Enterprise, Best Team Portfolio and Best Team Verbal Presentation.

Up north, in only their second appearance at a National Final, the Gold Coast Christian College (GCCC) ‘owned the track’. They entered four teams – the most from any school – and one team called Dark Matter made its presence felt with the slipperiest design. Not only were they runners-up to the National Champions (Professional), they won every on-track award: fastest lap, knockout competition, Grand Prix race and best reaction time (the cars are sent down the track by pressing a hand held trigger). A second team, Soar Racing, won the Development knockout competition - making it an all-Gold Coast affair. Vivacity received the award for Best Managed Enterprise, and student Amelia Tegler received the Engineers Australia Women in STEM Award for her work. A haul of nine awards in total! GCCC Principal Guy Lawson was honoured for his efforts, presented with the prestigious REA Founders Award. He was also made a Fellow of the REA Foundation.

While you work away in your business, there are more than 25,000 high schoolers busily preparing for the next round of F1 in Schools knockout finals. And, they are the newest contingent of close to one million students who have been a part of the REA Foundation’s project-based STEM programs since they started in 1998. www.rea.org.au

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TECH NEWS

Italy: 3D-printing emergency valves for COVID-19 patients in less than 6hrs In mid-March, an Italian The Isinnova team with their hospital ran out of valves 3D-printed valves. for ventilators needed by those most severely affected by COVID-19.

In less than six hours, a local startup 3D-printed the valves, which were then used among ten patients. The distress call from the hospital caught the attention of physicist Massimo Temporelli, founder of FabLab. Due to travel restrictions, he could not travel to the hospital, so he connected with startup Isinnova (near the hospital), which had a 3D printer. The company manufactured the valves within six hours. The medical device manufacturer threatened to sue the group due to patent-infringement. The valve typically costs about $11,000 but the volunteers printed the replicas for about $1. “The patients were in danger of life, and we acted. We have no intention of profit, we are not going to use the designs or product beyond the strict need for us forced to act, we are not going to spread the drawing” said Cristian Fracassi of Isinnova. The Italian Minister of Technological Innovation thanked the engineers for their work.

Business insider and mixed

USA: Stronger nickel for auto, medical, manufacturing Researches have created a hybrid technique to fabricate a new form of nickel that may help the future production of medical and high-tech devices and vehicles with strong corrosion-resistant protection. One of the biggest challenges for nickel is the boundary areas (vulnerable sites for corrosion). This unique nickel contains a high-density ultrafine twin structure but few conventional grain boundaries, which leads to superb mechanical, electrical properties and high corrosive resistance. The solution is to use a single crystal substrate as a growth template in conjunction with a designed electrochemical recipe to promote the formation of twin boundaries and inhibit the formation of conventional grain boundaries.

Purdue University

Japan: Airless paint atomizer Toyota has developed a new airless paint atomiser with over 95% coating efficiency: the highest in the world. It uses static electricity instead of air, to replace the conventional air paint atomisers used in vehicle body painting. It is expected to reduce CO2 emissions by about 7%. The new airless paint atomiser uses electricity to spray the paint (electrostatic atomisation), and the statically charged particles gravitate toward the vehicle body (electrostatic painting) instead of scattering. The unevenness of the vehicle body causes the distance between the cylindrical head and the vehicle body to fluctuate, making the electrical current unstable. However, the airless paint atomiser constantly monitors the variations in current and automatically controls the voltage, maintaining a distance of approximately 10cm between the cylindrical head and the vehicle body.

Toyota

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Belgium: First dual metal part 3D-printed Belgium company Aerosint has achieved a technical milestone by successfully 3D printing a circular test object and other complex parts made from two different types of metal using a laser-powered bed fusion process (L-PBF). Multi-metal printing is considered to be the holy grail of additive manufacturing. Aerosint made its breakthrough together with its partner Aconity 3D. Until now, only one alloy could be used in L-PBF because different metals have different fusing-melting points. Fusing multiple powders opens up new possibilities.

All3DP

USA: Assembly & manufacturing in space NASA has awarded a $142m contract to Maxar Technologies to robotically assemble a communications antenna and manufacture a spacecraft beam in orbit using a custom robotic platform. The Space Infrastructure Dexterous Robot (SPIDER) technology demonstration is slated to take place on NASA’s Restore-L spacecraft. SPIDER will assemble multiple antenna reflector elements into one large antenna reflector. This revolutionary process allows satellites, telescopes and other systems to use larger and more powerful components that might not fit into a standard rocket fairing when fully assembled. The demonstration will verify the capability to construct large spacecraft structures in orbit, after launch, and will open up a new world of in-space robotic capabilities. Launch date: 2023.

NASA/Maxar

Australia: Bendable, safe, longlasting cement-free concrete A new type of concrete made out of waste materials has been developed and patented. The material can bend under load, is suitable for earthquake zones and uses industrial waste products instead of cement. Traditional concrete is not only prone to shatter when being stretched or bent, but also has a huge carbon footprint due to calcination of limestone to produce its key ingredient: cement. Production of this novel concrete requires about 36% less energy and emits up to 76% less carbon dioxide as compared to conventional bendable concrete made of cement. The inclusion of short polymeric fibres in this novel concrete allows it to sustain multiple hair-sized cracks when put under tension or bending without breaking into pieces. It is about 400 times more bendable than normal concrete, yet has similar strength.

Swinburne

New Zealand: 3D printing ‘living’, ‘self-repairing’ plastics In a world-first, researchers have demonstrated how to 3D print a ‘living’ resin – i.e. a 3D printable material that can change its properties after it has been produced (‘growing’ in size and mass, as well as ‘self-repair’ when damaged). The novel technique is known as RAFT (reversible addition fragmentation chain transfer polymerisation). Shoes could be programmed to grow with the wearer; and the technique could also be used in medical implants and the recycling of plastics. Traditional 3D printed objects are ‘cured’ with UV light, but this new technique uses visible light,

TECH HEADING NEWS which requires less energy and is safer. This potentially opens new opportunities in biomedical applications where it is not safe to use harmful UV light.

overall weight of the orbital launch vehicle. Previously manufactured from aluminium, the tanks, while easier to produce, contributed to a large proportion of the vehicle’s weight. This will use carbon fibre composite tanks - achieving a lower weight. The result would allow for almost $1m of additional cargo revenue to be transported per launch. The first composite tanks will be manufactured with Sydneybased CST Aero using their filament winding process.

Advanced Manufacturing Growth Centre

The technique is demonstrated by producing the word RAFT as a yellow 3D printed object, and then exposing it to a growth medium.

The medium contained fluorescent compounds that were bound to the printed RAFT word to enable it to ‘grow’ and glow blue.

USA: A better way to build diamonds

University of Auckland

Scientists have synthesised diamonds for over 60 years, but it requires large amounts of energy, time or a catalyst that diminishes the quality. To synthesise diamonds, the team began with three types of powder (diamondoids) refined from petroleum. Unlike diamond, which is pure carbon, the diamondoids contain hydrogen.

The researchers loaded the samples into a pressure chamber. Next, they laser-heated the samples. They found that the diamondoid reorganised itself into diamond with surprisingly little energy; with the carbon atoms snapping into alignment and its hydrogen falling away. The transformation Diamond crystals takes fractions of a synthesised from second and the atoms triamantane, do not pass through a type of diamondoid. another form of carbon on their way to making diamond. Understanding this transformation will be important for many applications.

Japan: Efficiently fusing different polymers Scientists have developed a method that allows the fusion of different polymers together easily, allowing the precise tuning of the properties of the final material by selecting appropriate base polymers and mixing them at the right proportion. The breakthrough manages to cross-link different Cross-linked polymers (CPLs) together through an unprecedented approach.

Tokyo Institute of Technology

Germany: Wireless signals from ceiling lighting for connected manufacturing In manufacturing, conventional wireless communication is nearing its limits. In factories, data will soon be transmitted wirelessly over the visible light spectrum for wireless data transmission - named visible light communication (VLC), This spectrum is about 4000 times wider than the entire available wireless spectrum. VLC is already used elsewhere but factory buildings, where there are far more sources of interference, present significant challenges. Commercially available, energy-efficient LEDs will be used. This kind of system is reliable when coverage problems due to walls, metallic objects, machines and other interfering signals can be overcome. VLC not only offers greater bandwidths than WLAN, it also ensures data security.

Wireless signals travel through walls, so communications can be intercepted and manipulated. This is not possible with light.

Fraunhofer (www.smartfactory-owl.de)

Stanford University

Australia: Ultrasound - Stronger 3D-printed alloys Researchers have used sound vibrations to shake metal alloy grains into tighter formation during 3D printing; showing a significant impact on the inner micro-structure of 3D printed alloys, making them more consistent and stronger than those printed conventionally. 3D printed alloys are often made up of large and elongated crystals, increasing their tendency to crack during printing. But when ultrasound was applied during printing, the alloy crystals were very fine and formed equally in all directions. These parts were also stronger: they had a 12% improvement in tensile strength and yield stress compared to those made through conventional additive manufacturing. Two commercial grade alloys were used: a titanium alloy, Ti-6Al-4V, and a nickel-based superalloy. By simply switching the ultrasonic generator on and off during printing, the team also showed how specific parts of a 3D printed object can be made with different microscopic structures and compositions. It is expected that the method can be applicable to other commercial metals.

RMIT

In factory buildings, data will soon be transmitted wirelessly over the visible light spectrum.

Australia: Lighter composite tank increases rocket payload capacity Qld-based Gilmour Space Technologies is developing a hybrid propulsion launch vehicle to deliver payloads of up to 250 kg into Low Earth Orbits, with co-funding from the AMGC. The lighter, composite propulsion tank will increase rocket payload capacity by reducing the

Australian driverless mining trucks and remote health-tech could be key to NASA’s 2024 Moon mission “One of the technologies that’s at the forefront is anything to do with remote operations, particularly our proven world-class ability in remote operations associated with mining.” Rod Drury Space Industry Association of Australia Chairman in reference to automated technology machinery in WA’s Pilbara region — managed from 1,600km away in Perth. This technology would be needed by the US for their planned mission.

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PRODUCT NEWS

Kemppi’s new, high-performing Flexlite GX gun range delivers on ease and efficiency Kemppi will soon release its new Flexlite GX guns for MIG/MAG welding. Designed for comfort, reliability, performance and efficient use of consumables, the new Kemppi Flexlite GX welding guns will help users increase productivity, while saving on inventory costs.

Moreover, the pistol grip handle has been anatomically designed so that it feels like an extension of the welder’s hand.

Providing excellent balance, it allows for a natural wrist position, which makes the work at hand easier and more effortless, particularly when doing long welds, and allows the welder to concentrate on challenging tasks.

Together with the Flexlite TX range for TIG welding, the Flexlite GX guns deliver nextgeneration capability for professionals, and complete the Kemppi Flexlite family. Built to perform under extreme temperatures and in demanding environments, the Flexlite GX range delivers quality welds.

The sophisticated guns use power source capacity efficiently and help users create smooth and spatter-free welds. The shielding gas channels in the Flexlite GX gun have been separated and the cooling circulation runs to the very end of the gun neck. This keeps the neck gun cooler and enables cleaner welds, less spatter and reduced shielding gas consumption.

In addition, the innovative neck cooling system of the Flexlite GX series ensures that the temperature of the contact tip is up to 35% lower when compared to other corresponding welding guns. This helps extend the life of the contact tip and other consumables, while reducing costs and making spare parts management easier.

The Flexlite GX guns also deliver comfort in spades and help reduce welder fatigue thanks to their ergonomic design. Each gun is lightweight and features a flexible cable set and innovative balljointed cable protection that reduces the load on the welder’s wrist.

The number of changeable parts in the Flexlite GX guns has been reduced by improving cross-matching across corresponding models, and by combining the functions of some of the consumables.

The use of less parts reduces inventory costs so that welders can save.

Every Flexlite GX welding gun is equipped with a Quick Response code (QR) that quickly helps users find the right parts and accessories. Simply scan the QR code to access the information needed. Made from high-quality materials, the Flexlite GX range is strong and robust. Easy to operate, the range is available in three value levels: K3, K5 and K8. Each level is designed to serve specific welding needs. The guns are offered in alternate power classes and lengths, and in different neck versions. On-torch remote controls are also available as optional accessories. www.kemppi.com

FOBA Titus: World’s smallest and lightest fibre laser head FOBA’s new Vector Scan laser marking head Titus offers unprecedented flexibility in terms of line integration, usability and speed. At just over 20cm in length and weighing around 630 grams, Titus is part of FOBA’s new 20W or 30W fiber laser marking systems Y.0200-xs / Y.0300-xs.

Having first been previewed at several recent tradeshows, FOBA’s latest innovation is now available on the market.

Due to its small format and tubular shape, easy mounting with a clamping bracket and an optional supply line up to 10m long, the Titus marking head can be easily integrated into a wide range of production lines. Its flexibility is also based on an optional straight or inclined by 90 degrees exit angle of the laser beam and the ability to adjust the marking field size to the application requirements.

During installation, a saving of up to 90% of the time normally required is possible. Adjustment and focus determination, as well as application setup, are significantly accelerated by the integrated focus finder and pilot laser. The new laser marking system was developed in collaboration with and according to the needs of system integrators and the automotive industry.

“With Titus, we are ahead of the market, because such a compact, fast-to-install and easy-to-use, even remotely operable marking laser has never been there,” says Product Manager Philipp Febel.

The advantages of the new fiber laser not only result from its

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design, but also from the device software.

All three available user interfaces from FOBA can be used to operate the system: In addition to the user interfaces FOBA MarkUS and FOBA Draw, the new remote FOBA Go software is particularly suitable, which can be operated by any PC, touch display, tablet or other mobile device. All common industrial communication protocols are also compatible.

The maintenance of the system is simplified by the possibility of a minute-fast removal or conversion as well as a dust-protected lens. In harsh production conditions, the IP65 or IP69 standard of the marking head as well provides protection against dust and moisture. The low maintenance requirement also results from the very small number of wearing parts.

This new laser generation will redefine line compatibility, ease of installation, ease of use and speed. FOBA wants to help its customers with the innovative laser system Y.0200-xs / Y.0300xs and the unique scanning head Titus to fully exploit their possibilities in the direct marking of their components and to achieve optimum profitability. www.titus-laser.com

A drilling breakthrough Introducing CoroDrill® 860 with -GM geometry, the new short hole drill optimized for a wide range of applications in steel, stainless steel, cast iron and hardened materials.

CoroDrill® 860 with -GM geometry sets the standard for optimized multi-material drills, providing several benefits for your production.

• Significantly increased tool life in ISO P, M, K and H materials.

Also effective in ISO N and S materials.

• Robust new design providing excellent hole dimensional accuracy with improved tolerance and surface finish • One drill for all materials offers great machining flexibility, leading to reduced set-up time and reduced stock holding

www.sandvik.coromant.com/corodrill860

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Extending unmanned operations – Okuma’s next-gen ROID series Okuma is extending its product line for applications with the ARMROID and STANDROID next-generation robot systems, with enhanced functional and performance capacity.

Launched at the JIMTOF 2018 exhibition in Japan, the ROID Series has received a great response as an automated system that can be installed in a space-saving footprint and that can be used without the need for expertise in robotics. Okuma is now enhancing and expanding the variations available to provide a wider range of automation systems that are easy to implement for a broad range of users, regardless of the size of the company.

The ARMROID application has been advanced for a multitasking machine by developing a new type of robot, and it can also handle flange-shaped workpieces. A new type of robot has been developed, and the applicable range of workpieces has been expanded in one stroke by increasing the movable range and transport weight specifications.

With the MULTUS B250 II multitasking machine, Okuma has delivered what it describes as “robot/machine fusion”, with “the world’s first complete fusion of a multitasking machine and an articulated robot. The MULTUS B250 II ARMROID system can handle a workpiece transport weight of 10 kg (twice the previous model), and a maximum workpiece size of 80mm by 480mm (up 25% compared to the previous model). Capable of handling flange-shaped workpieces, it is compatible with work stockers equipped for automatic and continuous operation for about five hours, and is able to stock up to 50workpieces with diameters

of 150mm and 30mm thick. Okuma is also accelerating the extension of STANDROID-equipped products, with the expansion of peripheral device functionalities to a broader range of Okuma vertical machining centres, as well as simultaneous five-axis vertical machining centers equipped with turning functions.

In addition it is possible to build an automation system suitable for user needs by including workpiece turnaround that can automate front/ back operations.

With the ROID Navi EZ Operating Tool, compatibility with an increasing variety of machine models and peripheral devices will also be available. Even complex robot movements through setups with several peripheral devices can be navigated with ease from the first day of operation. Even for sudden workpiece changes, the start-up of automated continuous operation can be completed immediately, eliminating the need for a systems integrator. By following the guidance procedure, getting the optimal collision-free robot path is possible with only the input of the start and end points to automatically generate the required movements. Robot programs can be easily created without the need for special skills in robotics. Moreover, with the pulse handle, Okuma’s robot operating system can be used seamlessly with the machine tool, as if machine/robot operations were the same. www.okumaaustralia.com.au

optibelt: Improved durability, flexibility and power transmission The recently released optibelt SUPER XE-POWER PRO M=S is a revolutionary range of EPDM cogged v-belts with a redesigned moulded cogged profile which greatly improves durability, flexibility and power transmission.

With its innovative design, the new optibelt SUPER XE-POWER PRO M=S opens up new opportunities in the field of friction drives. The high modulus cords allows the v-belt to be totally maintenance-free, reducing downtime, improving drive efficiency, and increasing belt power capacity by up to 20% over other highperformance cogged v-belts. It has a redesigned moulded cogged profile which greatly improves durability, flexibility and power transmission.

The newly developed tooth shape makes it possible to use pulleys with extremely small diameters. The optibelt SUPER XE-POWER PRO M=S also has the advantage of being suitable for back bend idlers, therefore paving the way for the constructing of ultra-compact drive units. The unique power ratings achieved by the optibelt SUPER XE-POWER PRO M=S are the

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result of exceptionally powerful and low-stretch cords used in conjunction with a tooth form optimised for dynamic loads. The innovative red cushion compound gives a perfect adhesion for tension cords and high load capacity. The EPDM transverse fibre laden compound gives the belt an operational temperature range of -40°C to +120°C and it runs extremely quietly and smoothly - even at high speeds. optibelt SUPER XE-POWER PRO M=S v-belts can be used unmeasured in sets as it has the narrow length tolerance of Optibelt M=S (no matched sets are needed). They have helped optibelt earn recognition as the “Best of Drive and Fluid Technology” in the German Industry Awards (Industriepreis) 2018. www.optibelt.com

Materials Services

Reducing material cost through waterjet technology

Waterjet technology Waterjet cutting is a process of precision cutting that utilises high pressure water.

We can process a wide array of materials. Heavy gauge plate, thin sheet stock and composite materials (i.e. carbon fibre, phenolics etc.).

It is not uncommon for 6+ inch aluminium and titanium to be cut on waterjets to near final shapes.

Edge quality of the parts can vary depending on customer requirements.

We can process anything from a very rough cut for hog-outs, to a very fine edge for precision, finished parts:

Cut up to 6 m x 3 m (20 ft x 10 ft) Thickness up to 254 mm (10 in)

Improved yield and less waste material Supplied close to net shape reducing customer machine time Shorter lead times Zero heat effected zone Processing of customer supplied materials

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

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

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PRODUCT NEWS

New measurement arm complements Leussink metrology range Leussink Engineering has released a European-made metrology arm for measuring the geometry of physical objects. to maintain its high degree of accuracy, regardless of temperature change throughout the day. Available in both 1.3m and 1.8m models, the Tomelleri Mercury Measurement Arm works seamlessly with a number of leading software platforms, including Aberlink and the Geomagic suite of software.

The new Tomelleri Mercury six-axis measurement arm senses discrete points on the surface of the object with a probe.

The dimensions are immediately digitised and transferred to a CAD system, where surfaces are developed and drawings are finalised. Leussink Sales Manager Chris Walton says the new Mercury Measurement Arm is the most accurate metrology arm currently on the market for this measuring volume.

“At Leussink we know that one of the most important aspects of any type of engineering work is measurement accuracy,” adds Walton. “This applies to not only in the general manufacturing field but also in more specialist areas such as mining and defence, where accuracy in qualifying parts is paramount.”

The new Mercury model features a unique counterbalance system that makes the arm ergonomic and easy to use. The counterbalance system also means that a user doesn’t need to affix the arm to a table surface – just place it on a sturdy tabletop or solid interface like a steel or aluminium base

“The ability to reverse engineer a part or component is particularly applicable where there are machines that can run 24/7 for months on end, repeating the same process over and over again,” says Walton.

“Given the potential lifespan of some machinery, by the time a new major part is required, it may no longer be in production, or it may be too expensive to replace. with three support points and it is ready for use. This makes it ideal for organisations that need to complete metrology projects on the go. No need to take your part into a metrology lab, with Tomelleri you can take the metrology lab to the part.

For situations where there may be significant temperature variations, the Mercury is thermally compensated, meaning it is able

“This process was not possible a few decades ago, but with technological advancements like the Tomelleri range of mobile measurement arms, coupled with industry-leading software, it has become feasible and more economical to reverse engineer components that form part of an expensive plant or equipment.” www.leussink.com.au

Milling a deeper path Dormer Pramet has expanded its milling assortment for die and mold and general machining applications with several introductions. This includes the new double-sided SNGX11 insert for high feed milling with up to 1.7mm depths of cut.

A strong main cutting edge ensures high levels of durability and process security – especially when machining corners inside a pocket. With eight cutting edges, the square-shaped SNGX11 also represents an extremely economical solution.

Suitable for copy milling, helical interpolation, ramping, progressive plunging and face milling, the SNGX11 is available in two geometries. M is for machining steel, but also hardened steel and cast iron. MM provides a smoother cut and is more suitable for stainless steel, soft steel and super alloys.

The range is supplemented by the new SSN11 cutter, available in diameters from 32–125mm, with intermediate sizes for die and mould applications. All cutters feature a special through-coolant design to further improve process security and a high overhang to support deep milling up to 10xD. Meanwhile, Dormer Pramet has added to its ADMX07 milling program

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with a new F geometry for finishing and semi-finishing applications.

This sits alongside the existing M, FA and HF geometries and targets light machining of stainless steel and low carbon steels.

Extremely suited to vibration-sensitive machining, the chip breaker features a highly positive geometry with narrow peripheral land. This reduces chatter and enables a

smooth cutting action without burrs on the machined wall. Significantly, it also supports lower cutting forces which not only reduces energy consumption, but also prevents work hardening, meaning increased durability and longer tool life.

The ADMX range is a universal 90° tool suitable for a variety of milling applications. www.dormerpramet.com

PRODUCT NEWS

Freddy Vacuum Tramp oil skimmer further extends coolant life and reduces disposal costs Tramp oil is probably one of the most common contaminants in metalworking fluids. The term is a catchphrase for all sources of non-soluble contaminants (usually oil-based) that can come into contact with the metalworking fluid as a function of the process or the equipment. The sources are varied but can include hydraulic fluid as well as slideway oil, gear and spindle lubricants.

Whatever the source, tramp oil is a foreign contaminant that can create numerous problems. Most CNC machine tools, especially those using slideway oil will develop a layer of oil on top of the coolant.

This oil layer can lead to bacterial growth, resulting in poor performing coolant, dermatitis, unpleasant odours and reduced coolant life.

The unit connects easily and quickly to any Freddy model; once connected and the vacuum switched on, it is possible to easily regulate the flow to ensure only oil is collected rather than valuable coolant. Once collected, it is easy to empty out the Freddy into a barrel or IBC for waste removal.

Attachments that can be used with the new Freddy Oil Skimmer include a three-ball float, a hammerhead and a magnetic static pick up.

Freddy is a well-known and respected UKbased company established in 1962 and now offers an extensive range industrial vacuums and coolant filtration machines that cover all needs and budgets.

“The cost savings of refiltering coolant are enormous,” Fowler added. “Regular filtering means that the coolant degrades much slower, therefore lasting longer and requiring less to be bought. And because it remains uncontaminated, the associated WHS risks lessen and your machine tools live longer”.

Freddy’s extensive range kicks off with the Superminor. The Superminor range is the most widely used and well established

MELBOURNE IN-HOUSE SHOW 95 Highbury Rd, Burwood, VIC. Tuesday 16 June 7 am – 9.30 am Thursday 18 June from 4 pm

SYDNEY IN-HOUSE SHOW 23-25 Muriel Ave, Rydalmere, NSW. Tuesday 7 July 7 am – 9.30 am Thursday 9 July from 4 pm

Removal of the oil can be a time-consuming and unpleasant task but with the new Freddy Vacuum Tramp Oil Skimmer it is now possible to make any Freddy, no matter the age, into a quick and effective skimming device.

“There’s no need to wait for hours while the oil coalesces, or have the headache of what to do with lots of oil-contaminated paper,” said Dimac Managing Director Paul Fowler.

“The Freddy skimmer separates oil from the coolant and returns clean coolant to the sump, thereby increasing coolant lifetime and reducing disposal costs whilst saving time and labour – it’s simply a faster and more ecological way of removing oil.”

EXPERIENCE THE MOST VERSATILE SHEET METAL PROCESSING MACHINES DURING OUR IN-HOUSE SHOWS

BRISBANE IN-HOUSE SHOW 189 Wellington Rd, East Brisbane, QLD. Tuesday 28 July 7 am – 9.30 am Thursday 30 July from 4 pm

coolant vacuum in the world. It is designed to be easy to manoeuvre - featuring a tilt and lift design so it is effortless to empty - and is the only Freddy with interchangeable drums to prevent cross-contamination between fluids. Other models in the range include the Freddy Micro, Freddy Midi, Freddy Ecovac and the Mark V - one of the largest coolant recycling vacuums that Freddy makes.

“The new Freddy Tramp Oil Skimmer can be quickly and easily connected to any Freddy vacuum recycler regardless of its age and provides yet another filtration process to further extend the life of the coolant whilst reducing disposal costs,” said Fowler.

“Freddy has always led the way in coolant recycling and the company’s expertise and innovation in this area is unquestioned.

Quite simply, Freddy can extend the life of your coolant, lower your operating costs and extend the life of your equipment whilst at the same time protecting your employees.

“Whichever Freddy you choose, you’re guaranteed outstanding quality, ease of use and most importantly longevity. We see Freddys that are almost 30 years old come back to our workshop for an overhaul once completed, we know they will perform for many more years to come. Like all the products we sell, the Freddy range has the full back-up and support of Dimac’s technical personnel to ensure the product is installed correctly and operates at optimum performance.” www.dimac.com.au

+ DEBURRING + EDGE ROUNDING + FINISHING + LASER OXIDE REMOVAL + HEAVY SLAG REMOVAL

BOOK ONLINE AT: HEADLAND.COM.AU/TIMESAVERSHOW *Private demonstrations can be made outside these times, email: marketing@headland.com.au

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PRODUCT NEWS

New high-resolution blue laser profile scanner Bestech Australia has announced the release of the new high-resolution scanCONTROL 30xx/BL laser scanner, for dynamic measurement applications that require a system with high resolution and accuracy.

30xx/BL is available via the EtherNET or RS422 interface. As the scanCONTROL is designed for industrial measurement tasks, it is also available with the optional gateway to enable integration with other popular industrial communication interfaces such as ProfiNET, EtherCAT or Ethernet/IP industrial control systems.

The new laser scanner is primarily used for process automation tasks, but can also be applied in production, process monitoring and quality control. The scanCONTROL 30xx/BL is also integrated with a High Dynamic Range (HDR) feature which offers additional exposure and control features for generating accurate measurements on challenging surfaces.

The scanCONTROL laser profile scanners from Micro Epsilon are regarded as one of the highest performing laser profile scanners due to their superior accuracy and measuring rate. They are also compact and can be easily integrated in industrial environments and applications in areas where space is limited.

This new scanCONTROL scanner is available with a measuring range of 25 and 50mm along the laser line with a capability to measure up to 5.5 million points per second and generate up to 2048 measuring points per profile. This translates to extremely fine X-axis resolution of 12Îźm, which is ideal to measure in heterogenous surfaces. The sensor also offers a high

measuring speed of 10kHz for dynamic and high-speed measurement applications.

The output values from the scanCONTROL

The scanCONTROL 30xx/BL is also available with blue laser technology. The blue laser diode generates short-wavelength laser light which hardly penetrates the objects. This provides advantages in some measurement applications, particularly when used in measuring organic materials or objects with shiny, reflective and highlypolished surfaces. Some examples include wood or semi-transparent objects such as adhesive beads or plastic objects.

This laser scanner also sharply projects blue laser line on the surface which is reflected back onto the sensor elements.

This configuration guarantees stable and precise measurement results. www.bestech.com.au

Tungaloy’s new r2 insert eliminates finishing processes Tungaloy is expanding its TungForce-Feed line of indexable small-diameter high-feed milling cutters to include R2 inserts that feature a corner radii of 2mm.

Available in diameters of 8, 10, 12 and 16mm, the TungForce-Feed line ensures high productivity levels and offers an economic profiling solution for the mould and die industry when compared to conventional solid end mills and indexable tools of similar size.

When designing a CAM program for high feed machining of complex 3D profiles in typical mould making applications, it is common to use a theoretical corner radius for programming the insert radius.

This method leaves excessive stock on the workpiece after machining, adding processes. To create the ideal platform for subsequent finishing process, many job shops are using solid carbide square end mills with large radii in the roughing process. The new R2 inserts require no programming for the theoretical corner radius as its 2mm corner radius leaves no uncut material on the machined surface.

This ensures that the TungForce-Feed series makes a good replacement for costly solid carbide end mills, helping customers reduce tool costs.

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With an insert design that is 10% thicker than competitor products, the TungForceFeed line is built to perform at higher machining parameters by withstanding fracture forces. Furthermore, the robust insert screws and seat design reduce screw neck shearing under high cutting forces. The insert design incorporates a positive inclination angle that promotes smooth chip evacuation that further reduces cutting forces by controlling chip formation, especially when shoulder and slot machining.

Perfect for face and shoulder milling, as well as helical interpolation and ramping, the close insert pitch makes the TungForce-Feed line a formidable option for all your milling applications. The new series has been designed with a small entry angle for chatter stability that significantly improves efficiency and tool life even when machining in long reach areas. The new R2 insert has an optimised geometry that gives it the potential to perform as a full profiling insert that is ideal for semi-roughing and semi-finishing processes. The free

cutting geometry eliminates chatter and improves surface finish quality, and when this combines with the built-in side wiper that helps reduce burr formation on walls and corners while improving wall accuracy, the TungForce-Feed line proves itself as the ultimate performer for the mould and die market.

The TungForce-Feed line is available in two insert designations that include the AH3225 and AH8015 grades. The AH3225 grade incorporates nano multilayer coating technology with three major properties for optimal cutting edge integrity. This increases resistance to wear, fracture, oxidation, built-up edges and delamination. The AH8015 designation has a hard coating layer and carbide substrate with a strong resistance to wear, heat and built-up edges, this makes it ideal for machining hard or difficult materials. The two grades provide optimal machining performance on materials from carbon, alloy, prehardened and stainless steels through to cast iron, titanium and heat- resistant alloys. www.tungaloy.com.au

PRODUCT NEWS

OnRobot launches new three-finger electric gripper OnRobot, the maker of a full line of plug-and-produce robotics tools for collaborative applications, has announced the release of the compact, largestroke 3FG15 three-finger gripper.

The 3FG15 makes previously hard-toautomate precision handling of cylindrical parts easy to program and deploy, and provides flexibility for a wide range of part sizes.

“Our new 3FG15 three-finger gripper was developed as a response to existing pneumatic three-finger grippers that are bulkier and less flexible,” says CEO of OnRobot, Enrico Krog Iversen. “We have long defined the market for electric parallel grippers with the RG2 and RG6 series, and we look forward to addressing new market segments and applications with a new three-finger gripper that allows users to deploy applications faster even with highly accurate, fixed positioning.”

The 3FG15 gripper has a maximum stroke of 150mm that can easily handle multiple processes. The innovative three-finger design with a 15kg payload provides a strong, stable grip for both form fit (internal) or friction fit (external) gripping, adding flexibility to any implementation.

Ideal for CNC machine tending The gripper’s design, specifically developed for machine-tending tasks, automatically centers workpieces, resulting in a strong, stable grip and precise placement in machine chucks. With a gripping force from 10N to 240N, the 3FG15 competes with much less flexible finger grippers.

The gripper is also ideal for packaging and palletising applications, and is seamlessly compatible with any major collaborative or light industrial robot arm through OnRobot’s new award-winning One System Solution, the platform that provides a unified mechanical and electrical interface between the robot arms and any OnRobot end-ofarm tooling (EoAT).

Key features include: • Precise stable grip with automatic centering.

• Large 150mm stroke for parts from 20mm to 150mm.

3D Printing

Functional Metal Parts

• Form fit (internal) and friction fit (external) gripping.

• 15kg payload.

• Weight 1.15kg, gripping force 10-240 N. • Fast, flexible deployment.

According to Global Market Insights, the global robot EoAT market was worth more than US$2.5bn in 2018, with a projected CAGR of 14% from 2019 to 2025. Key factors driving growth include increasing adoption of robots for machine tending, welding and others. The EoAT market in Asia Pacific excluding Japan (APEJ) has been growing exponentially as developing countries transform their industrial landscape with emerging technologies.

In 2018, APEJ EoAT sales accounted for over 51 per cent of the global market.

McKinsey notes that automation and AI present an enormous opportunity for national and personal income growth and could add up to $4 trillion to the Australian economy. “Australia continues to be an important market for OnRobot as we see growing investment in robotic automation and a greater push by the government to encourage adoption,” said James Taylor, General Manager, APAC at OnRobot. “We are expanding our portfolio of products to provide manufacturers a wide range of automation solutions that not only offers flexibility and increased production efficiency, but also easy deployment and a quick return on investment.”

Markforged combines Metal

Injection Molding (MIM) technology with a unique 3D printing platform

www.onrobot.com

Call us now at

1 800 632 953

to discuss how you can transform your metal manufacturing processes emona.com.au/markforged

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PRODUCT NEWS

New Torrent 700 cleans large machine parts five times faster NCH Asia Pacific has announced the launch of the ‘Torrent 700’, a high-performance water-based parts-cleaning system for larger machine parts that is safe to use and kind to the environment.

Given the success of the Torrent 500 parts cleaning system, known as one of the best water-based parts-cleaning workstations on the market, industry has been demanding a system that can clean large parts without harsh chemicals. The Torrent 700 is a bigger model, designed to deal with larger and heavier parts that do not fit standard parts-washing stations.

Items up to 1,020mm x 720mm x 500mm can be accommodated and it holds up to 80kg.

Cleaning pressure is also variable with maximum 45bar or 652psi.

By reusing powerful water-based cleaning detergents called STORM, developed from NCH specially for Torrent application, the Torrent system eliminates one of the known dangers in the workplace—the inhalation and exposure to toxic and dangerous vapour from petrochemical solvents normally used in parts cleaning. As a fully integrated and enclosed unit, it prevents skin absorption of harmful hydrocarbons or from aggressive cleaning solutions, eliminates fumes and fire hazard, and decreases exposure to harmful chemicals.

The fully enclosed design increases cleaning productivity with powerful cleaning results in minutes. In fact, the combination of heat and pressure from the Torrent System means the ‘Torrent 700’ works five times faster than other automatic machines and cleans where automatic machines cannot. It contains powerful corrosion inhibitors allowing safe washing of all metals and materials.

Torrent 700 eliminates the use of organic solvents and their environmental impact, and drastically reduces generation of hazardous waste, and meets the ISO standard. All Torrents are maintained and serviced by NCH, which includes the maintenance and repair of the machine, and cleaning fluid management. www.nchasia.com

Sandvik Coromant: Advanced geometry for even more materials Sandvik Coromant has launched the latest addition to its CoroDrill 860 range. The CoroDrill 860 has an advanced -GM geometry that offers high-performance drilling across a wide range of materials and applications, as well as significantly improved tool life.

The new launch stems from one of the most popular product ranges from Sandvik Coromant, the R840. Currently, the R840 is the largest selling drill in the business’s solid round tools offering.

However, new advances in drilling technology, and customers’ needs to improve and better maintain their productivity, meant that it was time for an upgrade.

The CoroDrill 860 with -GM geometry features a new grade, innovative flute design with a multi-layer physical vapour deposition (PVD) coating on the drill tip. The results are improved drilling capabilities across a range of materials and applications — including general engineering and automotive — and a much greater tool life than its predecessor, the R840.

One of the most innovative qualities of the drill is its advanced geometry, with the double margin adding stability, increased core strength and reinforced corners; all of which contribute to process security and finished hole quality. The flute is highly polished, which helps improve chip evacuation and reduces heat buildup during the drilling process. The advanced geometry of the CoroDrill 860-GM makes it ideal for use with a variety of materials — including steel, stainless steel, cast iron and hardened metals.

It also performs competitively with non-ferrous metals, such as copper and aluminium, and heat-resistant super alloys.

James Thorpe, Global Product Manager at Sandvik Coromant, said: “Sandvik Coromant provides machining solutions for a multitude of industrial sectors. We are always improving our

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offering and understand that enhanced tool life and improved productivity are two of our customers’ major requirements.

The CoroDrill 860 with -GM geometry is suitable for applications where hole quality is critical within the automotive, general machinery and oil and gas industries.

“We wanted to offer an improved solution for a vast range of industrial applications, and also to streamline our product offering,” adds Thorpe. “We’ve achieved this with a single, multi-purpose drill that gives superior performance across a range of materials. As well as improved drilling quality for our customers, they can also reduce their tooling inventory and overall production costs, with greater machine flexibility and reduced set-up times. “With the new addition to the CoroDrill 860 family, we hope to target a greater variety of industrial sectors while continuing to offer even more possibilities to our existing customers.” www.sandvik.coromant.com

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Australia’s green manufacturing future

Interest in renewable energy and clean technologies is at an all-time high amid growing public concern over our changing climate. How can Australian manufacturing capitalise on the opportunities this shift represents? By William Poole.

It’s been an eventful summer. While the bushfires dominated the headlines, Sydney faced widespread flooding following its heaviest rains in three decades, and Canberra was battered by hailstones the size of golfballs. The Great Barrier Reef is reportedly on the brink of further major coral bleaching, and drought conditions persist across much of the country.

Meanwhile, schoolchildren abandoned classrooms to join nationwide Climate Strike demonstrations, and police battled protesters outside a mining conference in Melbourne. New research revealed that Australian summers are now on average 31 days longer compared to half a century ago. And Shane Warne voiced concern about how rising temperatures might impact cricket.

Recent opinion polls indicate that more than three-quarters of Australians are now concerned about climate change, with a strong majority wanting stronger government leadership in addressing the issue. Business attitudes are shifting too, with the the Australian Climate Roundtable - whose members include the AiGroup, the Business Council of Australia (BCA) and the Australian Energy Council - calling for “deep reductions in Australia’s net emissions”.

There’s something in the air.

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Except, perhaps, inside the ‘Canberra bubble’. At federal level, energy and emissions policy remains a long-favoured political football. In February, when Anthony Albanese committed to a target of net-zero emissions by 2050, there was justified scepticism over the lack of detail on how Labor would meet this target. However, the Coalition’s criticism, that Labor had not presented costings for the plan, carried a distinct impression of opportunistic point-scoring. Given the frequency of cost blowouts in much shorter-term government projects, forecasting for a 30year timeframe seems ambitious. And the Government doesn’t exactly have a clear set of policies in this area either.

Moreover, the net-zero target is hardly controversial. Most state and territory governments - Liberal and Labor alike - have already signed up for it (South Australia is on track to reach net-100% renewable power by 2030), as have the BCA, and several major corporations including Telstra, BHP and AGL. Around 80 countries and 400 cities have adopted the target, in a charge led

by British Prime Minister Boris Johnson - not exactly your typical tree-hugging “greenie” radical. Indeed, the Government arguably already took on the target in 2016 when Malcolm Turnbull ratified the Paris Agreement on climate change.

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But the continued political skirmishing over emissions and energy has consequences that are felt throughout the country and the economy. According to the Clean Energy Council (CEC), new investment in large-scale renewable energy projects slumped by more than 50% between 2018 and 2019, from 51 projects worth $10.7bn, to 28 projects worth $4.5bn. Kane Thornton, Chief Executive of the CEC, cited policy uncertainty, along with regulatory risks and under-investment in transmission, as key drivers behind the fall, adding that this has implications for the reliability and affordability of energy supplies.

“A continued slow-down in new investment will put greater pressure on reliability and power prices as Australia’s old coalfired power stations continue to close,” Thornton said. “New investment is critical to replacing these coal-fired power stations and delivering on Australia’s emission reduction targets.”

The collapse in investment reflected earlier findings from the CEC’s latest Clean Energy Outlook Index, released in November, which showed a drop in confidence in clean energy investment over the preceding six months.

“Without strategic and holistic reform of the Australian energy market, we are going to continue to see confidence in new clean energy investment continue to fall,” said Thornton.

“Australia has abundant natural resources and huge Kane Thornton, potential for renewable energy Chief Executive of the Clean Energy Council. generation, but the industry has been plagued by policy and political uncertainty at the federal level for several years and we are now starting to see the impact of this.”

Despite these setbacks, however, there are still Australian companies out there developing innovative new clean technologies and embracing the opportunities these create for the manufacturing industry in this country.

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RENEWABLE ENERGY & CLEAN TECHNOLOGY Capricorn Power demonstrated a pilot model of the Barton engine in June 2018 at Austeng’s facility in North Geelong.

Capricorn’s system is compact, versatile and scalable, delivered in a standard 20-foot shipping container.

Dr Noel Barton AM, inventor of the Barton Engine and CTO of Capricorn Power.

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Capricorn Power – An engine for opportunity The story of Capricorn Power begins with former CSIRO scientist Dr Noel Barton AM. Having long recognised the challenge posed by global warming, Dr Barton set about finding ways to tackle it after retiring from the CSIRO. The area where he realised he could make a difference was heat engines.

“Most people haven’t heard of heat engines, but over 75% of the world’s power comes from them,” say Mike Hodgkinson, CEO of Capricorn Power. “And yet 72% of the electricity generated by heat engines is wasted. They’re not all that efficient. So Dr Barton went out to create the world’s most efficient heat engine.”

Dr Barton took his concept to some angel investors, who initially thought it too good to be true, so they hired award-winning Geelongbased engineering company Austeng to independently assess it.

Not only did the concept hold up, but Austeng liked it so much they took an equity stake and became Capricorn’s manufacturing partner. Formally established in 2017, the company began work on a prototype; in a nice case of Australia’s manufacturing past laying the ground for its potential future, testing was conducted using engines from second-hand Holden Commodores.

“In early 2018 we won a Regional Innovation Grant, which allowed us to build the first prototype,” Hodgkinson continues.

“We successfully tested it at a customer site as well as in the factory. Then we designed the commercial engine. We lost a bit of time raising capital, then at the end of last year we finally raised investment through crowd-sourced funding and got a grant from the the Advanced Manufacturing Growth Centre (AMGC), which means we’re now actually in the final stage of detailed design for a demonstration in October.”

From left: Lyn George, Director of Austeng; Ross George, Managing Directorof Austeng); Dr Noel Barton AM; and Mike Hodgkinson, CEO of Capricorn Power.

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Capricorn today operates as a lean, light-on-its-feet start-up, working out of office space within the University of Melbourne.

Barton remains involved as the company’s Chief Technology Officer (CTO), with four permanent employees bolstered by a rolling line-up of contractors who come onboard for particular projects, bringing the total head count to around 16.

“I expect we’re about to hit the fast-growth period where you double the head count every year, which is a very exciting time,” adds Hodgkinson.

Capricorn’s technology has applications across a range of areas encompassing energy efficiency and renewable energy. The Barton engine can essentially be deployed with any heat source exceeding 300°C - for example, furnace waste, landfill gas, exhaust heat or waste incineration - and generate electricity.

“The analogy is that people use solar panels on their roofs at the moment to generate electricity,” says Hodgkinson. “We attach a container to your waste heat source, and generate on-site electricity.

And that’s a lot more electricity. We’ve got a footprint of less than 0.5% of solar PV panels per kilowatt-hour, so we generate with a much higher power density. And just like solar PV, anything you don’t use can be exported onto the grid.”

Compared with similar technologies already in operation, the Barton engine offers several advantages. For example, the most widely used process, the Organic Rankine Cycle (ORC) engine, generates a fraction of the electricity and is limited in the settings where it can be installed. Moreover, Capricorn’s system is compact, versatile and scalable, delivered ready for installation in a standard 20-foot shipping container.

Eventually Capricorn’s technology could be deployed in energy utilities or in heavy manufacturing operations such as BlueScope Steel. Initially, though, Capricorn is targeting small and medium enterprises (SMEs) where it can offer clear energy efficiency gains.

One early customer is Victorian manufacturer Furnace Engineering, which saw an opportunity to use Capricorn’s system coupled with thermal storage to load-shift the heat it creates overnight for electricity generation during the day.

Hodgkinson sees enormous export potential for his product: “I like to call it one of the biggest market opportunities in the history of markets, because the electricity market is large and growing. As the world’s population grows, it’s driving a desperate search for sustainable energy. Water-free energy as well. The Loy Yang Power Station uses about 20% of Melbourne’s water supply. As water becomes more scarce, that’s not sustainable. Our technology is water-free. So does this have export potential? Absolutely. If we can keep control of the intellectual property in Australia, this could be very big in terms of exports overseas.”

RENEWABLE ENERGY & CLEAN TECHNOLOGY Keeping that IP in the country is, according to Hodgkinson, one of the big challenges in developing innovative products and bringing them to market - a challenge he partly attributes to difficulties in raising early-stage investment: “There’s a real problem in Australia in terms of raising early stage investment, so it’s a pressing issue to keep IP in Australia. A lot of companies end up having to take on investment from overseas, which then draws them overseas.

“The biggest challenge for commercialising products is that it’s not enough to be right about something. You’ve got to be right at the right time. And more important than creating a great product, you’ve got to have customers that want to buy it.”

Looking to the future, the team at Capricorn is currently heavily focused on October, when the first commercial engine is due to be demonstrated. After that, once the system’s reliability is proven, Hodgkinson anticipates the business will be able to ramp up quickly.

One area that is gaining momentum is in the bio-energy space.

“We’ve got a partnership with a pyrolysis provider,” Hodgkinson explains. “Pyrolysis is taking waste, particularly green waste, and turning it into heat and biochar. This is a form of carbon capture and storage, because the biochar locks up the carbon for hundreds of years. So it’s almost an agribusiness play, because you can use the biochar for feedstock and enhancement of soil for agricultural production. And we take that heat and turn it into electricity. And our technology enables that to happen at relatively small scale. We’ve got a few projects we can host at landfill sites or other suitable locations, so it’s these distributed smart energy hubs that we can hook in. Wherever there’s green waste, we can put one of these systems in. And of course, those are manufactured systems as well.”

Indeed, Hodgkinson sees great opportunities for Australian manufacturers in renewable energy and right across clean tech: “The clean tech space is enormous; it is an absolutely huge opportunity.

There’s no reason why innovative Australian companies can’t make the most of that. It’s like a frontier opening up at the moment and people should grab it while they can, or obviously other companies around the world will take it instead. Australia certainly has worldleading ideas. Our challenge is commercialising them and taking full advantage of them globally.”

1414 Degrees – Hot prospects Based in Adelaide, 1414 Degrees specialises in large-scale energy storage systems. The company was first established in 2009 by a group of investors who recognised that the rise of renewables would create a need for storage to shore up the intermittency of electricity supplied from renewable sources. However, unlike electro-chemical batteries of the kind marketed by Elon Musk’s Tesla, 1414 Degrees’ devices store energy as heat in silicon, which can then be used either as a direct heat source, or to drive turbines and generate electricity.

One of 1414 Degrees’ devices has been operating for 12 months at SA Water’s wastewater treatment plant in Glenelg.

1414 Degress-GAS-TESS at SA Water Glenelg Wastewater Treatment Plant

“Our device is not a battery,” says Dr Kevin Moriarty, CEO at 1414 Degrees. “We do use electricity to charge it, but we store it thermally, recover that energy as thermal energy, and then we can use it to drive turbines or to provide heat - in the same way that conventional power stations are often positioned next to industry to provide heat for industrial processes.

“When you charge or discharge lithium-ion or lead acid batteries, it causes a chemical change. We’re not making any chemical changes to the silicon. It’s like water freezing and melting and then refreezing, we do the same with silicon. Pure silicon melts at 1414 degrees Celsius - hence our name.”

While working at such high temperatures requires some specialised engineering, Moriarty maintains that 1414 Degrees’ device is relatively simple, likening it to “a giant esky” - albeit with an extremely strong steel shell. Moreover, while minerals required for batteries, such as lithium, are comparatively rare, silicon is the second-most abundant element in the Earth’s crust. Silicon also has close to the highest latent heat of any element. And while the chemicals used in batteries eventually become depleted and can be difficult to recycle, the silicon in 1414 Degrees’ machines remains unchanged and can be reused in perpetuity.

Dr Kevin Moriarty, CEO and Executive Chairman at 1414 Degrees.

“Batteries are lovely things,” says Moriarty. “But they are good for short-term supply, not the industrial scale we work at. Our devices are built to be cycled as often as possible, preferably at least once a day, and they don’t degrade in performance or capacity. In fact, they’re most efficient when kept working around the clock.”

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RENEWABLE ENERGY & CLEAN TECHNOLOGY 1414 Degrees plans to install its technology at the Aurora Solar Energy Project near Port Augusta and deliver stable power to the grid.

Continued from previous page

Batteries are also direct current machines, whereas 1414 Degrees’ systems are based on alternating current. This means they don’t need to be close to an energy generation source, be that a wind or solar farm, or a conventional power station. Indeed, the devices are designed to be positioned around the electricity grid.

“We’ll probably position most of our storage out around the grid because we want to supply heat to industries. We’re positioning and building devices for a bunch of industries that have come to us saying ‘We want a solution for our heat. Electricity also, but batteries can’t do heat, and we want to lower our heating costs.’ So, our technology is currently being driven by industries - many of them, very large industry.”

Today 1414 Degrees employs a team of 23, most of whom are engineers. One of its devices has already been operating for 12 months at SA Water’s wastewater treatment plant in Glenelg.

Biogas produced by the plant had been burnt off using gas engines.

However, by-products of the gas include hydrogen sulphide, which was becoming sulphuric acid, and abrasive compounds that damaged the engines. SA Water figured that 1414 Degrees’ system could cleanly burn off the gas without the need to service or replace engines. The heat generated would sustain the microbes needed to break down the sewage in the process vats, and the accompanying energy could be stored and time-shifted to when power prices are high on the grid.

“SA Water asked us to test whether our device could replace or augment their biogas generation,” says Moriarty. “They asked us to put in a pilot machine, which we’ve done, and it operated - to everyone’s very pleasant surprise - instantly. It’s a 10MWh device, roughly the size of a shipping container, and it’s operating very satisfactorily.”

Another project in the pipeline has seen a feasibility study undertaken on installing an electrically charged device at the Stone & Wood brewery in Murwillumbah, New South Wales, later this year to replace the facility’s current LPG-fired boilers. And the company recently purchased SolarReserve Australia II, as part of a plan to install its technology at the Aurora Solar Energy Project near Port Augusta and deliver stable power to the grid.

Moriarty sees a significant breadth of industries where the technology could be implemented: “Everybody from packaging manufacturers to breweries, through oil refineries, food processing, especially large ones... We’re mainly interested in the big end. And power stations, even coal- or gas-fired ones, have been looking for ways to even out the big variations in power prices on the grid. They think it might be good to store the energy and then regenerate it.”

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It has been a lengthy undertaking getting 1414 Degrees to its current position, and Moriarty emphasises the need for a dedicated team: “As with any new technology, you might have the right idea, but you’ve got to actually come up with a device and get it working. You do need engineers and investors who are all prepared to invest the time and money in a relatively uncertain outcome. You need people driven by an understanding of the need for something new, people with a certain amount of what I call ‘relentless optimism’ that you’re going to come up with something that works.”

Nonetheless, he anticipates substantial interest in 1414 Degrees’ products, both in Australia and overseas: “There is huge demand.

We haven’t had to do any marketing to potential users or customers of our systems. They want to reduce costs, but in many cases, it’s been driven by two things: to have a reliable supply of heat and electricity, and to reduce emissions.”

It all seems to spell out a lot of positives for Australia: a groundbreaking clean technology, developed locally, using an element highly prevalent in the Earth’s crust, in a country with a strong record of digging stuff out of the Earth’s crust. Moriarty says most of the silicon will be sourced from smelters in Western Australia. But what about opportunities for Australian manufacturers?

“Well we already use them,” he says. “There were about 100 different suppliers for the biogas test, which we manufactured here in our own workshop in Adelaide. Everything from electrical components through to steel fabrication. There’s a lot of stuff that was made in Australia, manufactured to our specification, and a lot of specialised expertise from companies. “Down the road, we’re going to get big fast, so there’s going to be a big demand for everything. We’ll effectively create a new supply chain for building these silicon storage modules, thousands of tons of containment. There’s going to be a lot of manufacturing activity associated with that.”

Grasping the potential What’s striking about both Capricorn Power and 1414 Degrees is that neither of them are working in areas typically associated with renewable energy or clean tech - areas that might conjure images of wind turbines or solar panels. But these companies are instead developing innovative, high-value products occupying very specific niches, providing solutions to very specific problems. Both companies are engaged in a very Australian kind of innovation, and they tick a lot of the boxes usually cited as defining characteristics of the type of business that will provide the foundation for advanced manufacturing in Australia in the future.

Perhaps that’s the problem that has dictated the political and commercial response to climate change up to this point: an overwhelming focus on the cost of addressing the problems, rather than the opportunities that flow from finding those solutions.

RENEWABLE ENERGY & CLEAN TECHNOLOGY It’s a point not lost on economist Professor Ross Garnaut. A professorial research fellow at the University of Melbourne, Garnaut produced a review in 2008 for the Federal Government examining the impact of climate change on the Australian economy and outlining potential policy responses; he updated the review in 2011. Last November he published Superpower: Australia’s Low-Carbon Future, a book detailing how Australia could become an economic superpower in a post-carbon world.

The name to remember Professor Ross Garnaut.

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At a launch event for the book, Garnaut described how renewable costs have fallen far faster than he had forecast in his reviews: “I had to make assumptions about how rapidly the cost of renewable energy would fall - by about 3% per annum. In the decade after that, costs for solar fell by 85%, which is much greater than 3% per annum. We’ve also had very rapid reductions in the cost of storage of power. So in the best locations, with the richest renewable energy resources, it’s now substantially cheaper to produce power from new sources than from a new coal or gas power station.”

Moreover, the world’s richest renewable resources, in terms of wind and solar, are in Australia - “by a very wide margin”, according to Garnaut. “So in a world in which we’ll be producing everything with zero emissions, as we have all agreed to do (under the Paris Agreement), in Australia we’ll have some special advantages. We’ll be the low-energy-cost country in the world if we make good use of these resources.”

Garnaut sees all sorts of possibilities flowing from this for Australia, from exports of zero-emission industrial products such as ammonia, to transmission of electricity to Asia via high-voltage cables. He sees a parallel opportunity in our forests and woodlands for sequestering atmospheric carbon in the soil, potentially generating much needed income for rural Australia through the sale of carbon credits.

One particularly promising area is in metal exports. Australia is already the world’s largest exporter of aluminium and iron ores, which are processed into metals overseas, often to then be sold back to us. Garnaut envisages Australia becoming a global hub in the manufacture of zero-emissions aluminium and iron - the latter using green hydrogen.

“If we turn one-tenth of our exports of iron ore, and one-quarter of our exports of aluminium exports into metal, then that will produce more income and jobs and exports than all of our coal and liquefied natural gas exports.”

In an article he wrote recently for The Conversation, Garnaut outlined some of the policy steps the Government should adopt to realise this opportunity. But he also stresses that events elsewhere will dictate the pace of change, as other countries move quickly to decarbonise their economies and industries “Movement will come gradually, initially with public support for innovation; then suddenly, as business and government leaders realise the magnitude of the Australian opportunity,” Garnaut wrote.

“The pace will be governed by progress in decarbonisation globally.

That will suit us, as our new strengths in the zero-carbon world grow with the retreat of the old. We have an unparalleled opportunity. We are more than capable of grabbing it.” www.cleanenergycouncil.org.au www.capricornpower.com.au www.austeng.net.au www.1414degrees.com.au www.blackincbooks.com.au/books/superpower www.unimelb.edu.au

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How heavy industry can transition to more sustainable practices The future of the Australian manufacturing sector rests on its ability to transition to more cost-effective sustainable practices, but this move will take time, writes Rob Stummer.

The Australian manufacturing sector can achieve significant costs savings, by improving the efficiency of equipment and processes and lowering energy and water consumption. Other effective strategies will include increasing the use of renewables, reducing waste, emissions and packaging, as well as using fewer raw materials.

Wind and solar Wind and solar energy are becoming more cost-competitive.

This means the transition to clean renewable energies is either in progress or planned by heavy industries. Now that renewables are accountable for an ever-rising share of Australia’s power mix, supplying about 20% of demand, the transition is already in full swing. Australia has the highest average solar radiation per square metre of any continent. Manufacturers, who usually have extensive roof space, can harness the power of the greatest free energy source available – the sun.

B&R Enclosures, an electrical enclosures, racks and cabinets manufacturer and a loyal SYSPRO customer, has announced a piloted project at its Brisbane facility by installing a solar energy system. This has provided the company with a range of benefits including significant cost savings, and has allowed it to be more environmentally responsible.

Water harvesting While sun and wind are both important for the manufacturer to capture and use, there has been an increasing uptake of smart, water efficiency solutions, including rainwater harvesting, for non-filtered uses. This is a worthwhile alternative to the use of substantial quantities of expensive drinking water in production processes and sewerage. Around Australia, many sustainabilityfocused manufacturers have seen the sense in capturing this free resource, as well as introducing ways to be more efficient with using water with the aim of lowering their consumption.

Sustainable packaging There has been a huge generational shift in attitudes towards singleuse plastic. Consumers are now choosing to buy from brands they believe are doing social or environmental good. The reduction of paper and plastic in manufacturing, packaging and distribution and the further recycling of these resources after use is critical and currently in progress.

Some manufacturers are yet to sufficiently prioritise sustainability, and circularity when considering design, use and disposal of packaging, with a lot of packaging still single-use and nonrecyclable.

Some of the smaller manufacturers are now collaborating with larger ones to “close the plastic waste loop”. CSR collects its disused shrink-wrapped plastic and sends it to Plastic Forests, which has used it to produce air conditioning mounting blocks.

These mounting blocks can also be used to dampen vibration on machinery such as compressors.

Paperless manufacturing The paperless office has been an aspiration of the manufacturing industry for years. Saving costs and the environment are both achievable, however, going paperless will require more than simply recycling office memos and printing less. Paperless manufacturing is shifting the way manufacturing plants operate. Many manufacturing

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and distribution plants are using their ERP system to reduce manual processes and have moved to a paperless industrial environment.

B&R Enclosures has a predominantly paperless shopfloor, and Independent Liquor Group is integrating its ERP with its paperless warehousing system.

Grid-scale batteries As the industry grapples with the transition to renewables, batteries will be pivotal to providing capacity when the sun isn’t shining, when the wind isn’t blowing, and the market demand requires it.

One of Australia’s biggest batteries will be built by independent power supplier Vena Energy in Wandoan, Queensland, in 18 months under a deal involving energy giant AGL. This move will strengthen the grid’s ability to shift from coal to renewable power generation by smoothing out the intermittent nature of wind and solar power.

Although the grid-scale battery market is in its infancy, batteries are considered to be crucial in the nation’s move away from heavyemitting coal-fired power stations. This is due to their capacity to store electricity generated from renewable sources and dispense it at a later time, when conditions for renewables are unfavourable.

What does this mean?

Due to its significant resource use, waste and emissions, heavy industry has been an obstacle to sustainable development for many years. Many leading industrial players are starting to take sustainability seriously and are building it into their everyday operations. All manufacturers need to make a commitment to do more with less.

Sustainability trends are currently driving major changes in the industrial sector. Suppliers to this sector can play a key role in helping these companies meet these challenges. But they will only do so by the entire manufacturing industry working together to deliver big and bold innovations that will facilitate significant change.

Rob Stummer is the CEO for Asia Pacific at SYSPRO. au.syspro.com

RENEWABLE ENERGY & CLEAN TECHNOLOGY

Bubble tech blows microplastic problem out of the water An innovative Australian technology that uses bubbles to remove contaminants from water offers a solution to an emerging global pollution crisis – microplastics.

The technology belongs to EVOCRA, a water treatment company formed in Tasmania in 2011. The patented process, known as Ozofractionative Catalysed Reagent Addition (OCRA), literally floats the microplastic out of the water so it can be collected and sent for recycling. EVOCRA’s Managing Director Mark Sykes says OCRA is a solution for many water-based environmental challenges.

“Microplastics are plastic items smaller than 5mm that are found in everyday products such as sunscreen, shampoo and detergent,” says Sykes. “Too small to be filtered out in the treatment plants, they wash into waterways where they harm our aquatic wildlife. OCRA offers a positive solution to this complex environmental issue. The technology can be applied as a pre-treatment, that is, before the plastic enters the sewerage system or at the treatment plant to remove the particles before discharge.”

Dr Thava Palanisami, a world leader in microplastics research, is working with Evocra: “Evocra was an early entrant into finding a solution for microplastics which is a potential planetary boundary threat. OCRA has demonstrated it has a part to play in the solution of remediating the 12.7m metric tonnes of plastic litter than enter the ocean each year.”

Plastics can enter the human food chain, and when ingested by marine life, can potentially cause death from starvation.

According to Sykes, there are numerous applications for OCRA, with the potential to treat minerals and contaminants in mining, oil & gas extraction, agriculture and aquaculture, high-intensity industrial manufacturing, municipal water and wastewater treatment, and contaminated land remediation.

In the OCRA process, chemicals or metals attach to tiny, charged microbubbles, each the size of a width of hair, and balloon out of the water. In a world first, the technology was successfully used to help remediate a industrial sewer that had been polluted due to a firefighting foam spill at Brisbane Airport in 2017, removing more than 99.9% of contaminants.

Sykes believes OCRA can address old, new and future water contamination issues: “Our first commercial application was in acid mining drainage, which has been an ongoing problem for the mining sector. PFAS is an international challenge we are facing right now and microplastics are certainly an emerging issue. Evocra are passionate about delivering technologies that have high social impact and that offer solutions across the spectrum in Australia and globally.” www.evocra.com.au

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Batteries made with sulphur could be cheaper, greener and hold more energy Lithium-ion batteries have changed the world. Without the ability to store meaningful amounts of energy in a rechargeable, portable format we would have no smartphones or other personal electronic devices. The pioneers of the technology were awarded the 2019 Nobel Prize for chemistry. But as society moves away from fossil fuels, we will need more radical new technologies for storing energy to support renewable electricity generation, electric vehicles and other needs. By Mahdokt Shaibani.

One such technology could be lithium-sulphur batteries: they store considerably more energy than their lithium-ion cousins – in theory as much as six times the energy for a given weight. What’s more, they can be made from cheap materials that are readily available around the world. Until now, lithium-sulphur batteries have been impractical. Their chemistry allows them to store so much energy that the battery physically breaks apart under the stress.

However, my colleagues and I have engineered a new design for these batteries, which allows them to be charged and discharged hundreds of times without breaking down. We hope to have a commercial product ready in the next two to four years.

What’s so good about sulphur?

Lithium-ion batteries require minerals such as rare earths, nickel and cobalt to produce their positive electrodes. Supply of these metals is limited, prices are rising, and their mining often has great social and environmental costs. Industry insiders have even predicted serious shortages of these key materials in the near future, possibly as early as 2022. In contrast, sulphur is relatively common and cheap. Sulphur is the 16th most abundant element on Earth, and miners produce around 70 million tonnes of it each year. This makes it an ideal ingredient for batteries if we want them to be widely used. What’s more, lithium-sulphur batteries rely on a different kind of chemical reaction, which means their ability to store energy (known as “specific capacity”) is much greater than that of lithium-ion batteries.

Great capacity brings great stress A person faced with a demanding job may feel stress if the demands exceed their ability to cope, resulting in a drop-in productivity or performance. In much the same way, a battery electrode asked to store a lot of energy may be subjected to increased stress.

In a lithium-sulphur battery, energy is stored when positively charged lithium ions are absorbed by an electrode made of sulphur particles in a carbon matrix held together with a polymer binder.

The high storage capacity means that the electrode swells up to almost double its size when fully charged. The cycle of swelling and shrinking as the battery charges and discharges leads to a progressive loss of cohesion of particles and permanent distortion of the carbon matrix and the polymer binder.

The carbon matrix is a vital component of the battery that delivers electrons to the insulating sulphur, and the polymer glues the sulphur and carbon together.

When they are distorted, the paths for electrons to move across the electrode (effectively the electrical wiring) are destroyed and the battery’s performance decays very quickly.

A CT scan of sulfur electrodes shows the open structure allowing particles to expand as they charge.

Image courtesy of Mahdokht Shaibani.

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The prototype lithiumsulfur battery shows the technology works, but a commercial product is still years away. Image courtesy of Mahdokht Shaibani.

Giving particles some space to breathe The conventional way of producing batteries creates a continuous dense network of binder across the bulk of the electrode, which doesn’t leave much free space for movement.

The conventional method works for lithium-ion batteries, but for sulphur we have had to develop a new technique.

To make sure our batteries would be easy and cheap to manufacture, we used the same material as a binder but processed it a little differently. The result is a web-like network of binder that holds particles together but also leaves plenty of space for material to expand.

These expansion-tolerant electrodes can efficiently accommodate cycling stresses, allowing the sulphur particles to live up to their full energy storage capacity.

When will we see working sulphur batteries?

My colleagues Mainak Majumder and Matthew Hill have long histories of translating lab-scale discoveries to practical industry applications, and our multidisciplinary team contains expertise from materials synthesis and functionalization, to design and prototyping, to device implementation in power grids and electric vehicles.

The other key ingredient in these batteries is of course lithium. Given that Australia is a leading global producer, we think it is a natural fit to make the batteries here.

We hope to have a commercial product ready in the next two to four years. We are working with industry partners to scale up the breakthrough and looking toward developing a manufacturing line for commercial-level production.

Mahdokht Shaibani is a research fellow in mechanical and aerospace engineering at Monash University. This article was originally published by The Conversation. www.theconversation.com www.monash.edu

RENEWABLE ENERGY & CLEAN TECHNOLOGY

Driverless electric vehicle to be powered with solar rooftop An Australian start-up is developing an innovative autonomous electric vehicle (EV) that will utilise a solar PV roof and lithium-ion battery system.

The Australian Renewable Energy Agency (ARENA) has announced $2m in funding to Applied Electric Vehicles (AEV) to complete the next stage of its EV commercialisation. An early-stage prototype of AEV’s Modular Vehicle System (MVS) was showcased at the CES 19 tech convention in Las Vegas last year. Now the Melbourne-based robotics business is taking its solarpowered driverless EV to the next stage of development.

As part of this project, AEV will complete a pre-production prototype demonstrating the technology ahead of the final stages of design and testing.

AEV’s vehicle will generate up to 60% of its energy requirements from the sun. Because its battery pack is smaller it can be charged by a common 240V wall socket, without special charging infrastructure.

and optimising the vehicle’s mass, energy efficiency, solar gain and safety.

ARENA CEO Darren Miller said this is a great example of Australian innovation utilising renewable energy in vehicles: “EVs are expected to play an important role in the coming decade in reducing the carbon footprint of transport. We hope to see AEV commercialise a homegrown driverless electric vehicle and be among the first to unlock the global driverless EV market.

“There is significant opportunity in the low-speed vehicle market, which is expected to gain considerable traction in cities, campuses and factories over the next decade. AEV’s project could also unlock new applications for solar such as integrating it into curved surfaces and demonstrating that solar PV can directly power high-efficiency electric vehicles.”

AEV’s CEO Julian Broadbent added: “Our project with ARENA is AEV’s vehicles are designed for short trips at low speed, and could focusing on passenger vehicles but the learnings will be applied to be used for a range of applications in delivery, agriculture, industry, other vehicles, helping to reduce the charging infrastructure burden waste management as well as passenger transport. AEV’s vehicles as EVs roll-out globally. The MVS will offer companies access to combine a lightweight design with a solar roof and high efficiency transport that is cost effective, pedestrian friendly, gentle on the driveline. ARENA’s funding will go towards solving energy-related environment and very customisable to their business needs. challengesAMTIL-ADVERT-MAIN-2020-OUTLINED(FA).pdf such as selection of appropriate solar PV technology, 1 17/1/20 10:49 am www.arena.com.au www.aevrobotics.com

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Seabin – Bringing marine debris, and manufacturing, back onshore The team at the Seabin Project are bringing the manufacture of their marine debris collection technology back to Australian soil, with production of the latest model set to begin in Brisbane in June.

The Seabin Project came about from a simple idea: “If we can have rubbish bins on land, then why not have them in the water?” Cofounders Andrew Turton and Pete Ceglinski set about answering this question, ultimately creating the Seabin – an innovative device that removes marine debris such as trash, oil, fuel and detergents floating on the surface of marinas or waterways. The company was launched in 2015.

The Seabin moves up and down with the tide collecting floating rubbish. Water is sucked in from the surface and passes through a catch bag inside the device, with a submersible water pump capable of displacing 25,000 litres per hour. The water is then pumped back into the marina, leaving litter and debris, including micro-plastics down to 2mm, trapped in the catch bag to be disposed of properly. Each Seabin can catch an estimated 3.9kg of floating debris per day, or 1.4 tons per year – the equivalent of 90,000 plastic bags, 35,700 disposable cups, 16,500 plastic bottles, and 166,500 plastic utensils per year. The possibility of fish being caught? According to the Seabin team, this is highly unlikely.

The Seabin device removes marine debris such as trash, oil, fuel and detergents floating on the surface of marinas or waterways.

The Seabin Project has now partnered with Evolve Group, an Australian-owned advanced plastics manufacturer, to re-engineer, develop, manufacture and produce the latest version of the Seabin.

The Seabin Project is aiming to fully utilise recycled plastics in the manufacture of the device and with recycled fishing nets expected to make up 100% of the body of each Seabin. The Seabin 6.0 will have a range of improved digital features, which will allow waste and water to be analysed upon entering the bin.

“We are extremely excited to begin the process of bringing both our IP and manufacturing to Australia in June this year,” says Ceglinski, now the CEO of the Seabin Project. “Evolve Group has already become a trusted partner in the development of Seabin 6.0 and the switch to injection moulding enables us to build a far superior and smarter product using recycled plastics with far less steel structure. Manufacturing will now only be a two-hour drive away, allowing our team to become hands-on in the design and development process.”

Based in Crestmead, in Brisbane’s southern suburbs, Evolve Group provides a full range of services from plastic injection, compression, blow and rotational moulding, design and prototyping assistance, through to tool manufacture, component construction and finished goods assembly. At its ISO9001-accredited facility, Evolve Group focuses on product design and development as well as an extensive manufacturing division. The team at Evolve Group boasts almost half a century of experience in international design, revolutionary manufacturing techniques and commercialisation.

With the help of a Made in Queensland grant, Evolve Group has in recent years upgraded its machinery to transform it from a traditional manufacturing plant into a world-leading, advanced, automated facility. The company retained and retrained its employees in highvalue, knowledge-based jobs, and its workforce has undergone rapid growth with every new product it has begun manufacturing in Queensland. Evolve Group prides itself on being able to keep manufacturing jobs in Australia, at cost-effective prices comparable to overseas competitors, and exports to more than 128 countries around the world.

The Seabin Project will be utilising Evolve Group’s injection moulding technology, which will remove up to 70% of stainless steel that was previously required, and will allow for the utilisation of Netplus (a

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The Seabin can collect micro-plastics as small as 2mm.

plastic made from recycled fishing nets). The injection moulding will allow sensor technology and digital monitoring structures to monitor the contents of the bins, but to also monitor water temperatures, PH levels and more. The partnership between the Seabin Project and Evolve Group will further promote job growth in Australia, as none of the manufacturing will be completed off-shore.

“We are extremely proud to be helping another Aussie brand bring their design and manufacturing work back to Australian shores, with the new Seabin 6.0,” said Ty Hermans, Managing Director of

RENEWABLE ENERGY & CLEAN TECHNOLOGY

Seabin Project CEO and Co-Founder Pete Ceglinski.

Evolve Group. “The fact that the Seabin team is committed to using the right materials such as Netplus is fantastic, and it sets a benchmark for other Australian companies to follow.”

With $5m worth of its devices currently in operation in 52 countries, the Seabin Project recently launched a major fundraising drive. The campaign, conducted with the Australian equity crowdfunding platform Birchal, raised upward of $3m in its first four days in March. The company had previously raised $400,000 via Indiegogo in 2016.

The team hopes their work will inspire businesses and individuals alike to think about their recycling habits. Ceglinski has announced that the company will increase its research into the recycling of the plastics collected by the Seabin device. Another priority for the company is keeping its carbon footprint as low as possible – by manufacturing on Australian soil, the Seabin 6.0 will be produced with less energy and fewer materials, and will be less bulky for optimised shipping.

Public concern over the effect of plastic waste on marine life has increased substantially in recent years, as media reports on the issue have surged. In March, scientists discovered a new deep-sea crustacean species located 7km below the surface in the Pacific Ocean’s Mariana Trench, between Japan and the Philippines. The scientists later named the species ‘Eurythenes plasticus’, due to the plastic found in the contents of the crustacean’s stomach.

Ceglinski stresses that removing plastics from the ocean is only part of the solution in tackling the issue: “The issue of plastics in our oceans is everybody’s problem, so it’s going to take everybody to become the solution. The way we look at it is that tech is not a solution, education is the real solution. Plastic has a value and can be reused again and again, if we were all just a little bit smarter about plastics, we wouldn’t have it floating around in our oceans.” www.evolvegrp.com www.seabinproject.com

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Cutting out vibrations in machining Vibrations in machining are generally an unavoidable part of the metal cutting process. However, the selection of the right tool can have a significant impact in minimising the impact of vibrations.

Vibrations always accompany a cutting action, and have a forced or self-excited nature. Machining vibrations are referred to as “chatter”, highlighting their specific nature, which inheres in every processing where chips are formed. Even if cutting is considered as stable, it does not mean that vibrations do not take place. In this case, the vibrations simply remain on a level that provides the required machining results and the task is considered as a “no vibration” operation.

Applying serrated round inserts with a chip-splitting effect redresses this situation and substantially improves robustness.

In fact, vibrations in cutting are a damaging factor that reduces performance.

Manufacturers make every effort to diminish vibration and, ideally, bring them to a level that does not affect machining results.

Chatter is a subject of serious research that has already provided manufacturers with ways to model vibrations in machining which, despite their complexity, can be very effective in finding a way to reduce chatter.

However, this modelling takes time and requires various input data, including sometimes additional measurements. In most cases, when manufacturers face vibrations during machining, they only have a few tools at their disposal for a real-time response to decrease the chatter. The most common practice is to vary cutting speed and feed, which usually leads to productivity reduction. Therefore, any effective method of diminishing vibrations that does not adversely affect machining operation productivity will be attractive to manufacturers.

Vibration reduction in machining requires consideration of a manufacturing unit as a system comprising the following interrelated elements: a machine, a workpiece, a workholding device, and a cutting tool.

While the influence of each element on total vibration reduction is different, improving a vibration characteristic of one element may have a significant impact on the system’s overall dynamic behaviour. Most efforts to protect against vibrations focus on developing more rigid machines with intelligent sensors and computer control, and advanced vibration-dampening tooling.

Can a cutting tool, the smallest – and probably the simplest – system component, dramatically change the vibration strength of a manufacturing unit? Producers might not have great hopes for the role of cutting tools in decreasing chatter; however, in certain cases a correctly selected tool can simply stop vibration without any adverse effect on productivity.

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Cutting geometry The right tool geometry makes cutting action smooth and stable. The geometry strongly influences cutting force fluctuations, chip evacuation and other factors, which are connected directly with vibration modes.

Iscar’s tool design engineers believe that the cutting geometry can considerably strengthen vibration dampening of a tool and have developed interesting solutions accordingly.

Iscar’s various indexable inserts, exchangeable heads, and solid carbide tools feature chip-splitting cutting edges.

Such an edge may be serrated or have chip-splitting grooves. The chip splitting action causes a wide chip to be divided into small segments, resulting in better dynamic behaviour of a tool during machining, and vibration is stabilised. In rough machining, extended flute milling cutters remove a large material stock and work in heavy conditions. Significant cutting forces acting cyclically generate vibration problems.

When using chip-splitting indexable inserts, it is possible to tackle these difficulties.

Mills with round inserts, a real workhorse in machining cavities and pockets, particularly in die and mold making, are often operated at high overhang that affects rigidity and vibration resistance of a tool. Problems with cutting stability occur when the overhang already exceeds three tool diameters.

Applying serrated round inserts with a chipsplitting effect redresses this situation and substantially improves robustness.

A skilfully defined tooth pitch is an effective way of taking the dynamic behaviour of a cutting tool to the next level. Iscar’s ChatterFree family of solid carbide endmills (SCEM) was designed on the basis of a pitch control method. The family features a variable angle pitch in combination with a different helix angle. This concept ensures chatter free milling in a broad range of applications.

The FinishRed series of solid carbide endmills features chip-splitting geometry coupled with variable pitch flutes that

CUTTING TOOLS Right: The Finishred series of solid carbide endmills features chip-splitting geometry coupled with variable pitch flutes that provide surface finish when machined according to rough machining data.

provide surface finish when machined according to rough machining data.

The principles of vibration-proof cutting geometry, which demonstrated their effectiveness in solid carbide endmills, have been applied to the design of exchangeable multi-flute milling heads made from cemented carbides in the MultiMaster family.

The Sumocham-IQ family of HCP exchangeable carbide heads, intended for mounting in the bodies of standard Sumocham tools, can ensure reliable self-centering capabilities.

Chatter-free drilling Chatter in drilling leads to poor surface finish and accuracy problems. In Iscar’s SumoCham family of assembled drills with exchangeable carbide heads, the double margin design of QCP/ICP-2M heads substantially increases tool dynamic stability.

If vibration occurs when a drill enters material, it may cause serious damage and even breakage of the drill. The SumochamIQ family of HCP exchangeable carbide heads, intended for mounting in the bodies of standard Sumocham tools, can ensure reliable self-centering capabilities. The key is an unusual concave profile for the head cutting edge reminiscent of a pagoda shape. This original cutting geometry enables high-quality drilling holes of depths of up to twelve-hole diameters, directly into solid material without pre-drilling a pilot hole.

The “magic pagoda” features another Iscar innovation: the Logiq3cham family of latestgeneration drills carrying exchangeable carbide heads with three teeth to ensure higher productivity. The steel drill bodies have three helical flutes that weaken the body structure when compared with a twoflute assembled drill of the same diameter.

In order to improve the dynamic rigidity, the flute helix angle is variable. This design principle in combination with the pagodashaped cutting edge provides a durable chatter-proof solution for stable highefficiency drilling.

The Multi-Master, an Iscar family of rotating tools with exchangeable heads, provides a range of tool bodies, referred to as shanks, produced from steel, tungsten carbide or heavy metal. A steel shank is the most versatile. Tungsten carbide with its substantial Young’s modulus provides an extremely rigid design, so carbide shanks are used mainly when milling at high overhang and machining internal circumferential grooves. Heavy metal, an alloy containing around 90% tungsten, is characterised by its vibration-absorbing properties, and heavy metal shanks are most advantageous for light to medium cutting operations in unstable conditions.

Anti-vibration tools for deep turning A typical tool for internal turning or boring operations comprises a boring bar with a mounted insert or a cartridge carrying an insert. The bar is the main factor in the dynamic behaviour of a tool. Stiffness of a bar is the function of the bar overhang to diameter ratio, and large ratios may be a reason of tool deflection and vibrations, affecting dimensional accuracy and surface finish during machining.

Tool body material An assembled cutting tool comprises a body with mounted cutting elements such as indexable inserts or exchangeable heads. Choosing the right body material presents an additional option for forming a chatter-free tool structure. Most tool bodies are made from high-quality tool steel grades, for which the material stress-strain behaviour is similar. However, in some cases tool design engineers have identified successful material alternatives to improve vibration strength.

“Live” vibration-damping during machining enables effective boring with the overhang from seven to fourteen diameters.

Iscar has developed three types of boring bar to cover a wide range of boring applications: two integral (from steel and solid carbide) and one assembled, having a vibration dampening system inside.

The steel bars enable stable machining with the overhang up to four diameters.

Exceeding this value can induce vibrations due to steel’s elasticity characteristics.

Changing the bar material from steel to a more rigid solid carbide ensures efficient vibration-free boring with the overhang of up to seven diameters. However, further increasing the boring depth is also limited by the material stress-strain behaviour. In order to clear this overhang barrier, Iscar developed the Isoturn Whisperline family of anti-vibration cylindrical bars. The bars carry interchangeable boring heads for indexable inserts of different geometries and have inner coolant supply capability.

The main element of the bar design is a built-in vibration-dampening mechanism to provide “live” vibration damping during machining. This enables effective boring with the overhang from seven to 14 diameters.

A vibration-dampening unit is used also in Iscar deep grooving and parting tools.

The unit is in a tool blade under the insert pocket. Each blade is pre-calibrated by Iscar for optimal performance for a wide range of overhangs, but end-users can complete fine tuning calibration themselves if needed.

Cutting tool manufacturers have a limited choice of means in the abatement of machining vibrations, with only tool cutting geometry, tool body material, and maybe a cutting tool with built-in vibration-damping device at their disposition. Considerable skill and ingenuity are required to make a chatter-free tool with these limited resources. It is feasible, however, and Iscar’s solutions highlighted in the above examples affirm the possibilities. www.iscar.com.au

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CUTTING TOOLS

Keeping local manufacturers at the cutting-edge With the shift in the Australian manufacturing sector towards small to medium sized niche operations comes the increasing demand for specialist high-performance cutting tool solutions.

The machining of the complex parts, with intricate forms and profiles, has resulted in the need for local suppliers to deliver special cutting tools with unique geometries and advanced ceramic coatings in rapid delivery times.

Since 2016, Guhring has supplied customised cutting tools from its Production and Service Division based in Melbourne. The major growth area has been the supply of custom-made solid carbide rotating cutting tools. The high-performance range includes step drills, form/profile end mills, special reamers, compression routers and day model cutters. Encouraged by this success, Guhring has just announced a major new investment in CNC grinding and PVD coating equipment to further support local manufacturers.

“High productivity, excellent economic efficiency and optimal machining have been the hallmarks of Guhring products for over 100 years,” says Brendan Smith, Managing Director of Guhring Australia.

Guhring customers’ trust is well-founded, with tool material, geometry and coating all perfectly matched to one another.

Guhring’s revolutionary coating technology, complemented by state-of-the-art R&D, ensures technological leadership in rotary cutting tools worldwide.

Guhring Australia sources carbide rods exclusively from its production plants in Germany, to ensure the highest-quality materials. The grinding of special tools is done on Guhring-built CNC grinding machines and PVD coatings are deposited using advanced coating technology, developed at the company’s coating machine building division in Berlin, Germany.

Guhring-built seven-axis CNC grinding machines are utilised in its Melbourne production facility. A major upgrade of the PVD coating machine has helped to reduce delivery times and increase the range of products available.

“We are fortunate to be able to harness global expertise locally to best meet the strict delivery requirements of the most technologically astute customer.” adds Smith.

Super-fast special tool delivery The time required to supply special carbide cutting tools is influenced by three factors: the supply of raw materials, the machine capacity in the grinding division, and access to an advanced PVD coating chamber.

The Guhring grinding division operates 24-hours per day midweek, as well as regular weekend shifts to keep delivery times at a minimum. The team of highly skilled staff are specialists in small batch production of complex and intricate cutting tools. We are constantly investing in new CNC machinery to help reduce delivery times even further. The on-site PVD Coating Division at Guhring operates two shifts per day and provides a rapid coating service for special cutting tools. Urgent orders can be PVD-coated and ready for shipment within hours of grinding.

Guhring has over 47 service centres in all corners of the world. To maintain the highest standard in special tool production, Guhring uses a central tool design database located at its headquarters in Germany. This can be accessed online directly by the Melbourne office. The online SAP-integrated database uses Guhring’s own standard tool templates for designing special tool types such as step drills, profile end mills and reamers. The custom designs are then allocated a unique tool number. Production as well as customer approval drawings are issued via email. Using such a centralised system allows Guhring to design special high-performance tools anytime, anywhere around the world to the exact same standard.

Minimising machine downtime An important aspect of maintaining short turnaround times for special cutting tools is to keep machine downtime to a minimum.

This is achieved by keeping all production equipment serviced and maintained to the highest possible level. Guhring‘s machines are built by its machining division in Germany. Service, maintenance and upgrades are done by the same technicians that built the machines in the first place. The production staff working at the subsidiaries and the producers of machines in Germany work for the same company. This creates an alignment of knowledge that helps to minimise machine downtime and encourage the upgrading of machines with the latest hardware and most up-to-date software.

The combination of a large carbide stock, in-house CNC grinding and PVD coating makes Guhring the one-stop-shop for the supply of special tools in the fastest delivery times. The success of smallto-medium niche manufacturers of specialised and complex parts has resulted in a growth in demand for custom-made precision cutting tools. Guhring has recognised this growth in demand and responded by expanding its local production and service division with the installation of grinding machines and a major upgrade of its advanced PVD coating unit. The investment has significantly increased Guhring’s capacity to produce special carbide tools to meet unique customer demands. It all comes down to delivering sharper, more agile thinking, as required in today’s highly competitive manufacturing world. www.guhring.com.au

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Expert grooving for small part production Grooving processes play an important role, especially in mass production. The trend towards miniaturisation of even complex component geometries is one of the driving forces, especially in the field of parting off and grooving tools.

For several years now, Walter Tools has been known for its technological expertise in this area.

Markus Stumm, Product Manager for Grooving at Walter, states: “We have significantly expanded our portfolio in recent years. In 2020, we will further strengthen our activities in this field. With the Walter Cut DX18, we are launching a tool with innovative clamping that will set completely new standards.”

Conquering a conservative market with innovative solutions Users are particularly conservative when grooving. Stumm explains: “In mass production, when the process is running reasonably well, manufacturers rarely change the tooling system. We have to offer a clear advantage in terms of productivity and cost-efficiency to get to the machine.

Problems with process reliability with the existing tools, or when a machining strategy is changed, provide us with an opportunity.”

The parameters according to which the decision for a parting-off process and the corresponding tools is made, are machine run times, tool life and process reliability.

Typical problem areas, especially for machining operations grooving deeper into the workpiece, are the stable fixing of the indexable inserts, chip breaking, and cooling. Users who want to play it safe, therefore reduce the cutting data below the recommended values. Who wants to risk stopping the production process due to chip jams, a vibrating tool or even if a cutting-edge breaks?

This is exactly where the Walter grooving experts come in: with its portfolio of grooving tools, Walter already covers a wide range of grooving applications. Walter Cut DX18 is a double-edged system for grooving and parting off, especially on Swiss type auto lathes or multi-spindle machines.

Walter Cut DX18 – maximum stability,convenient changeover The Walter DX18 system is suitable for parting diameters of up to 35mm. With the innovative, patent-pending positive engagement system, Walter’s developers are addressing the fundamental problems of narrowly dimensioned parting-off tools: the stability and handling of the cutting insert. In conventional screw clamping, the cutting forces act in such a way that the existing clamping forces are not sufficient – with negative effects on machining quality and process reliability. In contrast, the new Walter Cut DX18 cutting insert geometry locks the insert securely via positive engagement.

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Walter’s G4014-P/DX18 grooving and parting-off tool, on a Swiss type auto lathe.

Another innovation is the SmartLock system, which considerably simplifies insert changeover. With conventional screwclamped systems, the machine operator has to remove the entire tool for this purpose – and this in cramped and not always userfriendly, “oily” machine conditions. With the Walter SmartLock system, the clamping screw is located on the side of the tool: simply insert the screwdriver, unscrew and change the indexable insert. Due to the positive engagement, the new cutting insert adjusts 100% correctly, even with very narrow insert widths.

The potential of the system was successfully proven in a tool life test on a Swiss-type auto lathe. An outer diameter of 12mm was parted off from 1.4057 material. The cutting-edge width used was 2mm.

Stumm explains how tool life has increased drastically: “With the new double-edged Walter Cut DX system, we were able to more than double the tool life compared to the single-edged competitor – with maximum process reliability and productivity. The customer particularly liked the fact that they no longer had to remove the tool for changing the insert.”

Walter Cut DX18: The patentpending positive engagement prevents incorrect fitting, especially with narrow insert widths.

Process reliability in focus: Walter Cut GX and MX systems The new DX system is the latest example of the Walter team’s high capacity for innovation in the field of grooving and parting-off.

With the double-edged Walter Cut GX34, the development engineers have already shown the optimisation potential that lies in targeted technical improvements. In the meantime, the system has established itself as a reliable problem-solver for parting-off diameters up to 65mm.

For example, a well-known customer from the automotive supply industry repeatedly experienced major problems with process reliability when parting-off drive shafts (nitriding steel with a diameter of 60mm).

Stumm and his team were given the opportunity to bring the double-edged Walter Cut GX34 system onto the machine.

Since its design has been optimised for the stability of the long cutting insert, the Walter system significantly reduced vibrations that previously occurred during machining. The feed during parting-off could therefore be increased by

CUTTING TOOLS

30% and the tool life quantity doubled. A further economic advantage resulted from the double-edged grooving insert instead of the single-edged competitor.

Stable, wide contact surfaces in the toolholder, regardless of cutting width, ensure low tool costs.

The Walter Cut MX with four cutting edges has proven to be particularly reliable, highly accurate and cost-efficient for the production of small precision parts up to a cutting depth of 6mm and insert widths from 0.8mm to 5.56mm. The self-aligning, tangential clamping of the system and the dowel pin location in the insert seat, lead to greater repeat accuracy, stability and process reliability. The special insert geometry also ensures that the inserts cannot be fitted incorrectly.

During a tool life test in a large-scale production setting on a Swiss-type auto lathe, the task involved parting-off precision stainless steel pipes with an outer diameter of 5mm from 1.4301 material. The cutting width used for this is 1mm. The system impressed with a significant improvement in tool life.

Self-aligning, highly accurate tangential screw clamping ensures optimal force absorption and user-friendliness.

www.walter-tools.com

Your Specialist in New CNC Machines, Service & Support Call us today for a quote 1300 252 262

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Tool holders provide the vital link to machining productivity Precise machine tools and advanced cutting tools together provide outstanding metalcutting productivity. However, the link between the cutting tool and machine spindle – the tool holder – is crucial in fully achieving that productivity.

By Yves Heitz.

Tooling manufacturers offer a wide variety of tool holder styles, with each engineered for optimum performance in certain machining applications. A machining shop, therefore, should base its choice of tool holders on its specific operations as well as on the parts it produces. Nevertheless, while shops seek to acquire the most advanced machine technology and cutting tool materials, they often place minimal importance on selecting, applying and maintaining tool holders that best fit their specific production needs.

All holders are not created equal No one tool holding method is appropriate for all possible applications.

A tool holder engineered to carry out high-speed finishing operations typically will lack the rigidity and strength needed to be effective in, for instance, deep roughing of raw castings. Conversely, a holder meant for rough machining usually will lack balance qualities that would allow it to run smoothly at high speeds in finishing operations.

Addition, the robust design and bulk of a roughing holder can limit its access to fine or deep part features. Tough workpiece materials require tool holders with enhanced strength and rigidity. Additionally, a toolholder’s abilities to damp vibration as well as deliver coolant are also important selection criteria. Use of an inappropriate tool holder can result in dimensional errors and scrapped parts along with excessive wear on machine tool spindles, shorter tool life and an increase in tool breakage. In noncritical jobs, a value-priced tool holder may produce satisfactory results. But in operations where repeatable precision is mandatory – and especially when scrapping an expensive workpiece will lessen part profit margins – the investment in application-focused, top-quality tool holders provides low-cost insurance against such unanticipated losses.

For some shop managers, long versions of tool holders used across a range of applications is a valid cost-saving strategy. However, always applying the shortest holder possible will maximise rigidity, minimise surface-degrading vibration and preserve tool life.

Tool holders represent less than 2% of total production costs. Even cutting that cost in half produces negligible savings, while a scrapped workpiece or broken tool has a measurable financial effect. Premium tools and holders can boost metal cutting production rates for immediate return on the tooling investment. Particularly in industries such as aerospace component manufacturing where stability of the machining process is paramount, many manufacturers focus above all on acquiring premium tooling to avoid producing defective parts and wasting time in troubleshooting activities and production stoppages. Aerospace manufacturers typically take extended time to validate new holder concepts before certifying them for production.

Workpiece factors influence holder selection Factors influencing toolholder selection include the machinability of the workpiece material in each job as well as the configuration of the final part, which may determine the tool holder dimensions needed to reach certain contours and/or features. Yet, tool holders should be as simple and easy to use as possible to minimise the possibility of operator error.

Regardless which tool holding technology is applied, a machine tool’s rigidity, spindle power and ability to generate tight tolerances will dictate what operations are feasible. For example, attempting to produce micron-scale tolerances on a worn machine is a waste of time.

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A machine tool’s basic elements play a key role – a fast machine with linear guideways will take best advantage of toolholders designed for high-speed application, while machines with box ways provide support for heavy machining. A multitasking machine will fully exploit the capabilities of toolholders that can accomplish both turning and milling/drilling operations.

The machining strategy in use will also guide toolholder selection.

For example, shops can choose tools to maximise productivity in high-speed cutting (HSC) operations involving lighter depths of cut, or in high-performance cutting (HPC) situations that focus on generating high metal removal rates on machines with adequate power but limited speed capability.

Low, repeatable runout can help ensure constant tool engagement and thereby reduce vibration and maximise tool life. Balance is crucial, and a high-quality toolholder should be fine balanced at G2,5-25000 rpm quality (1 g.mm). Machining shops can perform their own research and consult with their tooling suppliers to determine the toolholding system or systems that will cost-effectively fill their production needs.

Each holder has its niche Whether simple Weldon, collet, heat shrink, mechanical or hydraulic type, tool holders should also be matched to specific operational requirements. Simple endmill holders for Weldon shank tools, for instance, are rigid, easy to use, can transmit high torque and provide safe and strong clamping with a strong anti-pull-out action. They are well suited for heavy roughing but lack precise concentricity.

In general, they are inherently imbalanced and do not productively apply for applications using high rotational speeds.

Collet chucks and interchangeable collets are the most common form of round-tool holding technology. Cost-effective ER styles are available in a wide range of sizes and offer sufficient grip for reliable light milling and drilling operations. High-precision ER collet holders feature low runout (less than 5µm at the tool tip) and a symmetrical design that can be balanced for highspeed operations, and reinforced versions are available for heavy-duty machining. ER holders facilitate quick changeover and can accommodate a range of tool diameters.

CUTTING TOOLS

Heat shrinkfit holders offer strong clamping force, concentricity of 3Âľm at 3xD and excellent balance qualities. Their small, simple nose configurations provide good access to tight part features.

Reinforced versions can perform moderate to heavy milling, but gripping force depends on the ID tolerances of the tool shank and holder. Shrinkfit tools require purchase of a special heating unit, and the heating/cooling process consumes more setup time than simply switching collets. Mechanical milling chucks provide strong gripping force and high radial rigidity via multiple rows of needle bearings. The design enables heavy milling and quick tool changes, but runout can be greater than that of collet systems. Mechanical chucks generally are larger in size than other toolholder styles, which may restrict tool access to some part features.

Hydraulic chucks that use oil pressure to generate clamping force have fewer internal elements than do mechanical chucks, and as a result have a comparatively slimmer profile. Hydraulic chucks feature low runout and are effective for reaming, drilling and light milling at high spindle speeds, but are sensitive to heavy radial loads.

Just as important as how a holder secures a cutting tool so too is how it mounts to a machine tool spindle. The spindle or taper end of a tool holder determines torque transfer capability and establishes tool centering accuracy. Traditional BT, DIN and CAT tool tapers are effective on smaller machines but may be limited in high-speed capability. Versions that provide contact on both the holder taper and face provide increased rigidity and accuracy, especially in longoverhang situations. Larger taper sizes are required to reliably transmit greater torque. An HSK-E32 holder, for instance, cannot replace an HSK-A125A in a heavy machining situation.

Choice of the holder taper style often is determined by regional preferences. HSK emerged in Germany in the mid 1990s when fiveaxis machines grew in popularity. CAT tapers are predominantly in the United States, while in Asia BT shanks are popular, frequently in taper/face contact versions.

HSK is very common for five-axis machining. PSC (polygonal clamping system: Capto) and KM connections are used mainly on multi-tasking machines and are now ISO standards. Both KM and Capto are also modular systems, permitting assembly of specific tools in different lengths by stacking extensions or reducers. Tool holder styles that make it possible to turn, mill or drill parts in one fixturing are growing in popularity as multi-tasking machines increase in use. While there are proprietary tool holding systems that use unique holders and collets in innovative ways to achieve impressive results, a shop must calculate their benefits. These systems typically involve greater cost and limited tool choice being from a single supplier.

Cost and other considerations While the basic cost of hydraulic or mechanical type holder is higher compared to that of a collet or shrinkfit holder, other factors are involved, such as the expense of the shrinkfit heating system, and the time required to change tools. It also is necessary to have a shrinkfit holder to fit each tool diameter, compared to accommodating different diameters by simply switching collets in a collet chuck holder system.

Machine operators and tool maintenance personnel also play an important part in successful tool holder application. As with machine tools and other manufacturing equipment, toolholders require correct usage and maintenance to maximise their benefits and use them to their full potential. For example, the operator must insert the tool shank into the holder to its full length, because improper seating will lead to accuracy-destroying vibration or even ejection of the tool. Following tool assembly specifications is critical.

Operators should not use an extension handle to apply excessive torque when tightening a chuck, which twists the collet and results in a misaligned tool.

Tool maintenance also is important but often is ignored. Operators should always clean holders before use and inspect the machine tool spindle as well. Holders should be stored clean and dry, with caps to protect the tool taper. The fluid pressure of hydraulic chucks should be checked regularly.

Conclusion Machine shops need to recognise the importance of toolholders in the machining system and learn how properly matching the right tool holder to their specific machine tools, machining strategies and workpieces can boost productivity and reduce costs. At the same time, tool holder manufacturers are offering more comprehensive selections of holders (see sidebar) engineered to meet individual operational needs.

Future improvements go beyond holder hardware itself. Tool management using software and RFID tags is an element of databased manufacturing and is becoming more common. Advances in toolholder technology include sensor-equipped holders that permit monitoring of the forces on the holder in real time. The collected data enables in-process adjustment of machining parameters either by the operator or even automatically via artificial intelligence (AI) in link with the machine control unit. These and other new technologies will further reinforce the productive contributions that toolholders provide in machining operations. www.secotools.com

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Why automate your paint line?

Today’s paint finishing arena is extremely competitive. While the revenue received from painting a part has dropped considerably, the requirement for meeting colour and film-build specifications has tightened dramatically. Automating your paint line can bring significant benefits.

The world has become a far smaller operating environment, and customer’s demands have meant that manufacturers cannot afford to waste any paint, whether through rework or poor transfer efficiencies. Companies are being driven to adopt new technology through flexible automation, or face extinction.

Automation presents opportunities for improvements in quality, and particularly with part to part consistency through improvements in quality and consistency. In parallel, automation offers opportunities for enhanced throughput, as robots handle difficult, repetitive tasks with ease, and often remove operators from dangerous environments. By reducing waste at the point source of origin, automation also offers reduced paint consumption, and in turn, reduced solvent usage and emissions. Indirectly, the reduction in the number of rejects and rework of parts also reduces material usage and general overall waste.

Robotic painting solutions are slightly different to regular robot applications, in so far as the robot must meet specific conditions for operating in a hazardous environment. Paint automation has several complicating parameters affecting the result, such as fluid viscosity, booth humidity and temperature, that traditional robot programmers may not typically compensate for.

Paint solutions can be fixed, or flexible (robotic). Fixed solutions have substantial limitations where a myriad of different parts are processed down a common line. In comparison to a robotised solution, fixed guns need to use additional paint in order to get the required surface coverage, and quite often require manual reinforcement. They also require more spray guns, which in turn uses more compressed air, paint, and has significantly higher maintenance requirements.

Flexible automation provides a far more adaptive solution, where any number of parts can be processed through the same booth, and an accurate gun-to-target distance can be achieved. Using a gun or rotary atomised, the paint can be distributed far more evenly – the same technology used in automotive finishing is now applied to the small component industry. The nature of the atomiser used is dependent on several factors, but none more so than the ability to electrostatically ground the parts and have a conductive substrate.

A gun, or air atomised applicator, uses high-pressure or high-volume air impinging on the fluid to create atomised paint droplets. These droplets are shaped by the fan air into an elliptical spray pattern, which can be sprayed onto the part. Depending on the amount of paint required to be sprayed, the applicator can have one or more heads to accommodate for high fluid flows. The advantages of an air atomised gun are that the high velocity paint particle can be used to drive coating into recessed areas. The downside of this is it can also cause a considerable amount of overspray, which is wasted paint.

In contrast, a bell or rotary atomiser, uses a mechanical shearing action to create the paint droplets. The atomiser spins at between 20,000 and 70,000 rpm, and it is driven onto the part using shaping air. As the shaping air is increased, the pattern becomes smaller. The downside of the rotary bell applicator is its ability to get into recessed areas. These two atomisers are important when considering the transfer efficiency, and hence the paint waste generated, when comparing applications. Reducing waste at the point source of origin is the most important tool in reducing paint usage. A typical manual air-assisted application has a transfer efficiency of around 25%, depending on the shape and surface of the part. That is, for every litre of paint needed to get onto the part, four litres of paint are required. In the process, a huge amount of waste is generated – in this case, three litres.

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In comparison, a high-volume low-pressure (HVLP) spray gun can spray anywhere from 20% to 45%, again depending on the nature and shape of the part being sprayed. This would represent slightly over two litres of paint required to get one litre onto the part.

Moving up, advances in rotary atomiser technology have resulted in electrostatic applicators achieving transfer efficiencies upwards of 90% . That means that for every litre of paint that needed on a given part, only need 1.1 litres of paint are required. That 100 millilitres of paint wasted, versus the three litres lost during a regular hand air atomised spray, represents a huge impact on emissions generated (volatile organic compounds), the frequency of cleaning required from overspray, and of course the cost of the material itself.

In recent times, Automated Solutions Australia has been involved in some case studies, where customers have migrated from an automated HVLP gun application, to a rotary atomiser solution. The customer’s project was driven by the fact that its surface area had increased, and the customer wasn’t able to get enough film-build in these areas, so it looked to electrostatic rotary atomisers. Using advancements in technology, these rotary atomisers delivered the required film-build, as well as a 55% saving in paint usage per part.

So, not only was the customer getting more paint onto the part and meeting its requirements, but it also saved an enormous amount of paint per part.

These savings aren’t always typical – sometimes they can be as low as 30%, depending on the complexity of the shape and the grounding of the part. However, the flow-on effects from getting more paint onto the parts where the paint is required, and not onto the grates or into the atmosphere are typical. Yields from these systems are also usually very high – upwards of 85%, subject to the material, booth and oven metrics being held constant.

Although a vehicle’s exterior finish represents less than 10% of its cost, it is responsible for approximately 80% to 100% of the total volatile organic compounds emitted in the automotive production

ROBOTICS & AUTOMATION

Another factor to consider in the adoption of automation into a paint line is the materials being dispensed onto the substrate.

The nature of a solvent or paint can be determined from its Material Safety Data Sheet (MSDS) – this will identify whether the product has a serious effect on the human respiratory system. Although operators can wear respirators and take breaks, the best way to avoid a problem is to eliminate it, by removing operators from these potentially dangerous environments.

Flexible automation is the simplest and easiest way to avoid manual pick up for these parts.

process (70% to 80% are from the spray booth, while another 10% to 20% are emitted through the drying oven). Waste reduction isn’t just limited to the reduced paint usage and VOCs going out of the stack; it is also directly proportional to scrap rates due to quality improvements. Set correctly, a robot can be your best painter, on its best day, all day, every day, if all else is held equal.

Automating your paint line can be driven by many factors – quality and consistency, throughput improvements, reduction of waste and scrap, and eliminating manual operation in potentially hazardous environments. Flexible automation, in the form of robotics, is the adaptive solution for these situations, and can be modified for gun or rotary bell atomisers, depending on the nature of the products being sprayed, and whether they can be grounded for electrostatic charge. The overall return on investment must be considered when weighing up these factors to understand the true benefit of automating your paint line, and whether your company will innovate, or evaporate. www.automatedsolutions.com.au

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“Sensorised” skin helps soft robots find their bearings Flexible sensors and an artificial intelligence (AI) model create the ability to tell deformable robots how their bodies are positioned in a 3D environment.

For the first time, researchers at Massachusetts Institute of Technology (MIT) in the US have enabled a soft robotic arm to understand its configuration in 3D space, by leveraging only motion and position data from its own “sensorised” skin.

Soft robots constructed from highly compliant materials, similar to those found in living organisms, are being championed as safer, and more adaptable, resilient, and bioinspired alternatives to traditional rigid robots. But giving autonomous control to these deformable robots is a monumental task because they can move in a virtually infinite number of directions at any given moment. That makes it difficult to train planning and control models that drive automation.

Traditional methods to achieve autonomous control use large systems of multiple motion-capture cameras that provide the robots feedback about 3D movement and positions. But those are impractical for soft robots in real-world applications.

The researchers describe a system of soft sensors that cover a robot’s body to provide “proprioception” — meaning awareness of motion and position of its body. That feedback runs into a novel deep-learning model that sifts through the noise and captures clear signals to estimate the robot’s 3D configuration. The researchers validated their system on a soft robotic arm resembling an elephant trunk, that can predict its own position as it autonomously swings around and extends.

The sensors can be fabricated using offthe-shelf materials, meaning any lab can develop their own systems, says Ryan Truby, a postdoc in the MIT Computer Science and Artificial Laboratory (CSAIL) and co-first author on the paper along with CSAIL postdoc Cosimo Della Santina.

“We’re sensorising soft robots to get feedback for control from sensors, not vision systems, using a very easy, rapid method for fabrication,” Truby says. “We want to use these soft robotic trunks, for instance, to orient and control themselves automatically, to pick things up and interact with the world. This is a first step toward that type of more sophisticated automated control.”

One future aim is to help make artificial limbs that can more dexterously handle and manipulate objects in the environment.

“Think of your own body: You can close your eyes and reconstruct the world based on feedback from your skin,” says

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The researchers’ soft sensors are conductive silicone sheets cut into kirigami patterns.

They have “piezoresistive” properties, meaning they change in electrical resistance when strained.

As the sensor deforms in response to the robotic arm’s stretching and compressing, its electrical resistance is converted to an output voltage that’s then used as a signal correlating to that movement. Image: Ryan L Truby, MIT CSAIL.

co-author Daniela Rus, director of CSAIL and the Andrew and Erna Viterbi Professor of Electrical Engineering and Computer Science. “We want to design those same capabilities for soft robots.”

Shaping soft sensors A longtime goal in soft robotics has been fully integrated body sensors. Traditional rigid sensors detract from a soft robot body’s natural compliance, complicate its design and fabrication, and can cause various mechanical failures. Soft-materialbased sensors are a more suitable alternative, but require specialised materials and methods for their design, making them difficult for many robotics labs to fabricate and integrate in soft robots.

While working in his CSAIL lab one day looking for inspiration for sensor materials, Truby made an interesting connection.

“I found these sheets of conductive materials used for electromagnetic interference shielding, that you can buy anywhere in rolls,” he says. These materials have “piezoresistive” properties, meaning

they change in electrical resistance when strained. Truby realised they could make effective soft sensors if they were placed on certain spots on the trunk. As the sensor deforms in response to the trunk’s stretching and compressing, its electrical resistance is converted to a specific output voltage. The voltage is then used as a signal correlating to that movement.

However, the material didn’t stretch much, which would limit its use for soft robotics.

Inspired by kirigami — a variation of origami that includes making cuts in a material — Truby designed and laser-cut rectangular strips of conductive silicone sheets into various patterns, such as rows of tiny holes or crisscrossing slices like a chain link fence. That made them far more flexible, stretchable, “and beautiful to look at,” Truby says.

The researchers’ robotic trunk comprises three segments, each with four fluidic actuators (12 total) used to move the arm.

They fused one sensor over each segment, with each sensor covering and gathering data from one embedded actuator in the

ROBOTICS & AUTOMATION MIT researchers have created a “sensorised” skin, made with kirigami-inspired sensors, that gives soft robots greater awareness of the motion and position of their bodies.

Image: Ryan L Truby, MIT CSAIL.

soft robot. They used “plasma bonding”, a technique that energises a surface of a material to make it bond to another material. It takes roughly a couple hours to shape dozens of sensors that can be bonded to the soft robots using a handheld plasma-bonding device.

its predictions to that ground truth data which was being collected simultaneously.

In doing so, the model “learns” to map signal patterns from its sensors to realworld configurations. Results indicated that for certain and steadier configurations, the robot’s estimated shape matched the ground truth.

“Learning” configurations

Next, the researchers aim to explore new sensor designs for improved sensitivity and to develop new models and deep-learning methods to reduce the required training for every new soft robot. They also hope to refine the system to better capture the robot’s full dynamic motions.

As hypothesised, the sensors did capture the trunk’s general movement. But they were really noisy.

“Essentially, they’re nonideal sensors in many ways,” Truby says. “But that’s just a common fact of making sensors from soft conductive materials. Higher-performing and more reliable sensors require specialised tools that most robotics labs do not have.”

variables needed for their model to process.

To estimate the soft robot’s configuration using only the sensors, the researchers built a deep neural network to do most of the heavy lifting, by sifting through the noise to capture meaningful feedback signals.

The researchers developed a new model to kinematically describe the soft robot’s shape that vastly reduces the number of

In experiments, the researchers had the trunk swing around and extend itself in random configurations over approximately an hour and a half. They used the traditional motion-capture system for ground truth data. In training, the model analysed data from its sensors to predict a configuration, and compared

Currently, the neural network and sensor skin are not sensitive to capture subtle motions or dynamic movements. But according to Truby, for now, this is an important first step for learning-based approaches to soft robotic control.

“Like our soft robots, living systems don’t have to be totally precise,” he says.

“Humans are not precise machines, compared to our rigid robotic counterparts, and we do just fine.” www.mit.edu

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MATERIAL REMOVAL

ANCA develops hybrid additive-subtractive platform for machining tools ANCA Australia is expanding its in-house manufacturing capabilities, developing a hybrid additive-subtractive manufacturing platform to manufacture Tungsten custom-designed cutting tools.

The platform is being developed alongside CSIRO and Sutton Tools, and is supported with matched funding from the Advanced Manufacturing Growth Centre (AMGC).

Successful completion of the project will allow ANCA to commercialise the new hybrid additive-manufacturing machine platform while growing its workforce and revenue while fulfilling a gap in the global tooling market, to which it already supplies Airbus, Boeing, Renishaw and Fraisa.

The project builds on previous research & development (R&D) between ANCA and CSIRO through a six-month pilot program funded by the Victorian Government’s Boost Your Business voucher scheme. Together, ANCA and CSIRO have demonstrated that the tungsten-carbide tools could be made cheaper through improved production efficiencies compared to traditional tungsten products.

In 2015, ANCA began exploring the potential for additive manufacturing to disrupt the tungsten cutting tool market, worth an estimated $2.2bn globally. Following significant research and the development culminating in a report with CSIRO, both parties entered a six-month pilot program.

Dean McBain, ANCA’s Research and Technology Manager said: “Such a complex project and process wouldn’t be possible without the support of trusted partners such as CSIRO, Sutton Tools and AMGC. We rely on organisations like CSIRO who have the laboratory, equipment and knowledge that we do not have. Sutton Tools is also hugely important as they provide practical input from

the end-user perspective. Collaborating with others is vital and it makes sense to partner with organisations like them. “Similarly, AMGC is pretty much the only organisation that can provide funding assistance for a business of our size, apart from the much larger CRC-type projects, which need to run for two to three years. In terms of balancing what is applicable, AMGC works out perfectly for us.”

Jens Goennemann, Managing Director of AMGC, said ANCA’s successful pilot is a great example of collaboration and technology combining to solve a complex problem: “ANCA’s project is a perfect example of how collaboration can find solutions to complex issues. In this instance the collaboration of two leading Australian companies and the country’s preeminent research institution to deliver an innovative solution to a multi-billion dollar global market.

“Australia’s future prosperity lies in advanced manufacturing, in making complex things. It is the answer to many of the challenges that face us - be it energy, efficiency, resources, productivity and value. What ANCA, CSIRO and Sutton Tools have developed is a better value product that uses less raw material, is more durable and is manufactured here.”

CSIRO project leader Dayalan Gunasegaram added: “We’re looking forward to continuing to work with ANCA to refine and develop their additive manufacturing platform for new tungsten carbide tools, given the value that this could create for Australian manufacturing.” www.amgc.org.au www.anca.com

Laguna invests in ergonomic, flexible Tornos Swiss GT 13 Based in Saint-Petersburg, Russia, Laguna is one of Russia’s largest manufacturers of small workpieces equipped with more than 100 machine tools including 25 Tornos Swiss-type lathes.

Laguna was founded 21 years ago with the technical knowledge of talented Russian engineer Yuriy Lutskiy and the administrative skills of Klavdiya Antonova.

Remaining deeply loyal to its roots, the company has unparalleled expertise in manufacturing complicated and high-precision parts, producing thousands of small workpieces every month. Laguna manufactures everything from connectors through to bolts, screws and much more for the electronics, instrumentation & control, automotive, aerospace, medical, transport and telecommunications sectors.

Laguna consistently invests in modern technology to support its customers. Part of its investment strategy has seen the arrival of a Tornos Swiss GT 13. The advanced technical turning centre incorporates six-axis kinematics that make the Swiss GT 13 ideal for the most complex parts on the market. It has also provided Laguna with the required flexibility to expand its business. The Tornos Swiss GT 13 has enabled Laguna to substantially increase productivity, largely due to the machine’s rigidity and high coolant pressure, which evacuates chips and improves machining performance, especially during the machining of dental instruments.

With up to 30 tools, including 12 rotating tools, the Swiss GT 13 is equipped with three motors (two on the platen and one for

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counter operation) to drive numerous rotating tools.

A modular position is available to accommodate the addition of advanced tooling. The rotating tool holders on the rear platen and the counter operation station are easily exchangeable and these features allow Laguna operators to significantly reduce setup times for a large range of workpieces.

The Tornos Swiss GT 13 allows the company to save precious seconds while ensuring it meets the highest quality and precision levels during the machining of stainless-steel components. Tornos also helped Laguna to boost efficiency on short rigid parts and long parts with small diameters. The Swiss GT machine can be converted to run with or without a guide bush in less than 15 minutes. This fast turnaround is significantly improving productivity at Laguna.

From a management perspective, the TISIS software from Tornos improves production efficiency and it enables real-time process monitoring. Furthermore, the company says it helps when writing code as it points out any coding errors, reducing the risk of collisions and the resulting stoppages. The Tornos TISIS software can display the part program in an easy-to-read Gantt diagram, making it easy to see the critical path and react quickly to optimise the process. www.tornos.com

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MATERIAL REMOVAL

Cutting-edge machine tools and CAM software help job shop slash cycle time With consistent investments of more than US$1.5m per year, US job shop Arundel Machine boasts a workshop equipped with more than 40 CNC machines, including three DMG MORI NTX 2000 nine-axis mill/turn machines, two DMG MORI DMU50 universal milling machines, and one DMG MORI NMV 3000 five-axis machining centre, as well as several DMG MORI NHX4000/5000 multi-pallet horizontals.

Founded in 1984 and located in southern Maine, Arundel Machine has evolved into one of New England’s leading CNC manufacturers of precision-machined components. The company has built a fantastic team of manufacturing engineers that produce more than 1,500 CNC programs each year while also designing many custom fixtures and tooling.

Arundel Machine manufactures products to support clients including the US Department of Defence and the US Navy – all with stringent level one and safety critical requirements. It also serves the oil & gas industry, with level one subsea components that sustain the extreme pressures and temperatures of the ocean floor. A third major industry is aerospace, providing parts for engine and propulsion components, actuation, landing gear, and sensor components. Finally, the company provides flow and pressure components for the semiconductor sector, which requires a deep understanding of critical finishes, handling, and process controls.

As Arundel Machine increased its investment in advanced technology, the company soon recognised the limitations of its previous CAM software.

“The old software was cumbersome, hard to use, did not do 3D machining very well, and lacked good technical support,” says John Hebert, Engineering Manager at Arundel Machine. “I flew out to the software developer’s training facility to see if these issues could be resolved, but it wasn’t possible.”

Hebert searched for an alternative that could help the company progress to the next level.

He came across ESPRIT CAM software from DP Technology, which offers the ability to import a solid model from leading CAD software and use it as the basis for the CNC program. ESPRIT supports state-of-the-art technology, such as five-axis machining, mill/turn, and probing, which is available for any class of CNC machine tool.

“I talked to the owners of DP Technology and was impressed by the fact that they are machining guys as much as they are computer guys,” says Hebert. “ESPRIT gave us a trial version and at the end of the trial, we were impressed and purchased the software.”

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The team at Arundel Machine: Machinist Matt Dunham, Engineering Manager John Hebert, Manufacturing Engineer Tyler O’Donovan.

As an example of the parts that Arundel Machine successfully programs with ESPRIT, Hebert pointed to a shaft built for a defence application. The shaft had multiple concave and complex profiles, flat sections, and slots on the end of the shaft. In the past, this part would have been produced in two set-ups on a CNC lathe, one for each end of the part; three set-ups on a four-axis machining centre to produce the profiles, flat sections, and cross hole; and one setup on a three-axis vertical mill to produce the slot.

the 100+ features in the part. The engineer defined the rest of the features manually by changing the model to wireframe geometry, picking the edges to define each feature one by one, and selecting the ‘Chain’ command. In defining roughing toolpaths, the engineer used ESPRIT’s ProfitMilling strategy, which optimises engagement angle, chip load, lateral cutter force, and machine acceleration to reduce cycle time when cutting out large areas of stock.

ProfitTurning was also used for grooving out between the cams.

“Support is key to the success of any company, whether it’s mechanical support for your machine tools or technical support for your software,” says Hebert.

“Partners like DP Technology, with their terrific technical support team for ESPRIT, have proven to be a valued asset. They are prompt, supportive, understanding, and always willing to help you out, while educating you along the way.”

Compared to the traditional turning toolpath, this ESPRIT cycle worked wonderfully for breaking chips, resulting in increased removal rates and longer tool life.

ESPRIT’s four-axis wrap milling is used for cutting, while the C-axis is rotated to semifinish and finish machine the cam profiles.

Other finishing operations performed with a five-axis approach include contouring and composite cycles. These operations were apportioned among the machine’s two spindles in several steps:

Today, Arundel Machine produces this part in a single set-up by leveraging the DMG MORI NTX 2000 mill/turn machine and ESPRIT CAM software. One of Arundel’s manufacturing engineers created the CNC program by first importing the solid model provided by the customer into ESPRIT. He oriented the part and then used the CAM software to recognize the features. The software recognised most, but not all, of

1. The bar is fed into the first spindle.

2. Lathe and turning tools are used to machine the exposed sides of the part.

3. When these operations are completed, the bar is cut off and transferred to the second spindle, exposing the unmachined side of the part for machining.

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Machining a part on a DMG-MORI NTX 2000 nine-axis mill/turn centre.

A safety cam shaft programmed in ESPRIT for machining on a DMG MORI NTX 2000.

4. Meanwhile, the bar advances through the first spindle and the first side of this new part is machined.

as simulated on the machine and produced good parts from the very first time it was run.

The manufacturing engineer apportioned operations between the two spindles to equalise their cycle time by dragging and dropping operations from one spindle to the others.

“We could not have programmed this part with our old CAM software,” Hebert concluded. “ESPRIT not only provided a relatively painless programming process, but also enabled us to reduce the cycle time by 50% compared to similar but less complex parts that we programmed with our old software.”

When the engineer was satisfied, he ran a simulation of the machining operation to check for crashes or gouging, inspected the dimensions of the machined part, and looked for opportunities for cycle time improvement. The program worked exactly

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COMPANY FOCUS

Innovation and diversity – Driving Catten Industries forward Innovation in design and diversification are helping Australian precision sheet metal manufacturer Catten Industries succeed in a traditionally tough sector. The wide range of products Catten makes is as broad as the multiple industry sectors that it supplies. Carole Goldsmith reports.

Catten supplies many industry sectors such as: building, electrical and electronics, transport, shopfitting, communications, furniture, material handling, general engineering and defence.

Catten Industries is proudly owned and operated by husbandand-wife team Ian and Latinka Cubitt and their three talented adult children: Nicole, Sean and Bianca. A long-term AMTIL member based in Bayswater in Melbourne’s east, Catten is a thriving hub of custom design and creative activity. There is no typical work day for Ian, the company’s Managing Director, and Latinka, its General Manger - Administration, because of the variety of products it manufactures and the industries it supplies.

custom-made decorative products in both rusted and powdercoated finish. Daughter Bianca has been designing the products, after Latinka and the team research and visualise various product ideas for manufacture. They recently released an attractive catalogue of the growing LaTink range consisting of decorative metal garden screens, custom-made etched wooden products and metal wreaths, outdoor furniture, light boxes and an Australian animal range, all fabricated by Catten at the Bayswater factory.

“We are a jobbing shop and new varying jobs come in regularly,” says Ian. “At Catten, there is a constant requirement to innovate and develop new projects.”

“LaTink is currently working alongside AMTIL with an industry advisor, and are in the process of working through a Federal Government’s Entrepreneurs’ Programme grant to assist us with our LaTink marketing for further exposure,” says Latinka excitedly.

Ian speaks about some exciting jobs completed recently in the company’s factory: “We made a steel circular spinning apparatus for an Australian Institute of Sport supplier. This is used by highboard divers to practice their pikes and spinning plus it’s helped cut their training time substantially.

“We work with our customers to come up with solutions. For example, we recently made some handle prototypes for easier movement of humidity cribs for a medical company. We also made large metal stainless-steel hood/ducts for the CFA training centre, which they use to simulate the skills required to extinguish motor vehicle fires. The ducts ensure that the smoke is filtered before discharging to the atmosphere.

“Catten also supplied bracket work for a 3D ice glacier construction, ‘Floe’, that was on display in the National Gallery of Victoria (NGV)’s entrance. This installation has since travelled to galleries in Hong Kong and London.”

As well as these special projects that can come at any time, Catten also supplies to many different industry sectors such as: building, electrical and electronics, transport, shopfitting, display/ point of sale, communications, furniture, material handling, general engineering and defence.

In addition Latinka heads up an exciting product range, LaTink, which was launched in 2017. This started from a range of personal customised Christmas wreaths and then grew to offer further

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Catten’s history Catten Sheet Metal was started in 1993 by the Frederick’s family, and was purchased the McGovern family in 2000. A veteran of 35plus years in the metal industry, Ian had started out as an apprentice with Siemens, as a first-class sheet metal worker and then as an engineering draftsman. His career took in more than 12 years as an engineer at Eliott Engineering, as well as stints with an engineering firm in London, and back in Australia working on the Collins Class Submarine project at Rockwell Collins, before taking on the General Manager position at Catten in 2005.

“On Father’s Day 2016, I received a call asking if I was interested in purchasing Catten,” he explains. “Latinka, our children and I sat down as a family to discuss this offer and we decided to take it on as a family business early in January 2017. Each member of the family now contributes important skills to the business.

“Latinka with her extensive IT background has an MBA plus years of experience in project management and systems implementation.

Our oldest daughter Nicole is a qualified scientist, having worked in the pharmaceutical industry and in quality control. She helped further develop our quality systems and now operates and maintains them.

“Sean, our son, is a qualified plumber by trade and he has been learning the ropes of the operational factory floor and our machines.

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Ian and Latinka Cubitt, Catten Industries’ Managing Director and its General Manger – Administration.

As well as the LaTink design work, Bianca, who has a Cert IV in Design and a Bachelor’s Degree in Media & Communications, does our social media communications, plus the design and marketing aspect of LaTink and Catten.

“We also have 32 skilled employees and that’s a lot of people to keep busy, with safety at Catten being an obvious priority. When we look at the business, that’s 32 families that we need to support and provide a safe and rewarding workplace for, as every single family is very important “ Among the many employee activities offered by Catten, are the ‘RUOK’ mental health awareness days, and celebrations for Christmas, Easter and Chinese New Year.

“When we took over the business, we took on all of the existing personnel and we have had a big emphasis on training, including bringing trainers on site. Three of our staff members are completing their Cert III in Sheet Metal Engineering, while we have two sheet metal apprentices at second and third-year level. Other employees have recently been trained in various welding accreditations and International Welding Inspector certifications.

“At Catten, we have diversity with employees from around the world. Together we provide sheet metal solutions from concept to completion for our customers.”

Ian reflects on how being an AMTIL member for 11 years has assisted the business: “AMTIL provides great support and credibility as a respected advocacy body for the manufacturing sector – plus AMTIL staff understand manufacturers’ needs. There’s also training and networking events where we can meet potential business contacts and colleagues to collaborate and share our experiences.”

Diversity in action at Catten’s factory.

During a tour of Catten’s modern 2,564sqm facility, Catten’s industrial designers and engineers are busy at their desks designing new products for clients using 3D CAD systems. At the LaTink showroom, Latinka proudly shares the company’s motto: ‘From the seeds of an idea, we create a piece of beauty’. On display are etched wooden boards plus platypus, koala and kangaroo metal animal sculptures – sure to be popular with the tourism market. The outdoor furniture sofa has sustainable cushions filled from recycled plastic bottles (provided by a local supplier), with an attractive ModWood and stainless-steel base.

The Catten workshop is a hive of activity, with employees busy at machines and a multitude of products at various stages of production. To ensure an environment of quality awareness and safe work practices, Catten works to the Quality Management System AS/NZS ISO 9001.

Latinka points to the cloud-based enterprise resource planning (ERP) system screen at the entrance: “Our ERP system is very important for Catten, as it ensures that all our employees own the data and know what stage every product is at, plus how many jobs are in action. They have their toolbox meetings daily to discuss where the jobs are at.”

Catten Industries operates from a modern 2,564sqm facility in Bayswater, Victoria.

Our tour passes a stack of tram doors that Catten completed the metal work for; these doors are bound for a local Australian train and tram manufacturer. Further along, a CNC press brake has just folded steel destined as a component for an industrial Australianmanufactured machine. Then there’s a laser cut sign ready for a playground entrance on display and a frame component for an outdoor kitchen, just completed. The laser cutting machine is constantly in use for jobs of this kind, according to Ian. Catten uses many different types of metals: aluminium, mild steel, galvanized, copper, zinc and stainless-steel, to name a few.

Ian explains that this just depends on the customer’s specific requirements. He points to a set of steel lids that are just coming off Catten’s assembly line.

“We’ve been making many of these items for a renewable energy manufacturer,” he explains. “One of its recent customers is a Victorian dairy farmer who was quoted approximately $180,000 for a fixed mains supply install for electricity, plus ongoing charges.

The farmer’s renewable energy installation costs approximately $140,000 and this now generates and stores sufficient power for the entire farm, resulting in zero power expenses.”

Latinka adds: “Over there is the WiFi-controlled etching machine, which we are using for etching designs into our LaTink wooden products. Those stainless-steel electrical switch boards are for the mining industry and these soap dispensers are made for a supplier to domestic and global hotels.”

The diverse product range is very impressive indeed.

Business challenges and opportunities “Overall, there are peaks and troughs in the sheet metal industry,” says Ian. “Securing a consistent workload and good cash flow is always a challenge, especially if a few customers take a long time to pay their bills.

“Having our own products with LaTink will help expand our business even further. We never know when the next customer will walk in the door and what they will order; that’s the exciting part of the business. It could be a small job to start with and this could grow to a million-dollar business deal in the future. We encourage factory tours as the more people we get through the door, the more potential customers we have, as they may need our services down the track “It is vital that Australia continues to have a robust manufacturing sector. This requires ongoing support from State, Federal and Local Government, to ensure that Australian project requirements contain a large and achievable percentage of local content.

“Looking forward, our succession plan is already in place and the company will look to evolve, be agile and adaptable as required for our long-term future,” Ian concludes, with Latinka nodding in agreement. “We are constantly promoting and building the business for further success and to ensure manufacturing thrives into the future.” www.catten.com.au

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Tube bending with robots Robots have been used for some time as efficient and flexible bending machines to process tubes, and these systems are continually developed further and improved. For the engineers at transfluid, this means first of all to make the software user-friendly, so it is possible to work in an efficient and professional way.

Based in Schmallenberg, Germany, transfluid specialises in the production of tube bending and tube processing machines, and has been developing customer-focused technologies for tube processing since 1988. The high-tech engineering company offers tailor-made solutions for the construction of plants and machines, for the automotive, energy and shipbuilding sectors and the manufacturing of medical equipment. The bending systems produced by transfluid can take isometrics data and generate bending data without separate programming of the robot system. transfluid has now designed the next step in the development of its range of tube bending robots and improved it again. The online connection to CAD systems has always been possible, which reduces the set-up time a lot. Another important aspect is to simplify the software connection because of the robot programming capabilities of each customer.

The latest generation of machines can process isometrics data online. There are also positions stored in the control system, for where the piece is picked up and dropped off. In addition, it is also possible to retrieve the position for the necessary supports for long tubes. A complete, new, complex bending geometry can be programmed and bent quickly, in less than 30 minutes, including the set-up of the bending tools.

Synchronised and coded for clear identification The transfluid bending cells with two robots bend long tubes at both ends. This way, tubes can be supplied with forming, hoses or connection systems. The preparation and cleaning of the tubes becomes a lot easier. It is much better to process straight tubes, when the bending machine can bend at both ends. These benefits can be enjoyed either when bending with one or two robots.

With a set-up with two robots, it is possible to process tubes of up to 6,000mm in length without any problems. The two robots work in a synchronised way. Additional equipment, like clamping or support devices, also synchronise with the processing robot. The robots recognise the component with a code, generate the bending sequence and choose between different radii and diameters. It is possible to work with a total of six different tube diameters or radii without having to change the dies.

Advanced processing, greater output With the new developments and improvements from transfluid, a production cell with two robots can do more than bend a tube at both ends: each of the bending robots can also process different

A tube is processed mid-air.

geometries. Both machines are working all the time and the system can be used efficiently and with a significantly higher output.

The latest generation of transfluid bending robots offer safe handling: the grabbing co-ordinates on the tube for the pick-up from the magazine and for the dropping off can be retrieved from the pre-programmed parameters. This means that the user has almost no programming of the bending sequence or the handling steps. The machine simply refers to pre-loaded data.

Even tubes with long lengths, which are nearly impossible on conventional bending machines, can be processed without any problems, as the long sections will not cause any collision problems.

This is possible, because the last bending is done on the “floating� tube, just before the drop off. The whole system is operated by a bending machine control unit. The benefit is that it is possible to work both with x, y and z co-ordinates, but also with lengths and bending angles, just like a standard bending machine.

It is not necessary to have special knowledge of robot programming.

In order to keep the set-up times as short as possible, the robots have pre-programmed tool settings, including axes for the set-up position. This keeps the set-up time short for the operator. With the latest generation of bending robots, transfluid has expanded the possibilities of tube processing and made it more efficient. www.transfluid.de

Each robot can process different geometries in a manufacturing cell with two robots.

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Vawdrey saves manufacturing time with Demmeler table system Vawdrey Australia, a manufacturer of truck trailers and bodies, is saving 20% in the time it takes to manufacture its smaller parts thanks to the recent acquisition of the Demmeler modular table system from Leussink Engineering.

When Vawdrey’s Quality & Manufacturing Engineer, Bradley Kent, went in search of a bench for a recently acquired robot being used for welding, he was advised to take a look at the Demmeler modular table system. This led Kent to Wollongong-based Leussink, the exclusive Australian distributor of the German-made Demmeler modular table system.

“In my role with Vawdrey I’m constantly looking at ways to improve how we manufacture our trailers and truck bodies,” says Kent. “When this search led me to acquire a robot for welding, I was impressed when I discovered the way in which the Demmeler system allowed us to clamp the work.

“We estimate that we are saving about 20% in the time it takes to manufacture the smaller parts, with the added bonus of accuracy.

The Demmeler system is more precise, allows us to set up jigs, and clamp anywhere, not just at the sides of the bench. It allows us to repeat the same job over and over and it comes out the same way every time.

“After acquiring our first Demmeler table, we could see more applications for the system and now have three different size tables in our facility. We use the table system for our smaller parts that need jigging like drawbars, mezzanine posts, and of course the robot.”

Before acquiring the Demmeler system, Vawdrey was using a steel bench for the same tasks. Leussink Engineering worked closely with the Vawdrey management team to ensure they bought the

right combination of tables and accessories for their specific work requirements. “The people from Leussink Engineering have taught us how to get the most out of the Demmeler system,” says Kent.

“Initially, they provided advice on the best tables and accessories, and then provided training.

“Our guys really love the Demmeler table system. And we’ll certainly consider buying a few more. They really like how they don’t have to constantly reset a job, because once it’s set up, it stays in place.” www.leussink.com.au

BOC, EWM celebrate ten-year partnership BOC celebrated a decade of partnership with EWM through a series of February events showcasing the latest welding innovations to Australian fabricators and businesses.

In partnership with Weld Australia, BOC customers and members of Weld Australia attended ‘Discover the Welding 4.0 revolution’, which featured live welding demonstrations by digital welding experts from EWM, a global market leader in welding technology. Tony Newnham, Head of SPW Group & BOC Welding Business, said the event demonstrated how Welding 4.0 techniques can improve profitability and quality for Australian welders.

“Welding technology is undergoing revolutionary change with the emergence of more automation and data exchange between machines,” said Newnham. “Whether it’s small fabrication jobs or automated robotic applications, BOC understands the need to keep our customers up to speed on the latest developments in digital welding. These technologies are revolutionising how welders deliver quality jobs. Welding operations of all sizes can increase production efficiencies and save money.

“We are delighted to have our long-standing partner EWM deliver training in Australia and demonstrate their new range of Titan welding equipment, designed to future-proof welding operations for Industry 4.0.”

Susanne Szczesny-Oßing, Supervisory Board President of EWM, said that shared values and BOC’s expertise had been key to the successful partnership: “BOC’s technical expertise in welding

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and EWM’s passion for technology are the perfect combination to help our customers on their journey through this digital revolution.

Welding 4.0 has many benefits such as increased quality welds and improved production efficiency. The customers who attended the event in Sydney got exclusive demonstrations on how welding 4.0 can help them improve efficiencies in their own welding businesses.

“To date, our trusted partnership with BOC has led to almost 15,000 EWM welding machines currently being used by customers in Australia and New Zealand, and we look forward to building on this partnership in the future,” Szczesny-Oßing added.

Geoff Crittenden, CEO of Weld Australia, commented: “The implementation of i4.0 advanced welding technology into Australian manufacturing will deliver significant improvements in profitability, efficiency and quality. Importantly, it will also make our manufacturing more internationally competitive and lead to industry growth and higher employment,” Crittenden said.

As the exclusive distributor of leading German welding brand EWM, BOC now offers EWM’s new range of Titan welding equipment that features Rapid Response Control (RRC), intelligent monitoring and real-time welding data to ensure the highest levels of quality and efficiency. EWM’s Titan welding equipment is now available in Australia. www.boc.com.au

FORMING & FABRICATION

Prima Power – Unleashing Industry 4.0 IMTS Machinery has been involved with the Prima Power family of companies for more than 15 years and the relationship only gets stronger every year.

Prima Power is a leading specialist in machines and systems for sheet metal working. With manufacturing facilities in Italy, Finland and the US, it delivers machines and systems all over the world.

Its range of machinery in this field covers all applications: laser processing, punching, shearing, bending, automation and now additive manufacturing.

Empower Workshop Floor Data Collection & Scheduling Software For progressive engineers to manage your core business, your labour

90%+ of engineers achieve a 20%-40%+ reduction in time on jobs – therefore a 20%-40%+ reduction in labour costs on jobs!

The Prima family of highly advanced servo-electric solutions for punching, bending and integrated processes is the widest in the world. Prima has been at the forefront of this technology since 1998 and is a world leader in servo-electric machinery. The company is also among the main world players in the 2D laser segment, with a wide range of top-performance, highly efficient machines used in a multitude of fields around the globe. Prima is now one of the only laser system manufacturers able to offer its own solid state diode laser up to 10kW. All Prima products are developed according to a “Green Means” concept, combining sustainability and productivity.

Touch Screens on the Workshop Floor – Tracking: Jobs, Tasks and Workshop Staff Live

Industry 4.0 marks a new era in the history of manufacturing, revolutionising industrial technology and processes through cyberphysical production systems and Big Data. Following the Fourth Industrial Revolution digitisation trend, and focusing on connectivity and interaction between machines, people and processes, Prima is improving operational efficiency, connecting machines to a single platform, enabling seamless production information flow and maximising machine performance.

50 inch TV Monitors on Office Walls and Workshop Floor Walls – Report: Jobs, Tasks, Staff, Times, Job Status, Due By Dates, and more Live

To help its customers fully capture the experience of Industry 4.0 and unleash the business potential of digital manufacturing, Prima has built a unique Industry 4.0 solution offering in three key areas: • Smart Machines - Real-time and historical parameter data collected through sensors and cameras.

• Smart Software - Seamless production information flow, connectivity to ERP and MES through storing machinegenerated data in the cloud.

Scheduling is Updated Automatically and Live at Job Status Change

• Smart Remote Care - Machine data-driven analytics and predictive maintenance services.

Prima is driving the next industrial revolution as a provider of Industry 4.0 sheet metal manufacturing solutions, enabling smart industrial production. With the cutting edge technology and expertise, it incorporates Industry 4.0 insights into its products to solve latest manufacturing challenges and meet its customers’ needs. IMTS Machinery is a proud partner of Prima Power.

Essential Tool for Production Management to Drive Production

www.imts.com.au

• Empower is Add On Software. Empower is Cloud-based

• Software developed for engineers producing custom one off products or projects, 6 to 150+ workshop staff • Pricing is Low Cost weekly subscription • Supplying Australian engineers for 13 years • Available to you on request: information pack and free trial software • Engineering Client Short Videos on youtube.com. In Youtube type in and search: Empower MARs Transport, Empower Peppertree, Empower Express Sheetmetal, Empower Delta Stock Crates

Sean O’Sullivan

B Com (Hons) Otago University

Founding Director, Empower Software sean@manufacturingandengineering.co.nz +64 27 2284211 AMT Magazine 13/01/2020

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The total package: Saving energy costs with complete blower packages Aeration is a central part of the treatment process at a wastewater plant. It is also a major contributor to energy costs.

As a result, operators are always looking for ways to revamp, replace or modify the blowers and their packaging in order to improve the aeration stage. Understanding what makes an efficient and cost-saving blower system is therefore paramount. Here Kaeser Compressors explains the cost and energy efficiency gains that can be made with complete blower packages.

Blower packages assembled by sourcing components from a variety of suppliers is still quite common and usually a result of adding to the blower as new requirements arise. As an example, a blower is determined to be too loud, so a new silencer is sourced. Perhaps even a sound enclosure is purchased. However, this now means that being inside a box, the blower runs warm, so now the operating temperature must be monitored. Then, perhaps it is determined that the blower needs to make more or less air, so a frequency-controlled drive is installed. The needs grow, and so does the package and its components. There are many versions of these packages in the field and while they may get the job done, there is no clear way to see how efficient they are.

Packaged rotary screw blowers include everything in one enclosure for optimum performance and energy efficiency

With energy for aeration one of the highest operating costs to a wastewater treatment plant (WWTP), it is therefore essential to understand equipment efficiency in order to better control and manage these expenses.

The total package Opting for a fully packaged blower solution is one-way operators can meet all of their requirements in the most cost-effective and energy-efficient manner. Fully packaged blowers have been available for some years now, however, different manufacturers have different levels of packaging. Most includes the basics; full cabinet enclosure, motor, drive, inlet/outlet silencers, and basic instrumentation. Some manufacturers go a step further and have onboard sensors and controls. Packaged blowers from Kaeser, for example, include a full sensor kit that monitors several points on the machine for pressure and temperature. This information is fed back into the onboard controller which not only monitors these points, but also makes calculations for differential pressure and temperature. The machine is then able to provide alarms or warnings, notifying the user of impending problems. It can even turn the machine off to prevent catastrophic failures.

These machines are also fitted with motor starters or a frequencycontrolled drive. Here again, all of the devices feed into the controller, providing a central point for monitoring and operator interface. A communication module can even be purchased, which extracts all of this data to a plant program logic controller (PLC).

Saving energy costs with complete blower packages Significant energy cost savings in terms of specific performance (kW/m3/min) can be achieved with complete packaged blowers.

Specific performance is the ratio for how much power it takes to generate the desired air flow. When a decision is made on which blower to purchase, an evaluation is done to compare all of the quoted blowers. Quite often the values are stripped down to the bare blower block performance, before equal values are assigned to each blower for package losses in the form of motor efficiencies, silencer losses and so on. This is done in order to ascertain how much each machine will cost to operate over a period of time.

The problem, however, is that while the blower performance is guaranteed, the package performance is not. Again, this is because the end product is assembled from a variety of suppliers, where each of the suppliers is not able to guarantee an end result. However, when the end-user opts for a complete packaged blower system

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manufactured by one supplier, provided performance values can be guaranteed.

Optimised maintenance Whether it is a blower made up of various supplier components or a complete packaged system, the maintenance requirements remain the same, i.e. oil, belts, grease and air filters. The key benefit of complete packaged systems, such as those from Kaeser, are the onboard controllers which keep track of the running hours and maintenance intervals. When it is time to change the oil, inspect the belts or filter, or grease the motor, the controller notifies the user.

And, in order to clear an alarm, the user or maintenance person must log into the controller. All activity is kept as a log inside the controller, therefore should a problem occur, all data and activities can be accessed for future reference and troubleshooting.

Rotary lobe versus rotary screw blower packages A rotary lobe blower package, such as the ones manufactured by Kaeser, have all of the components required of a blower system; silencers, motor, air filter, belts, relief valves, sound enclosure, check valve, sensor kit, controller and starter (contactors or frequencycontrolled drive). As all plants require all of these elements, every plant can benefit from this design. For most WWTPs, these blowers will be running all day, every day. Performance, reliability and longevity are critical to the plant’s operation and compliance.

A factory-engineered and developed machine has been optimised through years of experience, to provide the best performance and highest reliability. Furthermore, integrating the blower package into a plant’s master control system, allows for better product maintenance monitoring which can reduce downtime and repair costs.

The rotary screw blower package has the same scope of supply as the lobe blower package. All of the package design concepts and goals remain more or less the same – low noise, easy access to maintenance, and a small footprint – but a screw blower gives

COMPRESSORS & AIR TECHNOLOGY A multiple Kaeser rotary screw blower system

a decided boost in efficiency over any lobe-type blower design.

Screw blowers offer the advantage of internal compression, which can result in up to a 35% gain over lobe technology under certain conditions.

Screw blower designs are beneficial for all aeration processes; however, they are best suited for a process with a constant fluid depth and with extended running hours. Constant fluid depths allow the user to accurately predict the efficiency gains and to realise the expected payback on the investment. Variable fluid depth applications will see fluctuations in efficiency gains and intermittent duty systems will experience extended payback on the investment,

both of which will extend payback periods. In these cases, it may be best to stick with the PD lobe machine.

If the effort required to install, wire, program and commission a blower is considered, the costs would easily surpass the cost of a complete packaged system. Additionally, the finished product would not provide the same level of functionality or protection as the complete packaged system offers. A completed packaged system also gives the peace of mind that the end-user is getting the performance calculated during their evaluation process. www.kaeser.com.au

Compact and versatile: BOGE’s new C-2 generation More compact, easier to operate and quieter than ever before: BOGE has introduced a new generation of screw compressors from its popular C-series.

The C-2 compressors are available as a complete solution ready for connection, together with compressed air receiver and dryer, as well as in a standalone version for larger complete systems.

The machines are compact in design and, thanks to their easily accessible components, particularly maintenancefriendly and ergonomic. Fitted with a sound insulation hood as standard, the new C-2 compressors are once again quieter than their predecessors.

BOGE has given all versions of the machine an elegant, uniform design with high recognition value – along with an impressive range of individual configuration options.

BOGE has optimised its popular C-series with an elegant, modern and uniform external design that is more diverse than ever before on the inside. BOGE offers its new C-2 compressors in options that are belt-driven, directly coupled, frequency-controlled and also directly coupled at the same time in the same casing. Thanks to a sound insulation hood that is built in as standard, all compressors are even quieter than before. With optional super-soundproofing, the noise level is reduced by even more decibels. While the C-2 compressors are fitted as standard

with a high-performance IE3 motor, efficiency is increased to new best values as required thanks to an IE4 motor.

From 7.5kW, the compressors are available with frequency-controlled fans: meaning the cooling capacity can be adapted optimally to the environmental conditions. A dryer can also be integrated across the entire series – and a control system ideally adapted to customer requirements. Users have the choice between the basic control and the highend focus control 2.0 version.

Regardless of which extras are required, it works the same for all users: with the machines from the new C-2 series, you obtain a complete compressed air station as a plug-and-play solution in the smallest space, whether without or – for the first time ever in this series with a performance up to 22 kW – also with a receiver.

BOGE has ergonomically optimised both installation versions and designed them to be particularly user-friendly: the control panel has been built directly into the front plate or angled, depending on the version. Control cabinet, belts and all other maintenance parts are accessible thanks to plates that are easy to remove. au.boge.com

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Compressed Air Alliance: Taking the pain out of your compressed air system With Industry 4.0 upon us, instrumentation, telemetry and endless amounts of data are being generated about every facet of the manufacturing world. Manufacturing facilities are getting leaner and leaner, with engineering and maintenance managers pulled from one side of the factory to the other. So, who has the time or resources to review this vast array of data, let alone understand it, analyse it and most importantly gain insights from it?

It takes time, energy and effort to become an expert in any specific field; being an expert in the multitude of possibilities in a factory is all but impossible, so you should rely on the true specialists to help keep your systems inline. How are you supposed to know if every one of these systems is running at peak efficiency? Or if something has started to change and needs attention? Or even worse, is on the brink of failure? Sure, it’s probably in the data somewhere, but you need the time and patience to find it.

Of course, there are some systems that should warrant at least some attention, and without these systems, the site simply stops producing. For most sites the worst offender is the compressed air system. This system typically uses anywhere from 10%-40% of your factory’s energy use. Compressed air is the easiest to waste, with leaks and inappropriate uses often going unchecked. Sadly, they are reliable enough that most people won’t look at them daily, weekly, or even monthly unless there is an issue. But when it all goes wrong, everyone from the site manager to the production personnel get involved.

Traditional analysis of compressed air systems involves someone installing a data logger with the appropriate sensors on site. These would normally be power, flow, pressure, dew point and temperature on the system supply, as well as several points around the plant.

There is usually a period of waiting for a pre-determined period to log enough data, at a high enough sample rate to provide the detail required, and finally, downloading the data from the logger to a computer and starting the analysis. Only to discover an issue with the equipment and having to start the whole process all over again.

With recent developments in technology, it’s now very straightforward to have experts monitoring your compressed air system 24 hours a day, seven days a week, letting you know the moment something is out and needs attention. As well as providing that much needed advice to optimise the system and reduce the operating costs of the equipment.

To the layperson, the lines on a chart or data plot are just that, but to an expert they can indicate a lack of capacity, over or under-pressure settings, poor controls, inefficient operation, filter blockages and potential issues or failures beginning to occur. Many of these issues can be analysed, isolated, rectified or even prevented in real time.

With the site benefitting from greater reliability and savings from maintenance and energy consumption.

Cloud-based platforms utilising data loggers connected via mobile networks now allow sensors and data gathering to be accessed anywhere in the world. The data is transmitted continuously, allowing an experienced auditor to watch the compressed air system as your factory operates each day. Historical data allows the individual to check the systems broader performance and then make recommendations for adjustments.

Savings at a meat processing plant A meat processing plant had a compressed air system that had not been optimised to the site’s operation. It has four compressors in total: three variable-speed drive (VSD) compressors and one fixed-speed. One of them is installed in a remote location to ensure pressure stability to specific areas of the plant. Two of the compressors had been recently replaced and everything had been

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setup by the local supplier. Of the other two, one compressor was drawing close to end of life and was the least efficient machine on the site.

Previously the system had been set up using basic settings, but without the ability to see the system performance from multiple locations in real time, it had been left to a best guess-type scenario and was assumed to be running well. After the sensors had been installed across the site, it was quickly noted that the oldest, least efficient machine was running for large portions of time, despite there being capacity in the newer compressors to deliver site’s requirements.

The fix was a simple adjustment of the target pressures on the newer compressors. This allowed them to become the dominant machines and return the older unit to its standby mode. With the recommended adjustments taking place over the phone while being watched by the compressed air system expert from their office, the site made savings of more than $10,000 per year in energy alone.

Savings at a sawmill A monitoring system was installed temporarily at a sawmill around 2,000km away from the monitoring office. Normally this would entail an expert to travel by plane to install the equipment, return to the office for a few weeks, then head back to site to gather the equipment and logged data.

COMPRESSORS & AIR TECHNOLOGY

“Traditional analysis of compressed air systems involves someone installing a data logger with the appropriate sensors on site… With recent developments in technology, it’s now very straightforward to have experts monitoring your compressed air system 24 hours a day, seven days a week, letting you know the moment something is out and needs attention.”

The Compressed Air Alliance logging device allows data to be sent from the compressed air system to the cloud-based platform, allowing their experts to analyse a system’s performance anywhere in the world.

The site had recently added a new VSD compressor that had three load/unload compressors already installed. Initially it appeared the setpoints of the compressors had been set adequately, but after some historical data was gathered, it became clear there was an issue.

The new VSD was spending most of its time fully loaded rather than trimming the system. At the same time the load/unload compressors were spending a lot of time unloaded. This was further verified by the number of unloaded hours on the load/unload compressors.

Typically, VSD compressors should be used to trim the system rather than supply the baseload.

Professional Measuring Instruments

Full range of industry standard measuring equipment with many popular sizes supplied with calibration certificates.

Specialist range of digital ultrasonic & laser measuring instruments and gauges.

Using remote monitoring it was possible to instruct the site remotely on how to make the adjustments to the system and watch as they implemented the changes, then verify the changes have had the desired effect. After these had been made, further data showed the VSD would now provide the trim as it should and the load/unload compressors would either run fully loaded or shut down when not required. Saving across the site amounted to around $22,000 per year in energy costs.

Compressed air systems are extremely inefficient and costly to run, but these examples of the power of remote monitoring by compressed air experts show how simple incremental changes to the system can lead to big savings.

Compressed Air Alliance are experts in the compressed air industry.

We work with manufacturers to reduce compressed air demand and improve the efficiency and reliability of compressed air systems. We also provide compressed air training and products. We can help businesses with compressed air leak detection, monitoring and measurement, independent advice, air purity testing and project management.

By Warwick Rampley of Compressed Air Alliance (Australia), and Ron Marshall of Marshall Compressed Air Consulting (Canada). www.compressedairalliance.com

Available now at:

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ONE-ON-ONE

Colin Thomas is the Manager of the Tonsley Manufacturing Innovation Hub, part of Flinders University’s campus within the Tonsley Innovation Precinct in Adelaide’s southern suburbs. He spoke to William Poole.

AMT: What is the Tonsley Manufacturing Innovation Hub and what are its objectives?

Colin Thomas: Well there are two ways of looking at that. You can look at it in the small scale, which is that on the ground floor here, we have our cyber-physical factory, which we established with the South Australian Government and the Innovative Manufacturing Co-operative Research Centre (IMCRC), which is a showcase of Industry 4.0 technologies, interconnectivity of devices, augmented reality, RFID technologies, and also collaborative robots and industrial robots. So in the lab itself is a demonstration of advanced technologies.

But you can also look at the Hub as a bigger hub, with all of the resources of Flinders University and the Tonsley Innovation Precinct – all of those resources collaborating to assist manufacturing.

Collaboration in the Tonsley precinct is enjoyable and advantageous, with innovative companies like Sage, AZZO, Phoenix Contact, Micro X and Zeiss based here, and TAFE SA as well. So when you find an issue, you’re able to refer people to others around the place.

We’re collaborating with TAFE SA on some training opportunities around Industry 4.0, with the AI Group. Rockwell Automation is moving in too, so work on Industry 4.0-level, machine-to-machine communication is going to take off here.

AMT What are some of the notable projects you’ve got currently in progress here?

CT: The biggest project that we’ve got at the moment, which was only announced in February, is with BAE Systems and the Australian Submarine Corporation (ASC), assisting them with developing innovative and advanced technologies to be used in shipbuilding over the next few years. They’ve established a laboratory here equipped with collaborative robots, with augmented reality (AR) and virtual reality (VR), automatic guided vehicles (AGVs) or autonomous intelligent vehicles (AIVs), visual systems and product tracking. I think there’ll be about 20 people in there, working to develop advanced technologies for use by BAE and by suppliers to BAE in the building of ships. That really is quite an open collaboration between a defence leader and other SMEs, which is quite new.

Through Flinders University’s New Venture Institute, there’s also a program called the Innovative Manufacturing Accelerator, which runs about three or four times a year over a six-week period.

Companies and occasionally individuals sign up for it, and we work through their business problems and solve them. That program encompasses companies involved in water treatment, electric blowmoulding machinery, in vineyard management, in problem-solving in glass factories – there’s a really broad range. We just try to get them to clarify their problems, and work with the tools and the capabilities and the people we have here and in industry to solve those problems.

We’re also working on a proposal to prepare more hands-on, practical shipbuilding prototype process development. Whether it’s welding, or product tracking and movement, etc., we’re working to develop another facility here at Tonsley. We’ve got the collaboration lab with BAE, and the next step is a digital transformation lab with some 3D vision systems, and some Industry 4.0 connectivity and automation projects. And the next step after that, which is still under development, would be a new area where we can build prototype ships, prototypes of shipbuilding processes.

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AMT In what ways can manufacturers engage with the Hub? CT: There are a number of ways: through work-integrated learning; through research projects; through attending some of the events that we run. We run events such as training programs – sometimes suppliers will come and demonstrate their product and we’ll facilitate that – or other events with the Advanced Manufacturing Growth Centre (AMGC), the IMCRC, the Entrepreneurs’ Programme.

Manufacturers can also engage through things like the Innovative Manufacturing Accelerator program. Or they can get a visit from myself or others within Flinders to just talk about what they’re doing, how they’re doing it, and how they might make changes.

We’ve also facilitated the IMCRC’s FutureMap project, where companies undertake a survey to understand their position in Industry 4.0, where they are, and where they want to be.

AMT How important is it to have places like the Manufacturing Innovation Hub that can facilitate collaboration between universities or research bodies and industry?

CT: I think it’s critical, both for us to develop new technologies, and to make the best of existing technologies. For Australia to be competitive, we need to be at the leading edge, and quite a lot of that work can be done, and is being done, with the universities.

It really builds manufacturers’ capabilities, to use the smarts and the resources of a university to find the next better thing – not just using the current best thing … that’s important too, and that’s all that some companies need, but there are other companies that need the higher-level technology and research & development, to take that next step. I think, from what I’m seeing, the companies that are really doing well in manufacturing are the ones that are collaborating. When you look at the leading companies in South Australia, the leading manufacturers, there’s a very strong correlation between ones that are really doing things well, and the ones that are collaborating with the universities. Companies like Redarc, Schneider Electric, SMR, Supashock, AML Technologies... The ones that are doing the leading-edge development work are the ones working with universities.

AMT There’s clearly a strong emphasis on Industry 4.0, and digitalisation of manufacturing processes, in what you’re doing here.

CT: Certainly. My background is that I was a manufacturing engineering manager for several years at Electrolux. And as well as product standardisation and rationalisation being an important part of the success of Electrolux, so was staying in touch and implementing advanced manufacturing technologies. We worked with SAGE for 20-plus years in developing advanced conveyor systems and control systems and identification systems, and also lots of automation. There were more than a dozen discrete robotic automation cells, and more than 50 robots. They were really taking the best of European manufacturing and applying that in a better way to local Australian needs.

And a lot of that was developed by local integrators; we used the local capabilities of Australian electrical and automation integrators to build those capabilities and improve the production systems at Electrolux, including lots of things that are now under the Industry 4.0 umbrella. So I guess using those technologies was the way I’ve worked throughout my career, and now I’m able to assist others in applying them.

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And the other part is about the general connection with the university. That can be through promoting work-integrated learning, providing work experience for our students with manufacturers; and it can also be through research projects like the BAE project, developing the abilities within the university to work more closely with manufacturers.

One other significant task I undertake is that I lead a robotics and automation group in South Australia. It’s called an Emerging Technologies Interest Group (ETIG); five of them were established by the State Government early last year. This one is a businessto-business collaboration on automation and robotics. There’s over 150 companies listed and there’s about 50-60 active members of that group who collaborate on how to implement advanced technologies and automation. We’ve been meeting once a month and visiting lots of sites around the place. So 20 or 30 people will go and visit a manufacturer and learn about what automation they’ve done. There’s really great sharing of capabilities.

AMT Can you just tell us about your professional background and how you ended up at Tonsley?

AMT What’s your view of the current outlook for manufacturing, in South Australia in particular, and across Australia more generally?

CT: It’s never easy and it’s never been easy. But South Australia is buoyed by sectors such as shipbuilding and the space sector, and that does give an injection of enthusiasm and optimism for ongoing manufacturing in the state. More broadly in Australia, I think there are lots of people doing some amazing stuff, like Evolve and ANCA, and others that are really doing great work and great new product development. So yeah, I’m optimistic from that point of view.

AMT What do you think are the big opportunities for the sector, over the next few years?

CT: I guess I’m disappointed we don’t make more of our renewable opportunities. There’s just one manufacturer of solar panels in Australia. It’s disappointing to me that we’re not a powerhouse in solar panel manufacturer.

My ideal is that new lower-cost automation will give us more and more opportunities to make our own things. I think certainly the food industry is showing that you can do it and you can be successful.

If that level of technology and automation was adopted by other manufacturers, I think they’d be increasingly competitive.

AMT What does your role here entail?

CT: There’s two parts to the role. One is to assist local industry in understanding advanced technologies. So that’s assisting them to learn about what technologies are around and available, to understand how they can be deployed, what benefits they get from them, and to assist them in deploying them, whether that’s through education or through connection with others that do that.

CT: Sure. Well I started out by taking a general engineering course in Detroit, because I was living there in my late teens. I transferred that back to the University of NSW and finished off with a bachelor’s degree in industrial engineering. Then I got a job at Email Ltd in Orange, NSW, where they made refrigerators and stoves. I did a great project there on computer-integrated manufacturing back in the late 1980s, as a new plant making small refrigerators using lots of new technologies and systems. And then after five years, I moved to Adelaide to work at the cooker factory here.

I then worked for Electrolux for more than 25 years in a number of roles, including maintenance management, project management and manufacturing engineering management, as well as new product projects. The largest project was the BIOS rationalisation, standardisation and modularisation of all of the products onto a single platform, which is what allowed Electrolux to invest in high-volume manufacturing on a single platform. In doing that we implemented a number of automation projects. One of the most significant was taking hands out of presses, so there were no manual mechanical press operations left. Instead it was all done remotely by robots, keeping people away from those dangers. The lost-time injury rate fell dramatically over that automation period, from a hundred or more injuries a year, to going two or three years without a lost-time injury.

And then the opportunity arose here at Flinders, to apply what I’d learned more broadly on a broader manufacturing basis.

AMT And what’s the most satisfying aspect of working here?

CT: It’s the sharing of technologies, leading a group of interested parties, showing other manufacturers what they can be doing and have them directly helping each other. That’s very satisfying. It’s also satisfying seeing where the students go, opening up some doors in industry for them, and letting them find interesting work in industry. www.tmihub.com.au

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Driving digital manufacturing in the Hunter Class Frigate program A $1.45m grant from the Innovative Manufacturing Cooperative Research Centre (IMCRC), matched by industry funding, will help develop and pilot cutting-edge manufacturing technologies that will be used to build nine new antisubmarine warfare frigates.

The new manufacturing technologies will be used

by BAE Systems Australia’s shipbuilding business, ASC Shipbuilding, to build the Hunter-class frigates for the Royal Australian Navy (RAN) at the world-class Osborne Naval Shipyard in South Australia.

“Digital technologies such as artificial intelligence, robotics, cognitive automation and advanced analytics are redefining the Australian manufacturing sector and therefore the nature of its work,” explained David Chuter, CEO and Managing Director of the IMCRC. “Australian manufacturers, particularly small and medium enterprises (SMEs), need to learn how to embrace and contribute to new work environments that blend advanced technologies and digital skills with uniquely human skills.

“The project researches pathways to successfully adopt new technologies and develop human capabilities that – while focused on shipbuilding – can help Australian industry as a whole prepare for a future that is driven by digital transformation.”

In partnership with Flinders University and local SMEs, the project will drive digital transformation through advanced robotics, assistive manufacturing and readiness for Industry 4.0 utilisation – both inside the Osborne shipyard and more widely in the Australian supply chain.

BAE Systems has welcomed the funding from the IMCRC, which matches the company’s own $1.45m investment and comes on top of $5m that has already been invested in developing digital technologies, to turn the digital shipyard concept into reality.

“Our employees will use these technologies alongside advanced manufacturing techniques to drive greater efficiency and increased productivity, enabling us to operate smarter and be more agile in our decision-making and responsive to our environment,” said ASC Managing Director Craig Lockhart. “An important aspect of the research at the collaboration hub is that we want to share the outcomes with industry, to help educate others on the importance and implementation of industry 4.0.”

Prototyping on the Hunter program will begin late this year. All the processes, systems, tools, facilities and workforce competencies will be tested and refined before construction on the first frigate commences at the Osborne yard in 2022. From March 2020 until 2022 – when steel is cut on the first Hunter class frigate – the researchers will work with the shipbuilding workforce to trial advanced manufacturing technologies for application in the shipyard and beyond. These technologies enable connectivity between manufacturing equipment to databases that will provide real-time insights into shipyard and supply chain performance, leading to enhanced productivity, safety and quality outcomes.

Minister for Defence Industry Melissa Price said it is an exciting time for South Australia’s defence industry as work ramps up on the Hunter class project.

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“South Australia has a critical role to play in delivering our $90bn Naval Shipbuilding Plan, with local workers building two Offshore Patrol Vessels, nine frigates and 12 Attack class submarines,” said Price. “We’re talking about a generation of shipbuilding work which will create thousands of local jobs.”

In October 2019, ASC and Flinders University announced a partnership to establish the digital test and trial collaboration hub, located within the university’s advanced manufacturing research facility at Tonsley. Situated at the former Mitsubishi car factory in Adelaide’s south, the Tonsley Innovation District features Flinders University and Tonsley TAFE, as well as a range of businesses – new and established – focusing on advanced manufacturing. By June 2020, it is expected there will be more than 20 researchers working in the hub, together with other SME collaborators.

Flinders University President and Vice-Chancellor Professor Colin Stirling said: “Thanks to this strategic investment, Flinders University’s research expertise in advanced manufacturing will help to ensure that the Hunter class frigates will be built by ASC Shipbuilding using world-leading technologies. Our strengths in Industry 4.0 and cutting-edge digital laboratories will enable the development and testing of bespoke technologies to advance the specialised construction processes required for this nationally significant project.

“The IMCRC’s commitment recognises the value of the partnership that Flinders University has forged with ASC Shipbuilding and is further testament to the calibre of our researchers, our exceptional facilities and our leadership in innovation.”

South Australia Premier Steven Marshall said the $90bn investment from the Federal Government is creating an unprecedented pipeline of jobs and business opportunities in the state for generations to come.

“South Australia is now unquestionably the centre of defence and space, and this is a prime example of local expertise being used on a multibillion-dollar project,” said Marshall. “There are many great local companies that are contributing to the enormous naval ship build, and many more that can be involved in the years ahead.

“We know that the technologies being developed at Tonsley are driving growth across high-tech industries, creating jobs and cementing our state as a national leader in defence and space.

Along with the massive pipeline of defence projects and jobs, developments like Lot Fourteen, the home of the Australian Space Agency and SmartSat CRC, South Australia is fast becoming a renowned leader in future industries and advanced manufacturing.”

The Hunter Class Frigate Program will create and sustain 5,000 jobs across BAE Systems Australia and the defence supply chain over the life of the program. www.imcrc.org

SOUTH AUSTRALIA

STATE SPOTLIGHT

The end of Holden does not mean the end of manufacturing in SA General Motors’ announcement that it is axing the Holden brand and closing down operations in Australia by the end of 2021 prompted speculation that it marked the final nail in the coffin of manufacturing in South Australia, where Holden’s Elizabeth plant was the centre of the company’s production in this country. However, it is not all doom and gloom for manufacturing in SA. Basic Trailers is a shining example of a young, vibrant and innovative SA manufacturer meeting growing demand for locally designed and built products. Its trailers – designed, manufactured and distributed in Adelaide – have proven exceptionally popular with people across the state, in part as a backlash by customers against cheaper but inferior imported trailers that recently flooded the market.

Since opening its doors in 2018, Basic Trailers has expanded rapidly, to the extent that it has now had to move into larger premises in Pooraka to fulfil demand for its innovative trailers, all of which are built from Australian steel.

Furthermore, in addition to its existing workforce of six full-time employees, the company plans to hire at least four more workers at its new workshop facility.

Sam Francis, General Manager of Basic Trailers, describes the move to new premises as a: “significant expansion, and means we can continue to meet the demand of people across SA for our locally built trailers. We are now able to offer an even bigger selection

of trailers and expand the range we have in stock at any one time, meaning there is little or no waiting time for our customers who want to buy a locally built trailer and tow it home the same day.” Basic Trailers has invested heavily in CAD simulation software and CNC machinery, enabling it to explore the limits of trailer design. This also means that it can produce customised trailers designed to customers’ precise specifications. This ability is a feature that a local manufacturer like Basic Trailers can offer that importers can’t, and has contributed significantly to its success.

“Lots of people want to talk down manufacturing in SA and say there is no industry here,” adds Francis. “Yet the rapidly growing demand we have experienced goes against this. Our customers constantly tell us that they value the fact that our trailers are designed and built in Adelaide, and they would always prefer to buy a locally manufactured product over an imported one. Our having to move to accommodate demand tells me that there is definitely still a future for manufacturing in South Australia.” www.basictrailers.com.au

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First Australian-built electric aircraft prepare for take off Entrepreneurial Adelaide company Eyre to There Aviation is planning to be Australia’s first manufacturer of electric aircraft after signing an agreement with a European designer.

Company Managing Director Barrie Rogers says his fully electric aeroplane, designed by Pipistrel in Slovenia, was set to take off in the flight training market. His company plans to initially import 15 assembled aircraft with plans to establish an assembly line in Adelaide to manufacture up to 100 aircraft a year. The first of the planes is already in Adelaide and made its maiden South Australian flight in February.

Barrie Rogers plans to build Australia’s first electric planes in Adelaide.

Rogers was previously Airport Manager at Parafield Airport in Adelaide and also at Port Lincoln Airport on South Australia’s Eyre Peninsula. Rogers expects his company would be the first electric aircraft manufacturer to be based in Australia.

One of the key drivers was Australia being ahead of the regulation game in terms of flying the electric aircraft, according to Rogers, who claims the planes will be ideal for the more than 250 registered flight schools in Australia. There are an estimated 3,400 training aircraft being used by flight schools in Australia, and about 25% of flight training covers the beginner phase involving circuit training for take-offs and landings with training close to airfields.

“Australia is currently the only country in the world that already certifies electric aircraft for training purposes, so we have an opportunity to be a world leader,” says Rogers. “Electric aircraft are cheaper to buy, cheaper to run, are significantly quieter than conventional aircraft and don’t rely on fossil fuels. And they are ideally suited for short range flight training activities.”

Until now, the electric aircraft industry had been hampered by the heavy weight of the battery needed in each plane but Rogers says that technological advancements have reduced its size “to a point where electric aircraft are now commercially viable in Australia”.

The time range for the Pipistrel Alpha Electro is one hour plus a 30-minute reserve. The 6.5m-long aircraft is able to climb 370m per

minute and has a cruising speed of 157km/hour.

“Electric aircraft don’t yet have the range of other aircraft,” he says.

“But they’re perfect for short flights such as flight training and particularly circuit training, which is a core activity in obtaining a private pilot licence.”

Rogers believes the time was right to introduce the new technology as the average age of a small single engine aeroplane in Australia is 36.4 years, with many nearing the end of their life span.

“We see a clear market opportunity to provide brand new, low-cost aircraft that have zero emissions,” Rogers adds.

Amaero launches Adelaide 3D printing facility Amaero International, a world leader in metal additive manufacturing, officially launched a new facility in Adelaide on 12 March, in partnership with the University of Adelaide.

The new facility was opened by David Pisoni, South Australian Minister for Innovation and Skills. Amaero aims to work with the University of Adelaide to make Adelaide a leader in 3D printing research, education, training and manufacturing. The partnership will continue the activities of the South Australian Additive Manufacturing Applied Research Network (AMARN), which involves expanding equipment, human capital and capability.

Amaero manufactures complex metallic components by laserbased additive manufacturing. The company uses two techniques: selective laser melting (SLM) and blown powder laser melting. Its SLM machines have the largest build volume in the world. Amaero produces components for a range of companies in North America, Europe, Asia and Australia.

In October 2019, the University of Adelaide and Amaero signed a strategic partnership agreement focused on developing additive manufacturing capability in South Australia. The facility was originally established by the University, with funding from the State Government, and Amaero has now joined the site as a leading industry partner.

Located in Adelaide’s northern suburbs, the new facility contains three state-of-the-art Renishaw AM 400 3D printing machines and ancillary equipment. The Adelaide site adds to Amaero’s other facilities in Melbourne and El Segundo, California.

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Amaero CEO, Barrie Finnin, commented: “Amaero is thrilled to be establishing a facility in South Australia, which is fast becoming a centre of aerospace and the defence industry. Additive manufacturing is one of the most promising sectors for the Australian economy and it is growing in strategic importance.” www.amaero.com.au

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Welding disruptor signs major Singapore deal Adelaide-based company K-TIG is commercialising its industry-disruptive high-speed welding technology under a Welding-as-a-Service (WaaS) business model.

The K-TIG system can perform a traditional six-hour weld in less than four minutes to a quality standard and unlike traditional welding, it requires no edged preparation or filler materials.

Its cloud-based software control platform allows it to remotely monitor, support, control and record operational performance and output.

Under the deal with Steel-Ti, K-TIG will also provide extensive advice and support in relation to materials handling, cutting and automation equipment that will facilitate exceptional quality, high-volume output from the facility. K-TIG’s technology will record and monitor all usage to provide a transparent reporting and billing system for its licensing arrangements.

The K-TIG technology has been exported to 20 countries with blue-chip customers including GE, Siemens, Bilfinger, Doncasters and the UK Nuclear Advanced Manufacturing Research Centre. K-TIG recently signed an eight-year deal with Singapore manufacturer Steel-Ti Precision Welding to use its technology to supply tanks and vessels to Asian markets. Steel Ti is the first customer in South-East Asia to adopt the new WaaS model.

K-TIG licence fees adjust automatically in line with actual production and utilisation of its technology. The technology’s cloud feature allows K-TIG to continuously support its customers by storing their welding data, providing updates to software and firmware and uploading new weld routines that customers may require.

Steel-Ti is a newly incorporated venture by Michael Teo that will supply high value tanks and vessels to the oil & gas, aviation and shipping industries, and piping for the liquefied natural gas industry, to the growing South-East Asian and Japanese markets. The Teo family has a strong track record of successful business ventures and are synonymous with fabrication, global shipping and logistics through a conglomerate of family-owned and controlled companies across Southeast Asia, including Pacific International Lines (PIL) and Singamas. K-TIG CEO David Williams said the agreement with Steel-TI illustrated the strategic growth priority on long-term recurring revenue generation: “Signing an eight-year agreement with Steel-Ti demonstrates how transformative our technology is for the industry and the market’s willingness to adopt the technology.”

“We are strategically located in one of the world’s highest-growth regions, we have exceptional commercial networks throughout South-East Asia and Japan, and plan to leverage this to grow our welding business exponentially.”

Teo said K-TIG’s recent move to the WaaS business model made the decision straightforward: “We are excited to be the first company in South-East Asia to deploy the latest generation of K-TIG’s technology and one of the first companies in the world to adopt the WaaS model pioneered by K-TIG.

K-TIG re-listed on the Australian Securities Exchange (ASX) last year following the successful acquisition by Serpentine Technologies, which has now been renamed K-TIG Limited. The re-listing followed a successful $7m capital raise. www.k-tig.com

Tecalemit – 80 years of success Established in 1940, Tecalemit is a privately-owned South Australian company that manufactures a range of lubrication equipment and centralised lubrication systems at its Adelaide facility, and is a leading supplier of RAASM high-quality pumps and workshop equipment.

With 80 years of experience, Tecalemit has become a name synonymous with lubrication equipment, fluid transfer, fluid measurement and workshop equipment for the automotive, transport, agriculture, industrial and mining industries around the globe. Customers include well-known companies such as Caterpillar Underground, BHP and Rio Tinto.

the high-rigidity linear roller guides and direct coupled servo motors on all linear axes.

The new Mazak was purchased to replace another brand CNC machine, which – unlike the Mazak Tecalemit purchased in 2001 – was struggling to hold tolerances and spare parts were becoming harder to come by.

When questioned about the reasons behind choosing another Mazak, Tecalemit’s General Manager David Livingston, explained: “We found our existing Mazak machines to be reliable and accurate over very long periods of continuous production Tecalemit’s Production Supervisor Nobin Thomas (left) and CNC Operator Peter with minimal downtime, and we have been Lechelt in front of one the company’s able to depend on John Hart to provide long-serving Mazak machines, purchased timely service, support and spare parts to in 2002. suit our demanding production timeframes, so purchasing another Mazak just made Tecalemit recently purchased a new Mazak, a Quick Turn Compact sense. “It is extremely important to ensure Tecalemit can meet our 100MY CNC turning centre. The machine features milling capability customers’ demands, maintain our world-class reputation and and Y-axis functionality and is equipped with a high-rigidity integral minimise risk to invoke penalty rates. John Hart and Mazak help us spindle/motor for unsurpassed machining performance. It is to achieve these goals.” equipped with a 12-position turret with high-speed indexing and Tecalemit has a long-standing relationship with John Hart, a testament to the longevity and reliability of the first Mazak machine the company purchased. Nobin Thomas, Production Supervisor at Tecalemit, comments: “We bought our first Mazak in 2001, and it’s still going strong today due to the world-class service and spare parts from John Hart.”

minimum tool interference. High-accuracy positioning is ensured by

www.johnhart.com.au www.tecalemit.com.au

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Bygen – Adelaide start-up in activated carbon breakthrough Adelaide-based company Bygen has developed a breakthrough new technology that can produce activated carbon from plastics and agricultural waste, raising the potential of a new sustainable option in the multi-billion-dollar industry.

Activated carbon is one of the most widely used materials for environmental remediation in the world. It contains small holes, or ‘pores’, which give it an extremely high internal surface area, which allows pollutants to ‘stick’ to the inside of the carbon, removing them from the ecosystem. Activated carbon can be used in a range of applications, including water purification, remediating contaminated soils, treating air pollution, and recovering gold from mine sites.

Globally, approximately 3 million tonnes of activated carbon are used every year for the purposes of cleaning up contaminated soil, water, and air, as well as recovering precious metals. Most activated carbon is made from expensive and non-renewable hardwood or coal, rather than cheap and abundant sources of agricultural waste, or from coconut shells in developing countries.

Founded by Dr Lewis Dunnigan and Ben Morton, Bygen has ambitions to become the world’s first sustainable producer of high-quality, bespoke activated carbon.

The company first began transforming low-value agricultural waste into activated carbon in 2018, but a recent breakthrough

by Bygen now allows it to turn plastic waste, including polyethylene terephthalate (PET), into the high-value material.

“Currently, not only is activated carbon typically made from non-renewable materials like coal in hugely carbon intensive processes, but the products available in the market also suffer from a ‘one-size-fits-all’ approach, with little to no tailoring for the wide array of users,” says Dr Dunnigan. “The end result is that

Bygen has demonstrated its technology in a pilot-plant validated with industry standard testing.

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customers are paying significant sums for unsustainable activated carbon that has not been optimised for their application.

Our novel activation method allows us to produce activated carbon at a fraction of the traditional manufacturing cost, while also allowing us to tailor the properties of the product in order to achieve significant improvements in performance for different applications.”

Bygen’s production sites are situated either next to, or on-site, at locations where there are significant quantities (more than 5,000 tonnes) of waste either generated or processed every year. This offers significant amounts of co-generated energy to the waste provider, while reducing transportation costs.

“By using renewable materials such as agricultural wastes, we are ensuring that farmers can value-add to current wastes, and that harmful practices such as open burning of agricultural wastes are avoided,” Dr Dunnigan explains. “Importantly, our method works to ensure activated carbon is made in a safe and responsible manner.

“In addition, our technology can be used for mixed or contaminated plastics, which are causing so many problems in the recycling industry. This is particularly true in Australia now, with several countries having stopped accepting our waste.”

Bygen is currently working with a number of companies involved in a diverse range of industries, including water treatment, soil remediation, and petrochemical refining.

The company has demonstrated the technology in its pilot-plant with industry standard testing. It is currently in the process of raising a second seed round of

Globally, approximately 3 million tonnes of activated carbon are used every year for the purposes of cleaning up contaminated soil, water, and air, as well as recovering precious metals.

$600,000 to add to its initial seed round of $300,000. Bygen will look to do its ‘Series A’ funding round towards the middle of the year, which will go towards building a full-scale plant capable of producing commercial quantities of activated carbon.

Bygen is one of four companies in the current Startmate climate accelerator program, which is backed by Michael Cannon-Brookes’ Grok Ventures.

Startmate’s climate accelerator stream invests $75,000 in up to 15 start-ups at their latest valuation. The three-month-long climate program, which runs alongside Startmate’s regular accelerator program, is focused on launching the next wave of ambitious start-ups working on innovative technologies that will have large CO2equivalent reduction.

Startmate is backed by some of the world’s most successful entrepreneurs and venture capitalists, making up a worldclass community of mentors and alumni.

Startmate shares that knowledge through its 12-week accelerator program, oneon-one bespoke coaching and in-person events. Startmate encourages ambitious founders to hit their next milestone, and offers invaluable resources, advice and support along the way. Since 2010, Startmate has been welcoming exceptional founders into a community for life as they create ground-breaking businesses of tomorrow.

“Startmate is such a prestigious program with so many great connections and amazing alumni,” says Morton. “We have been blown away by the help offered by the mentors and the squad we’ve been paired with. There’s no doubt that the company is advancing quicker now with all the help and support we are getting from Startmate.” www.startmate.com.au www.bygen.com.au

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

amtil.com.au 1311AMTIL/BD

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Adaptalift: New cost-effective Hyster UT and Yale UX forklift ranges Adaptalift Group is backing the new Hyster UT and Yale UX Series lift trucks to satisfy a strong need in the Australian market for quality-engineered, cost-effective forklifts suited to lower frequency applications typically limited to 1,000 hours a year.

“We’ve been an Australian Hyster dealer for many years, and we see the new UT Series forklift model opening up the opportunity to have three levels of product in markets with significant volumes, like retail, warehousing, food and beverage, and logistics,” said Steven Taylor, CEO of Adaptalift Group. “Through our long-term relationship with Hyster-Yale Group, we were appointed as one of their Yale dealers in Australia in 2018, and we see the new Yale UX Series as an ideal opportunity to lift the profile of Yale in key markets with lower-intensity usage forklift demands.”

The new Hyster UT Series and Yale UX Series diesel or dual-fuel counterbalance forklifts, pallet trucks and stackers come in six different capacities from 1.5 to 3.5 tonnes, delivering an attractive, affordable and uncomplicated range for enhanced user choice across many industries. The new ranges provide an attractive option for customers who require quality materials handling equipment – backed by service provided by the dealer network and support of the globally leading Hyster-Yale Group – but don’t need advanced functionalities for their tasks.

Adaptalift is a major dealer for both Hyster and Yale in Australia and is demonstrating its full support for the launches of the reliable new forklift ranges through strong local stock levels. Hyster-Yale Asia-Pacific Managing Director Tony Fagg says he’s delighted that Adaptalift is providing its full support and backing for the launch of the new ranges.

“Adaptalift has always been an innovative, forward-thinking and active dealer,” said Fagg. “They’re a highly regarded dealer and we’re already impressed with their plans to tackle new markets with the new lift truck ranges.”

Yale’s value proposition – “Simply Efficient” – has at its core the understanding that, if a forklift usage is only around four hours a day, companies don’t need a more expensive forklift that has been designed to handle all-day, everyday applications.

“But what such users do want – and which is provided by the new Yale UX range – is a strong global brand backed by a professional dealer and service network across Asia-Pacific,” explained Fagg.

Customer benefits

The Yale dealer and service network are in turn backed by the global Hyster-Yale Group with a full product line of lift trucks in operation across hundreds of industries worldwide. Yale is one of the oldest original brands of lift trucks and warehouse equipment in the world, having been in the lifting business for more than 140 years.

Hyster and Yale’s new ranges provide a simple approach to materials handling, backed by 24/7 service – which is particularly attractive to customers whose equipment is required to work intermittently over a working week, on an as-required basis, typically up to 1,000 hours a year.

“The Yale brand – with its ‘People, Products, Productivity’ tagline – prides itself on helping customers solve materials handling challenges with solutions that individual organisations need, when and how they need them,” added Fagg. “This requires the type of backing provided with the UX Series throughout Asia-Pacific.”

“Not only do the new ranges fill a gap in the market for a high quality, low usage forklift backed by reliable service, they also have outstanding features for the user,” said Taylor. “We’re impressed with the three-piece overhead guard, comfortable seat and access step. Several Adaptalift forklift operators tested the new units and were impressed with the responsiveness of the hydraulics and smooth operation of the machine. It’s rare to find such quality engineering for low-use forklifts, which I believe will be a welcome change in the market.”

Strong distributor network

Hyster’s value proposition – “Meets the Need. Makes the Move.”

– relates to customers who don’t need particular advanced functionality features but prefer proven materials handling solutions backed by a supplier they can trust.

“The advantage the new range brings with its ‘Meets the Need’ value proposition is fine-tuned responsiveness to customers’ individual needs, including varying hours of service, different applications, cost of ownership, capability, strength and dependability of the product,” said Fagg. Rather than pigeonholing basic utility needs or offering one-size-fits-all solutions, the UT Series philosophy opens a discussion with customers on what their specific needs are and how long they need to use equipment each day.

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Hyster-Yale has a strong, established professional dealer and service network extending across Asia-Pacific, a strength that is in turn backed by Hyster-Yale globally, which has been building relationships and partnering with customers, suppliers, dealers, and employees over many decades.

“Hyster-Yale’s Asia-Pacific network of especially chosen, experienced, independent dealers such as Adaptalift Group offers outstanding service back-up. Their wide range of support services deliver reliability and productivity to their customers,” said Fagg.

“The advantage the new ranges bring is fine-tuned responsiveness to customers’ individual needs, including varying hours of service, different applications, cost of ownership, capability, strength and dependability of the product.” www.adaptalift.com.au

MATERIALS HANDLING

Enmin’s industrial vibrators keep bulk materials, profits flowing Ensuring smooth, unrestricted flow of materials in any bulk handling situation is crucial for maximising productivity and cost efficiency. However, issues such as compaction, bridging and rat-holing can arise when normally free flowing products have been stored for long periods of time. The solution for this is often as simple as shaking the product loose.

Manually tapping hoppers and other storage containers with rubber mallets or other devices can be unsafe, time consuming and inefficient, which is why Enmin offers a cost-effective alternative with its range of Industrial vibrators. Based in Melbourne, Enmin is an Australian market leader in the areas of standard and nonstandard materials handling systems and applications.

Enmin’s customised range of industrial vibrators suits any industry that handles bulk material. The range is specifically designed to suit Australia’s environment and covers a multitude of applications such as mining, quarrying, food processing and agriculture. Enmin stocks an extensive range of both pneumatic and electric industrial vibrators for hopper agitation and unloading.

“By de-compacting materials, industrial vibrators improve the flow of product and reduce workload whilst improving workplace safety,” says Enmin General Manager Anthony Gallaher.

In most instances, industrial vibrators are installed externally. This requires minimal modification to the hopper as they are attached via a weld-on mounting assembly. If there is a gate or door, the vibrator can be automatically activated whenever it is opened, meaning no more production interruptions to free up the material. Because there are no internal modifications to the structure required, installation is completed in a matter of hours.

Individual hoppers can vary in size, shape and the material it holds, which can make it difficult to fix flow issues with a generic solution.

To counter this, Enmin can modify existing plant drawings to show the exact positioning of the vibrator according to a customer’s needs; particularly useful if a customer’s plant is in a remote location.

“We are one of the few companies that can offer the complete package; not only the vibrator but also the mounting plate and the pneumatic control system, the tubes and the fittings,” says Gallaher.

“Quite simply we offer a complete one-stop solution.”

Enmin has a full range of air and ball vibrators that come with quick-release air fittings and mufflers. In addition, Enmin also stocks Food & Drug Administration (FDA)-approved acetal plastic turbine vibrators for food applications and ‘Steel-lite’ coated piston vibrators for added protection in harsh environments – a feature most competitors don’t offer!

“In workplaces where noise is an issue, Enmin has a range of nonimpacting and air-cushioned vibrators,” Gallaher adds. “Where noise is not an issue Enmin can supply vibrators that offer a big punch! And for companies that need to minimise air consumption, Enmin has a range of air-efficient vibrators.”

While hoppers are a key market, industrial vibrators will aid material flow in other parts of the bulk handling process such as industrial chutes and pipes. Enmin vibrators have the capability to withstand harsh conditions and are available with an array of force, frequency and power options to fit most chutes and pipe applications.

Industrial vibrators can also be used for settling and packing materials in drums, containers, packages, moulds and forms for optimisation of container space and cost reduction. Like all Enmin equipment, its industrial vibrators are designed and manufactured to provide excellent reliability and outstanding durability providing they are correctly maintained.

“It is important to ensure the air supplying a vibrator is clean, dry and regulated,” Gallaher notes. “Once every 12 months we recommend removing the vibrator and disassembling and cleaning the internal components. By performing regular preventative maintenance and depending upon the environment it’s located in, an industrial vibrator can last for up to 25 years.

“There is a perception that industrial vibrators are costly products, but nothing could be further from the truth. Prices for our industrial vibrators range from $250 to $2,500 depending on the size and application. When you factor in the immediate improvement in productivity, the return on investment is quickly achieved.”

In addition to industrial vibrators Enmin is a market leader in the design and manufacture of vibratory and product handling equipment for the food industry, producing an extensive range of equipment for numerous food and pet food products. The company’s list of customers includes most leading food industry manufacturers. “With over 40 years of experience in the application of industrial vibrators throughout Australia, Enmin has unparalleled expertise in providing a solution for any bulk material flow problem,” Gallaher concludes. www.enmin.com.au

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Right part, right place, right time: The keys to successful Lean material management Many manufacturers have adopted Lean tools focused on improving the efficiency of production processes. However, often despite these efforts, manufacturers still suffer downtime, poor productivity and missed deliveries. The cause is the inability to get materials to the right place in the right time and in the right quantity. By Tim McLean.

Many companies know about Kanban and pull systems, but few seem confident to use them. Instead they often rely on cumbersome and ineffective spreadsheets. ERP systems also fail to offer solutions to many companies. A value stream map will show the process steps and, critically, the information flows that trigger the movement of materials and production jobs from one process to the next. From this you can develop your future state map. It is at this point you will probably be introduced to some new concepts for managing the flow of production jobs and materials.

The difference between push, pull and flow The first response many companies adopt to overcome problems with material shortages and late deliveries, is to look for a software solution. I call this automating the chaos! There are very many systems available, but most offer a enterprise resource planning or ERP approach. In this approach, the business enters a forecast for expected customer requirements in the future. This is called a “push” system, since materials and production are “pushed” through the production process in anticipation of future customer demand. This approach relies on customer forecasts being accurate. If you are one of the many companies which cannot get accurate forecasts from customers, then the ERP approach will be ineffective.

A Kanban control board.

by the downstream process over this replenishment lead time.

Divide this by the number of parts per container to work out the number of Kanban cards you need in circulation for each part. You can then adjust the amount of parts in circulation up or down by adding or removing Kanban cards to the system.

Two-bin system

In a Lean process, we aim to achieve “flow”. This means that individual products flow from process to process in sequence. The ideal is “one piece flow” such as on an assembly line or production “cell”. Each process hands the product on to the next process, without work in progress or delay between processes. Failing that, a “First in First Out” (FIFO) lane can be used to control work between processes. A FIFO lane has space for a limited amount of product, usually no more than a few hours of production. Once the lane is full, the upstream process needs to stop. This controls the work in progress and ensures consistent, fast lead time for all products flowing between the two processes. Sometimes, you cannot achieve flow. For example, a process where it is necessary to run a batch of product, such as heat treatment or plating, or where set-up times are too long to permit a batch size of one unit. Where processes have different hours of operation (e.g. one shift assembly vs. three shift machining), it can also be very difficult to achieve flow. In these situations, a pull approach can be used. This means that production at the upstream process is “pulled” by the consumption of parts at the downstream process.

For small low-value items, a two-bin system can be a simple alternative to Kanban cards. In a two-bin system, a maximum of two bins of parts are held at the downstream process. The bins are usually clearly labelled with the part number and quantity of parts they are supposed to contain. One bin will be in use and the second bin will be full awaiting use. When the first bin is empty the operator drops it down a return chute or places it in a designated location for material handlers to pick up. The empty bin is then returned to the store, refilled and returned full to the line. The quantity in each bin needs to be enough to allow time for the empty bin to be replenished before the operator is using runs out of parts.

Kanban

Batch processes

There are many different types of pull systems used in Lean manufacturing processes. The one readers are likely to be most familiar with is Kanban. In a Kanban system, a card is attached to each container of materials. As the materials are consumed on the production line, the cards are removed and returned to the upstream process or to the supplier. Parts are then picked or manufactured in the quantities specified on the Kanban cards, the cards are attached to the containers and the replacement parts sent back to the line.

Usually multiple Kanban cards will be required for each part.

In many cases, upstream processes that are supplying parts will manufacture them in batches. In this case, a system is needed to accumulate Kanban requirements, until the target batch quantity is achieved. One way to do this is to set up a Kanban control board as shown in the picture above.

To calculate the number of cards required, you need to work out the lead time essential to return the cards to the upstream process or supplier, to replenish the consumed parts and then to return these parts to the downstream process. You then need to calculate the maximum (not the average) number of parts that will be consumed

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Two-bin systems work well, but rely on short replenishment lead times, as the parts must be replenished before the bin in use is finished. They generally only work for items that can be supplied from a store to the line, or for items where the supplier offers regular (at least daily) deliveries. They are very commonly used for fasteners and consumables. As the replenishment lead time increases, it becomes necessary to introduce more bins to maintain supply and the system reverts to the multi-card Kanban system.

Kanbans are returned to this board and grouped by product. In this case, the target batch size is four. When a product has four cards on the control board, the Kanban cards are then hung on the rail above the board. The machine operator then takes the cards in batches of four. There is no need for a production schedule, as the order of production jobs is simply the order that the batches are loaded on to the rail. There are many other variations on pull systems for batch processes, but these require more detailed explanation than is possible in this article.

BUSINESS MANAGEMENT

ARE YOU OPTIMISING YOUR R&D CLAIM POTENTIAL? Kanban cards like these trigger replenishment of materials. They are the most well-known Lean material management tool, but by no means the only one.

A two-bin Kanban system. When the bin at the front is empty, the bin behind slides down to replace it and the first bin is replenished.

Purchased parts supermarket A common challenge in manufacturing is ensuring that purchased parts arrive on time. The traditional approach is to break down the bill of materials for a job and order the parts for each job individually.

However, in most cases parts are used in many jobs and matching up the parts requirements with individual jobs involves many transactions and is highly error-prone. In your local supermarket, the shelves are replenished at a regular interval to replace the products that have been sold. Each location in the supermarket is sized to ensure that the product does not run out before the shelves are restocked. A purchased parts supermarket operates on exactly the same approach. A “plan for every part” is developed which has the characteristic of each part including its usage, supplier lead time, pack type, pack size and type of storage (eg. shelving, racking or block stacked). Each part is then stored in a dedicated location to make checking stock easy. On a designated day each week (or each day if necessary), the locations storing that suppliers’ parts are checked and the quantity needed to restock the shelves is ordered.

An even better alternative is to get the suppliers to restock the “supermarket shelves” themselves.

The need to change culture Any system for controlling material requires a level of shop floor discipline and the systems described above are no exception. If products are not returned to their correct location or Kanban cards and product bins get lost, then the system will quickly break down.

To create this level of shop floor control we frequently implement 5S techniques to create a discipline of a “place for everything and everything in its place”. The role of the front line supervisor is also critical in ensuring the system is maintained and improved. In our experience, the effort is worth it. Shortages are typically reduced by more than 90%, customer lead times are cut in half and inventory reduced by 50%. The level of expediting and stress is also dramatically reduced – which is often the benefit that our clients enjoy the most!

William Buck are the accountants and advisers to Australian Manufacturing Technology Institute Limited (AMTIL) and preferred supplier to members. William Buck has a dedicated R&D Incentives team with over 15 years experience consulting in the R&D space. We offer a complimentary consultation to assess your businesses opportunity to make R&D Tax Incentive claims.

In a complimentary consultation we will undergo the following; — Preliminary evaluation of R&D claim eligibility — Review of past R&D claims — Explore opportunities to maximise R&D claims (past and future) — Uncover Accelerating Commercialisation (AC) grant opportunities.

A personal touch backed by relevant experience We work with a wide range of manufacturing clients offering a complete range of R&D, business, tax and advisory services from a network of local offices. This gives our team key insights to the industry and the ability to offer a complete business solution.

To book your William Buck Hour contact Dr Rita Choueiri Dr Rita Choueiri Principal, R&D Incentives Ph: 03 8823 6840 rita.choueiri@williambuck.com

Tim McLean is the Director of leading Lean consultants TXM Lean Solutions. www.txm.com

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Design thinking… or design doing?

Broadmeadows-based manufacturer Integra Systems recently received mentoring from design specialist Roger Simpson under the Victorian Government’s Design2Thrive program. Simpson shared some of his design insights.

The process known as ‘Design Thinking’ has been adopted as standard practice at some of the world’s most successful companies – Apple, Google, Samsung and GE, to name just a few. Similarly, some of the most prestigious seats of learning teach courses in this progressive approach to problem-solving.

Rikke Friis Dam, Co-Founder and Editor-in-Chief of Interaction Design Foundation and product designer Yu Siang Teo, explain the main phases of the Design Thinking process as taught at Stanford University’s renowned school design institute: • Empathise with your users.

• Define your users’ needs.

• Ideate by challenging assumptions and creating ideas for innovative solutions.

• Prototype to start creating solutions.

• Test your solutions.

As they explain, these steps are not linear: “You should not understand the phases as a hierarchical or step-by-step process.

Instead, you should look at it as an overview of the modes or phases that contribute to an innovative project, rather than sequential steps.”

To implement a focus on the end-user experience in the workplace, Simpson believes in top-down implementation. He uses Australia’s four major banks as an example of industries that can talk the talk yet struggle to walk the walk.

“In any corporation, the person who’s CEO of that organisation, and that company’s board, they need to deeply understand why it’s important to focus on end-user outcomes. If they don’t believe in that, they will be motivated by other priorities. How do you fix that?

Well, if the people that are running the organisation don’t believe it’s important, nothing will change. So that’s not such an easy thing to do.”

In Australia, many businesses may project an image of putting customers first yet, in reality, their practices suggest otherwise.

“You don’t need to look any further than the big four banks in Australia. They would claim in their vision, values and purpose or mission statement to be doing everything for the end-user – the customer – but, as we’ve seen, their practices, arguably, show they’re not at all prioritising end-user needs.”

Roger Simpson, design consultant and mentor to the team at Integra believes that ‘Design Thinking’ as a term is highly misleading.

Instead, he poses the alternative of ‘Design Doing’ as far more apt description of an effective design process for delivering a best-inclass product.

When asked if there are countries that have a more end-userfocused approach, Simpson cites Denmark as a prime example.

A small country in terms of landmass and population, and without natural resources to the extent of Australia, the Danes boast a number of global brands that are considered best in their category: Velux Windows, Kvadrat fabrics, and the rejuvenated Lego, among others.

“I think it’s an empty phrase,” he answers bluntly when asked why Design Thinking is so important. “I think that Design Thinking has been invented by people who are not designers to try and create some theory around the practice of design. Designers don’t sit around contemplating their navel and waiting for a light bulb moment. I think the processes that designers go through are far more important than a catch-cry term.

“They’re really interested in what works for their existing end-users, and also people they might like to have as customers,” Simpson explains. “They have a kind of open development process where they guard against assumptive thinking. That’s really important.

Those Danish companies know the world’s changing really fast, and they know they can’t stand still, so they don’t assume they can keep doing things the same way as they’ve done them before.”

“It’s not about the thinking, it’s about the process,” he emphasises.

“It’s about going out and trying to discover what gaps and opportunities there are, and what are the unmet end-user needs.

I don’t think that’s got anything to do with thinking, but it’s got everything to do with processes around doing.”

Which isn’t to say that Australian manufacturers across the board need to smarten up. With an admitted bias (as a keen surfer), Simpson cites Torquay-based Rip Curl as a classic example of one Australian company wisely executing an end-user focus and reaping rewards on a global scale.

When Simpson talks about Design Doing, he’s talking about experimentation. He believes the process is fundamentally about being really close to the end-user, being – as he describes it – “in touching distance of the end-user”. The ability to listen, learn and observe what’s happening are just some of the essential skills needed to discover gaps and opportunities, and then turn those discoveries into solutions.

“Doug Warbrick and Brian Singer [the founders of Rip Curl] were shaping surfboards, and then they decided they wanted to make wetsuits,” he explains. “They were using the best wetsuits in the world, mostly from America. And they wanted to make a wetsuit that was better than the stuff they were already using. So, their ambition on day one was to not copy the stuff they were using but to make a better wetsuit.”

For Simpson, the most important part of the Design Doing process is to think from the perspective of the end-user. Through this approach, ‘disruption’ takes care of itself.

“It started as a little craft industry. They made the best wetsuit in the world and they actually still make the best wetsuit in the world.

As a surfer and a watersports person I can tell you that’s my view!”

Simpson laughs. “And I think that’s been the difference between them and their other competitors in that space. I think the driving force for Rip Curl was to understand the end-users and deliver the best products. Now they’re into fashion and there’s a bit of arbitrary stock in there, but I think that’s the difference between Rip Curl and those other companies that haven’t survived.”

“What’s going on in [the end-user’s] brain? What do they need? What haven’t they got?” he expounds. “You’ve got to find out what they aspire to, what their unmet needs are, and always be thinking from the point of view of the person who’s going to be using the product or service – not the channel partner like Bunnings or Woolworths or someone, but the person who’s going to be actually using the product in the end.

“It’s all about process,” he continues. “I’m not saying process is boring – it’s exciting – but it’s about researching, and not through market research but through real presence in the marketplace.

When you’re close to end-use products and services, that’s when discoveries are made, and great products and services are crafted.”

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While Rip Curl isn’t Australia’s only Design Doing success story, in Simpson’s eyes, some Australian companies have still yet to come to terms with what they need to do to survive.

“We tend to think that all we need to do is be competitive, have a competitive product, but I think the counter argument is, if you can’t have the best product, don’t compete, don’t bother, don’t do it, do

BUSINESS MANAGEMENT

something else. Find another product or service where you can be the best.”

“It doesn’t matter what sector you’re in, or what you’re trying to do,” he concludes. “You’ve got to have the best product or service in their category. If you don’t, someone who has got that aspiration or has access to those products will simply come over the top and gazump

you. You won’t survive. You’ll be pushed down to trading on price only, and you’ll find there’s no advantage in that if you haven’t got a product that is the best in the category.”

And how do you get best in category product? Design Doing, of course. www.design2thrive.com.au www.integrasystems.com.au

Understanding the science behind work-life balance Ever wondered what balance of exercise, sleep, food and work delivers the best physical and mental health?

A team of scientists led by researchers in South Australia is embarking on a four-year study to find out.

The international team will use 200,000 data sources from Fitbits, activity monitors and time-use surveys linked with health data to create a prototype. University of South Australia lead researcher Dr Dot Dumuid said first-class prototype would provide personalised advice on how best to use a 24-hour period for specific health outcomes.

She said Israeli mathematicians, University of Adelaide computer scientists as well as global behavioural epidemiologists and public health specialists would develop an analytical method to work out the ideal length of time needed on activities in order to achieve particular outcomes. The software will form the basis of an online tool allowing people to improve time management while achieving the optimal health for their lifestyle.

“Every day everybody is given 24 hours. How people allocate that time to activities impacts their health,” Dr Dumuid said. “We already know that things like screen time, exercise, sleep and work-life balance influence health, but now we are thinking about these things as linked parts that together make up a complete day. So, rather than talking about activities in isolation, we talk about ‘healthy days’ or ‘the optimal mix of activities’.”

The project was recently awarded a $951,708 grant from Australia’s National Health and Medical Research Council to collate data, create and test optimisation methods and develop a prototype.

“We already have access to many such data sets and we are reaching out to studies across the world to gain access to their data also,” Dr Dumuid said. “But because people measure time in lots of different ways and there are different brands and different parameters that people have used in their studies, we will have to do some calibration across the different studies to make sure they can be put together.

“In industry optimisation, this kind of data happens all the time.

For example, people optimise the mix of fertilizer to get the best crop yields but then there are also other factors like the lowest cost.”

Dr Dumuid said the usability of the prototype would be tested in a series of focus group sessions. Despite the plethora of international health data available, she said previous studies had focused on single outcomes opposed to providing the perfect mix of activities for an individual.

“We’re all interested in different health outcomes but so far we’ve really just looked at one sort of health outcome at a time. For example, getting a lot of exercise may be best for adiposity outcomes, whereas getting enough sitting time might be best for academic outcomes. So, the best day or the best activity for one type of outcome won’t necessarily be the best for another type of outcome.” www.unisa.edu.au

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From offshoring to rightshoring: Transforming manufacturing in three easy steps After two decades of offshore production in low-cost countries, many manufacturers are now asking: do we continue offshoring or should we consider reshoring? The right answer, writes Paavo Kakela, is that manufacturers should transform their operations to “rightshoring”.

In the 1990s, manufacturers across the world – including Australia – were sold on the lower cost of Asian labour. This is how the global offshoring boom started in Asia. In the millennium, offshoring peaked, and between 2011 and 2016, the number of Australian manufacturing jobs fell by a staggering 24%.

How times have changed since then. Manufacturing salaries in Asia have risen dramatically, and manufacturers have experienced the flip-side of cheap overseas production: these include low quality, high duties and taxes, expensive freight costs, bloated inventories, and long lead times. China’s 2017 National Intelligence Law, which requires Chinese companies to contribute to national intelligence, has made intellectual property thefts a nightmare. Environmental and social issues are causing substantial damage to manufacturers’ reputations. Lastly, the rise of protectionist policies and continuous global uncertainty has turned the tide for offshoring – it simply doesn’t guarantee profits anymore.

Rapid advancements in automation technologies, robotics and predictive analytics have propelled reshoring since 2010 to become a more prominent alternative for offshoring globally.

According to the Reshoring Initiative, a US-based pro-reshoring industry coalition, reshoring now generates more manufacturing jobs in the US than what’s offshored overseas – in 2018, 1,389 companies announced a total of 145,000 jobs. In Australia, too, the recent reports signal a positive trend – more than 85,000 new manufacturing jobs appeared in the country in 2018.

Benefits of reshoring The benefits of reshoring sound great. How can you, as manufacturer resist the perks – tax incentives, higher quality, shorter lead times, smaller inventories – while also meeting fluctuating customer demands quickly, easier collaboration, skilled and innovative workers, and protected intellectual property? Selling locally made, premium-priced products, eliminating import duties, and reducing transportation costs can increase profits substantially.

So, the benefits of reshoring can eventually exceed the savings that firms get due to low overseas wages. Despite its lucrative benefits, however, reshoring is not as easy as you might think.

Reshoring challenges Many companies have reshored at least a part of their production.

However, most companies still continue their manufacturing in Asia – simply because it’s often more cost-efficient, due to the vast infrastructure that has been built up in the region over the past decades.

Some countries have lost skilled manufacturing engineers, technicians, and tooling specialists as a result of offshoring. The recruitment could become a severe roadblock for large-scale reshoring. Further barriers include the high labour costs of the West, and, in turn, the expensive energy costs found in Europe.

Interestingly, a survey by the Manufacturing Group at the University of Warwick in the UK, conducted for the industry body Reshoring UK, found that only 13% of companies have directly reshored.

However, 52% have reshored indirectly – this means, instead of bringing the bulk of production home, they instead built additional capacity at home.

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Reshoring in large volumes is difficult and costly. As a result, the forerunner industries have stopped thinking of whether to offshore or reshore. Instead, they have moved onto seeking strategies for “rightshoring”!

A smart rightshoring strategy can generate positive economic net value and deliver a competitive advantage in the long term and help to contribute to a more sustainable future.

How can I build a profitable rightshoring model?

There is no single rightshoring model that works for every manufacturer. We developed a three-step approach to plan rightshoring: this involves having a business case, a strategy and technology. We suggest you start by calculating the return on investment (ROI) to see if there is a business case that will work for your company!

Step 1 – Business case: Rightshoring is just like any other investment – it must pay back the initial costs, or otherwise it’s not worth pursuing. Here are the three primary value contributors to consider: • Cost savings due to higher quality. One of the biggest offshoring disappointments has been inferior product quality, which increases the costs in multiple ways – through customer reclamations, re-production, waste, and lost sales. For example, a LED tube manufacturer with an annual production capacity of one million units could reduce the share of faulty units from 3.5% to 0.5% by moving production from a Chinese factory to a fully automated microfactory in the US. • Supply chain benefits. The simplified supply chain is a crucial benefit in rightshoring. It saves money because of the lower working capital. In the case of the LED tube manufacturer, the delivery time was reduced from five weeks to one week by radically streamlining the supply chain. You can stack up savings from reduced logistics costs, shorter lead times, more accurate forecasting, better flexibility, smaller inventories, and reduced waste and obsoletion.

• Additional sales through higher brand value. As a local manufacturer, you can tag a Made in Australia label on your products. Depending on the sector, the selling price for domestic products can be as high as double compared to imported products. Even in the commoditised LED tube market, the price of a local product was estimated to be 12% higher compared to Chinese products. Additionally, domestic products can sometimes open you to the public procurement markets.

Step 2 – Strategy: To create a rightshoring strategy in today’s complicated, highly competitive and globally networked world is not easy. By asking yourself the right questions, it can help to you approach the strategy – for example, by answering ‘yes’ to these questions might help you decide the case for reshoring or rightshoring: • Do you want to protect your immaterial property rights by manufacturing locally? Or do you want to develop a new manufacturing process in conjunction with your R&D? • Are you making high-margin, short-run products designed for local markets? Or are you serving multiple seasons with regional variations?

BUSINESS MANAGEMENT

• Do you need to reduce lead times because of customised products, frequent updates, or highly variable regional demands?

• Does your company have a global system for sourcing raw materials with regional manufacturing, and local distribution?

• Do you have exceptionally high transport costs, or are you transporting a lot of individual parts? Could you optimise costs by manufacturing pre-assembly modules near the needed raw materials if there were cost-efficient, highly robotised microfactories?

• Do you have significant production volumes, bulky or heavy products, energy-intensive manufacturing, or special logistics requirements?

Step 3 – Technology: Let’s face it, reshoring or rightshoring won’t work out simply by moving your overseas production lines home. Cost-efficient and competitive manufacturing in the Western continent requires a lean, centralised organisation, one that is extensively robotised, with automated production, big data, and predictive maintenance algorithms.

demand. Microfactory lines can be installed in one workday. If you need to change your product design suddenly, they allow for easy modifications and updates. You can add additional modules later if, for instance, testing or packaging is needed. The set-up time for installing new modules can be counted in hours.

If there are several distribution plants involved, a Cloud-based control solution allows you to centralise the operational team and remotely support the on-site field engineers to guarantee minimum downtime in the process with lower operating expenses (opex).

When new, updated parts are needed, regardless of a different size or form factor, vision-guided general feeders can enable quick and easy changes to new parts. For an uninterrupted operation, big data is continuously collected from your product lines and analysed in the Cloud. In case of any deviations in the process, problems can be fixed remotely before they stop the production line.

By harnessing advanced manufacturing technologies, you can minimise the initial capital expenditure (capex) and risks, reduce operational costs in the long run, and gain maximum flexibility in your operations.

Since the beginning of history, manufacturing has been in a continuous state of transformation. When the global offshoring boom came to its end, manufacturers quickly started to board the reshoring strategy. However, the world is becoming an everchanging and complicated business environment. In the future, the winning manufacturers are those who are the quickest to harness the new technologies, including automation, robotics, and data analytics – and those who can carve out a smart, agile, and scalable rightshoring strategy!

Agility and scalability are crucial for efficient rightshoring. To get this right, you will need a modular microfactory platform, which allows you to increase the investment gradually, in line with the actual

Paavo Kakela is the CEO of EID Robotics Oy, a global provider of modular microfactory systems. www.eidrobotics.com

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Manufacturing myth-busting – Why we must get behind Australian manufacturing Busting the myth that Australian manufacturing is dead and buried is a driving passion of Australian electronics manufacturer Ray Keefe, who has developed market-leading products in Australia for more than 30 years.

“Unfortunately, a belief among many homesoil manufacturers that overseas competition has killed off Australian manufacturing fuels a public misconception that the industry is all but phased out. But the facts defy the myth,” says Keefe. “Recent statistics show that manufacturing in this country has grown almost every month since October 2015, and 2018 saw 85,000 new jobs created in manufacturing, among the highest of any sector.”

Keefe is the head of Melbourne-based electronics design and embedded software development firm Successful Endeavours, whose electronics product excellence and business acumen has seen the company recently notch up its 47th award win.

“The biggest barrier to Australian manufacturing is not overseas competition,” Keefe adds. “It’s the mindset of many Australian manufacturers who think that manufacturing products overseas is the only viable option. That may be true for highly commoditised products and where quality and longevity are not the highest priorities.

But when you want to produce a highly reliable product, Australian manufacturing changes the sales conversation because of the integrity of the process and ability to directly follow up the manufacturer if you need something addressed with the product.”

Keefe finds it hugely satisfying that his business is recognised for developing world-class, cost-effective technologies

for Australian electronics manufacturers.

However, it is his laser-focussed vision to see the continued growth and long-term resilience of the manufacturing industry that fuels his drive to push the limits of innovation.

“To underline the importance of manufacturing, think of a world without it,” Keefe says. “There would be no cars, no public transport, no utilities, empty shelves on supermarkets, no furniture, no clothes, no buildings, no mobile phones, computers or televisions, and the list goes on. Almost every facet of modern-day living is made possible because of a manufacturing process; so as a nation we need to do everything in our power to support and nurture its continued growth.”

In the mid-1900s, 90% of all manufactured products used in Australia were made in Australia but this had plummeted to just 10% by the early-2000s and just 7% in recent years.

While manufacturing may not return to the peak of last century, the fact that Australian manufacturing has been on an upward trajectory for nearly four years now is a positive trend that Keefe is determined to see continue.

Why? “Because I’ve got grandchildren!” he explains. “I asked myself 20 years ago where jobs in the future would come from.

That’s why I’m supporting the industry that generates more jobs for this country than any other industry.”

Keefe cites data from the Victorian Government showing that, for every direct job in manufacturing, up to five indirect jobs are created.

“In fact, about 40% of the nation’s approximately 11 million jobs depend on manufacturing if you follow the figures through,” he notes. “There is a clear message to all governments in these figures. Knowing that manufacturing is the most critical sector in Australia in terms of job creation, governments at all levels need to prioritise the industry when developing economic policy.

“Contrary to what’s happening in Australia, the world’s top manufacturing nations including Switzerland, Sweden, Norway, Finland, Germany, Japan and China, have strong manufacturing industries and clear industry policies. They have attractive government incentives and tax concessions that make it conducive for local suppliers to bid for the work, and every level of government and business work together to ensure what happens is in everyone’s best interest.

“If we want to grow Australian jobs, maintain our standard of living and maintain our position in the world economy; then governments need to better support industries that make things and create fundamental value, like manufacturing.”

A prolific manufacturer Successful Endeavours is a prolific maker of things. Since its establishment in 1997,

Ray Keefe with some of the Successful Endeavours team.

Back row (from left): Ben Hearne, Rob Struthers, John Ziino, Pouya Mansouri, Yi Liu. Front row: Matt Ratten, Dana Jing, Ray Keefe.

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BUSINESS MANAGEMENT

the company has produced more than 2,000 products or product enhancements.

It currently finishes a design, component, upgrade or complete electronics product every three days.

“We have positioned ourselves at the point of maximum economic leverage in the manufacturing supply chain because this is how we can make the biggest difference,” Keefe says. “For every $1 spent with our firm, there’s $100 worth of economic generation downstream with other businesses valueadding to the process.

“I believe that a rising tide lifts all boats and manufacturing is the engine to do the lifting.

That’s why our focus is on collaborating with other Australian manufacturers to design and make new products in Australia.”

Successful Endeavours is leading the way to retain value creation in Australia, with many ground-breaking projects designed for Australian manufacturers and other businesses.

Some examples of recent projects include: • Design of an environmental monitoring device, the arcHub Smart Cities Telemetry sensor suite, for The Active Reactor Company. This device measures multiple sensor types

including particulates, gases, microclimate, pedestrian traffic and water level, and supports a host of other sensor types. This design came runner up in the Agilent Innovation in Analytical Science Award at the international CleanUp 2017 conference.

• Design of an early fault detection product for IND Technology, which detects when a piece of equipment in the electricity distribution grid is starting to fail and where it is located. This won the Best Network Implementation category at the 2016 PACE Zenith Awards and the updated version for rural networks that can detect symptoms that ultimately lead to bushfires, won the IoT Innovation award for Australia in 2018.

• Design of capacitor bank controllers for ABB’s High Voltage Division.

These controllers “clean up” power in the electricity grid so energy can be used efficiently while producing less greenhouse gas emissions.

While Keefe has a message for government, he also believes Australian businesses can do more to support Australian manufacturers.

“For instance, many Australian power companies are importing capacitor bank controllers rather than buying them from Australian-based companies such as ABB, which make the same component here,” he remarks.

“The manufacturing industry can also help itself, particularly in the area of collaboration.

The OECD ranks Australia low on collaboration. I believe we could achieve so much more if, as a nation, we were more open to working with each other rather than having a silo mentality. People are worried that their portion of the pie will be reduced if they work with others because they will have to share. On the contrary, the more we work together, the more value we can create so the bigger the pie will become for all of us.

“Australian manufacturing is growing but to grow exponentially, we need to get everyone behind it: government, businesses and the manufacturing industry itself. We have the opportunity to support future generations of workers and the prosperity of our nation if we do.” www.successful.com.au

HR WORKSHOP: Understanding Modern Awards Tuesday 21 April 2020 8.30 am – 12.00 pm Melbourne CBD AMTIL member discount applies!

It’s been all across the news… the number of high-profile companies exposed to wage underpayment claims goes to show how difficult Modern Awards can be to navigate.

Our workshop will simplify this legal minefield and is suitable for Managers and Human Resources professionals. $425.00 includes GST and AMTIL member discount. Use code: <AMTMA> when booking to receive your discount.

Purchase your tickets today via EventBrite: https://bit.ly/38jY5NO

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SEW Eurodrive - The taste of sweet success SEW Eurodrive’s MOVI-C Modular Automation System can cover a range of complex motion control applications, helping one confectionery manufacturer achieve optimum results.

When a candy manufacturer in the US needed a specific machine to manufacture soft-gummy candies it turned to JH Tester Industrial Automation, which has been providing the candy manufacturer with machine control solutions for more than 10 years.

Located in the western suburbs of Sydney, JH Tester has been in operation for over 35 years. Family-owned and operated, the company was started in 1980 by John Tester providing technical service and support to the textile industry. Over 20 years ago, JH Tester transitioned its focus to the design and manufacture of automated systems for a variety of sectors, including manufacturing, food and beverage, building, mining, infrastructure, and water processing.

“Our specific strength is motion and motion control – anything that has servo controls is our sweet spot,” Tester said. “And we also have strengths in PLCs and HMIs. We pride ourselves on providing innovative simple automation solutions to often complex challenges in the manufacturing sector.”

Four modules – one solution Designed and built in Australia, the confectionery machine features 18 MOVI-C Movidrive modules axis-controlled by the SEW Eurodrive MOVI-C Controller motion platform.

“We’ve had a very close relationship with SEW ever since they entered the variable speed drive (VSD) market in Australia – around 30 years ago. The quality and reliability of their products and services make them an obvious choice for us,” said Tester.

The MoviSuite software package offers a powerful but flexible programming package that provides planning, commissioning, operation and diagnostics software, electronic control and monitoring devices, mechanical drives and gearmotors in an allin-one solution. All components can be fully integrated into most automation concepts, fieldbus topologies and network standards.

In addition, it is also highly energy-efficient: “It shares a common powerbase, which means that if any axis is in re-generation, or generating power, I can actually use that power by another axis.”

This means that if one axis is slowing down or putting power back into the DC bus, other axis can utilise that power. With effective project planning, this it is possible to have a smaller power section than the collective sum of the control axis, if all axes are not motoring simultaneously, offering a significant savings from an OEM perspective. Aside from the smarter power solutions and compact design platform, the MOVI-C Movidrive Modular also presented performance enhancements with motor resolution of 65,536ppr, which has proven to offer exceptional motor performance. Another important aspect for implementing this hardware was the integrated safe circuit with level PLe performance.

The simplicity of the MOVI-C MoviSuite software package allowed easy integration for the entire hardware package.

The MOVI-C Controller motion platform receives setpoints for single-axis or coordinated motions and determines the motion path for the connected application axis, thereby taking care of tasks such as phase-synchronous operation, electronic CAM function or kinematics. Predefined software modules are used to implement the motion control drive function quickly and reliably with the aid of graphical editors. Over 50 kinematic models provide for a broad range of mechanical configurations already being covered. Data is stored via a data exchange function on a memory card in the MOVI-C controller.

“It also has only one platform to program for the 18 axes – it uses a common master virtual encoder to co-ordinate many axis, making it highly co-ordinated,” said Tester. “The end product, in this example the confection machine, is therefore highly user-friendly and meets our standard for creating simple solutions to complex challenges.

All drive functions of the motion control topology are available in the module automation topology. In addition to the graphical editors for the drive functions, automation tasks associated with the higherlevel master controller can also be implemented in part or in full in a straightforward and flexible approach using the programming system in the MOVI-C controller.

“Because it is a highly integrated automated solution, we have very precise CAM arrangements. While, normally, you’ll see clients using mechanical CAMs, we are using electronic CAMs to more effectively tie axis together,” Tester said. “And the CAMs can be changed onthe-fly, which allows configuration of the machine while it is actually working. It means that we can change and modify the CAM while the motor is running, modify the time unit of the machine and modify the lathe profile of the pumps during operation. These things are ordinarily very difficult to do while a machine is in motion. So, on-thefly updating of CAMs is a big advantage in this package.”

“The all-in-one integrated features of the MOVI-C motion package made it an obvious choice for the project,” said Tester. “Because it is a highly integrated solution, the MOVI-C was perfectly suited for this specific confection machine application, the heart of which was the motion platform that our internal software design engineer developed.

“The MOVI-C is a neat package – it is a compact practical solution.

Because of the MoviDrive Modular dual axis control mounted in one hardware platform, you don’t need to occupy vast cabinet space to house it. Moreover, it reduces the switch gear and auxiliary components required. “

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High rates of productivity can be achieved with the application of the MOVI-C, with up to 2.5 tonnes of candy per hour able to be produced by the confection machine. The centrally-co-ordinating, multiple electronics CAM curves enables multiple axis synchronisation for a virtual axis.

If there are issues with the drive, they can be swapped for others, while the SEW MOVI-C controller can download the parameters in the drive and reconfigure a drive with a minimum of disturbance.

“This kind of flexibility eliminates downtime. You don’t have to stop the machine to load up a CAM profile,” Tester said. “And this, once again, creates higher productivity and higher efficiency in all sorts of ways.”

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The MOVI-C’s Ethernet connectivity also means that JH Tester can deliver high-level after-sales support with remote access.

“We remotely monitor the machine and make sure it is functioning efficiently and as designed for purpose.”

Indeed, customer service and support on both a local and international level is something that JH Tester prides itself in providing to the manufacturing sector.

“We reduce complexity in what can be very complex systems; we’ve simplified the cabinets; we provide high-speed communications on the motion platform. The resultant benefits are simplicity and power,” said Tester. “And, using the MOVI-C, it is very configurable for the end client: it is a stable, reliable, powerful platform that is energy efficient, that doesn’t stop when we change CAMs, that gives you real-time statistics on what it is doing, as well as real-time power consumption and real-position monitoring of every axis. SEW uses ‘smart’ IoT (Internet of Things)-enabled-encoders, so positional data is retained during a power cycle.”

Using the latest technology integrated into the MOVI-C product range has provided many advantages for JH Tester: “We were ahead of the market using such innovative new technologies. We have had a close relationship with SEW for a long time now, and they’re a great company to work with.

“As we develop new solutions with their products, we are now piloting many advanced and cutting-edge industrial automation solutions with SEW. So, it is a very fruitful relationship that works very well for both of us.”

According to Darren Klonowski, National Product Manager at SEW Eurodrive, the new innovative MOVI-C Automation System is a game changer: “MOVI-C is the complete solution for your automation tasks. With the four modules, MoviSuite engineering software, MOVI-C controller technology, compact or modular inverter technology, and centralised or decentralised drive technology, SEW Eurodrive provides a comprehensive modular automation solution from a single source.” www.jhtester.com.au www.sew-eurodrive.com.au

maxon is flying to the sun In February, the Solar Orbiter space probe launched its mission to collect new data about the Sun – with drives from maxon Group playing a substantial role in the construction of the space probe.

The European Space Agency (ESA) wants to study the Sun up close. The Solar Orbiter space probe is equipped with 10 measuring instruments, and scientists hope that the mission, which will last several years, will provide them with new insights into phenomena such as the solar wind, as well as the complex dynamics that are responsible for solar eruptions. Solar Orbiter will fly to within 45 million kilometres of the Sun – closer than Mercury, its nearest planet. At this distance, the side of the probe facing the Sun will be exposed to intense heat: more than 500°C. A heat shield will protect the important instruments on board the probe, equipped with shutters to provide a view of the Sun only when measurements are being taken.

The same applies to the spectrometer-telescope for imaging X-rays (STIX), whose purpose is to study solar eruptions more closely, possibly enabling large-scale eruptions to be predicted in future.

STIX was developed at the University of Applied Sciences and Arts Northwestern Switzerland (FHNW) in collaboration with several industrial partners from Switzerland, including Almatech.

Drives made by Maxon are among the components used in the X-ray telescope. Two specially modified DC motors with diameters of 13mm move an aluminium attenuator, which slides in front of STIX’s 30 detectors as required. The micro drives are wired in parallel and can be used together or individually, thus ensuring that they’ll run smoothly for the entire five years planned for the mission.

The design is based on micromotors that will soon be used in ESA’s ExoMars Rover. Key factors when selecting the drives were their low weight, energy efficiency, and resistance to vibration.

Solar Orbiter is one of ESA’s flagship projects and has cost more than $1.5bn . The probe will journey for almost two years before it can start taking measurements. The mission is scheduled to end in 2025.

In the wake of Solar Orbiter’s launch, preparations are underway for the next two major Mars projects, which are scheduled to start in mid-2020: NASA’s Mars2020 Rover and ESA’s ExoMars Rover. The aim of both missions is to provide new information about the Red Planet, answering questions such as whether there has ever been life on Mars. Mars2020 also carries a small helicopter to deliver a proof of concept that flights are possible on Mars despite the very thin atmosphere.

Maxon drives are used for mission-critical tasks in both projects, including wheel drives, handling soil samples, and steering the Mars helicopter. www.maxongroup.net.au

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Chemical-harmonisation: Australia to adopt Revision 7 of the GHS The Globally Harmonised System (GHS) is a framework for harmonisation of rules and regulations on chemicals.

Australia will adopt Revision 7 from 1 July 2020. Laura Whiteman explains the requirements, including the need for manufacturers and importers to produce new safety data sheets and labels during the two-year transition period.

The proper labelling, use and storage of chemicals is a critically important component of safety in modern industry. In an interconnected business world, it is even more important that chemicals are treated with the same standards internationally. To address this issue, the United Nations developed an approach to create consistent standards for classification, labelling and safety data sheets (SDS), through the introduction of the Globally Harmonised System of Classification and Labelling of Chemicals (GHS). The GHS acts as a framework for harmonisation of rules and regulations on chemicals at a national, regional and global level.

The initial edition of the GHS was released in 2003 and first revised in 2005, and has been updated every subsequent two years. The most recent version of the GHS, Revision 8, was published in 2019.

Every country is responsible for its own adoption of the GHS, so each country is at a different stage in its implementation of the standard.

Australia’s adoption of Revision 7 deadlines Australia announced on 10 January this year, that it will move from the Revision 3 to 7 of the GHS. This will be adopted under the Model Work Health and Safety (WHS) laws for workplace hazardous chemicals from 1 July 2020.

The European Union has already incorporated GHS Revisions 6 and 7 into their legislation, with the deadline for updates coming in October of this year. Multiple economies have declared their intent to move to GHS Revision 7: Australia, New Zealand, Canada, Indonesia, Malaysia, Russian Federation and the USA. Of these economies, Australia is the furthest along in its implantation plan, with New Zealand close behind. New Zealand has already run consultation studies on the change, and an analysis report is due out in May 2020.

Australia will adopt GHS Revision 7 with a 2-year transition period, allowing time for manufacturers and importers to produce new SDS sheets and labels. However, one should note that suppliers and users will be allowed to continue using chemicals with GHS Revision 3 SDS sheets and labels until their stocks run out. This solution was developed by Safe Work Australia members - a committee of 15 people made up of members from the states and territories - as well as representatives for workers and employers.

Safe Work Australia held face to face consultation sessions as well as online public consultations in June and July 2019. During these consultations, all respondents supported moving from GHS Revision 3 to Revision 7. This will help ensure Australia stays in line with its major trading partners.

Eye irritation – subcategory change One important issue, that will change with the adoption of GHS Revision 7, is the treatment of subcategory 2B eye irritation.

Currently, Australia has adopted 2A eye irritation, but chose not to adopt 2B. This has led to confusion in the industry, with chemicals classified as 2B eye irritation not being classified as hazardous. This was not the intent of the regulation, so it will be changed to use the entire Category 2 eye irritation designation, with optional breakout into 2A/2B.

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“Industry recognises the longterm benefits that will be realised by Australia maintaining alignment with other GHS countries, including reduced costs for chemical imports” (Safe Work Australia)

The maintaining of ingredient proportions Ingredient proportions on labels has been a unique Australian requirement, and during the consultation period they discussed whether to remove this requirement. While industry supported removing the requirement, the WHS regulators did not support this.

As such, it is likely that Australia will maintain this requirement.

Recommended action items in advance of the change: 1. Register with Safe Work Australia to receive updates on the GHS Revision 7 adoption in Australia (www.safeworkaustralia. gov.au/subscribe-updates).

2. For manufacturers and importers: Once Revision 7 guidelines for Australia are released, determine what changes will need to be made to SDS sheets and labels. Ensure that these changes are completed by 30 June 2022.

3. For suppliers and users: Be aware that product labels and SDS sheets may have some small changes with the transition to GHS Revision 7.

Laura Whiteman is a senior regulatory specialist at UL, which provides innovative material and regulatory data solutions to facilitate a transparent and sustainable product supply chain.

With fully automated chemical compliance software platforms, industry-leading data resources, and an unprecedented global network of regulatory expertise, UL removes barriers and solves critical challenges to help companies stay one step ahead of global regulations. UL’s GHS training course teaches the requirements for the harmonised documents under GHS, along with the status of GHS implementation globally. Also available is the Asia Pacific SDS and Labelling Training - a modular online training series for 15 countries in the Asia Pacific region. msc.ul.com customerservice.anz@ul.com Ph : 03 9846 2751

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Distribution Agreements: Make them work for you, not against you.

In this article, Julia Cameron and Katerina Poulakis set out some of the most common issues to serve as a reminder to principals and distributors when negotiating and reviewing distribution agreements.

In manufacturing, distribution agreements are a key method of broadening the application of a product in a global market. We regularly assist our clients in drafting and negotiating distribution agreements (both as principal and distributor) to serve our client’s key commercial objectives. We are also often called on to assist clients who come to us as victims of pro-forma or poorly worded distribution agreements and in circumstances where there is no documented agreement in place at all.

Document, document, document There is often substantial goodwill between a principal and distributor at the start of a commercial relationship, leading parties to assume that a ‘handshake’ deal or an exchange of emails is sufficient comfort that the parties will do as they have agreed and that the arrangement is legally enforceable. This is a dangerous assumption.

From a principal’s perspective, if you do not have a binding agreement in place which specifies the period of notice required to be given to a distributor to terminate the agreement, the risk is that a court may find that the distributor is entitled to a period of ‘reasonable notice’ of termination, or damages in lieu of such notice.

Damages are generally calculated by reference to the profit the distributor would have made during the notice period and the notice period can be in excess of 12 months if the arrangement is long term.

Who are you?

It is critical to understand who you are contracting with to ensure there is a solvent, legal entity standing behind the agreement who will assume liability under the agreement. Is it an individual, a sole trader with an ABN, or a company? Is it a foreign entity?

Franchise trap Clauses in distribution agreements which tightly control how marketing funds are to be used, impose strict marketing plans, require upfront payments and which allow a distributor to use the principal’s trade marks can be franchise agreements and subject to Franchising Code of Conduct. Even though the parties may not intend to enter into a franchise, the law may say otherwise. A failure to comply with the Franchising Code of Conduct can lead to serious consequences for a principal.

To arbitrate or not to arbitrate An effective dispute resolution clause is dependent on a number of factors, including the location of each party. Careful consideration must be given to the chosen jurisdiction and the dispute resolution procedures to be implemented (such as mediation, arbitration and court proceedings) and whether any notices need to be issued before a party can enforce the dispute resolution procedure.

Bad territory

If it is a foreign entity, your recourse when things go wrong may be limited, particularly if the entity has no presence or assets in Australia. We can help you with due diligence on prospective parties and recommend appropriate guarantee or security arrangements where you contract with foreign entities.

It is harder to confine a territory once it has been set. So, whilst it may seem beneficial to have your product sold in a wide market, it is often sensible to start distribution within a smaller territory. Once a distributor has proven themselves to be successful and suitable for the principal’s needs, the territory can be expanded.

Governing law

Are we exclusive?

If you contract with foreign entities, the governing law of the contract will generally determine the place in which legal proceedings relating to the agreement must be brought and the law under which the agreement must be interpreted. It is generally preferable to insist that the governing law is an Australian State or Territory, but this should be considered on a case by case basis.

Targets need a bullseye A distribution agreement should set out clear performance or minimum purchase targets for its distributor. Performance targets should be reviewed and updated regularly to deal with marketrelated factors and other factors.

Principals should also turn their minds to the consequences of a failure to achieve performance targets, whether it be loss of exclusivity or an ability to terminate the distribution agreement. When a principal tries to impose consequences for a failure to achieve performance targets and those targets are not accurately documented, this can be more readily challenged by a distributor and can damage the principal who can get ‘stuck’ with a poorly performing distributor.

Distributors often want exclusivity in the market. This can work in a principal’s favour by ensuring that a distributor is focused on their product only. However, there will be circumstances where it is beneficial to start with a non-exclusive territory. This allows a principal to make sure that the distributor is right for before handing over the reins of exclusivity.

If you would like us to review your current distribution agreements or just discuss distribution agreements more generally, please contact us. As an AMTIL member, we can offer you a discount on our fees.

Julia Cameron is a Partner in the Corporate and Commercial Group at Rigby Cooke Lawyers and regularly works with clients to draft and negotiate distribution agreements.

Ph: +61 3 93217807; E: JCameron@rigbcooke.com.au www.rigbycooke.com.au Katerina Poulakis is a Senior Associate in the Litigation Group at Rigby Cooke Lawyers and often assists her clients to navigate through complex disputes relating to distribution agreements.

Ph: +61 3 93217818; E: KPoulakis@rigbcooke.com.au www.rigbycooke.com.au

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FORUM LOGISTICS

Better freight management: Turning chaos into order Moving freight globally and domestically can be expensive and complicated. What can importing/exporting businesses do to make the process easier and more cost efficient? Cesar Lopez offers some useful advice.

If you were to ask almost any business in Australia which relies on imported or exported goods to comment on their supply chain costs, the resounding groan and corresponding eye-roll should provide a fairly good indication of the pain being felt by many.

Let’s not beat around the bush, moving freight globally and even domestically can be downright expensive. We’ve all heard the horror stories of freight costs equalling or exceeding the actual value of the goods being transported – whilst that’s a terrifying scenario, unfortunately it’s nothing new. The real question is ‘why?’ – Why does it cost so much to move something from point A to point B? Surely it can’t be that complicated, right?

The truth is, it kind of is complicated. *Correction – it can be complicated.

The sheer number of parties that may be involved in any one shipment can knock the uninitiated about – seller, buyer, shipper, consignee, consignor, notify party, manufacturer, shipping line, brokers, forwarders, insurance, trucking or rail. Where it gets really fun, is that most of these parties could be the same company, or each party could be a different company – and not just in the destination country, but also in the country of origin.

It’s no surprise that astute businesses are ‘partnering up’ with logistics firms to drive a more collaborative and consultative approach to their business decisions – after all, logistics costs can be sizeable for many businesses, and as the groaning and eyeballrolling mentioned above suggests, can be the cause of great angst.

So what can importing/exporting businesses do to make the process easier and more cost-efficient? The overarching answer is three-part: 1. Find a logistics partner you can trust, who aligns with your business’ values 2. Find a logistics partner you can trust, who aligns with your business’ values 3. See 1 & 2 above There is obviously more to it, but we will get to that shortly.

The reason I reiterate this point an annoying three times is because it seems to be so frequently overlooked. It is fair and reasonable for businesses to choose whom they work with in the logistical realm based on the implied understanding that all firms will have their best interests at heart? Unfortunately it’s all too common that that’s not the case.

Aligning your business with a logistics supplier of the same ilk is a tried, tested & proven recipe for effective control of freight costs.

It brings with it a level of communication and understanding that cannot be replicated in the cold buyer-seller type of transaction we see all too often in this space. With understanding comes trust, with trust comes better process, and with better process comes cost reduction and improved efficiency. As mentioned earlier, moving freight can be exceedingly complicated, you need sound and honest advice from your logistics supplier to help you make effective decisions and achieve optimal outcomes for your business.

So if you’ve found the right logistics partner, what else can be considered to improve the process?

There are still a number of internal considerations that can drive a better outcome for your business. Being aware of the options available to you is an important factor when choosing how you move your freight and in what frequency. Some factors for consideration:

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1. Think efficient packaging.

The correct packaging can cut down on the amount of space and weight a product occupies in a container or an aircraft. If packaged optimally, you will receive the lowest possible fee for the space your cargo requires. There’s no sense in packaging a stapler in a guitar case and complaining about the cost of shipping a stapler.

2. Ship more products, less frequently.

This may sound a little strange, but the logic is basic. Whenever possible, wait until you have the largest volume of cargo available before shipping. Generally speaking - the bigger the consignment, the better you can spread the shipping cost across your products.

Your freight can be consolidated along with other businesses’ cargo if you can’t fill a container yourself, but it may not be costeffective in some cases. Also, you should consider shipping 20ft containers even if you only have 15-16 cubic metres of cargo – you may be shocked at how competitive this option is compared to LCL cartage. Of course it all depends on the type of product and the cost of it.

3. Plan ahead.

If you plan your moves in advance, you can lower your transportation costs by taking advantage of competitive sea freight rates instead of using airfreight.

4. Using a GOOD freight forwarder = cost savings.

Due to the high volume of shipments handled, good forwarders are able to negotiate better deals with carriers. Those savings are passed straight on to you. Due to this advantage, a freight forwarder can offer better rates on consolidation and other types of shipments.

5. Evaluate the service level you need.

There’s no need to overpay for same-day deliveries if the client requires the product three days later.

It’s important to work with your logistics supplier as a partner and not as a commodity to streamline the movement of your products.

Taking this approach along with consideration of how you move your freight will improve the overall experience, and stop the eyerolling and groans!

At SternaGL, we combine our logistics experience and knowledge with exceptional human talent to provide you with a tailored solution for your cargo needs. From small parcels, to over-dimensional project cargo, and everything in between - our dedicated team utilise their extensive skill and expertise to manage the journey of your freight from origin to destination - intact and on time.

Cesar Lopez – Director – cesar@sternagl.com www.sternagl.com

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Industrial manslaughter: New laws and huge potential penalties, but what does it mean in practice?

State and Territory governments across the country have recently moved to introduce manslaughter offences that apply specifically to the workplace. With potential penalties as high as life imprisonment for individuals and fines of over $16m for body corporates, the stakes are extremely high. Craig Salter and Sam Jackson explain.

The introduction of industrial manslaughter offences has come about following substantial community pressure after the Dreamworld and Eagle Farm Racecourse incidents in 2016. Since then, much has been reported about the changes. But do the new laws require duty holders to take any new or different steps?

In this article, we provide an update on industrial manslaughter and explain what it means for you in practice.

At the time of writing, industrial or workplace manslaughter offences were in operation in the ACT, NT and Queensland. Laws have been passed and will commence on 1 July 2020 in Victoria, while the Western Australian Government is currently debating the introduction of industrial manslaughter offences.

Until recently, there have been no prosecutions for industrial manslaughter offences in Australia. However, in October 2019 the first prosecution commenced against Brisbane Auto Recycling Pty Ltd following the May 2019 death of a worker struck by a reversing forklift at a car wrecking yard in Rocklea, Queensland. The two directors of the company have been charged with ‘category 1’ WHS offences, not industrial manslaughter. It is understood that the company has recently entered a plea of guilty to the charge of industrial manslaughter and will be sentenced later in 2020.

The laws – what are the differences across the country?

Despite WHS harmonisation occurring in the early 2010s, there remain a number of differences in the way WHS/OHS legislation is enacted across Australia. The move to introduce industrial manslaughter offences only adds to these disparities. Each jurisdiction that has already introduced, or plans to introduce, a form of the offence has adopted a different approach. However, the laws do have common elements, including requirements for: a) the duty holder to have engaged in negligent or, in some jurisdictions, reckless conduct; and b) the duty holder’s conduct to have caused the death of a worker or, in some jurisdictions, the death of another person at or near a workplace.

The laws in most jurisdictions also require the duty holder’s conduct to constitute a breach of an existing WHS/OHS duty. However, the ACT and Queensland industrial manslaughter offences sit outside the existing duty framework.

What do you need to do differently?

Nothing, provided you are already complying with existing WHS/ OHS laws. Although the new laws introduce different standards for compliance and bring with them substantial potential penalties, companies and senior officers complying with existing WHS/OHS laws will continue to comply with industrial manslaughter laws. The new offences are reserved for the most serious of criminal offending, involving grossly negligent or reckless conduct that causes the death of a person at or near a workplace. However, the new laws do serve as a timely reminder to reconsider the robustness of existing WHS/OHS systems and procedures, particularly in relation to critical safety risks.

Practical tips and guidance Within the workplace setting, the new legislation continues the requirement for duty holders to develop clear processes that define how safety of their workers is proactively managed.

Duty holders should: • Understand the high-consequence hazards associated with operations (i.e. those potentially leading to a fatality) and ensure that these hazards are managed. Conduct a comprehensive review of your operations. Ensure that there is an explicit focus on plant and machinery. Start by confirming that your plant aligns with the requirements of AS/NZS 4024 – Safety of Machinery. Ensure that you routinely review your risk register. Consider how a fatality may occur; then confirm that your established controls: (i) eliminate, or (ii) reduce the consequence, of the hazard.

• In addition to incident and hazard reporting, confirm that there is a robust investigation and corrective action process in place. The purpose of reporting is to manage against future recurrence.

• Refresh your consultation processes. With your workers, communicate how they can raise safety opportunities with management. Management teams should ask workers, “what practices make them feel less safe?”

• Ensure that workers have the skills to undertake their role.

Captured the required training for each role by building a Training Needs Analysis. Start with your induction program.

• Report WHS/OHS performance to your management team.

Don’t just report on incidents, report on the implementation of your entire WHS/OHS program (i.e. inspections, maintenance, meetings, training, etc). A cloud-based technology, such as Safety Champion Software, will provide you with visibility of how effective your WHS/OHS program is.

• Focus on safety leadership. As recognised in the recent Findings and Recommendations issued by Coroner James McDougall following the Inquest into the deaths at Dreamworld in 2016, leadership from the Board down is critical to ensuing workplace safety. As noted by the Coroner, “[s]uch a culpable culture can exist only when leadership from the Board down are careless in respect of safety. That cannot be allowed”.

Importantly, keep in mind that you have a legal duty to ensure that a suitably qualified person is providing WHS/OHS advice.

Craig Salter is Director of Action OHS Consulting - a leading Australian-owned workplace health and safety consulting firm operating in Melbourne, Sydney, and Brisbane. With a team of experienced and qualified health and safety consultants, Action OHS Consulting specialises in supporting businesses to build effective health and safety practices to meet their legal duties. craig.salter@actionohs.com.au + 61 (0) 409 772 499 1300 101 OHS | 1300 101 647 www.actionohs.com.au Action OHS Consulting thanks Sam Jackson from Sparke Helmore Lawyers for his assistance in providing the legal content for this article.

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Message to all members on the COVID-19 pandemic As the COVID-19 has now obtained a foothold in Australia, it is timely that we take appropriate measures to reduce the likelihood of infection across our industry. It is understandable that some members may feel anxious about the spread of infection.

AMTIL has been monitoring and preparing for the potential impact that COVID-19 could have on our staff, on our members and on the continuation of services and benefits. Like you, our first concern is for the health of employees and their families, members, business partners and the people with whom we work. As such, I wanted to bring you up to speed with what we are doing to protect our community.

At the time of writing, the following staff policies have been implemented: -

All staff who are able to work from home have been instructed to do so. The AMTIL office is still being manned by a core team of staff.

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Unless absolutely necessary no company visits are being scheduled. If necessary to make a company visit, staff should self-isolate for the remainder of that day and not return to the AMTIL office.

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Unless absolutely necessary, no external visitors to AMTIL will be allowed. Making sensible arrangements to meet external people outside of our office is acceptable.

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All staff have been advised not to consider work-related domestic travel and to implement other forms of communication such as tele or video-conferencing.

For the most up-to-date information and immediate access to AMTIL news, please follow us on LinkedIn, Twitter and review our website regularly for updated news and calendar of events.

Our aim is to continue offering ongoing support to our members, no matter what challenges arise, by bringing AMTIL to you through technology channels that will help support the continuity of services, business and projects. Together, we will get through it stronger.

Unfortunately, as a result of COVID-19 and the Government bans on gatherings, AMTIL has also made the disappointing decision to cancel all events, workshops and activities until the end of June. These include: 16th Mar - The Changing Face of Manufacturing Deakin University 27th Mar - CEO Dinner Melbourne 12th May - The Changing Face of Manufacturing UTS 13th May - Maximise your Membership Networking Sydney 14th May - Women in Manufacturing Networking breakfast 14th May - AMTIL Booth at AMX 10th Jun - Maximise your Membership Networking Perth 11th Jun - Maximise your Membership Networking Adelaide 18th Jun - The Changing Face of Manufacturing Griffith University 30th Jun - Maximise your Membership Networking Melbourne We hope to be in a position next financial year to begin a new round of activities and look forward to our members interacting with us then.

Stay safe everybody.

Shane Infanti, CEO AMTIL

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Coronavirus â&#x20AC;&#x201C; Information for manufacturing businesses and staff The ongoing outbreak of coronavirus disease (COVID-19) has now been declared a global pandemic, with significant implications for individuals and for businesses.

Several AMTIL events have been cancelled over the coming months, in line with official advice on avoiding large public gatherings. A large number of industry events, both in Australia and overseas, have also been cancelled or postponed. AMTIL is working to ensure that we have the latest up-to-date information on our website about further cancellations and postponements.

More generally, AMTIL is continuing to monitor the situation and will continue to do all we can in support of our members, partner organisations and the broader industry.

Advice on workplace safety Under WHS laws, employers must have measures in place to eliminate or manage the risks arising from COVID-19. Safe Work Australia has released guidelines advising businesses and workplaces on how to manage the risks. Details can be found here: www.safeworkaustralia.gov.au/doc/coronavirus-covid-19advice-employers

Advice on travel

As the COVID-19 crisis continues, the health, safety and wellbeing of the general public is of paramount importance. The Federal Government, state and local authorities, and several other bodies are continuing to provide up-to-date information on the outbreak and its implications.

Severe restrictions have been on travel, both domestic and international, with further controls to be expected as the situation evolves. For up-to-the-minute advice on travel, visit: www.smartraveller.gov.au/crisis/covid-19-and-travel

There is also widespread concern about the impact the crisis will have on the economy, including on the manufacturing sector; the Federal Government has announced a range of measures to support businesses, with further announcements expected in this area. Further support measures are also expected.

The Federal Government has announced a range of measures to assist small businesses with cash flow, and to support investment.

AMTIL recommends the following resources for you, your colleagues and your business.

Advice for individuals The Federal Government is making available the latest official medical advice for the general public on protecting yourself and others and containing the spread of the virus. Details can be found at: www.health.gov.au/news/health-alerts/novel-coronavirus2019-ncov-health-alert

Advice on business support

For measures to assist small businesses with cash flow, visit: www.treasury.gov.au/sites/default/files/2020-03/Fact_sheetAssistance_for_businesses.pdf Details on measures to support investment can be found here: www.treasury.gov.au/sites/default/files/2020-03/Fact_sheetSupport_for_business_investment.pdf The COVID-19 crisis continues to evolve rapidly with new information emerging all the time. AMTIL strongly advises all our members and the wider manufacturing community to monitor events closely, and take the appropriate measures to stay safe. www.amtil.com.au

1382AMTIL

AMTIL gratefully acknowledges the support of its Corporate Partners.

AMTILâ&#x20AC;&#x2122;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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Tax stimulus package for businesses in response to coronavirus On 12 March, the Government announced a stimulus package totalling $17.6bn to address the economic impacts of the Coronavirus outbreak. Included in the package are tax incentives and cash flow assistance for businesses, in order to support investment and help small businesses manage short-term cash flow challenges. Tamara Cardan of AMTIL corporate partner Rigby Cooke Lawyers explains the measures.

The business investment measures are designed to assist economic growth in the short term and encourage a stronger economic recovery following the coronavirus outbreak.

Tax incentives for businesses The below tax incentives will support over 3.5m businesses employing more than 9.7m employees.

• Increasing the instant asset write-off. The instant asset write-off allows small businesses an immediate deduction for depreciating assets costing less than the threshold of $30,000 (which will revert to $1,000 from 1 July 2020), to the extent that the asset is to be used for tax-deductible purposes.

With effect from 12 March 2020, the instant asset write-off threshold is increased from $30,000 to $150,000, and access will be expanded to include businesses with an aggregated annual turnover of less than $500m (up from $50m) until 30 June 2020. The rules apply from 12 March 2020 until 30 June 2020, for new or second-hand assets first used or installed ready for use in this timeframe. The threshold applies per asset; as such, multiple assets can be purchased with each one entitled to a full tax deduction (assuming it is below the threshold).

• Accelerated depreciation deductions. The Government is introducing a time-limited 15-month investment incentive (through to 30 June 2021) to support business investment and economic growth over the short term, by accelerating depreciation deductions. Businesses with a turnover of less than $500m will be able to deduct 50% of the cost of an eligible asset on installation, which was acquired after 12 March 2020 and first used or installed ready for use by 30 June 2021. Existing depreciation rules applying to the balance of the asset’s cost.

Cash flow assistance for businesses The Government’s cash flow assistance will support businesses to manage cash flow challenges resulting from the economic impacts of the coronavirus, and help businesses retain their employees.

• Boosting cash flow for employers. The Government will provide a tax-free payment of up to $25,000 to small and medium-sized businesses, with a minimum payment of $2,000 for eligible businesses. The payment is intended to provide cash flow support to businesses with a turnover of less than $50m that employ staff.

• Supporting apprentices and trainees. Under this measure, eligible employers can apply for a wage subsidy of 50% of their apprentice’s or trainee’s wage for up to nine months from 1 January 2020 to 30 September 2020. Where a small business is not able to retain an apprentice, the subsidy will be available to a new employer that employs that apprentice.

ATO relief for businesses On 12 March 2020, the Australian Taxation Office (ATO) announced that it will implement a series of administrative measures to assist businesses experiencing financial difficulty as a result of the coronavirus outbreak.

AMT APR/MAY 2020

Options available to assist businesses include: • Deferring by up to four months the payment date of amounts due through the business activity statement (including Pay As You Go (PAYG) instalments), income tax assessments, fringe benefits tax assessments and excise.

• Allowing businesses on a quarterly reporting cycle to opt into monthly GST reporting in order to get quicker access to GST refunds.

• Allowing businesses to vary PAYG instalment amounts to zero for the March 2020 quarter. Businesses that vary their PAYG instalment to zero can also claim a refund for any instalments made for the September 2019 and December 2019 quarters.

• Remitting any interest and penalties, incurred on or after 23 January 2020, that have been applied to tax liabilities.

• Working with affected businesses to help them pay their existing and ongoing tax liabilities by allowing them to enter into low-interest payment plans.

These concessions do not apply automatically – owners of affected businesses must first contact the ATO, after which the ATO will implement a plan to suit the particular circumstances of the specific business.

Employers will still need to meet their ongoing superannuation guarantee obligations for their employees.

How can Rigby Cooke help?

The Government will work quickly to implement its above stimulus package. We expect that these measures will be passed imminently, and we would recommend that businesses consider taking appropriate measures now, given the tight timeframes in respect of eligibility to tax incentives for assets acquired between 12 March 2020 and 30 June 2021.

We can advise you regarding the eligibility of your business to access the tax incentives and cash flow assistance as announced by the Government.

We can also work with the ATO to implement a suitable plan for your business in order to access the administrative concessions and provide you with some financial relief during this difficult time. © Rigby Cooke 2020. Reproduced with permission. All rights reserved. This article was first published as Tax stimulus package for businesses in response to the Coronavirus.

Dated 17 March 2020 on www.rigbycooke.com.au.

Explore your unlimited possibilities additively The Additive Manufacturing Hub is a $1.85m programme 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 programme 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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New members AMTIL would like to welcome the following companies who have signed up as new members of our association.

DIAMOND ABRASIVES AUSTRALIA POB 524 Flinders Lane PO Melbourne VIC 8009 www.diamondabrasivesaustralia.com.au

LEUSSINK ENGINEERING PTY LTD 16-18 Doyle Ave. Unanderra NSW 2526 www.leussink.com.au

MEGAFUN Level2, 358 Lonsdale St Melbourne VIC 3000 www.megafun.com.au

HELIMODS PTY LTD Cnr Pathfinder Dr & Henebery Pl. Caloundra Airport QLD 4551 www.helimods.com

LINEAR TECHNIK PTY LTD 54-58 Arkwright Dve Dandenong South VIC 3175 www.lineartechnik.com.au

MULTIPOD INTERNATIONAL 38 Latitude Blvd Thomastown VIC 3074 www.multipodinternational.com

KEMPPI AUSTRALIA PTY LTD 13 Cullen Pl. Smithfield NSW 2164 www.kemppi.com

MANO DESIGN 17 Diana Dve Blackburn North VIC 3130 www.manodesign.com.au

TEC FIT 20 Macquarrie St Prahran VIC 3181 www.tec.fit

Helping manufacturers tell their stories Getting word out about your company and what it does is an increasingly important part of being in business. To help our members in this area, AMTIL has compiled a list of approved specialists who are able to support them in their media and communications.

“We know that there are great stories to be told out there among AMTIL’s membership,” says William Poole, Editor of AMT Magazine.

“However, most of our members are relatively small outfits who don’t have much experience of creating editorial material or press releases. At AMT we try to help out by writing stories about them, but there’s only so much we can do. And when we do, we like to keep those stories for AMT, whereas the companies might like to see them in as many media outlets as possible.”

All of the companies and specialists included on AMTIL’s list of approved providers have extensive experience of media and communications work, specifically for the manufacturing industry in Australia. As well as help in writing press releases and articles for magazines like AMT, they can assist with distribution of material, as well as in other areas such as social media, web design, media strategy and more. “All these guys have had material published in AMT, and other publications

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Brilliant Digital Telephone: 02 9939 5223 Email: deb@brilliantdigital.com.au Website: www.brilliantdigital.com.au

•

Ausvex Public Relations Telephone: 0419 264 465 Email: mp@ausvex.com.au Website: www.ausvex.com.au

• Brent Balinski Telephone: 0431 510 339 Email: bmbalinski@gmail.com

too,” adds Poole. “We know they have the capabilities to help manufacturing companies get word out about what they’re doing – and we know they offer excellent value for money in doing so. What’s more, they’re all AMTIL members, so they’re part of our manufacturing community and they know the industry.” For support in the area of media and communications, AMTIL recommends the following providers:

• Graeme McLean & Associates Pty Ltd Telephone: 03 9583 6694 Mobile: 0438 806 090 Email: graeme@mcleanassoc.com.au AMTIL aims to continue adding to its list of recommended media and communications specialists. For more information, contact William Poole at wpoole@amtil.com.au. www.amtil.com.au

AMTIL INSIDE

Golf Day heads up busy AMTIL events program AMTIL members and guests gathered at Riversdale Golf Club on 7 February for our annual Corporate Golf Day, in a series of recent AMTIL social events.

DONE ‘N DUSTED!

At the time of writing, we had just completed Round One of the 2020 AFL season. A start we’ve never seen like before, and hopefuly will never see again and just like that it’s all over… for the minute. Teams battled it out in front of the odd seagull wondering where all the hot chips have gone. Players, coaches were running out the line they were grateful to be playing, but ultimately at what cost? Much discussion was had should any football be played, but for us tragics, some was better than none. Of the matches played, no real suprises… Richmond toyed with the Blues thinking they had a chance, Gold Coast have taken up their normal position at the foot of the ladder and the Pies provided a semi-closed circle of animated hand-clapping mixed in with a few ‘Wooos!!’ when they sang their club song post victory. The season is scheduled to recommence in June but who knows really – maybe 2020 is the season that was after Round One. Stay safe until next time – if there is a next time, Sanchez ROUND 01 1 Neil [DMGMORI] 2 Shane Infanti 3 Nick_Langdon 4 Michael@CNCD 5 Rita WB 6 Kings-man 7 Colesy 8 Tungaloy Australia 9 Lou 10 davec

8 (1) 8 (4) 7 (0) 7 (1) 7 (1) 7 (3) 7 (4) 7 (5) 7 (6) 7 (7)

The day went ahead amid bright sunny weather conditions. After play was completed, those in attendance enjoyed a barbecue lunch and networking drinks as the prizes were handed out.

Congratulations to Shisham Stanley Group, the winning team on the day. AMTIL would like to thank the event’s sponsors: William Buck; Iscar Australia; Metal Industries Insurance Brokers; Wadeson IP; Harry the Hirer; Dimac Tooling; and Australian Precision Technologies (APT).

In addition to the Golf Day, AMTIL held a number of social and networking gettogethers during February around the country. Maximise Your Membership events took place in Perth, Adelaide, Sydney and Melbourne. All events drew a strong turnout with those who attended getting the opportunity to network with industry peers while enjoying drinks and snacks. www.amtil.com.au/events

AMTIL Golf Day

The Golf Day winning team, from Shisham Stanley Group.

Maximise Your Membership Adelaide

Maximise Your Memb

Maximise Your Membership Perth

ership Melbourne

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INDUSTRY CALENDAR Due to the ongoing coronavirus pandemic, almost all industry events world-wide have been postponed, rescheduled or cancelled, while both domestic and international travel has been severely disrupted. Readers are advised to check direct with event organisers for the latest information. For up-to-date advice on coronavirus, visit: www.health.gov.au/health-topics/novel-coronavirus-2019-ncov INTERNATIONAL MACH UK, Birmingham 20-24 April 2020

METAL SHOW & TIB Romania, Bucharest 12-15 May 2020

ROSMOULD Russia, Moscow 8-10 June 2020

www.machexhibition.com

www.metalshow-tib.ro

www.rosmould.com

HANNOVER MESSE Germany, Hannover 20-24 April 2020

METAL EXPO OSAKA Japan, Osaka 13-15 May 2020

ADVANCED MANUFACTURING UK, Birmingham 9-11 June 2020

www.hannovermesse.de/en

www.metal-kansai.jp/en

www.advancedmanufacturingshow.co.uk

EXPOMAQ Mexico, Leon 21-24 April 2020

METAL + METALLURGY CHINA China, Shanghai 13-16 May 2020

FABTECH CANADA Canada. Toronto 16 - 18 June 2020

www.expomaq.org.mx

www.mm-china.com

www.canada.fabtechexpo.com

SIAMS Switzerland, Moutier 21-24 April 2020 Microtechnology exhibition

INTERMACH & MTA Thailand, Bangkok 13-16 May 2020

AUTOMATICA Germany, Munich 16-19 June 2020

www.intermachshow.com

www.automatica-munich.com/en

CIMES China, Beijing 18-22 May 2020

KOREA METAL WEEK South Korea, Goyang 17-20 June 2020

www.cimes.net.cn/en

www.korea-metal.com

SPACE TECH EXPO USA USA, California 18-20 May 2020

INSIDE 3D PRINTING South Korea, Seoul 24-26 June 2020

www.spacetechexpo.com

http://3d.micen.kr/2020

INTERNATIONAL TECHNICAL FAIR Serbia, Belgrade 19-22 May 2020 www.tehnika.talkb2b.net/en

MANUFACTURING EXPO Thailand, Bangkok 24-27 June 2020

www.siams.ch

CHENGDU INTL INDUSTRY FAIR China, Chengdu 27-29 April 2020 www.cdiif.com

EMEX New Zealand, Auckland 5-7 May 2020 www.emex.co.nz

INDUSTRY DAYS Hungary, Budapest 5-8 May 2020 www.iparnapjai.hu/en

FEIMEC Brazil, Sao Paulo 5-9 May 2020 www.feimec.com.br/en

IMTDUO Taipei, Taiwan 6-9 May 2020 www.imtduo.com.tw

FABTECH MEXICO Mexico, Mexico City 12-14 May 2020 https://mexico.fabtechexpo.com

MACHINE TOOLS AFRICA South Africa, Johannesburg 12-15 May 2020 www.machinetoolsafrica.co.za

ELMIA 3D, ELMIA AUTOMATION & ELMIA SHEET METAL Sweden, Jonkoping 12-15 May 2020 www.elmia.se/3D

INTERTOOL Austria, Vienna 12-15 May 2020 www.intertool.at

PLASTPOL

POLAND, KIELCE 19-22 May 2020 Plastics processing exhibition www.targikielce.pl/pl/plastpol.htm

METALLOOBRABOTKA Russia, Moscow 25-29 May 2020 www.metobr-expo.ru/en

FASTENER FAIR FRANCE France, Paris 27-28 May 2020 www.fastenerfairfrance.com

EUROSURFAS Spain, Barcelona 2-5 June 2020 www.eurosurfas.com

ITM INDUSTRY EUROPE Poland, Poznan 2-5 June 2020 www.itm-europe.pl

LASERFAIR China, Shenzhen 2-5 June 2020 www.laserfair.cn

SOUTH CHINA INTL INDUSTRY FAIR China, Shenzhen 2-5 June 2020 www.sciif.com/en

AMT APR/MAY 2020

www.manufacturing-expo.com

ROBOT TECHNOLOGY JAPAN Japan, Nagoya 2-4 July 2020 https://robot-technology.jp/2020/en

INNOPROM METALWORKING Russia, Ekaterinburg 6-9 July 2020 www.metalworking-expo.com/en

MTA VIETNAM Vietnam, Ho Chi Minh City 7-10 July 2020 www.mtavietnam.com/en-us

AMTEX India, New Delhi 11-14 July 2020 www.amtex-expo.com

MANUFACTURING SURABAYA Indonesia, Surabaya 15-18 July 2020 www.manufacturingsurabaya.com

INTERMOLD/DIE & MOLD NAGOYA Japan, Nagoya 17-18 July 2020 www.intermold.jp/english

IMTS USA, Chicago 14-19 September 2020 www.imts.com

INDUSTRY CALENDAR HEADING LOCAL DESIGNBUILD MELBOURNE, MCEC 21-23 APRIL 2020 Architecture, building, construction and design sector.

CEMAT MELBOURNE, MCEC 14-16 JULY 2020 leading trade fair for materials handling, intralogistics and supply chain management.

www.designbuildexpo.com.au

www.cemat.com.au

ADVANCED MANUFACTURING EXPO (AMX) SYDNEY SHOWGROUND 13-15 MAY 2020 High-tech manufacturing products and advanced processes.

QLD MINING EXHIBITION MACKAY, QLD 21-23 JULY 2020

www.advancedmanufacturingexpo.com.au

AUSMEDTECH MELBOURNE MCEC 20-21 MAY 2020 Medical technology conference. www.ausmedtech.com.au

AUSTRALIAN ENERGY STORAGE ADELAIDE CONVENTION CENTRE 20-21 MAY 2020 Advances in energy storage, new energy and energy-efficient technologies. www.australianenergystorage.com.au

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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 36

“LET’S MAKE IT OURSELVES!” PART 2

“Optical glass-making in Australia is wasteful of the war effort” The year is 1940 and World War 2 has cast its threatening shadow over the world. Australia has became isolated from the Mother Country to the extent that the field artillery weapons which Australia hastily managed to manufacture were rendered useless because England could not supply the necessary telescopic sights. Devoid of an optical-glass industry at the time, Australia was cast adrift. What to do? Laurence, upbeat as ever, declares: “we’ll make them ourselves”.

M

“

ake them ourselves?!” bellowed Ordnance Maj.Gen. Tock Williams …“A gunsight is the most complicated part of the whole gun. They’ve got a special section in England which does nothing else. It takes years to develop. Australia hasn’t even got any optical glass!”

On 26 June I940, I called the physicists together. An Advisory Committee was formed with Prof. E. J. Hartung as chairman. He enlisted the support of Australian Consolidated Industries. A.C.I the most experienced glass-manufacturing firm in Australia - had no background of optical glass work, but they did know all about melting and clays, and they had knowledge of the raw materials and where to get them. They immediately offered every assistance, and Prof.

Hartung built a small experimental gas-fired furnace at Melbourne University, where he carried out valuable experiments. Chance Brothers of England (Britain’s leading optical-instrument firm), would not or could not help us. We asked for the loan of an expert, but this was refused.

Prof. Hartung built a furnace at Melbourne Uni. in order to produce optical glass of the required purity. Here, experiments with local sands and blends of fire clays were conducted. Within months, optical glass was being manufactured in Australia for the first time in Sept. 1941.

Pictured here is Prof E J Hartung (L) and Dr Erich Heymann adding a mix to a pot in the furnace. (University Of Melbourne Archives. Optical Munitions, 1940-42)

Then carne a great stroke of good fortune. A.C.I. sent one of their top technical men to Canada and the US with a Munitions Department man, to learn all they could of optical-glass manufacturing techniques.

The two Australians got a very lukewarm reception at every commercial glass-making plant, learning almost nothing because no one would discuss technical matters with them. Downhearted, they tried, as a last resort, the US National Bureau of Standards. To their delight, the bureau welcomed them and turned over much of their optical instrument-making knowledge.

While the pair was in America, we had been making desperate new efforts in Britain to get help from Chance Brothers. Our High Commissioner arranged a conference between Chance Brothers, the Admiralty and himself. As a result of that meeting, he sent our Prime Minister a cable saying: “HAVE CONFERRED WITH ADMIRALTY AND CHANCE BROTHERS STOP VERY EMPHATIC THAT THE MAKING OF OPTICAL GLASS IN AUSTRALIA WOULD BE WASTEFUL OF WAR EFFORT AS IT WOULD PROBABLY TAKE FOUR YEARS BEFORE SUCCESSFUL PRODUCTION COULD BE ACHIEVED AND COST WOULD PROBABLY BE MILLION POUNDS STOP ACCORDINGLY THEY DISCOURAGE. PM Menzies passed the cable along to Essington Lewis (DG, Munitions Dept), who referred it to me with the comment: “See what they think in Britain of your chances.” I read it and said: “We’ve hardly started yet. I’ll not accept this view until we’ve gone a lot further. I think they’re wrong, and we’ll prove it.” “Well, good luck to you! I think you will prove it too” said Lewis, “but what will it cost?”. “I don’t know, but I think it will only be a fraction of what we’ve been told.” “Well, go to it.” he said.

That was just the sort of challenge we needed. Four years and a million pounds, eh? Well, they might be right, but we’d have a darned good try at doing it a lot faster and a lot cheaper before we’d acknowledge that they were right. We didn’t have a choice anyhow - the orders were pouring in from the fighting services for optical equipment of all kinds: sighting-telescopes, binoculars, signalling-telescopes, range-finders, stereoscopes, compasses. They didn’t want them by the dozen: they needed them by the thousand. And we had no industry to make them, no knowledge, no idea of what raw materials were available and no help from Britain or America.

Then, when things looked their blackest, we had breakthroughs. First, the Optical Panel, with much ingenuity, managed to fuse plate-glass and had produced prototypes of gun-sights. Next, Prof. Hartung produced three melts of optical glass of an acceptable standard.

Then, valuable information had been found in an American book on optical-glass manufacture that had turned up as the result of an appeal I made to public libraries. A.C.I. was able to adapt many of the American practices to local conditions, and the company established a modern optical glass annexe at Australian Window Glass P/L., Sydney.

More than a hundred different clays were tested: clays from all parts of Australia. Slowly, painstakingly, the experiments went on. With every test, a little more was learned. On 21 September 1941 - a day of wonderful achievement in Australian industrial history - the first large-scale batch of optical glass ever to be made in Australia was produced. The first melt passed all the stringent tests laid down.

Australia had done it again! And we’d done it in only ten months for a cost of £60,000. So much for the English prediction.

By the time Japan came into the war less than three months later, the supply of glass was adequate for our needs. We had industry organised to make the glass into lenses and prisms, and produce binoculars, gunsight mountings and a thousand other things. The making of the glass itself and the refusal to admit defeat, all combined to make the optical glass triumph one of our proudest achievements of the war. It proved to me once again that if the right brains were brought to the fore and the right spirit was present, we could do as well or better than anyone in the world.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT APR/MAY 2020

To be continued…

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