Asia Manufacturing News June 2014

ASIA

Asia Manufacturing News

June 2014

MANUFACTURING NEWS Success Through Innovation

June 2014

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asiamanufacturingnewstoday.com

The Interview John Watts

Rockwell Automation

The Interview KC Yee

Siemens PLM Unified communications in manufacturing

Keeping SMBs ahead of the innovation curve asiamanufacturingnewstoday.com

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EDITORIAL

Sharing the knowledge for better manufacturing Over the past five years Rockwell Automation has experienced good growth in Asia. Last year, Forbes

Doug Green

listed the company as one of the world’s top 100 most In this issue John Watts, Director, Integrated Architecture, Asia Pacific talks to Asia Manufacturing News talks about the way ahead, the company’s Oil & Gas business and its growth in Southeast Asia, Rockwell’s involvement in Mining in China and Australia and much more including the pride they take in meeting customers’ sustainability objectives in all facets of their production. Read the full Interview on Page 4.

Bruce Downing, Managing Director Asia and South Africa for Shoretel shares his picture of Unified Communications and how UC solutions can help manufacturers meet key industrial challenges. Page 10.

Rajiv Ghatikar, Vice President and General Manager, Siemens PLM Software, ASEAN/Australasia considers

“

Many traditional manufacturing companies are not equipped with in-depth IT infrastructure on the product design side.

SMBs who account for between 60% and 85% of all

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innovative companies.

domestic employment. In Singapore they are important to the economy contributing more than 50% of the economic output and 70% of employment.

He discusses with Asia Manufacturing News how to keep SMBs of the manufacturing innovation curve in Southeast Asia. Page 28.

And amongst other great articles in this issue is another Interview, this time with K C Yee, Senior Vice President and Managing Director, Asia Pacific, Siemens PLM. He has a view on simulation- driven design in today’s manufacturing world and how it can increase productivity, efficiency and profitability.

Mr Yee describes how we are beginning to see the convergence of manufacturing and information technology –the “The Internet of Things”.

He says that with product complexity becoming a big issue, many traditional manufacturing companies are not equipped with in-depth IT infrastructure on the product design side. Page 32.

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Asia Manufacturing News

June 2014

CONTENTS 4 - 6 | THE INTERVIEW John Watts

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7 | BUSINESS NEWS Fuji eyes growing demand in Southeast Asia

BOEING MAY HAVE FOUND ULTIMATE JET FUEL

8 - 9 | BUSINESS NEWS Aurecon appointment to expand manufacturing business.

10 - 12 | ANALYSIS The benefits of unified communications in manufacturing.

14 | AVIATION Boeing may have found ultimate jet fuel.

16 | MANUFACTURING TECHNOLOGY

I2R showcases innovations for a world of increased productivity and efficiency.

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20 - 26 | DEVELOPMENTS Veolia implements water metric at TNB power plants.

3D printed material stronger than steel, less dense than water.

New injection technology in one machine cell.

Laying the groundwork for a manufacturing revolution.

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28 - 30 | ANALYSIS Keeping SMBs ahead of the manufacturing innovation curve in Southeast Asia.

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32 - 35 THE INTERVIEW

K C Yee, Vice President and Managing Director, Asia Pacific, Siemens PLM.

36 - 39 | DEVELOPMENTS Ruggedised PLCs boost processing time at gold mine.

Alstom supplies turbine and generator sets for power plant.

40 - 41 | ANALYSIS Will 3D printing cause traditional manufacturing to collapse?

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THE INTERVIEW: JOHN WATTS, Director – Integrated Architecture Asia Pacific, Ro

OPTIMISM HIGH IN 2014

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offices in Bangkok, Ho Chi Minh City, Jakarta, Kuala Lumpur, Manila, and Singapore, which serves as our South East Asia Headquarters.

Our Integrated Architecture, Intelligent Motor Control, Solutions and Services – combined with our acquisitions throughout the year – provided significant growth in the Energy, Infrastructure, Mining and Consumer markets across Asia.

The Oil and Gas industry in APAC continues to grow as energy needs rise, and Infrastructure is becoming more important as the market matures and expands. Capturing growth in the key Consumer Industry segments will continue to be a critical part of our strategy, since a thriving middle class will require investments across the region.

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Last year, Forbes listed Rockwell Automation as one of the world’s top 100 most innovative companies.

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What have been some of the significant milestones for Rockwell Automation recently?

As we look back on 2013, Rockwell Automation continued to see more stability in our local markets and the global economy.

We planned for the second half of the year to be stronger in Asia and that is exactly how we performed.

How do you see 2014 for Rockwell Automation?

Many of the key indicators we track point towards greater year-over-year growth in 2014.

Our growth in the last six months, combined with favourable indicators in the developing markets, creates a very good base for optimism in 2014.

How is Asia performing vis-a-vis the rest of the company?

Over the last five years we have had good growth in Asia. It has been exciting for the company to witness overall strong performance in all regions over the last few years, despite some of the challenges the global economy has presented.

Where do you see manufacturing growth across Asia coming from?

The industries that we have seen – and expect to see – good growth include Oil & Gas and Mining. In addition, we expect, and are beginning to see, higher growth from the Consumer Packaged Goods industry as emerging markets look to fuel more domestic growth.

Which export markets are you moving into?

Rockwell Automation has enjoyed significant growth over the last 10 years. We now have

ockwell Automation SEA Pte Ltd.

Basically, our strategy is to align our focus to these growth industries where we have domain expertise, and continue to expand our capabilities in these growing markets around OEM and end-user segments. OEMs remain a growth engine for us, with international companies increasingly locating manufacturing and engineering across the region.

Specifically, our Oil & Gas business is growing in Southeast Asia. Our business in China is strengthening – including two recent acquisitions there. We have a strong presence in China’s Manufacturing industries including the Automotive and Food/Beverage sectors, and we are doing well in Mining in both China and Australia. We are building our Life Sciences business in Asia’s emerging markets, and we have a strong OEM focus across APAC, especially with our midrange products.

Is R & D important for your company?

Last year, Forbes listed Rockwell Automation as one of the world’s top 100 most innovative companies. To remain at the technology forefront, we absolutely require a strong commitment to R&D; not just through investments, but also by creating a culture of innovation and engineering excellence.

What kind of investments did Rockwell Automation make in 2013? What companies were acquired?

Our market-access model uniquely allows us to provide a differentiated level of service and support locally in Asia, as well as globally.

This model, along with our partners, is critical to both our short-term and long-term growth.

We will continue making investments to

Asia Manufacturing News

June 2014

strengthen and enhance these relationships – propelling further market differentiation with our customers.

Secondly, the most important part of our organisation is our people in all the markets that help us drive our strategy every day. We have added great talent to the organisation in 2013, which helps build depth across our entire talent pool. Building a stable, committed and energised work force that derives pleasure from achieving individual and team objectives is our number-one priority for delivering on our Growth and Performance Strategy moving forward.

Finally, in 2013, we announced acquisitions of vMonitor, a global technology leader for wireless solutions in the Oil and Gas industry, and Jacobs Automation, the leader in intelligent track-motion control technology.

Also, in late 2012, we acquired Harbin JiuZhou asiamanufacturingnewstoday.com

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THE INTERVIEW

Electric Co. Ltd – continuing our commitment to invest in Asia, whilst also significantly broadening our Medium Voltage Drives portfolio.

Many governments and organisations are now pushing companies to practise sustainable development. How is Rockwell Automation answering this call?

Rockwell Automation solutions for sustainable development address three major corporate sustainability objectives through automation: 1. Energy resource management 2. Environmental responsibility 3. Safety for workers, machinery, processes and products We offer a comprehensive approach to meeting our customers’ sustainability objectives in all facets of their production. Our approach is specifically designed to help our customers turn sustainability challenges into business advantages.

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About John Watts, Director – Integrated Architecture, Asia Pacific is responsible for the business management and marketing of Integrated Architecture products including PLC / PAC controllers, motion control, software, operator interface and condition monitoring.

John has 18 years of experience in automation and process control sales and marketing. Apart from his time at Rockwell Automation, John has held sales and sales management positions with Yokogawa.

He joined Rockwell Automation in 2006 as Manager, Process Solutions Asia Pacific prior to taking up his current role in 2010.

He holds a Master’s in Business Administration from Melbourne Business School and a degree in Electrical and Electronic Engineering from the University of Melbourne.

John is based in Singapore.

BUSINESS NEWS

Asia Manufacturing News

June 2014

FUJI ELECTRIC EYES GROWING DEMAND IN SOUTHEAST ASIA Fuji Electric Co., Ltd., the leading energy technology company, is poised to aggressively participate the burgeoning growth in the region after developing their variable speed drive HVAC series specially to address the demand in the Asian market.

Hiromu Hayama, President of Fuji Electric Asia Pacific said, “We see a high potential for growth in the HVAC segment in Southeast Asia which is attributed to the strong demand for energy savings in the region. The increase in the number of green buildings being developed will also be a contributing factor towards this growth.”

In 1976, Fuji Electric was the first in the industry to develop general purpose Variable Speed Drives, and since then, the company has been involved in the low and medium voltage drive markets with a extensive product line up that caters to the industrial and commercial sectors.

The development of HVAC series variable

Having already established offices in Singapore, Thailand and Indonesia, Fuji Electric has recently set up a new sales subsidiary in Vietnam and representative offices in Cambodia and Myanmar last year. In addition, Fuji electric has established an Engineering Center in Singapore, Competency Center in India and a new power electronics factory in Thailand to increase manufacturing capacity to efficiently meet the needs of customer and provide a more flexible specification of products in South East Asia.

With the support of a strengthened organization, Fuji Electric is well prepared to address the growing needs of HVAC Variable Speed Drive in this region.

Fuji Electric Asia Pacific has supplied HVAC Variable Speed Drives to iconic buildings including Garden’s By The Bay and Suntec City in Singapore.

Fuji Electric Co., Ltd. (TSE:6504) is a world

speed Drive was based on demand from

leader in electronics manufacturing and energy

customers around the world for energy savings

technology with 91 years of accumulated

with superior fan / pump and AHU control.

technology and experience.

The FRENIC-HVAC is designed to optimize

Through innovations in electric and thermal

energy consumption in office and industrial

energy technology, Fuji Electric develops

buildings related to air-conditioning which

products that maximize energy efficiency, with

generally consumes 50% of the total electricity.

the aim towards promoting a responsible and

Active fine-tuning of water and air flow rates

sustainable society.

made it possible to achieve adequate pressure

As the sales and marketing hub in South East

and temperature of fans and pumps, thus

Asia, Fuji Electric Asia Pacific is mainly focus on

contributing to greater energy savings and cost

industrial infrastructure, industrial automation,

reduction.

building HVAC (HVAC Variable Speed Drives),

Construction of the Slim type series and IP55

Power Conditioning System (PCS) for mega solar

series made it possible to be mounted closer to

plant and Uninterruptible Power Supply(UPS) for

the application area without being installed in the

Data Centre and industrial application in South

electrical control panel.

East Asia, Middle East market. asiamanufacturingnewstoday.com

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SUBHEADING equipment from FARO permits high-precision 3D measurement and comparison of parts and compound structures within production and quality assurance processes.

The devices are used for inspecting components and assemblies, production planning, inventory documentation, as well as for investigation and reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites.

With FARO, 3D measurement and documentation needs can be fulfilled confidently. As a pioneer and market leader in portable computer-aided measurement, FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate, reliable, and easy to use.

The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs.

ASIA MANUFACTURING NEWS • FEBRUARY 2014

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THE INTERVIEW – JOSEPH AREZONE, FARO ASIA PACIFIC

AURECON APPO The manufacturing sector is undergoing a major structural shift worldwide as it moves from mass production systems to those of customised goods and services dependent on supply chains with global reach. This shift places demand on manufacturers to become technologically rich to connect to the world of their customers.

Stephen Wells, Chief Business Development Officer, said: “Increased speed to market, productivity and knowing and understanding consumer behaviour, trends, and client needs will become critical in keeping

Worldwide, approximately manufacturers competitive across 15,000 customers are operating more than installations the globe. ohn30,000 McGuire has been of appointed as FARO’s systems. The company’s “Having John come on board is a great start to Industry global global headquarters areDirector, located Manufacturing – in LakeBuildings.

Mary, Florida, with its the year for Aurecon. Drawing on his previous European head office in Stuttgart, experience leading international businesses He will be directly responsible for leading the Germany and its Asia-Pacific and growing them relevant to a globally businesses strategy head office ingrowth, Singapore.

FAROand sophisticated has branch locations in Japan, interconnected world, John will be responsible client offerings for Aurecon’s manufacturing China, India, South Korea, for helping Aurecon’s manufacturing clients business.Malaysia, Vietnam, Thailand, Canada, Mexico, United navigate the rapidly changing landscape.”

Kingdom, France, Spain, Italy, Poland, and The Netherlands. u Joseph Arezone, Senior Vice-President, Managing Director for FARO Asia Pacific

J

Community Planning, Sustainable Business and Waste Minimisation Strategies www.envision-nz.com

www.asiamanufacturingnewstoday.com

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Asia Manufacturing News

June 2014

OINTMENT TO EXPAND MANUFACTURING BUSINESS John is an experienced business leader, offering over 25 years of experience in consulting and contracting in Australia, the

University of Western Australia and Curtin University.

Commenting on joining Aurecon, John

Middle East and the United Kingdom. He has

said: “Aurecon is at the nexus of helping

been involved in a wide range of projects,

manufacturers transform their businesses in

specifically in health care, forensic and specialist

the face of the competitive and cost pressure

containment laboratories and is highly regarded

challenges they face, into highly connected,

and recognised throughout Australia for his

productive and technologically enabled

creative and innovative design approach to

organisations that are geared for success in our

engineering and project leadership. Notable

new age societies. I have been impressed with

projects with which John has been involved

Aurecon’s skills, research, thought leadership

include the AUD 1.78 billion Fiona Stanley

and capability in this space and am delighted

Hospital in Western Australia, the AUD 450

to be able help enrich the offering that Aurecon

million Austin Repat Mercy Redevelopment in Victoria, and the Auckland City Hospital in New Zealand.

John was most recently Global Director (Health) – Building Systems with AECOM, where he was responsible for the growth and development of the health market sector internationally across all of AECOM’s geographies in the Building Engineering

can deliver to our manufacturing clients.”

About Aurecon Aurecon provides engineering, management and specialist technical services for public and private sector clients globally. With an office network extending across 26 countries, Aurecon has been involved in projects in over 80 countries across Africa, Asia Pacific, the Middle East and the Americas and employs around 7 500 people throughout 12 industry groups:

practice line, as well as its development across

Construction; Data & Telecommunications;

all practice lines in the Asia Pacific region. He is

Defence, Energy; Government; International

also a guest lecturer in building environmental

Development Assistance; Manufacturing; Oil

design at Schools of Architecture in both the

and Gas; Property; Resources; Transport; Water

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ANALYSIS

THE BENEFITS OF UNIFIED COMMUNICATIONS IN - Bruce Downing (Managing THE MANUFACTURING INDUSTRY What is unified communications (UC)?

Unified Communications, or UC, is a term used to describe a communications system that includes voice and data, as well as collaboration tools and applications delivered on a single platform. ShoreTel UC leverages Voice over IP to bring together VoIP telephony, instant messaging, video conferencing, mobility, presence and collaboration capabilities into a seamless business environment.

How can UC solutions help manufacturers meet the key industry challenges and the growing pressure to innovate?

Unified Communications solutions that offer scalability, availability and reliability, as well as ease of use and management, deliver the most value to manufacturers. Dealing with distributed offices or multiple remote plants can be a challenge for manufacturing companies; however, a UC solution that allows integration between legacy systems, whilst consolidating communications technology onto a single platform, will ensure continued growth – leveraging existing assets without costly production days.

Using advanced call-routing features and centralised management across the system, ShoreTel helps minimise operational headaches, whilst maximising user adoption and customer satisfaction. Providing the organisation with the means to communicate easily and effectively – across diverse geographies, time zones and devices – enables better collaboration; and through that, there is more dynamic innovation.

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Can you share examples of ShoreTel customers who have successfully adopted UC in their manufacturing facilities, and the benefits they have reaped since?

ShoreTel has a number of manufacturing customers in Asia using our UC, Contact Centre and Mobility solutions. For example, Tien Wah Press (TWP) was first established in Singapore as a family-run letterpress business in 1935. TWP has two main locations – its sales office and manufacturing plant are in Singapore, and it has two additional plants in Malaysia. They wanted to upgrade their old analogue phones and reduce costs across their multiple plants internationally, so they

Asia Manufacturing News

June 2014

Director, Asia and South Africa) of ShoreTel. decided to implement a ShoreTel UC solution because of its affordability and flexibility.

A second customer who is still rolling out ShoreTel UC solutions across Asia Pacific is a global manufacturing company, with its APAC regional headquarters in Singapore, as well as a manufacturing plant and additional sites in India, Korea, Japan, China, Indonesia and the Philippines. This customer deployed ShoreTel Contact Centre, UC, Conference bridges and IPhones across the entire organisation.

The company needed a scalable multi-site communications platform to replace its ageing PABX systems. After significant evaluation, it decided ShoreTel’s simplified infrastructure – which could be managed by a regional team with call cost savings – was compelling enough to upgrade the telephony system to a full UC solution.

What have been some of the significant milestones for ShoreTel recently?

ShoreTel has had a very successful last 12 months in Asia. We doubled the number of new customers in the region in 2013; we were awarded the NetworkWorld Asia’s Rising Star Award for Communications and Collaboration; we made significant investments in new headcount in sales and marketing; and we appointed a new distributor in Singapore – Ingram Micro.

We also had a number of major product launches across our entire solution suite – including the ShoreTel Dock, ShoreTel Contact Centre 9.0, ShoreTel Mobility 7.0, as well as ShoreTel 14.2, our fully

virtualised Unified Communications (UC) solution.

How do you see 2014 for ShoreTel Asia?

In 2014, we expect to continue the growth that has been characteristic of ShoreTel in Asia over the last three years, and to consolidate our presence in key verticals.

We expect to have a number of existing customers complete their UC roll outs and be available to speak to the media and deliver case studies about the benefits they have realised as a result of their investment in ShoreTel UC solutions.

How is Asia performing vis-a-vis the rest of the company?

With more than 50 per cent of the world’s population based in Asia, this is a significant market for ShoreTel and one that has the focus of the organisation. In early 2014, our

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ANALYSIS

Global Product Management team visited the region to talk to partners and customers and help them better understand the drivers and unique market concerns in Asia. Our objective is significant growth in Asia, in line with company performance across the world.

Where do you see manufacturing growth for ShoreTel in Asia?

Business has never been more challenging for manufacturers that are faced with more competitors, as well as increasingly aggressive pricing and demanding customers. Regardless of the nature of the manufacturing business, the performance of the communications system can help manufacturing organisations meet these challenges, across the entire value chain.

ShoreTel has a number of Asian manufacturing customers who use our UC solutions, that their workers can reliably contact one another with speed and ease, regardless of their locations. As these organisations scale up and down, the process needs to be smooth and efficient for those managing the communications systems.

Even a small glitch or missing feature can contribute to costly delays or shutdowns; which, in turn, hurt both the bottom line and the company’s reputation.

With the growing need for optimal business communications in this industry, ShoreTel’s competitive edge with our UC solutions will continue to drive new Asian manufacturing firms to adopt ShoreTel for the foreseeable future.

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Describe the importance of R & D at ShoreTel. ShoreTel places a very high degree of focus on innovation, research and development.

This is demonstrated by the appointment in 2013 of Don Joos as our CEO, an executive with very broad business experience, including direct management of the ShoreTel engineering/R&D organisation.

What kind of investments did ShoreTel make in 2013?

Globally, in fiscal year 2013, ShoreTel invested about 17 per cent of total annual revenue in R&D. This reflected in the regular release of improved features and functions of our existing UC, Mobility and Contact Centre solutions, as well as the brand new and innovative solutions that are part of our product suite, like the award-winning ShoreTel Dock. *Bruce Downing is Managing Director, Asia and South Africa, and his current focus is to establish and build new partnerships, create market demand in ShoreTel’s new markets of operation across Asia, as well as continue to grow ShoreTel’s business in its more established Asia markets – including Singapore, Hong Kong and the Philippines.

Based in ShoreTel’s regional head office in Singapore, Bruce is responsible for managing ShoreTel’s business operations, sales, channels and go-to-market strategy across the Asian and South African regions.

Asia Manufacturing News

June 2014

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AVIATION

BOEING MAY HAVE FOUND ULTIMATE JET FUEL

A

irline manufacturer Boeing claims to have identified a new renewable fuel that emits at least 50% less carbon dioxide than fossil fuel over its lifecycle.

The company is working with the US Federal Aviation Administration to gain approval for its new ‘green diesel’ which could power aircraft, cutting the aviation industry’s carbon footprint significantly.

Boeing researchers have found that green diesel, which is made from oils and fats, is chemically similar to today’s aviation biofuel.

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If approved, the fuel could be blended directly with traditional jet fuel.

“Green diesel approval would be a major breakthrough in the availability of competitively-priced, sustainable aviation fuel,” said Dr. James Kinder, a technical fellow in Boeing Commercial Airplanes Propulsion Systems Division.

“We’re collaborating with our industry partners and the aviation community to move this innovative solution forward and reduce the industry’s reliance on fossil fuel.”

Asia Manufacturing News

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Green diesel approval would be a major breakthrough in the availability of competitively -priced, sustainable aviation fuel

“

“Green diesel approval would be a major breakthrough in the availability of competitively-priced, sustainable aviation fuel”.

Significant green diesel production capacity already exists in the US, Europe and Singapore that could supply as much as 1% – about 600 million gallons – of global commercial jet fuel demand. The wholesale cost – about $3 a gallon with US government incentives – is competitive with petroleum jet fuel.

Boeing, the FAA, engine manufacturers, green diesel producers and others are now compiling a detailed research report that will be submitted to key stakeholders in the fuel approvals process.

In 2011, Boeing worked with the aviation community to include a blend of up to 50% aviation biofuel in international jet fuel specifications. Biofuel approved for aviation must meet or exceed stringent jet fuel performance requirements.

“Boeing wants to establish new pathways for sustainable jet fuel, and this green diesel initiative is a groundbreaking step in that long journey,” added Julie Felgar, managing director of Boeing Commercial Airplanes Environmental Strategy and Integration.

The green diesel can be used in any diesel engine. It is chemically different and a different product than the fuel known as ‘biodiesel’.

June 2014

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MANUFACTURING TECHNOLOGY

I2R showcases innovations for a world o Singapore - A*STARís Institute for Infocomm Research (I2R) is continuing its efforts to help international organisations move their business forward and enabling local SMEs gain their competitive edge through increased productivity. The home-grown innovations showcased at IoT (Internet of Things) Asia 2014 in April and at A*STAR’s SME Day. Last October, I2R exhibited its ‘ready-to-go’ ICM productivity solutions at its annual flagship event, ICM Horizons. This was in response to the National Productivity Councilís call to boost the productivity and efficiency of Singapore’s local enterprises to drive productivity for labour-constrained SMEs. Within a span of six months, more than 57 of I2R’s technology deployments have been

implemented by 27 SMEs, with technologies ranging from image recognition, augmented reality to sensor networks.

Feinmetall, a local SME in precision engineering, is now using the image recognition technology ‘Snap2Tell Alive’ mobile application, which streams instructional videos of production equipment to mobile devices, allowing customers to view these easily instead of referring to printed manuals or consulting technicians.

This enhances the productivity of Feinmetall as their technicians need not be present at their customersí premises. At the same time, customers’ equipment downtime is reduced, as they can now bring the equipment back to operation without much delay.

The Age & Gender Recognition Technology is able to measure audience demographic by detecting frontal human faces on digital video strea 16

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Asia Manufacturing News

June 2014

of increased productivity and efficiency IoT Asia 2014 The inaugural IoT (Internet of Things) Asia Exhibition and Conference is the first in the region to focus on bringing IoT technology and tranformation to end-businesses, governments and society. It provides a spectrum of enterprise platform solutions for Multinational Corporations (MNCs) and Small and Medium Enterprises (SMEs) to integrate within their product or solution offerings and enables them to gain an edge in information business.

I2R is one of the founding members of IoT Asia 2014.

At the event, I2R is showcasing three exciting IoT innovations: the Toilet Cleanliness Monitoring System, Taxi Queue Monitoring System and Outdoor Car Park Monitoring System. These three systems have been installed at the Singapore EXPO Convention and Exhibition Centre (Singex) for test bedding as part of a 3-year MOU between I2R and Singex. a) Toilet Cleanliness Monitoring System The Toilet Cleanliness Monitoring System is maintenance-free as it applies energy-harvesting technologies to power the sensors that count the number of users going past the toiletís main door. Cleaning companies can deploy their workers more effectively to clean the toilets according to their ëcleanliness levelí using this technology.

The system is scalable as it also has the option to include ammonia sensors and ‘on-demand’ requests to alert the cleaners if a particular toilet needs additional attention.

This technology is expected to improve the productivity of cleaning companies by up to 20 percent. Usually, public toilets are cleaned at regular intervals, regardless of the number of times the toilet is used. This results in manpower wastage.

I2R will be working with cleaning companies and commercial building owners to deploy this system, under A*STARís Technology Adoption Programme (TAP).

The research institute is also working with system integration companies to license this technology and introduce it to the mass market. b) Taxi Queue Monitoring System Most of us have encountered a situation where we have to queue for a long time before boarding a taxi. I2Rís Taxi Queue Monitoring System aims to provide an effective system of measuring the number of people queuing at a taxi stand. Using innovative human detection and tracking technology through images captured by a CCTV, the system is able to analyse and forecast the average waiting time by taking into account the number of people waiting in line.

A Proof-of-Concept System has been set up at the taxi stand near Foyer 1 at Singapore Expo. The information analysed and forecasted will be showcased at IoT Asia 2014.

I2R plans to work with taxi operators and building owners to install the Taxi Queue Monitoring System, which will provide real-time information for taxi companies to

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MANUFACTURING TECHNOLOGY

deploy their available taxis efficiently and provide convenience to passengers. c) Outdoor Car Park Monitoring System

at Car Park A at Singapore EXPO. Dr. Lee Shiang Long, Executive Director of I2R, said, “I2R is adopting a Whole-of-I2R approach in

I2R’s Outdoor Car Park Monitoring System

bringing the diverse and relevant range of

is a visual system that enables car park

technology capabilities to boost productivity

management companies to track outdoor

and efficiency of large organisations and local

car park lots occupancy in a cost-effective

SMEs.

manner. By using a network of wireless

The showcase of our home-grown

cameras to detect vacated car park lots, this

technologies at premier platforms such as

system provides motorists with real-time

IoT Asia is a great opportunity for companies

information on parking lots availability in an

to share and learn about how innovations

outdoor environment. The system also works

can positively impact their businesses and

at night, with the availability of street lights.

meeting their customers’ needs by boosting

The Outdoor Car Park Monitoring System

productivity and efficiency.”

differs from the conventional indoor car park

Ready-To-Go Technologies for SMEs I2R also

monitoring system as it does not require

showcased its ‘ready-to-go’ innovations at

sensors to be installed overhead or embedded

A*STAR’s SME Day. These ICM technologies

underground. This translates to lower

that can be readily adopted by SMEs are

system hardware and installation costs. Car

translated from I2R’s research efforts to

owners can locate empty car park lots more

readily deployable technologies and platform

efficiently and within a shorter time, saving

solutions for easy adoption by SMEs to meet

petrol and reducing their carbon footprint. A

their customers’ needs. I2R will continue to

proof-of-concept system has been deployed

work directly with government agencies, trade associations and local SMEs to deploy more of these ‘ready-to-go’ technologies for quick and easy deployment and adoption. In line with its mission-oriented mandate, A*STAR spearheads research and development in fields that are essential to growing Singapore’s manufacturing sector and catalysing new growth industries.

A*STAR supports these economic clusters by providing intellectual, human and industrial capital to its partners in industry.

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Asia Manufacturing News

June 2014

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MANUFACTURING TECHNOLOGY

VEOLIA IMPLEMENTS WATER M Singapore: Veolia Water Solutions & Technologies is proud to announce a project win to implement its in-house water metric at Tenaga Nasional Berhad (TNB) thermal power plants.

The appointment was made by TNBR, a wholly-owned Research and Development subsidiary company of TNB, which is Malaysia’s national electricity utility company.

Veolia will be working in collaboration with TNBR by providing technical expertise in the research of water utilization and treatment technology to achieve zero liquid discharge.

As the technical collaborator, Veolia will lead the Water Impact Index™ (WiiX) studies at all of the seven thermal power plants managed

by TNB in Peninsular Malaysia.

According to Dr. Ir. Cheong Kam Hoong, Managing Director of TNBR, “The two most important natural resources for TNB are fuel and water. Worries about global warming, contaminated air and water have encouraged many organizations such as TNB to evaluate how much of the earth’s water resources we are using so that we can plan and make improvements and responsible decisions.”

“Adopting WiiX has placed TNB at the forefront of water resource management among major industrial companies in Malaysia, and reinforced the company’s environmental leadership in the power industry, while contributing to TNB’s corporate social responsibility objectives for the nation’s benefit” said Duncan Briggs, Commercial Director, Operations & Maintenance, Veolia, South East Asia.

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Independent research has shown that failure to account for the plant locations and the quality of water abstracted and released by such plants can distort the environmental effect that companies have in undertaking their business activities. The Water Impact Index methodology can help to better establish water footprint boundaries and water footprint measurement (quantification).

Johann Clere (Global Director - Business Development) shared, “Water is increasingly becoming a global concern and, at Veolia, we work hard to help companies transform risks into opportunities. We are delighted to work with TNB to create more awareness on water scarcity challenges and we believe that with the implementation of the WiiX metric, we will help to shed focus on problematic areas where more efforts can be invested to correct outstanding problems.”

Tenaga Nasional Berhad (TNB) is the largest electric utility company in Malaysia and also the largest power company in Southeast Asia with MYR 69.8 billion worth of assets. It serves over seven million customers throughout Peninsular Malaysia.

TNB’s core activities are in the generation, transmission, and distribution of electricity.

Other activities include repairing, testing, and maintaining power plants; providing engineering, procurement, and construction

Asia Manufacturing News

June 2014

METRIC AT TNB POWER PLANTS services for power plants related products; and assembling and manufacturing high voltage switchgears, coal mining, and trading.

Operations are carried out in Malaysia, Mauritius, Pakistan, India, and Indonesia.

Veolia Water Solutions & Technologies is the Veolia Water subsidiary specialized in technical solutions and design & build projects for water and wastewater treatment, for industrial and municipal clients. Veolia Water Solutions & Technologies recorded revenue of £2.4 billion in 2012.

Veolia Water, the water division of Veolia Environnement, is the world leader in water and wastewater services. Specialized in outsourcing services for municipal authorities, as well as industrial and service companies, it is also one of the world’s major designers of technological solutions and constructor of facilities needed in water and wastewater services. With 89,094 employees, Veolia Water provides water service to 100 million people and wastewater service to 71 million. Its 2012 revenue amounted to £12.078 billion.

The Water Impact Index, a new decision making tool for sustainability

First indicator enabling a comprehensive assessment of the impact of human activity on water resources

asiamanufacturingnewstoday.com

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MANUFACTURING TECHNOLOGY

3D-PRINTED MATERIAL IS STRONGER THAN STEEL, LESS DENSE THAN WATER

Researchers at the Karlsruhe Institute of Technology (KIT) has leveraged a new type of nanoscale 3D printing to push the limits of material science forward. Using a process developed by a German company called Nanoscribe, Jens Bauer and his team developed a new material that is less dense than water, but as strong as some forms of steel. This is the first evidence that these theorized materials can actually exist.

Every material is characterised by its range of strength and density. In most instances, things get stronger as the become more dense, which has led to materials scientists searching for ways to buck the trend.

Something that is very strong and not very dense is great for building anything where overall weight is a factor. In the graph below, the middle density line at 1000kg/m^3 is water. So the best material designed by Bauer and colleagues is toward the upper left, indicated by the pink dots.

Advanced materials are often made with composites or plastic, but can also rely on careful structural design. To design this new material, Bauer looked at the 3-dimensional 22

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structure of substances that are less dense than water, but still fairly strong, like wood and bone. The KIT material is inspired by those delicate structures produced in nature.

Nanoscribe’s technology works by illuminating a drop of viscous polymer with a laser in a precise pattern. The points in the material hit by the laser solidify and the excess can be washed off. The resulting 3D structure is then coated with a layer of aluminium oxide for added strength. This helps refine ideas about how to design new materials, but it isn’t practical on its own.

The Nanoscribe process is currently only able to produce objects under 100 micrometers in size, which structures around a millimetre coming later.

Asia Manufacturing News

June 2014

NEW INJECTION TECHNOLOGY IN ONE MACHINE CELL Krauss Maffei exhibited at Chinaplas a KM CX 200-180/180 W twin injection moulding machine in collaboration with Zahoransky Group of Germany and their innovative patented ‘cube technology’ concept TIM (Total Integrated Manufacturing) enabling the moulding, assembly and testing of multi-component parts in one injection moulding cell.

The key to the efficiency of the system is the two mounting plates which are positioned outside the tool. This allows complex assembly processes to be carried out in parallel to the production without increasing the cycle time. The mounting plates can be moved on the X and Y axis by 180º and at the completion of the injection process the moulded parts can be picked up by the

assembly jig and combined with the parts that have already been produced.

The rotary cube mould system is run on Krauss Maffei CXW Spin Form Series Injection Moulding machinery. This series combines the proven dual platen technology of the CX and MX series and offers ideal accessibility to the mould and space for the integrated assembly stations. The central positioning of the two opposing injection units allows for hot runner systems with natural balancing and short flow paths.

Energy saving servomotors control the movement of reversing the plates in the opening direction and the rotation of the cube mould with absolute position accuracy. The unique system provides energy and space savings and is available in clamp sizes ranging from 1,800 kN to 40,000kN.

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MANUFACTURING TECHNOLOGY

LAYING THE GROUNDWORK FOR A MANUFACTURING REVOLUTION For centuries, manufacturers have relied on ‘subtractive’ techniques to fabricate objects — cutting, milling and grinding away substances such as ceramic and steel. But the waste associated with traditional processing is becoming problematic as the cost of raw materials increases.

In aerospace applications, for example, up to 90 per cent of high-tech alloys are machined away during component fabrication.

Furthermore, devices containing intricate internal features or extremely thin dimensions are difficult to produce with conventional techniques.

New methods of ‘additive’ manufacturing are emerging, however, that could potentially solve these problems and trigger radical changes in traditional economies of scale.

Based on three-dimensional (3D) printing technology — which generates 3D objects from computational data by building them up in layers from materials such as plastic or metal — the approach allows rapid production of complex, customized and previously inaccessible designs. Moreover, the precise addition of material minimizes waste for a reduced environmental footprint.

To help prepare manufacturers for the coming revolution in on-demand fabrication, A*STAR has launched a US$12 million Industrial Additive Manufacturing Programme, led by the A*STAR Singapore Institute of Manufacturing Technology (SIMTech).

In partnership with Nanyang Technological University (NTU), a leader in additive 24

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manufacturing research, the program will advance specific technologies and training to assist Singapore’s diverse range of aerospace, automotive, marine and petroleum manufacturers in the adoption of additive manufacturing techniques — a critical step toward strengthening a sector that contributed over 20 per cent of the country’s gross domestic product in 2012.

“This program aims to develop innovative additive manufacturing technologies and capabilities to transform the manufacturing landscape of Singapore,” says Tan Geok Leng, executive director of A*STAR’s Science and Engineering Research Council. “Singapore is well positioned to respond to the needs of this new growth area and introducing such advanced manufacturing techniques could rejuvenate the existing workforce. Established sectors — such as the precision engineering and aerospace maintenance, repair and overhaul industries — are poised to be the lead demand drivers.”

Answering the billion-dollar question Forecasts estimate that the market potential of additive manufacturing will expand from its current value of US$2.2 billion to US$10.8 billion in 2021. Although the business outlook is positive, there are many challenges to overcome to achieve this goal. These include the development of appropriate printing materials, machinery design and calibration and post-processing methodologies, in addition to providing workers with the necessary training.

Asia Manufacturing News

Fortunately, A*STAR is home to a wide spectrum of knowledge and expertise, making it the ideal setting in which to explore new manufacturing technologies. Accordingly, SIMTech and NTU are set to collaborate with two other A*STAR research institutes — the A*STAR Institute of Materials Research and Engineering and the A*STAR Institute of High Performance Computing — by tapping into their expertise in the modeling, simulation and production of novel materials and innovative devices. The four institutes will train students in 3D printing techniques and hope to apply their research findings to Singapore’s manufacturing industry within the next three years.

Six to watch As part of its remit, the A*STAR–NTU Industrial Additive Manufacturing Programme has identified six key additive manufacturing technologies that could benefit from sustained research.

The first of these, ‘stereolithography’, operates much like an inkjet printer, except that the ‘ink’ is a liquid photopolymer that

June 2014

solidifies under ultraviolet laser light and joins successive layers together to form a 3D object.

While this system allows for the speedy production of functional parts and prototypes, it is also prohibitively expensive due to the high cost of proprietary photopolymers.

Hence, researchers are seeking out inexpensive photopolymers with improved abilities to withstand sudden impacts.

Eventually, they hope to print large-format and lightweight polymer components with customizable internal structures that provide distinct advantages over current designs.

‘Polyjet’ printing is another polymer-based additive manufacturing technique gaining favor. These 3D printers have two different jetting heads — one that sprays an ultraviolet-curable photopolymer and another that emits a gel-like support structure, which can be easily washed away after printing is complete. The A*STAR and NTU research teams intend to use polyjet technology to produce novel geometries, such as honeycomb hexagonal cells, which are sought-after for their strength and light weight asiamanufacturingnewstoday.com

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but are typically constructed through lengthy and repetitive bonding processes.

The ability of lasers to achieve extreme heating and cooling rates within the near-surface regions of materials while leaving the bulk untouched makes them ideal for use in layer-by-layer assembly techniques. One such technology, ‘laser-aided additive manufacturing’ (LAAM), fabricates metal parts by controlled heating of metal powders — particularly useful for assembling high-value parts from difficult-to-machine metals, such as titanium or nickel alloys. Yet at present, LAAM is simply used in repairs and re-manufacturing. A*STAR and NTU researchers therefore plan to deploy LAAM in the fabrication of innovative, large-format structures, 2 to 8 meters long, which can be used as downhole components in the oil and gas industries or as mold and die inserts for heavy vehicle production.

Another way that powdered materials can be fused together is through the ‘selective laser melting’ (SLM) and ‘selective laser sintering’ (SLS) additive manufacturing techniques.

A*STAR researchers are using computational studies to develop material distribution algorithms that will reduce the need for support structures in SLM and physics-based models that address consistency issues in SLS — huge advances for both methods.

The final area of focus for the A*STAR additive manufacturing program will be ‘electron-beam melting’ (EBM), which uses focused beams of electrons instead of photons of light to produce 3D metal 26

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parts from powders under high-temperature, low-pressure conditions. EBM is one of the most efficient additive manufacturing processes, producing extremely strong and distortion-free parts. However, dimensional accuracy is difficult to achieve and components often have rough surface finishes — problems that researchers intend to tackle through multidisciplinary investigations.

Maintaining Singapore manufacturing’s competitive edge With the worldwide 3D printing market now on the verge of taking off, NTU’s dean of engineering, Ng Wun Jern, notes that the Industrial Additive Manufacturing Programme will benefit companies in Singapore by providing support for scaling up and integrating the technology at a critical time in its development.

“Understanding industry needs and developing innovative solutions is key to keeping Singapore’s competitive edge in today’s high-tech manufacturing sector,” says Ng. “NTU and A*STAR are well placed to make this new program a success. Together, we are poised to support our industry’s move into next-generation manufacturing.”

MANUFACTURING TECHNOLOGY

Asia Manufacturing News

June 2014

CIMA NANOTECH ANNOUNCES PRODUCTION OF SANTE FS200 TOUCH FILMS Singapore: Cima NanoTech, a smart materials company and developer of the disruptive SANTE(R) self-assembling nanoparticle technology for transparent conductors, has announced successful commercial production and sales of its high performance SANTE FS200 Touch Films for large format, multi-touch displays.

Designed to enable faster response, lower cost, multi-touch displays with excellent conductivity, transparency, color neutrality, clarity and flexibility, the film is perfect for large format touch screens over 21” for applications such as all-in-one monitors, interactive table-tops, gaming and signages.

SANTE FS200 Touch Films was announced last May at SID Display Week 2013. Unlike Indium Tin Oxide (ITO)-based films, SANTE Touch Films are flexible, thus increasing handleability and improving product design freedom by supporting curved, flexible and rollable touch displays.

Cima NanoTech is partnering with top opto-materials coating company in Japan, Korea and Taiwan for high volume manufacturing of SANTE FS200 Touch Films.

SANTE FS200 Touch Films have achieved successful spec-in with touch panel makers in Taiwan and China, with numerous active customer engagements globally. The transparent conductive film will be integrated in industrial and consumer touch screen products and begin shipping in the second half of 2014.

“The touch industry is evolving faster than ever, and today’s new applications require larger sized touch screens with superior optics and faster response time. These requirements are beyond capabilities of ITO, the incumbent touch screen material today,” commented Jon Brodd, Chief Executive Officer, Cima NanoTech. “We strongly believe that our products provide touch panel manufacturers with the performance, quality, and cost structure to enable them to win new large format touch screen designs and enable consumers to enjoy touch on a much larger surface.”

Cima NanoTech is a smart materials company specialising in the development of next-generation transparent conductors. The company developed its proprietary SANTE self-assembling silver nanoparticle conductive coating, which enables high performance transparent conductors in a multitude of markets from large-format multi-touch displays to capacitive sensors, transparent and moldable EMI shielding, transparent heaters, transparent antennas, OLED lighting, photovoltaic and others.

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SUBHEADING

KEEPING SMBS AHEAD OF THE MANUFACTURING INNOVATION CURVE IN SOUTHEAST ASIA The Southeast Asia region as a whole has achieved unprecedented growth and development in recent decades and is increasingly playing the role of a global growth pole, fast emerging as a manufacturing and information technology hub of the world economy.

According to a recent report from the Association of Southeast Asian Nations (ASEAN), more than 96% of all enterprises across the region are considered SMBs, and those organizations account for between 50% and 85% of all domestic employment.

Specifically, the SMB sector is an important pillar of Singapore’s economy as they contribute more than 50% of the economic output and 70% of employment. Needless to say, it is clear that small and mid-sized businesses play a unique and integral role across the region, serving as suppliers to large firms, customers of large firms and their own customers.

Yet scale and making significant economic contributions have not protected SMBs from the pressures of the global economic slump, rising costs, competition from neighbouring countries and a shortage of skilled workers. GDP growth in the Southeast Asia manufacturing industry is predicted to accelerate modestly from 6.3% in 2013 to 6.5% in 2014 – slower in both years than the 6.9% growth in 2012, meaning manufacturing growth is dependent on the future of its smallest but most significant contributors.

Against this backdrop, innovative SMBs are looking for the next generation of tools and 28

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strategies to stay ahead of the competition.

As stated in a recent SBF DP SME Index, a joint initiative of the Singapore Business Federation and DP Information Group, manufacturers are tackling the challenges first hand by embracing a new wave of technologies and innovations. Product lifecycle management (PLM) software, which includes computer-aided design (CAD) and simulation technologies, is one such innovation.

PLM solutions optimising resources and driving success Company leaders have reported that the biggest obstacles to generating return on investments in innovation are lengthy product development times and a lack of coordination within the company. PLM solutions enable manufacturers to drive success by streamlining their productivity and performance and in turn, maximising the value derived from their products throughout the manufacturing lifecycle.

With PLM software, businesses can create a single master plan with schedules, tasks, deliverables, milestones, baselines and constraints. This creates a consistent process for planning, optimizing and designing

Asia Manufacturing News

June 2014

By Rajiv Ghatikar, Vice President and General Manager, Siemens PLM Software, ASEAN / Australasia

products while monitoring costs and resources. Ultimately, this allows SMBs to meet customer commitments on time and on budget.

PLM’s integrated approach also enables businesses to significantly streamline their activities, validate that goals have been met and accelerate product delivery. The software’s performance-tracking capabilities allow business owners to make informed decisions, fast-track successful projects, narrow down projects of low value or change directions completely.

The value of CAD Solutions that enable computer-aided design (CAD) modelling offer SMB manufacturers another opportunity to lower product development costs, increase productivity and improve product quality and time to market. The advanced modelling and analysis functionalities allow SMBs to more accurately visualise the final product and its constituent parts, as well as provide more robust documentation of designs and easy re-use of design data and best practices.

The use of CAD models has already proven successful for South East Asian SMBs. For example, Heatec Jietong Pte Ltd, a midsized provider of piping and heat exchange services for the marine and oil and gas industries based in Singapore, faced a competitive environment dominated by large-enterprise companies. The company prides itself on

providing high quality services with an emphasis on timely delivery and realized that despite its midsized business model and capacity, the use of technology would allow them to compete effectively and retain its quality promise.

To achieve this, Heatec JieTong realised that it needed to address several issues that were slowing its manufacturing process. Among the most critical, the company was using a 2D drawing package to design its systems and recognised that the 2D approach was especially cumbersome in responding to tight deadlines.

Turning to Siemens PLM Software’s Solid Edge software, Heatec JieTong’s design teams adopted best-in-class 3D drafting and visualization, which produced immediate results. For the first time, designers found it easier to keep up with engineering changes.

Just as importantly, design errors were essentially eliminated, which resulted in better quality bills of material. The company’s designers also were able to tightly track their edits and audit the necessary changes.

Overall, adapting 3D CAD solutions enabled the company to operate like a large manufacturer while maintaining its mid-sized business model. Profitability increased as the company demonstrated forward-thinking strategies and advanced technology.

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SUBHEADING

Simulation at the core of modern day manufacturing Simulation software was once the exclusive domain of large companies. However today, with an increasing requirement to produce designs in shorter cycles, reduced time-to-market has become a foremost business pressure. This drives the adoption of simulation in design.

Prototype manufacturing and testing can take up a significant amount of time and manpower, two resources that SMBs don’t have in abundance. Simulated design testing reduces the reliance upon physical testing and prototyping which allows designs to be brought to market sooner, in a more cost efficient manner. Simulation software programs such as Solid Edge Simulation allow design engineers to model components and enable assemblies or systems to determine the behavioural response for a given operating environment. Further analysis can help identify and resolve issues, reduce material usage, and optimise performance.

Malaysia based contract manufacturer, UWC Holdings used Solid Edge Simulation to

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significantly reduce its product development and manufacturing cycle time for automation solutions. The simulation software allowed the company’s design team to work with embedded class rules, enabling higher standards to be systematically incorporated into the product development process. UWC Holdings is now able to concentrate on high-speed development and manufacturing, and enjoys streamlined compliance with industry standards whilst delivering on expectations.

Staying ahead with PLM Today’s global economy means manufacturers of all sizes must do more with less and for South East Asia’s small and medium enterprises, embracing new technology is key. Shifting investments toward PLM software provides a competitive advantage, accelerating innovation, supporting global collaboration and improving business performance to ensure South East Asian manufacturers remain one step ahead of the competition.

Asia Manufacturing News

June 2014

www.10thousandtrees.com

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THE INTERVIEW

THE INTERVIEW

Attributed to KC Yee, Senior Vice President and Managing Dire

KC Yee discusses the Asian manufacturing industry and the need for simulation-driven design in today’s manufacturing world to increase efficiency, productivity and profitability.

How do you see the future of manufacturing industries globally? And what is Siemens PLM’s role for the future growth for the manufacturing industry?

We’re beginning to see the convergence of manufacturing and information technology, also known as the “Internet of Things.” With more ‘smart’ machinery now connected to the internet and capable of capturing real-time data, product complexity is becoming a big issue, and many traditional manufacturing companies just aren’t equipped with the kind of in-depth IT infrastructure on the product design side.

The important thing to realize here is that the manufacturers need to effectively become IT companies in order to capture, control and profit from the data generated by this new generation of smart industrial technology.

By controlling and owning that data, it opens up a whole new platform of business.

So we believe manufacturers will begin to dramatically build out that infrastructure – most likely through strategic partnerships – and the product lifecycle management (PLM) process itself must now expand to enable and incorporate these new capabilities.

Manufacturers must find a way to quickly and efficiently build these vastly more technologically complex products and then leverage that data to drive intelligent business decisions in real-time. Having the ability to capture and analyze real-time data will allow 32

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manufacturers to minimise the mistakes that can cost valuable time and resources, but first they must find new ways to incorporate and enable new project stakeholders by providing easier access to product information on an intuitive, user-friendly platform.

We see PLM solutions evolving in three major ways, all having to do with enablement.

Firstly, through intelligently integrated information - how information is organized to extract value from large amounts of information; secondly through future-proven architecture in order to protect investment and minimize total cost of ownership and finally towards a user experience that ensures easy access to the right information when needed, to help guide the smartest decisions.

The PLM process will soon be driven through comprehensive and immersive environments that enhance, facilitate and will accelerate the product development decision-making process through a high-definition user experience where each decision maker can access exactly what is needed in real time.

How do you see the Asian manufacturing market? Are they competitive?

While the previous generation of leading Asian companies were heavily dependent on global export-led production and growth, a new breed of Asian manufacturing companies now have access to large, fast developing domestic local markets and possess not only

Asia Manufacturing News

June 2014

ector, Asia Pacific, Siemens PLM.

the skills but also the technology to capitalize.

However, while some say that the expansion of domestic consumer demand is inevitable, that is a long term view.

Now more than ever, the success of Asia’s manufacturers lies in making smarter decisions and getting a better portfolio of products to market in a very short space of time, not just building cheaper and better.

PLM gives our Asian heroes the ability to do that, by accurately forecasting the cost of developing a product portfolio either in-house or through partners, testing against requirements virtually and reporting on this. It also provides a collaboration environment for all players in the value-chain to work together.

Some examples of companies now benefiting from PLM technology and best practices in Asia include Haier, Midea, Hyundai/Kia, AVIC, Beijing Auto, IHI Marine, Nissan Motors and ST Group, among others.

That said, building the right product – and building a product right the first time – becomes imperative in order for today’s Asian manufacturers to remain competitive. There are no second chances. It is now a one-shot deal for them to get it right the first time for cost, productivity and capability reasons.

Market pressure forces manufacturers to go full steam ahead with innovation and productivity, leaving no room for mistakes during the design, engineering, production and supply chain processes.

We have been hearing a lot about simulation-driven design. How are manufacturers

adopting this to improve assembly operations in the plant and overall business profitability?

Simulation and modelling for automation has come a long way in recent years. It has proven to be a time and cost-effective alternative to physical testing, allowing more design options to be considered in shorter time frames.

The rapid feedback and the ability to see and manipulate high-quality computer images spur greater innovation. Many design possibilities can be explored in real time, yet virtually and in rapid iterations. Design engineers, unburdened from the need to build expensive prototypes, are leveraging virtual models to now load the same product data the engineers are using to analyse and improve assembly, therefore making the asiamanufacturingnewstoday.com

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THE INTERVIEW

product manufacturing process easier and faster. Simulation is also fast becoming a management tool since the results of the simulation are pertinent to making significant business decisions.

What are some of the challenges to simulation-driven design?

Manufactures are sometimes caught in a conflict between reducing time in the testing phase and spending more time in the design phase performing early analysis. Additionally, challenges such as lack of expertise and complex product behaviours for performing simulation also affect the process.

When simulation processes take too long, designs continue to move forward without any input from simulation results. A primary reason for this is that there simply aren’t enough CAE analysts available to meet the simulation demands of many companies.

When you combine this with the inefficiencies of traditional CAE tools, the result is a simulation bottleneck, forcing designers to wait for feedback on their designs, and delaying the development process.

Manufacturers can eliminate the simulation bottleneck by empowering their design team to perform CAE analysis. Siemens PLM’s NX CAE provides the tools for simulation analysts to guide the design team. Using simulation automation processes developed with NX Open, the common foundation for automation and programming in NX, expert CAE engineers can capture, author and publish simulation processes to guide less-experienced engineers or designers. This can 34

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accelerate the development process, while ensuring accuracy in modelling and results.

Is there any truth to the suggestion that using simulation during design eliminates unnecessary rounds of prototyping? What are some of the Best-in-Class strategies?

Definitely. It’s not about using simulation to eliminate physical prototypes but rather using simulation and adopting new strategies to augment traditional testing processes.

The benefits companies have seen from their use of simulation to assess product form, fit and function virtually have been significant, reducing physical rounds of testing which can reap considerable savings to product development schedules and budgets.

Companies that have deployed best-in-class simulation strategies build on average 1.4 fewer prototypes than the industry average.

Using simulation means that the first prototype can be very close to a production unit. Physical testing still needs to happen, but many issues can be found in the initial digital mockup and the move to physical prototypes is more tweaking than redesign.

For example, Siemens PLM’s NX™ Design Simulation software delivers design-integrated structural and thermal simulation tools to help design engineers compare design alternatives and optimize performance characteristics of products from the earliest stages of the design process. Complementary and scalable to the NX Advanced Simulation applications suite, these tools are tightly linked with NX 3D design geometry to accelerate simulation modelling, analysis

Asia Manufacturing News

and results evaluation, so that functional performance simulation results can directly influence design. The result is a highly iterative and predictive engineering process that delivers innovative designs, higher quality products and reduced time-to-market.

As companies drive towards virtual product development and simulation-driven design, the need for simulation data becomes critical.

Why? The different phases of simulation-driven product development generate significant and increasing amounts of diverse data whose loose management leads to error prone procedures that delay crucial decisions.

Integration of the various CAE disciplines in a common PLM environment will help enhance communication, accelerate PLM process and increase the impact of simulation on all product development phases.

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June 2014

Teamcenter® for Simulation software provides flexible, “out of the box” simulation process and data management capabilities that enable companies to cost effectively implement a complete digital product development environment. Extending the core data model and integrating specialist simulation capabilities means manufacturers can efficiently leverage Teamcenter – the world’s leading digital lifecycle management solution and de facto standard for deploying PLM initiatives – to automate simulation processes in the broader context of new product development.

By optimising and validating process performance before production, eliminating inefficiencies, shortening ramp-up times and increasing quality, organizations can achieve smart, fast, lean manufacturing.

Shanghai New International Expo Centre asiamanufacturingnewstoday.com

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SUBHEADING

RUGGEDISED PLCS BOOST PROCESSING TIME AT GOLD MINE Subang Jaya, Malaysia: ABB is currently upgrading the automation system at Agnico Eagle’s gold mine in Lapland, with eight of its latest ruggedized PLCs for controlling equipment in harsh conditions and extreme climates. The PLCs will control the sedimentation process of the concentrating mill at Europe’s largest gold mine: Agnico Eagle’s mine in northern Finland which is 150 km inside the Arctic circle near the town of Kittila.

ABB won the original contract for the main automation system at the gold mine, and configured and installed electrical automation based on its 800xA Extended Automation system and industrial IT architecture. The project involved a large amount of ABB automation components including ABB’s 800 series operator interface panels and AC500 PLCs for the underground control of pumps, air conditioning, the motors used in ore crushing and processing, etc.

However, a number of items of plant equipment came with automation from other vendors, including PLCs that were supplied with the sedimentation facility that forms part of the mine’s concentrating mill. The PLCs were normal industrial grade types, but housed in freeze-protected cabinets located outdoors.

Since installation however, this facility has suffered a number of process stoppages because of the environment at the mine which includes very wet and humid conditions and winter temperatures as low as -40 degrees C. If a process stoppage happens 36

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in winter the impact can be severe, as the weather can quickly add to the problem by freezing and blocking pipelines.

There have been some four or five stoppages a year, stemming from power outages, extreme cold temperatures, or water droplets that form on the PLC modules when the cabinet doors were opened.

In wintertime, condensation can happens in seconds - almost the instant the cabinet doors are opened and the benefits of the cabinet’s ingress protection are lost - because of the very low temperatures and the moisture-laden air around the concentrating mill. The same problem can also happen in springtime, as temperatures can swing between -25 and +15 degrees C from night to day - leading to heavy condensation.

The mine operators decided to upgrade this part of the control system to improve reliability and uptime. They were very happy with the PLCs that provided control in the hot and humid underground environment and turned to the supplier of these - main automation vendor ABB - who proposed a solution based on the XC PLC. XC is an ‘extreme conditions’ variant of the well-known AC500 PLC family that is installed underground.

It has built-in protection against a very wide variety of threats posed by harsh environmental and operating conditions including high and low temperatures, high humidity, low air pressure, salt mist and hazardous gases, and vibration and shock.

In this case, the new ABB XC PLCs will

DEVELOPMENTS

Asia Manufacturing News

be installed at the mine’s above-ground processing centre - with some I/O modules located at a remote water pumping location and connected using ProfiNET. Mining is one of the key target applications for this PLC. The harsh environment at Kittila poses no problem for the XC PLC which can operate in temperatures from -30 degrees C, with reliable system start-ups in temperatures as low as -40 C, more than meeting the problems that might arise. Its circuit boards are conformally coated to protect against moisture ingress. And the PLC is protected against vibration and shock and will tolerate a lot of mechanical stress such as accelerations up to 4 g from random vibrations up to 500 Hz, or 2 g from sinusoidal vibration.

This built-in protection means that the ABB PLCs are being installed in standard uninsulated stainless steel cabinets - without any need for freeze-protection heaters.

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June 2014

“Ruggedised PLC technology opens up new design possibilities, allowing automation to be sited right where the control I/O is needed, in many cases without high-specification environmental protection - as at this mine is deep inside the Arctic circle” says Risto Haavisto of ABB Finland.

Agnico Eagle’s gold mine in Finland is located in Kittila, in the northern Lapland region. With an estimated lifetime to 2037, Kittila’s reserves are estimated at almost 33 million tonnes. The mine employs over 600 staff and contractors, most of whom are local residents, making a big contribution to the regional economy. Ore was originally mined from two open pits, starting in 2008.

Since 2010,the mining has moved underground. Some 3,000 tonnes of ore is currently transported daily to the surface crusher using underground haul trucks via a 3km-long ramp access system.

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DEVELOPMENTS

ALSTOM TO SUPPLY STEAM TURBINE AND GENERATOR SETS FOR POWER PLANT

Alstom, together with The First Northeast Electric Power Engineering Co. of China Engineering Group[1] (NEPC), has signed a contract to supply Filinvest Development Corp Utilities Inc’s (FDC) with equipment for the 405MW Circulating Fluidized Bed Power Plant located at Phividec Industrial Estate located in Misamis Oriental, Philippines.

Alstom will deliver three 135MW steam turbines and generator sets, as well as condensers, and will provide the necessary advisory services for the construction of FDC’s Misamis CFB Power Plant.

The units are expected to go online by 2016, taking the total power contribution from all the generating units to 405MW. The steam turbine generator equipment will be manufactured in Alstom’s facilities across France and Poland. The power plant will generate electricity for the Mindanao Island, 38

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as part of the long term solution to its energy issues, in particular preventing the recurring blackouts the island has been suffering from.

This is the second contract that Alstom was awarded with NEPC in Philippines.

The first one, announced in July this year, was covering the supply of steam turbine generators for the Concepcion power plant.

Daniel Wahler Alstom’s Vice president for industrial steam turbines says ”Alstom’s stellar track record as a leading energy solutions provider is the key reason why we were awarded this contract and this is a testament to Alstom’s cutting edge power solutions. We are proud to be partnering with FDCUI and NEPC to provide Philippines with a solid power infrastructure for its development.”

Alstom is a global leader in the world of power generation, power transmission and

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rail infrastructure and sets the benchmark for innovative and environmentally friendly technologies.

Alstom builds the fastest train and the highest capacity automated metro in the world, provides turnkey integrated power plant solutions and associated services for a wide variety of energy sources, including hydro, nuclear, gas, coal and wind, and it offers a wide range of solutions for power transmission, with a focus on smart grids.

The Group employs 93,000 people in around 100 countries. It had sales of over £20 billion and booked close to £24 billion in orders in 2012/13.

Alstom Grid has one clear vision: to develop innovative solutions for a flexible,

June 2014

reliable, affordable and sustainable electrical grid, everywhere. We design, manufacture, install and service the power transmission and distribution products and systems that empower the planet’s low carbon economy... for now and for the future.

Alstom Grid has over 130 years’ experience and ranks among the top three in the electrical transmission sector with an annual sales turnover of more than £4 billion. Alstom Grid’s 19,000 employees are spread across 88 manufacturing and engineering sites worldwide and have one common mission: be our customers’ trusted partner, from the source to the city.

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ANALYSIS

WILL 3-D PRINTING CAUSE TRADITIONAL MANUFACTURING TO COLLAPSE? by Ed Bernstein and Ted Farrington

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ow accurately can we anticipate the future given today’s emerging technologies? Take 3-D printing. Our current model of producing goods is built around large-scale, globally linked manufacturing facilities with massive, complex lines of supply and delivery. What happens when 3-D printers overtake current models in terms of speed and cost effectiveness, allowing goods to be custom made for little cost by localised manufacturing hubs?

Will we still need today’s manufacturing model?

Through the Industrial Research Institute’s foresights study — IRI2038 — several plausible scenarios of the future of R&D were explored. In one scenario, traditional manufacturing collapses under the strain placed on it by 3-D printing and heightened speed-to-market practices and is largely replaced by local manufacturing networks.

A Low End of ‘Beta Tests’ At the low end of the market, new products are churned out as beta tests, released with little prior market research. At the high end are premium products developed by specially formed R&D communities that are working on solving the big challenges of the 21st century.

The “buyer beware” model of the low-end churn arises from the convergence of three factors: e-commerce, just-in-time manufacturing bolstered by 3-D printing, and predictive algorithms for market behaviour.

The result is a more anticipatory model of manufacturing and new product development that quickly produces goods for small 40

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markets in order to test which products will be successful on a larger scale. All products bear a licensing agreement that makes each consumer an official beta tester of the purchased “prototype.”

To give order to the broad, scattered, and diverse line of new products churned out by these smaller networks, companies begin to develop hardware as a service — hardware platforms similar to today’s smart phone app markets. Such platforms may also come with crowd-sourced ratings systems for products linked to the hardware. A documentation network will help service this market with product reviews, FAQs, easter eggs, and hacks, dividing the new product landscape between producers and support services.

Reduced product lifecycles and development costs bring an end to current project portfolio methods and the speed of new product delivery becomes essential as IP laws dissolve. Launching beta products and letting natural selection in the marketplace identify winners becomes more accurate and cost effective for companies.

A High End Serviced by R&D Communities But not everyone is interested in this low end product churn. R&D communities form both inside and outside traditional companies to pursue solutions to some of the greater challenges facing humanity such as planetary warming, rising carbon dioxide levels, and resource scarcity. The PR boost such research generates leads to greater investment in their capabilities.

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One side effect of this division between high- and low-end products is the rise of social-value metrics as the key measure for evaluating purchases of new products. Market behaviour ceases to be driven solely by concerns about cost and effectiveness of the product. When every small-scale, 3-D printing business can churn out new products, the value an organisations will be differentiated by the value they add to the quality of life of target communities or society as a whole.

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Much of traditional large-scale manufacturing may cease to exist. Small, agile manufacturers will link with large R&D organisations in order to be associated with the social reputation they develop. And the corporation of the future will resemble a colony of like-minded researchers bounded by a common social purpose and protective of its expertise instead of its intellectual property.

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SUBHEADING 36

ASIA MANUFACTURING NEWS • FEBRUARY 2014

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