OCTOBER 2018 | WWW.PLANT.CA | $12
DYNAMOPOWERED PLAY Manufacturer taps dynamic design energy
Fortress is biorefining for sweet success Legalized pot: what a drag for employers! Modernize payments and save money Thordon Bearings seals a deal with a miner Smart but rugged labelling DAILY MANUFACTURING NEWS www.plant.ca
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CONTENTS
October 2018 Vol. 77, No. 07
FEATURES 16 EMPLOYMENT Study reveals business leaders are optimistic about hiring. 18 STRATEGY Add lean to optimize preventive maintenance programs. 19 THINK LEAN Focus on reducing cycle times to improve delivery. 20 SEALS Thordon Bearings lowers maintenance costs for a miner. 22 CCOHS SAFETY TIPS Guard against carbon monoxide poisoning. 23 LUBRICATION How to keep fluids in top working order.
10 INNOVATION
Dynamo Playgrounds expands the possibilities of play.
TECH TIP Keep your eyes on electrical equipment.
24 SUSTAINABILITY 3M shares how to build an effective energy management plan. 25 BIOPRODUCTS Fortress sweetens its business mix with biorefining.
DEPARTMENTS
13 WEED Legalized pot and what it means in the workplace.
15 ACCOUNTING Modernizing payments processes will lower costs.
16 PERFORMANCE Avoid training to fail, focus on what trainees do right.
17 INSIDE MAINTENANCE How to improve the quality of inspection data.
4 Editorial 6 News Bulletins 7 Careers 8 PLANT Online 9 Economy PLANT Pulse 27 Tech Centre Feature: Smart but rugged marking systems Supply Lines 28 Leading Edge: Innovative ideas for plants 30 Products and Equipment 33 Plantware Events 34 Postscript
Cover: Alexei Quintero
PLANT—established 1941, is published 8 times per year by Annex Business Media. Publications Mail Agreement #40065710. Circulation email: blao@annexbusinessmedia.com Tel: 416442-5600, ext 3552 Fax: 416-510-6875 or 416-442-2191 Mail: 111 Gordon Baker Road, Suite 400, Toronto, ON M2H 3R1. Occasionally, PLANT will mail information on behalf of industry-related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. Annex Privacy Officer: privacy@annexbusinessmedia.com Tel: 800-668-2374. No part of the editorial content of this publication may be reprinted without the publisher’s written permission. ©2018 Annex Publishing & Printing Inc. All rights reserved. Performance claims for products listed in this issue are made by contributing manufacturers and agencies. PLANT receives unsolicited materials including letters to the editor, press releases, promotional items and images from time to time. PLANT, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. This statement does not apply to materials/pitches submitted by freelance writers, photographers or illustrators in accordance with known industry practices. Printed in Canada. ISSN: 1929-6606 (Print), 1929-6614 (Online).
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EDITORIAL
USMCA: An agreement between friends?
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anufacturers may be inclined to join politicians, other business leaders and Mexico in a collective sigh of relief that Canada and the US have agreed to terms on a revised North American trade deal. Don’t get too comfortable. The NAFTA renegotiation, which became a US attack on its continental allies, has ended up as a flawed peace. As a result, we know who our friends are, and US President Donald Trump isn’t one of them. He may be satiated for the time being, but having a protectionist administration in the White House means there will likely be more disruption and trouble to come, even with an agreement. Note that the contentious tariffs on steel and aluminium, levied by executive order because of a trumped up (excuse the pun) national security issue (via Section 232) were still in place as of Oct. 1. They’ll be dealt with on a separate track and there’s no timeline. We should not underestimate Trump’s potential for creative application of the security play elsewhere. There were few details at this writing, but one thing we do know is the United States-Mexico-Canada Agreement (USMCA) isn’t so different from NAFTA in structure, which is puzzling. Trump declared NAFTA to be the worst deal ever made. But it will be up for review after six years. If it passes muster, the agreement will be good for 16 years, then another review. This is a compromise from a five-year sunset clause, something the Trudeau government resisted because of the uncertainty that would directly impact investment in Canada. Nonetheless, this review process still suggests some lingering uncertainty. It could conceivably impact the shorter-term plans of Canadian companies and those who would otherwise consider Canada as a place to locate manufacturing operations. Trump will be gone or on the way out by the time the first review comes up. Except the next administration may be protectionist and inclined to bullying. Who knows? And that is surely the point. Canada has taken the trade relationship with the US for granted. Thank you, Mr. Trump, for the wake-up call. He has demonstrated how fast a friend and ally can become an adversary. We will not soon forget his threat of a 25% auto tariff and a promise of ruination falling upon the Canadian economy for failing to arrive at a deal by his arbitrary deadlines. That’s some negotiating tactic, and an interesting way to treat a friend and ally. Another lesson learned. The US accounts for about 75% of Canada’s exports. Manufacturers have been advised, cajoled and warned to look beyond Canada and the US to new markets. Surely the time has come to do so. As important as the US may be, manufacturers can no longer rely so exclusively on our neighbours to the south for economic prosperity, and let’s just say any friendship that exists should be guarded. But let us also be mindful that business is changing beyond trade and Canadian companies must adapt. A Deloitte study shows many companies on the TSX and TSXV (including manufacturers) are falling short when it comes to putting money into products and services that won’t come to market for at least a year; having processes in place to test and scale innovations; investing in the people and technology they need for the future; heavily investing resources in developing talent; and investing heavily in the technology they believe will help them get ahead. The advisory firm warns this makes these companies vulnerable to economic shocks and technological disruptions. There is no advantage to being complacent. With trade peace more or less restored on the continent, manufacturers must embrace technology and the trade opportunities that exist beyond North America. Think of it as protection against the protectionist forces assailing global trade.
Publisher Jeff Brownlee 416-277-8428 jbrownlee@annexbusinessmedia.com Editor Joe Terrett 416-442-5600 ext. 3219 jterrett@plant.ca Art Director Andrea M. Smith National Account Manager Ilana Fawcett 416-510-5202 ifawcett@plant.ca Account Coordinator Debbie Smith 416-442-5600 ext 3221 dsmith@annexbusinessmedia.com Annex Business Media Vice President/Executive Publisher Tim Dimopoulos (416) 510-5100 tdimopoulos@annexbusinessmedia.com President & CEO Mike Fredericks Circulation Manager Beata Olechnowicz 416-442-5600 ext. 3543 bolechnowicz@annexbusinessmedia.com Subscription Price Canada $74.50 per year, US $151.50 (US) per year, Foregin $171.00 (US) per year. Single Copy Canada $12.00. Add applicable taxes to all rates. Combined, expanded or premium issues, which count as two subscription issues. Mailing Address Annex Business Media 111 Gordon Baker Road, Suite 400 Toronto, ON M2H 3R1 Circulation Bona Lao 416-442-5600 ext. 3552 blao@annexbusinessmedia.com Fax: 416-510-6875 or 416-442-2191
Joe Terrett, Editor Comments? E-mail jterrett@plant.ca.
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NEWS BULLETINS Demers-Braun, an ambulance manufacturer based in Montreal, is expanding its reach with the acquisition of Crestline Coach Ltd. The manufacturer of ambulances and specialized vehicles in Saskatoon also distributes small and medium buses in Canada. Invictus’s subsidiary Acreage Pharms has been granted conditional approval to become a registered supplier to the Saskatchewan Liquor and Gaming Authority once marijuana is legalized for recreational use. Invictus MD is a producer of cannabis products based in White Rock, BC. Manac Inc., a manufacturer of semi-trailers based in St-George, Que., has completed the acquisition of Alutrec Inc., a manufacturer of aluminum semi-trailers. Alutrec will continue to operate out of its Laurier Station, Que. location. Manac will support component purchasing, manufacturing processes and marketing strategies. Kontrol Energy Corp., a specialist in energy efficiency through IOT, cloud and blockchain technology based in Vaughan, Ont., has completed the almost $3.4 million acquisition of CEM Specialties Inc. in London, Ont. The company is an integrator of turnkey emission monitoring equipment and solutions. The emission monitoring systems market is estimated to reach US$4.44 billion by 2025, according to a System Type Global Forecast report. ONEX, the private equity firm in Toronto, has purchased a majority stake in Walter Surface Technologies in Montreal, in partnership with the existing management team. The Walter Group will retain a minority interest in the company that provides abrasives, tools and tooling to the metal working industry. Enerkem Inc., a waste-to-biofuels company based in Montreal, endorsed the Ocean Plastics Charter during the G7 Energy and Oceans Ministerial Meeting in September. The company seeks to apply its carbon recycling technology to produce low carbon transportation fuels and chemicals from plastic waste accumulating in the world’s oceans.
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Ballard unveils next-gen heavy-duty fuel cell stack For use in buses, commercial vehicles and trains
Ballard’s new FCgen-LCS fuel cell stack for heavy-duty transportation PHOTO: BALLARD applications.
VANCOUVER — Ballard Power Systems introduced its next-generation fuel cell stack for heavy-duty transportation at the IAA Commercial Vehicles Trade Fair and Convention in Hannover, Germany. The hydrogen technology manufacturer’s liquid-cooled FCgen-LCS represents a core technology component of the eighth-generation power module portfolio for use in buses, commercial trucks and trains, and other applications such as forklifts with a planned launch next year. Ballard, based in Burnaby, BC, is touting several improvements over the current generation liquid-cooled fuel cell stack that include a 40% reduction in total cost of ownership; a planned operating lifetime of more than 30,000 hours; a 33% increase in power density, which reduces the stack size; cold temperature starts from -25 degrees C and operations in temperatures up to 85 degrees C; and simplified systems integration. Sustainability features include higher efficiency, use of reusable, low-cost carbon plates and compression hardware; and the ability to recover catalyst material.
Nova Bus wins new Montreal order SAINT-EUSTACHE, Que. — Nova Bus has been awarded a new contract by the STM Société de transport de Montréal, the city’s transit authority The contract calls for four fully electric 40-foot LFSe buses, for delivery in 2019. They’ll replace diesel-powered buses currently running the Square Victoria to the Angrignon terminal route. Since the first Nova Bus electric buses for Montreal were commissioned in May 2017, they’ve travelled more than 100,000 kilometres and undergone more than 11,000 quick charges. The vehicles also proved to be robust while operating in extreme weather conditions. Nova Bus is bus manufacturer based in Saint-Eustache, Que.
Gray Tools launches auto aftermarket division BRAMPTON, Ont. — Gray Tools Canada Inc. has launched a new division that will serve the automotive and heavy truck aftermarket. The manufacturer of hand tools based in Brampton, Ont. says it will leverage its tool knowledge, operational and service expertise to the new channel, under its Gray and Dynamic brands. The company is also engaging young people to consider industrial skills. It has launched an online game (www.student. graytools.com) that began Sept. 1 and runs until Dec. 31. It engages students, program coordinators and professors who teach post-secondary trades programs such as millwright, pipefitter, welding and automotive technician. Students complete a series of activities to earn points. Some of the activities include logging in on consecutive days, sharing the game with friends, posting on social media and completing daily tasks. The top 151 players ranked by the number of points will be awarded prizes that include a master set worth more than $3,400, gift cards and baseball caps.
More EV capability added to ATS CAMBRIDGE, Ont. — ATS Automation Tooling Systems Inc. is acquiring a German-based supplier of custom micro-assembly systems and test equipment for almost $30 million. The provider of automation technology based in Cambridge, Ont. said KMW Konstruktion, Maschinen & Werkzeugbau GmbH & Co. KG, and KMW GmbH (KMW), will strengthen ATS’s offerings in the electric vehicle (EV) market. Micro-assembly systems are used in motors, power storage systems, braking, steering, and electronic modules. KMW will also provide ATS with an
internal source for conveyorized micro-assembly and test capabilities. KMW, based in Koblenz, Germany, employs 68 people and makes custom micro-assembly machines and solutions; clamps and tooling; and in-process test systems. ATS also won an $80 million order from an unidentified global automotive manufacturer for a fully automated battery assembly system. It will design, build, install and provide post-delivery coverage for the turnkey system to support the automaker’s entry into the EV market.
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The wet gas cleaning plant at Vale’s Sudbury, Ont. facilities.
PHOTO: VALE
Vale completes $1 billion Clean AER emissions project Sudbury smelter reduces SO2, metal particulates SUDBURY, Ont. — Vale Canada Ltd. has completed its $1 billion Clean AER (Atmospheric Emission Reduction) project, which is reducing emissions from the metal miner’s Sudbury, Ont. facilities. “The completion of our Clean AER project is a historic milestone that demonstrates how far we have come as a company in reducing our environmental footprint,” said Ri-
cus Grimbeek, chief operating officer of Vale’s North Atlantic Base Metals Operations and Asian Refineries, at a celebration held Sept. 14. The project is reducing sulphur dioxide emissions from previous levels by 85%, and metal particulate emissions by 40% reduction. Work began in 2012 and included the construction of two new converters, a wet gas
Pinnacle buys into Alabama wood pellet plant Aliceville adds an annual production capacity of 270,000 tonnes VANCOUVER — Pinnacle Renewable Holdings Inc. is acquiring a 70% interest in an industrial wood pellet production facility located in Aliceville, Ala. Pinnacle, an industrial wood pellet manufacturer based in Richmond, BC, is purchasing its stake from the Westervelt Co., a diversified land resources company that will retain 30%. The plant has an annual production capacity of approximately 270,000 tonnes of industrial wood pellets. Approximately 210,000 tonnes is committed under a long-term off-take contract to a major European utility. The remaining production volume will be sold through Pinnacle’s contracts. Westervelt is currently Wood pellets are used as a renew- ramping up production at the PHOTO: PINNACLE plant. able fuel.
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cleaning plant, a new secondary baghouse and fan building, and reconstruction of the smelter converter flues. Construction took place while the Copper Cliff Smelter continued to operate. “Emissions are so significantly reduced by the Clean AER Project that we will no longer require our iconic superstack,” said Dave Stefanuto, Vale’s vice-president of North Atlantic Projects. Two new 137-metre (450foot) stacks are being constructed in the Copper Cliff Smelter, which will require far less energy to operate than the superstack, and will reduce greenhouse gas emissions from the smelter by approximately 40%. Following construction of the concrete shells, steel liners will be installed in the new stacks next year. In 2020, the steel liner will be removed from the superstack, which will be taken out of service. Removal of the concrete shell will follow and continue over several years.
Phase 1 begins for Solargise plant MONTREAL — Solargise Canada Inc. has signed a contract with Salaberry-de-Valleyfield, Que. to acquire land for phase one of a plant that will make of solar panels without plastic. The first phase will cost approximately $950 million and lead to the hiring of 450 employees. The project will involve the construction plants for the production of polysilicon ingots, wafers, HIT photovoltaic cells, as well as plastic-free, glass photovoltaic solar panels. The company, a unit of UK-based Solargise Ltd., said construction will require 600 workers. Solargise is evaluating sites for phase 2 of the project. It will involve the construction of an 11N semiconductor grade polysilicon plant, metallurgical grade silicon facilities and glass plant.
CAREERS Lars Hanseid is the new president and general manager of 3M Canada. He’ll lead the company that makes tapes, adhesives and films through its digital Lars Hanseid and commercial transformation. Most recently he was vice-president of the Central East Europe, Middle East and Africa area. He succeeds Mojdeh Poul, who is now executive vice-president of 3M’s Safety and Graphics Business Group. Phil Hufton is Bombardier Transportation’s new managing director and chairman of the board for Bombardier Transportation UK Ltd. He’ll also head up Projects UK and lead the UK Phil Hufton management team. He joins the Berlin-based Bombardier from Network Rail where he was managing director, England and Wales. The transportation subsidiary is part of Bombardier Inc., based in Montreal. Avcorp Industries Inc., a manufacturer of airframes, has appointed Cedric Savineau general manager of its Delta, BC facility. He has more than 20 years of international experience in the transport sector, heading up major programs, product development and manufacturing organizations. Tony Kelsey is the new general manager of the company’s Gardena, Calif. facility. He’s an aerospace executive with more than 25 years of experience in operations leadership as a program manager, vice-president, group vice-president and president. Avcorp also has a plant in Burlington Ont. Marat Nogerov, Buhler Industries Inc.’s new president, joins the Winnipeg manufacturer of agricultural equipment from Rostselmash Combine Plant LLC, a Russian manufacturer of agricultural machinery where he was most recently director of aftermarket sales. Buhler has plants and warehouses in Canada and the US.
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NEWS
McGill, Xebec partner on energy storage Power-to-gas project will harness CO2 generated from waste MONTREAL — McGill University is co-developing a prototype reactor to produce renewable natural gas (RNG) with Xebec Adsorption Inc. Xebec, based in Montreal, manufactures gas generation, purification and filtration systems for the industrial, energy and renewables marketplace. The collaborators will use a power-to-gas (P2G) process that combines electricity generated by renewable sources and CO2 generated from waste. The project is being partially funded by a three-year, $360,000 grant from the Natural Sciences and Engineering Research Council of Canada (NSERC). “The power-to-gas process has been proven extensively in other markets but there is a real lack of this technology here in Canada that must be filled,” said professor Jan Kopy-
scinski, from the Montreal university’s Department of Chemical Engineering and principal investigator on the project. Generating electricity from renewable energy sources such as wind and solar is growing worldwide. However, wind energy fluctuates and is intermittent, making energy storage key to bridgXebec captures the offstream CO2 necessary for the power-to-gas process ing the time and geographPHOTO: XEBEC through its biogas upgrading plants. ical gaps between energy electrolysis, which is further converted into supply and demand. methane using the carbon dioxide captured Xebec’s P2G process offers a much larger from municipal waste. storage capacity and discharge time than The prototype reactor will have an output technologies currently in use, such as batterof 0.3 to 0.5 kilowatts, with plans to scale up ies and pumped hydro storage. Renewable the project in a second phase. electricity produces hydrogen via water
PLANT ONLINE SOUNDING OFF
What readers have to say about breaking news Have you checked out PLANT’s daily news online? Here are some headlines that have inspired members of the Canadian manufacturing community to chime in. They’re edited, but use the links to see the raw – and for some – longer versions of their remarks plus the stories that inspired their reactions. Stay up-to-date on the developments – domestic and global – that affect Canada’s industrial sectors by watching the news feed at www. plant.ca or reading PLANT’s twice-weekly newsletter (hit Subscribe on the website). 5 ways Trump’s tariffs on US$200B in China goods could be felt http://www.plant.ca/OKYbR Get rid of Trump by whatever means necessary. This is urgent, if we are to save the United States and ultimately the world. Hopefully there will be a massive blue wave in November, then impeachment. Freeland briefs PM on NAFTA, not returning to Washington immediately http://www.plant.ca/fkVCd I find it embarrassing Freeland and the CBC spend so much time
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bashing our neighbours then complain they’re not getting the deal they want. Perhaps Canada would be better served with an actual individual who has true trade experience versus a journalist. Wow, an update on trade that comes on more than one napkin. How did they keep Trudeau’s attention for so long? Trump: Apple can avoid tariffs by shifting production to US http://www.plant.ca/XO6v3 Trump is a grossly uninformed clown. He does not understand the first thing about international trade. If he is not curtailed, he
will do immeasurable harm to world economies. Trump, Trudeau raise NAFTA brinkmanship, muse about walking away http://www.plant.ca/yG5Ij Trump is a bully, a very jealous individual and selfish. Canada should retaliate by closing American companies like McDonalds, Starducks and retail clothing companies. Most of the world population is in Asia/Africa. Canada should be looking at expanding and enhancing third world countries. The unemployed techs can go to foreign Asiatic/African countries to open businesses. Trans Mountain expansion could be delayed for years by court decision: experts http://www.plant.ca/4HRWV This debacle has gone from the sublime to the ridiculous. What has been lacking is strong, assertive federal government
leadership and unequivocal support for the energy sector. Likewise, the Notley-Trudeau love fest with the so-called ‘social licence’ has proven to be tantamount to a fraud. Canada is the laughingstock of the world with its obsession with over-democratization. What we need now more than ever is a federal leader with testicular fortitude who will declare, unashamedly and unapologetically, that our energy pipeline infrastructure projects are a national, strategic imperative, and WILL be built! Ontario changes EV program after Porsche buyers get $5,000 rebate http://www.plant.ca/Qv8jl A way to make EVs more feasible is to standardize battery modules for cars, like propane tanks for BBQs. Pull into an EV station and just swap out an empty module for a recharged one, pay a fee and drive away. Governments boycotting Nike or considering it are mounting http://www.plant.ca/kAPpY NFL – Done Nike – Like Dinner
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ECONOMY
Uncertainty impacts growth OECD update revises outlook
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rospects for global economic growth have weakened since a May outlook report, according to an update by the Organisation for Economic Co-operation and Development (OECD). The Paris-based international policy organization says escalating trade tensions, tightening financial conditions in emerging markets and political risks could further undermine strong, sustainable medium-term growth in G20 economies. The OECD projects 3.7% growth in both 2018 and 2019, up from 3.6% last year, but not the broad-based expansion seen in the latter part of 2017 and earlier this year. The May forecast was 3.8% this year, 3.9% next year. Canada’s growth was also revised downward. In May the OECD was anticipating GDP of 2.1% this year and 2.2% in 2019. Now GDP is projected to be 2% next year. The OECD says strong US demand continues to support exports, but higher borrowing costs have begun to check household spending growth and the housing market, while rising trade uncertainty could “temper” business investment. “Trade tensions are starting to bite, and are already having adverse effects on confidence and investment plans,” said OECD chief economist Laurence Boone. “Trade growth has stalled, restrictions are having marked sectoral effects and the level of uncertainty on trade stances remains high.” She stressed the urgency for countries to end the slide towards further protectionism, reinforce the global rules‑based international trade system and boost international dialogue, “which will provide business with the confidence to invest.” The US is to blame for the trade friction, yet its growth for the year remains unchanged at 2.9%, but 2.7% in 2019 as US import tariffs kick in. That’s down from 2.8% in May. Overall prices will rise by 0.3% to 0.4%. Some prices, such as washing machines, have jumped by as much as 20%. Additional tariffs on Chinese imports, autos and parts could raise overall prices to a little more than 1%.
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INDUSTRIAL CAPACITY USE RISES Canadian industries operated at 85.5% of their production capacity in Q2, up from 83.7% in the first quarter, reports Statistics Canada. The increase was led by the mining, quarrying and oil and gas extraction. Manufacturing was also a contributor, but to a lesser extent. It rose 1.8 percentage points to 81.8%. Year-over-year, the rate was up 0.7 percentage points, driven by durable goods. Sixteen of 21 major manufacturing groups reported increases in capacity utilization, accounting for approximately 80% of the sector’s GDP.
Manufacturing Food manufacturing Beverage and tobacco products manufacturing Textile mills Textile product mills Clothing manufacturing Leather and allied products manufacturing Wood products manufacturing Paper manufacturing Printing and related support activities Petroleum and coal products manufacturing Chemical products manufacturing Plastic and rubber products manufacturing Non-metallic mineral products manufacturing Primary metal manufacturing Fabricated metal products manufacturing Machinery manufacturing Computer and electronic products manufacturing Electrical equipment appliances and components manufacturing Transportation equipment manufacturing Furniture and related products manufacturing Miscellaneous manufacturing
Source: Statistics Canada
-15 -10 -5 0 percentage points
5 10
8.9%
$58.6B
July’s manufacturing sales, up 0.9% with increases in 11 of 21 industries driven by the transportation equipment and chemical industries.
The drop in investment in machinery and equipment (2015), as a share of total gross fixed capital formation. That’s down from 15.7% in 2000, says a Fraser Institute report. Investments in patents, ideas and innovation also declined from 15% in 2000 to 11.5% in 2017.
10
th
The reduction in competitiveness between 2000 and 2014 caused by the loonie’s rise. The Centre for Productivity and Prosperity says the economy’s effective competitiveness fell by 16.7%.
26.6%
Canada’s ranking, last among countries adopting artificial intelligence with just 31% of adopters claiming successful deployment. That compares to 59% in India and 58% in Germany, according to a Forbes Insights study.
30%
Canadian businesses impacted by US tariffs, mainly from price increases of goods and services, rising raw materials prices and loss of competitiveness. Decision makers surveyed by the Business Development Bank are countering tariffs by: increasing focus on local markets (25%); increasing trade with other countries (17%); developing partnerships/ alliances (15%); investing more in innovation/R&D (14%); and restructuring operations (13%).
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INNOVATION
PLAY POWERED BY
DYNAMO MANUFACTURER TAPS DYNAMIC DESIGN ENERGY Ontario company exports innovative playground experiences to 50 countries. BY DIANA FISHER
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ichard Martin is a man of many metaphors. He likes to speak in pictures and this is fitting, because he is a visionary. It’s this type of creative thinking that fuels the growth and success of Dynamo Playgrounds, an innovative play structure manufacturer. Martin knows playgrounds. In 1993 he worked for a school board, maintaining and repairing the structures to keep them safe and enjoyable for local children. He noticed that school boards, municipalities and community organizations were investing a lot of money in these playgrounds, but there wasn’t much to them. “They were all post and deck,” he explains. “It’s hard to justify play value when it’s always the same thing: a slide, some swings, maybe a fireman’s pole – there was no new and exciting equipment.” Martin started to think about ways playgrounds could attract and appeal to all children, of every age and ability. Growing up with a disabled brother made him realize the limitations of traditional equipment. And while modern playgrounds were becoming increasingly acces-
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sible to children with physical challenges, they weren’t allowing handicapped kids to fully integrate into the play. “You could roll them up onto the play structure in their wheelchair, park them in front of a steering wheel, lock the wheels of the chair and say: ‘There. Now watch the other kids play.’ ” There are also many different levels of physical disability. How do you design a playground to not only accommodate but also engage every child? Martin feels that everyone deserves to experience the sensation and motion. The traditional Canadian playground structure is intended for children 5 to 12 years old. That’s quite a span when you are trying to keep kids entertained and physically active. Martin decided to do some research into how playgrounds are designed in other parts of the world, such as Europe. He made some interesting discoveries, was inspired to create some new pieces and in 1997 he found himself going into business as a maker of playground equipment. But he encountered some challenges right from the start. Canadian playground standards have changed consider-
Bottom L-R: Vincent Marcoux smooths rough sections of pipe prior to sandblasting. Cedric Lacasse prepares pipes for a ropes course prior to painting. Dan Lamothe uses a hydraulic press machine to join ropes.
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Richard Martin, play visionary and CEO of Dynamo Playgrounds. PHOTOS: ALEXEI QUINTERO
ably over the past few decades, with a targeted focus on safety as opposed to functionality or entertainment value. For a while, Martin says, every municipality and school board was removing spinning equipment. Kids were spinning too fast, flying off and hurting themselves. He wanted to create spinning equipment that would be attractive and appealing to all ages, but safe enough for someone in a wheelchair to enjoy.
Aiming for fun Martin did his research and due diligence, and brought his vision to life. When people saw the equipment in action, they were converted. But he had to jump through a lot of hoops – a metaphor he might use himself – to turn naysayers into believers. Every piece of playground equipment Martin invented pushed the limits. He wanted to prove he could make equipment that was fun and safe – including a spinner that stood 13 feet off the ground. As Martin continued to challenge and push the envelope, standards began to change. Dynamo built up a portfolio and became a manufacturer. Outsourcing was necessary during the first stage of the company’s growth, but Martin always held the IP on design. “It’s difficult to maintain a playground business in the Canadian winter, however,” he explains. In 2000 the company branched out to Florida, and California. Martin continued to design, invent and innovate. His playground games invited children with physical disabilities to safely join right in to play beside their friends. Older children were enticed to put down their screens and devices and wander back outside to try out the cool
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child might see a mountain to climb. Another sees a cave. Some pieces resemble a giant spider or the crow’s nest of a ship. The playground offers a different setting on each visit, with endless opportunities to balance, swing, climb, dangle and jump. Martin explains there isn’t much competition at his level. Most playground manufacturers are giants of the industry. He likes that he can inspire and set an example for other innovators. “They can see what we have achieved. It’s possible to build equipment that high that’s still safe. And a 40-pound swing can have less impact than a threepound traditional belt swing seat.”
Brian Gill works on a custom design project.
Higher standards
A Dynamo ropes course at Fox Hill Park in Las Vegas.
new equipment at the park. The appeal couldn’t be denied, and this factor helped Martin and Dynamo to overcome obstacles, break down the barriers and pave the way for innovation in the playground industry. By May 2015, Dynamo was ready to purchase its first building. After two and a half years of steady work, Martin made the investment to become a fullfledged manufacturer. Here’s how the Dynamo playground comes together. First, a member of the manufacturing team develops a relationship with the client. They learn what’s wanted and needed for the park project, and bring it back to the designers. Designs are put through the proper procedures to comply with worldwide safety standards. Then the drawings go to the engineering department. Once approved, they’re sent to production. Dynamo uses a CNC machine in the design and fabrication of its playground elements. The drill, saw or lathe is guided by
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PHOTO: DYNAMO
computer, which delivers a more accurate cut to ensure a wellmade, safe piece of equipment. On high custom projects, Dynamo offers setup. They will fly all over the world and help guide the local contractors through the setup. Many of the items within the unique Dynamo portfolio, such as the Biggo Swings, Quad Pods, and Appollo equipment, are kept in their regular inventory. These day-today items are sold on a regular basis and have all passed the test of enduring quality, appeal and safety. Dynamo operates out of 27,000 square feet of manufacturing space next to their sales office in Plantagenet, Ont. Martin is extremely proud of his company and passionate about the contribution his playground equipment is making to improve play for the younger generation. The playgrounds leave a great deal to the imagination. Upon entering a park full of colourful, interlocking pieces of bars, ropes, tunnels and platforms, one
Dynamo has kids’ best interests in mind, with every design it brings to life. Martin says the company is known for its unique products, including the tallest pyramid net in the world. “We build the games and let the children decide how high they should go.” Martin has obtained voting rights on North American safety standards boards because he feels it’s important “to open the doors to innovation.” Dynamo is experiencing, one might say, dynamic growth. Since Martin designed his first piece of equipment, the company has blossomed organically, through trial and error, challenge and success. Staff has grown from 18 employees “practically overnight” to 50 designers, welders, engineers, sand blasters and painters. They do their own crating. The products leave the factory finished and ready for assembly on site. The company is now growing steadily at a rate of 20% to 30%, exporting to 50 countries including New Zealand, Australia, Europe, Chile and the United Arab Emirates. “We learn as we go. We are now an $8 million company. In five years, we see ourselves as a $20 million company,” Martin says.
Dynamo’s custom designed ropes courses are sought after, such as a $5 million project recently installed in a Las Vegas resort. “We are grabbing people’s attention with what we can do,” Martin says. Exciting new games appeal to resorts with a focus on families, where guests appreciate having something fun and safe for their kids to do. The traditional playground client base would be school boards and municipalities, so the landscape architect is typically the first person who is introduced to the Dynamo designs. A member of the design team travels to the intended site and draws up a plan for equipment. The landscape architect is coached on the use, unique aspects and key safety features of each ride or game. Once they fully understand how the equipment is designed to be used safely, they can help to sell others on the vision. “Just the unique look of our playground equipment attracts them,” Martin explains, “but they need to understand how they work.” A quick run through of the company website offers a glimpse of the world they’re creating for today’s children. If you like what you see, you can click on the “let’s start building” link. This page provides a step-by-step guide to help you decide what sort of playground structure would be best in your school, venue or community. With equipment like the Quad Pod, where older kids climb aboard, buckle in and spin in opposite directions, to the Ovni Swing, which accommodates multiple users, Dynamo will soon have adults sneaking off to take turns on the playground. Diana Fisher is a freelance writer from Oxford Mills, Ont. Visit www.dianafisherbooks. com. Comments? E-mail jterrett@plant.ca.
October 2018
2018-10-05 1:00 PM
LAW How decriminalizing marijuana will impact management strategies. BY LISA BOLTON
T
he Trudeau government has committed to passing and implementing the Cannabis Act (Bill C 45) this year (Oct. 17). In addition to making recreational use of the drug legal, the legislation will regulate marijuana production, distribution and retail sale. Legalization of cannabis compounds concerns many employers already have about medicinal marijuana in the workplace, particularly in hazardous and safety sensitive environments. Relying on testing to address workplace drug use or impairment may seem appealing; however, it’s currently permitted only in limited circumstances and, depending on the methods used, results may not be considered reliable. Drug testing’s primary purpose is to indicate the presence and extent of on-the-job impairment. Historically, courts and arbitrators have taken a cautious approach to permitting testing. Methods were not able to measure current impairment due to the long period of time some drugs take to metabolize. However, a recent Ontario Divisional Court decision
Decriminalized pot, federal target Oct. 17.
Workplace
DRUG USE LEGALIZED POT A BUZZ-KILLER FOR EMPLOYERS
favourably commented on the reliability of oral fluid testing to measure recent drug use and impairment. The court also accepted that obtaining fluid via mouth swab for testing was less invasive than more traditional testing of blood or urine samples. Several Canadian
Prepare for legalized pot
E • •
• • • • •
nsure drug and alcohol policy is broad enough to address impairment from prescription, illegal and legal recreational drugs. A minimum policy should: Prohibit an employee in a safety-sensitive position from working while impaired. Require an employee to disclose information about any drug use that may impair safe work performance, including proactive disclosure of drug use by an employee with a dependency. Obtain information regarding the use of impairing drugs in a way that respects privacy and encourages compliance. Set out a process for obtaining additional medical information to facilitate accommodation. Ensure the employee (and union, if applicable) participates in the accommodation process. Identify appropriate restrictions on the use of marijuana. Identify consequences in the event of a breach of the policy (discipline and termination).
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PHOTO: FOTOLIA
police forces implemented oral swab testing as a pilot study to assess its reliability for roadside applications. Although advances are being made to improve testing reliability and minimize privacy concerns, it remains to be seen whether oral fluid testing will gain widespread acceptance by other courts and adjudicators.
Duty to accommodate When can an employer test? Note the following: Pre-employment and pre-access testing. Canadian courts and arbitrators have typically held this type of testing is not permitted because it neither demonstrates impairment at work (testing occurs before work begins); nor predicts future impairment. Random testing. It’s only permitted in rare circumstances. An employer must demonstrate a unionized workplace is dangerous and there’s evidence
of an ongoing drug problem. Canadian courts have permitted random alcohol testing in a non-unionized workplace where: an employee works in a safety-sensitive position in a dangerous work environment; and there’s an alcohol abuse problem in that workplace. Post-incident and reasonable cause testing. If, after a significant workplace accident or near miss, there’s a reasonable basis to suspect impairment as a factor, an employer may require testing of those involved. Similarly, if an employee whose actions suggest impairment (slurred speech and/or the smell of marijuana), an employer may wish to test. In both of these contexts testing is generally permissible provided the employee works in a safety-sensitive position and the workplace has appropriate policies in place identifying the circumstances in which testing may occur. Return to work testing. It’s typically part of a return to work program or a condition of a last chance agreement stipulating a positive test result will result in termination. Ongoing testing for monitoring purposes may also be an appropriate requirement for an employee returning to work from drug dependency treatment. Special considerations apply when marijuana is used to treat
PLANT 13
2018-10-05 1:00 PM
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a disabling medical condition such as epilepsy, chronic pain or post-traumatic stress disorder. Human rights legislation requires an employee to be accommodated unless it would result in undue hardship for the employer. This may mean permitting an employee to use marijuana during working hours if it’s medically required (subject to safety considerations). However, an employer may implement rules regarding the use of medical marijuana, so long as appropriate accommodation is provided. This may include exploring alternatives to smoking (such as ingesting marijuana) or requiring the employee to smoke in a designated area during scheduled breaks or meal periods; and restricting the employee from smoking while in uniform, in public view, in a company vehicle, or in the vicinity of others who may come into contact with the smoke or lingering odour.
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Accommodation does not mean allowing an employee to carry out his or her duties while impaired. Under Ontario’s Occupational Health and Safety Act (OHSA), an employer has an obligation to take every reasonable precaution to protect the health and safety of workers. This includes identifying hazards that may result from an employee working while under the influence of medical marijuana. Bottom line: an employer must consider health and safety when assessing possible accommodation options for an employee who uses medical marijuana for treatment of a disability. In the case of a safety-sensitive position, this may mean considering whether the employee can be reassigned to a non-safety-sensitive position. Drug dependency can be a disability triggering the duty to accommodate. To evaluate the need for accommodation and address any potential safety risks, an employer may implement a policy requiring proactive
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disclosure of drug or alcohol dependency and use. In a recent Supreme Court of Canada decision, the court found an employer did not discriminate against a truck driver when it terminated his employment following a positive drug test administered in response to a workplace accident. The employer’s policy required employees to proactively disclose drug or alcohol dependency without fear of discipline or termination, with the promise of rehabilitation assistance. However, the policy stated if disclosure occurred after an incident and positive test, the employee would not be protected from discipline or termination. The employee, who advised of his drug dependency and use only after the accident, was terminated for failing to comply with the disclosure requirement in the policy. The Supreme Court of Canada upheld the dismissal, finding the employee’s addiction did not prevent or shield him from complying with the employer’s policy. While each situation must be assessed on its own facts, this decision is welcome news for employers that may wish to require proactive disclosure of drug or alcohol use as a means of reducing the potential for workplace accidents. The Cannabis Act’s removal of incidental marijuana consumption and possession from the Criminal Code will present challenges for employers. Manufacturers should prepare by updating management controls that cover policy, accommodation, discipline and discharge. Lisa Bolton is a lawyer with Sherrard Kuzz LLP, an employment and labour law firm representing management. E-mail lbolton@sherrardkuzz. com. Call (416) 603-6958, (416) 603-0700 (main) or (416) 4200738 (24 hour). Visit www. sherrardkuzz.com. Comments? E-mail jterrett@plant.ca.
October 2018 8/15/18 10:01 2018-08-27 1:50 AM PM
2018-10-05 1:00 PM
ACCOUNTING Key factors: real-time delivery of low-value payments and a datamessaging standard.
Inefficiencies include manual processing of accounts receivables and payables. PHOTO: FOTOLIA
BY JAN PILBAUER AND JANET LALONDE
T
echnology is disrupting just about everything, including the way payments are made. Companies that experience a high volume of payments between suppliers, customers and partners stand to benefit the most from their modernization. A Payments Canada study, in partnership with Ernst & Young LLP (EY Canada), quantified the current cost of payments processing for Canadian business to be between $3 billion and $6.5 billion annually. The research looked at current payment processes and identified inefficiencies, such as the manual handling of accounts receivables and payables among all sizes of businesses. A faster, safer and more data-rich payments system will reduce many of these operational inefficiencies, and help lower costs while boosting bottom-line returns over time. Manufacturers can prepare for payments modernization by focusing more on processing and taking note of two opportunities. The first is the real-time rail, and it’s all about speed. This new, 24/7/365 system will facilitate the real-time delivery of low-value payments in a matter of seconds. The second is called ISO 20022, which is all about data. This messaging standard will underpin all of Canada’s new payments systems. Real-time payments will be made almost instantly, providing significantly faster alternatives to current methods. With speed at its core, Canada’s rail also opens the door to a world of possibilities for businesses. A secure, regulated system will enable a variety of players to connect and innovate by developing new ways to pay for goods and services, as well as trans-
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Modernize your
PAYMENTS MORE EFFICIENT MEANS LOWER OPERATIONS COSTS fer funds and related business information. Real-time payments are already a reality. Australia makes fast payments supported by payID, an addressing service that allows consumers and businesses to create an identifier for receiving payments across multiple platforms, such as social media or by text. In the UK, Pingit and Paym link mobile numbers with bank accounts, allowing users to send money back and forth as easily as they text. These innovations are just the beginning. For businesses, the appeal of real-time payments boils down to operational efficiency. The EY research finds moving from legacy technology to automation will save $2.1 billion to $3.4 billion annually. But adding more data to payments is key to maximizing the benefits. Why does data matter? On a practical level for manufacturers, it significantly reduces headaches for accounts receivable and payable, as well as treasury
departments. Many large companies have moved to electronic payments and invoicing in an effort to streamline and expedite their processes. However a payment may arrive separately from an invoice, or with no invoice data.
Faster payments This leads to manual payment-invoice matching that requires time-consuming and error prone re-keying. Not only does this mean resources must be allocated to process and match payments to data, it also creates enough friction in the system to delay payment processing and collection, which has an negative impact on cash flow. Let’s say, for example, eight invoices are sent over two months to a customer who sends a lump sum payment of $10,000 with no accompanying information. While you’re pleased to have the $10,000, the accounts receivable team will scramble to balance books by tracking down invoices, calculating sums, calling the
customer to verify the match, correcting any inaccuracies or discounts, then keying in the information manually. Providing more information with the payment has two benefits: you’re providing better service to partners and customers by streamlining operations for them; and it reduces the load on your customer service or accounting teams. ISO 20022 will allow information to flow easily and quickly to whoever needs it, whenever it’s needed. Immediate access to specific data will smooth processes, from purchasing and shipping to managing customer relations, and every step in between. Coupled with new payments systems, such as the real-time rail, Canada’s economy is set to reap the benefits. Ultimately it’s still up to suppliers, customers and partners to make payments on time, but the looming modernization of payments systems will help everyone. To prepare for the coming changes, stay informed by following updates from Payments Canada, and connect with other key partners such as suppliers and vendors to find out who is already ISO 20022-enabled. Also connect with your financial institution about modernizing your transactions. The more early adopters, the faster everyone benefits. Jan Pilbauer is executive director, modernization and CIO for Payments Canada. Janet Lalonde is director, modernization. Payments Canada, a public purpose, non-profit organization based in Ottawa, is responsible for the clearing and settlement infrastructure, processes and rules essential to daily financial transactions. Visit www.payments.ca. Comments? E-mail jterrett@plant.ca.
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PERFORMANCE Focus on what the trainee does right, address what needs improving. BY HUGH ALLEY
A
supervisor who worked for me assumed four out of five people were incompetent. After hiring a new person, he would put very little effort into training because he expected the trainee to fail. Of course, with such cursory training, most did, which reinforced his belief. His approach cost the company thousands of dollars in hiring costs and lost productivity. When we train someone, we tell ourselves a story about that person. It turns out the story we tell matters. There’s a stream of research involving elementary school children that shows a teacher’s expectations affects a student’s performance. The impact is greater when the teacher expects the student will do poorly. Ditto for workers. If you expect one of your crew members to mess up while he/ she learns a new skill, you’re going to be looking for every sign that person is messing up. But you’ll miss all the elements the trainie gets right. Since people respond better to positive reinforcement, you have set the odds against that worker learning the new skill. What stories might we be telling ourselves about the people we’re training? Here are four beliefs that affect our instruction: • Biases about the capabilities of people from particular cultures or nations. • People of a certain age are more or less capable. • Women or men are more suited to a particular task. Don’t laugh… recently I had a plant supervisor tell me that he doesn’t hire women because they can’t do the jobs in his area well. I didn’t buy it. • Only someone with a particular background or experience can learn a particular skill or machine.
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Use a proven methodology for training.
PHOTO: FOTOLIA
Training to
FAIL
NEGATIVE EXPECTATIONS SABOTAGE RESULTS Accepting these stories does a disservice to three groups: people from that group because you deny them opportunity; your company, because you have significantly narrowed the range of people from which to draw;
and you, because you’ll miss out on interesting learning opportunities. How do we counter this? Here are three things that will significantly shift expectations for how well people will learn:
• Use a proven methodology for your training, such as the Job Instruction module in Training Within Industry. • Look for one or two examples of inspirational people from your new learner’s group as reminder of how much trainees are capable of achieving. • Ask your learner about the hardest thing he/she ever learned, and you will be amazed at what that individual has already mastered, and is capable of learning. When you go into an instruction session knowing you are using a great method inspired by what has been done by people from your learner’s group, and by what he/she has already learned, you’ll be more likely to tell a positive story about your learner. That will help everyone learn better. Training will be faster, cost less and your boss will thank you for both. Hugh Alley is an industrial engineer based in the Vancouver area who helps organizations achieve significant performance gains in delivery, quality and cost over a short timeframe. Call (604) 866-1502 or e-mail hughralley@gmail.com. Comments? E-mail jterrett@plant.ca.
EMPLOYMENT
Hiring plans for Q4 cautious
Opportunities in manufacturing.
PHOTO: FOTOLIA
Job prospects in manufacturing improving
C
anadian employers are expected to make slow but steady gains hiring over the fourth quarter, according to an outlook report by the ManpowerGroup, the global workforce company. Its Employment Outlook Survey of 1,900 employers across Canada reveals 16% plan to increase their staffing levels, 6% anticipate cutbacks and 77% expect current staffing levels to remain unchanged. One per cent are unsure of their hiring intentions. Durables manufacturing is among those sectors with a respectable showing. Its net employment outlook (increasing hiring minus decreasing) is 18%, a 5% improvement over the last quarter and the same quarter last year. Prospects were strongest in public administration at 19%. Quebec employers anticipate the most favourable hiring
climate with an 18% outlook. Ontario has a 13% outlook and the western provinces 12%. Job seekers in Atlantic Canada can expect a conservative hiring climate (9%). The most positive hiring plans come from large (250+ employees) and medium (50-249) organizations that report seasonally adjusted outlooks of 29% and 17%. Small employers (10-49) report a moderate 11%, while those in micro-sized organizations (1-9) expect a limited hiring pace at 4%. For more information visit www.manpowergroup.com and click on Research Center.
October 2018
2018-10-05 1:00 PM
INSIDE MAINTENANCE More efficient machinery reduces maintenance costs. BY STEVE GAHBAUER
F
inding efficiencies is difficult but the benefits are great. It can transform maintenance from a cost centre to a bottom line contributor. One area that offers cost savings though efficiencies is equipment inspection. As the importance of smart equipment management grows, so grows the inspection function. Yet the cost and payback from inspections – and the efficient use of relative data – is frequently not addressed. Ben Stevens, a CMMS-EAM expert and the principal of DataTrak Systems Inc. in Godfrey, Ont., wrote about improving the quality of inspection data – and making good use of the information collected – in an Asset Management Solutions Newsletter 9 (www.asset-management-solutions.com/ newsletters.htm) published by consultant Leonard Middleton. Stevens argues that the purpose of inspections is to verify the “okay” status of equipment and to record it for future use. True enough, however, that’s often the end of the story. When the inspection work order is closed and maintenance moves on to the next job, important opportunities are lost. One of the opportunities is to test the actual condition of a machine or system against potential failure with the data used as part of a simple trend analysis to predict future degradation and remaining useful life, as well as for failure or reliability analysis. Stevens says in these cases the data must include equipment condition readings, such as temperature, pressure, vibration and wear. They’re at the core of condition-based maintenance inspections. Beyond “as-found” and “as-left” condition data before and after an install, a repair or replacement is best integrat-
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Trend analysis predicts future failure.
Tracking asset
STATUS
HOW TO IMPROVE THE QUALITY OF INSPECTION DATA
ed into the standard work order format. In this way it’s possible to track the equipment condition at the end of an operating cycle and the end of the maintenance cycle. Such trending information is key to understanding the longterm degradation of an asset and clearly shows where the degradation is occurring.
Work left to do The next step is to record the work remaining to be done on the equipment at the end of a job. This may come from: • impending potential failures that have been noted during the work (such as partially worn belt); • work left undone because of a lack of time or materials; or • other anomalies not part of the normal condition or op-
eration of the equipment that need attention. This is an important contribution to smart planning and should be an automatic feedback via the work order to the planner for inclusion in future work for the asset. An inspector should let maintenance know whether there are specific issues with the data collection, such as: • awkwardness of the data collection procedure (the more difficult it is, the more likely the collection process will be skipped or done incorrectly); • unreliable measuring equipment and inconsistent condition output readings; • problems with the inspection work order’s pre-prepared data for normal operating range, potential failure and
PHOTO: FOTOLIA
functional failure levels; or • inadequate time allocated, incorrect procedure and missing tools. To improve the quality of inspection data, collection needs to be consistent, timely and accurate. Stevens suggests a series of steps. Only collect data that will actually be used. Automate the data collection wherever technically and financially reasonable. If not, make the data collection process as easy as possible. If automatic data collection is not feasible, specify the data collection (and the data analysis)
Verifying okay status.
PHOTO: FOTOLIA
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STRATEGY tasks on the work order. That way, time and resources will be allocated. So will a priority. That means it will be part of the backlog management process. Document the data collection process and train inspectors and technicians. They need to understand why, what the collection process is, what will be done with the results, the effect of errors, and the availability of retraining if needed. By adding trend analysis, failure prediction and decision-making to the inspection task, the inspector will feel he/she is an integral and important part of the team. Set the responsibility and accountability for accuracy and completeness with the inspectors and technicians. Their supervisor’s job is to provide the means to prompt them to do a first-class job. Catch and correct errors fast and do not accept suspect data. Finally, publish the results and show what action has been taken as a result of the data collection. If no action was taken, ask why the data is being collected. Increasingly, maintenance managers are being required to justify budgets and expenditures based on need and returns to the organization. This is not possible without reliable data collection. Remember, the main inspection functions are to: check asset status or equipment condition; examine a failed or problem asset to decide what maintenance activity is required; ensure equipment is fit for purpose on return to operation; and collect data to meet government regulations. The most important issue is the quality of work. Poor inspections mean poor work, leading to more costly work. Steve Gahbauer is an engineer, a Toronto-based business writer and a regular contributing editor. E-mail gahbauer55@ gmail.com. Comments? E-mail jterrett@plant.ca.
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Eliminating eight wastes leads to world-class performance.
T
here are many ways to reduce maintenance costs and preventive maintenance (PM) is among the most effective. It’s an accepted practice in most plants, but the efficiency of the PM routine as a strategy is often overlooked. Achieving world-class levels requires more than just doing the right maintenance. It must be done efficiently. Optimizing PM is the first step to improving any maintenance strategy and by doing so, achieve notable cost savings, said James Kovacevic, the principal consultant of HP Reliability Inc. of Bell River, Ont., distributors of vibration instruments and products for lubrication engineers. He presented a technical paper on this subject at the MainTrain maintenance conference (convened by the Plant Engineering and Maintenance Association of Canada), noting that combining optimization with lean techniques enhances efficiency. Waste is a common problem that adds unnecessary, and often huge costs to the maintenance process. To reduce – or better yet, eliminate – waste, be aware of
Target waste in maintenance processes to decrease downtime.
Optimize PM
PROGRAMS ADD LEAN TO IMPROVE YOUR PLANT’S EFFICIENCY eight types: defects; overproduction; waiting times; not utilizing talent; transportation; motion waste; inventory excess; and excess processing. What follows is an unrelenting focus on eliminating waste and minimizing planned downtime.
Useful tools There are several lean tools available. One is the single minute exchange of dies (SMED). This system dramatically reduces the time it takes to complete equip-
LEAN TECHNIQUES
Continuous flow
A look at the visual factory
A method of manufacturing that moves a single unit in each step of a process, rather than treating units as batches for each step.
H
ow is data and information conveyed in a lean manufacturing environment? Visuals such as signs and charts make information easily accessible. Current status is immediately apparent.
PHOTO: FOLOLIA
Total productive maintenance Integrates equipment maintenance into the manufacturing process to stabilize equipment while increasing availability, performance and quality.
Value-stream mapping
5S
Analyzes the current and designs a future state for the events that take a product or service from its beginning to the customer.
A workplace organization method that includes sort, set in order, shine, standardize and sustain. 5S+1 adds safety.
ment changeovers. It involves converting as many changeover steps as possible to “external” execution (performed while the equipment is running) and to simplify and streamline the remaining steps. Other techniques include visual factory, value stream mapping, continuous flow, total productive maintenance and 5S. Improving efficiency extends past the initial optimization phase to the PM routine. At the conclusion, perform a quick analysis to identify any lingering wastes and what can be done to reduce or eliminate them. Also focus on the critical assets or bottlenecks. Full optimization requires extensive time and resources, but not every piece of equipment needs to achieve this level of optimization. Once the results and benefits are observed, move on to the next optimization project. After a couple of projects are completed, plant and maintenance managers will be more likely to support full optimizations that lead to additional maintenance cost savings. — Steve Gahbauer Comments? E-mail jterrett@plant.ca.
October 2018
2018-10-05 1:00 PM
THINK LEAN Improve on-time delivery with a build/test program. BY RICHARD KUNST
T
he lean journey is usually approached incorrectly. Many start by implementing 5S but this soon becomes a major housekeeping event instead of supporting improved velocity. Focus on cycle times. Why? Because they have a huge impact on the bottom line. Long cycle times are a symptom of poor manufacturing performance and high non-value added costs. Focus on the continuous reduction of all cycle times. Success requires a specific management style that emphasizes proactive problem solving rather than firefighting. Management assumes a coaching role, bringing everyone into the process and supporting them in their efforts to improve productivity, customer satisfaction and profitability. Product build/test cycle time is an important element of the production flow process and provides an excellent focus for an improvement program. Time is calculated as the hourly work content through the longest path of the lean manufacturing process. In the sequential production process, product build/ test cycle time is calculated by starting at the end of the process and following the longest, cumulative, single path back, regardless of whether it traces the main path or trails off to a sub-assembly path. Many manufacturers have increased their on-time delivery and product profit margins by implementing a build/test cycle time reduction program. The main focus is the elimination of all non-value-add activities along the path. In a Harvard Business Review article by Joseph Bower and Thomas Hout, the authors make a good case for “fast-cycle capability for competitive power.” They observe people in fast-cycle companies think of themselves as part of an integrated system, a linked chain of
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Time has a major impact on the bottom line.
Increase your
VELOCITY BE PROACTIVE, FOCUS ON REDUCING CYCLE TIMES operations and decision-making points that continuously delivers value to customers. Individuals understand how their activities relate to the rest of the company, how work is supposed to flow and how time is used. This way of thinking is second nature in many small companies. People find it easy to stay focused on creating value because almost everyone works directly on the product or with a customer. Policies, procedures, practices, or people that interfere with getting the product out the door are easy to see and can be dealt with quickly.
Heighten awareness As companies grow, distances increase as functions focus on their own needs, support activities multiply, specialists are hired and reports replace face-to-face conversations. Before long the product’s clear visibility and the essential elements of the delivery process are lost. Instead of operating as a smoothly linked system, the company becomes a tangle of conflicting constituencies whose own demands
and disagreements frustrate the customer. “I don’t care what your job is,” the overwhelmed customer finally complains. “When can I get my order?” Fast-cycle companies – especially the big ones – recognize this danger and work hard to avoid it by heightening everyone’s awareness of how and where time is spent. They make the main flow of operations from start to finish visible and comprehensible to all employees, and they invest in this understanding with training in lean basics. They highlight the main interfaces between functions and show how they affect the workflow, compensating based on group success. And most important, they reinforce the systemic nature of the organization in their operations architecture. Fast-cycle companies differ from traditional organizations in how they structure work, how they measure performance and how they view organizational learning. Time is used as a critical performance measure. They insist everyone learn about
PHOTO: FOLOLIA
customers, competitors and the company’s own operations. A few hints to keep in mind when attacking and improving your cycle time management. Many organizations are fixated on controlling labour content and are constantly asking leaders to reduce headcount, but this may be the wrong approach. First, check the rate at which your customer is looking to receive your product or service. This will determine the required cadence within your operation. Once it’s defined, engineer your process step within a work balance chart. This may tell you to add people within the process even though the overall labour content will not change, but cycle time will improve. People feel getting an office is a right of promotion, but offices and cubicles are so counter-productive. Any form of wall acts as a barrier and barriers curb open communication. Tear them down. Establish natural work groups or cells and watch productivity grow while cycle time is quickly reduced. Richard Kunst is president and CEO of Cambridge, Ont.-based Kunst Solutions Corp., which helps companies become more agile, develop evolutionary management and implement lean solutions. Visit www. kunstsolutions.com. E-mail rkunst@kunstartofsolutions. com. Comments? E-mail jterrett@plant.ca.
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2018-10-05 1:00 PM
SEALS Thordon Bearings replaces rubber seals with its elastomeric polymer.
T
hordon Bearings, a manufacturer of water-lubricated, marine shaft bearings and seals, scored a recent win in the mining sector with its Thor-Flex seal. The Burlington, Ont. company replaced conventional rubber seals on 28 pneumatic cylinders, which were sent for refurbishment (by an unidentified customer) to RMH Industries, Thordon’s authorized distributor in Saint-Augustin-Desmaures, Que. The cylinders are used for unloading mining dump wagons. A wagon is equipped with two air cylinders on each side, operating at 861 kPa (125 psi), under highly abrasive conditions. Each cylinder relies on two seals, one 711 mm in diameter, and the other 635 mm. The seals were made from a rubber material, but the distributor suggested Thor-Flex seals would last much longer. This elastomeric polymer material is highly resistant to permanent deformation with high mechanical strength and self-lubricating properties. The seals operate safely at temperatures from -50 to 90 degrees C, at pressures up to 103,421 kPa (15,000 psi), and they work in abrasive, corrosive environments with high levels of
Mining dump wagon cylinders ready for shipment.
Extending seal
LIFE
MINING DUMP WAGONS GO WITH THOR-FLEX
humidity. They also resist high impact loads. Thordon manufactures high performance, oil and greasefree bearing systems, plus other shaft line products for the global marine, clean power, pump and industrial markets. The company won an additional order for its grease-free ThorPlas-Blue bearings thanks to an installation on a Mississippi
Thor-Flex seals installed in a refurbished pneumatic cylinder.
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River line haul boat that helped to reduce the vessel’s operating costs.
Grease-free bearings “It is typical of these Mississippi workhorses to drydock frequently to replace their greased sleeve type bushings,” says Jason Perry, Thordon Bearings’ business development manager, USA. “These types of bearings are unable to tolerate angular misalignments resulting from deflection or improper mounting, which can place considerable stresses on the steering system, causing high levels of vibration, corrosion and, in some cases, pollution.” The nature of the work done by these vessels and the environments in which they operate also means metal-on-metal bearings are more susceptible to damage and rapid rates of wear, which increases costs. The unidentified customer requested grease and corrosion-free tiller linkage capable of withstanding greater vertical movement of the tiller pins.
PHOTOS: THORDON BEARINGS
Thordon’s ThorPlas-Blue bearings were retrofitted to the triple screw towboat in 2016 with precision field machining company Mactech On-Site replacing the bronze bushings in the vessel’s steering. The homogeneous, self-lubricating polymer bearing has a low dry coefficient of friction, high strength and low creep. When this 180-foot (54.9-metre) triple-screw work boat recently docked for repairs, the ThorPlas-Blue bearings retrofitted to the vessel’s tiller and jockey bars showed no signs of wear, despite two years operating in the river’s abrasive, low draught waters. “The commercial benefits of no longer having to replace metal-on-metal bearings every one or two years, or purchase, store and apply lubricating greases are obvious, but the vessel’s crew has also remarked that the tiller flat is a cleaner, safer working environment. The linkage system is completely grease-free, so there’s no chance of slipping on greasy decks,” Perry says. Based on bearings’ performance on this vessel, the customer has opted to retrofit 10 additional workboats with ThorPlas-Blue. Thordon Bearings Inc. is a Thomson-Gordon Group company, and a family-owned business. It operates plants in Burlington and Slupsk, Poland. Comments? E-mail jterrett@plant.ca.
October 2018
2018-10-05 1:00 PM
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2018-09-25 2018-09-24 11:48 2018-10-05 4:48 PM 1:00 PM AM
CCOHS SAFETY TIPS High concentrations of the gas can lead to a loss of consciousness, even death.
Exposure risk is high in steel production. PHOTO: FOTOLIA
I
t’s silent but deadly – a poisonous gas you can’t see, smell, taste or touch, but what carbon monoxide (CO) lacks in personality, it makes up for in potency. Carbon monoxide poisoning is responsible for hundreds of deaths and thousands of hospital visits every year in North America. The Ontario Association of Fire Chiefs reports that more than 50 people die each year from carbon monoxide poisoning in Canada, including 11 on average in Ontario. A common and deadly hazard, carbon monoxide results from the incomplete burning of natural gas and any other material containing carbon such as gasoline, kerosene, oil, propane, coal or wood. Other sources are cigarette smoke and motor vehicle exhaust. Internal combustion engines are the most common source of carbon monoxide in the workplace. There is also a risk of exposure in boiler rooms, warehouses, petroleum refineries, blast furnaces, steel production, pulp and paper production and welding. Emergency workers entering uncontrolled environments without wearing a carbon monoxide detector have also been subject to serious injury and even death. When we breathe in carbon monoxide, it interferes with the ability of red blood cells to carry oxygen to the heart, brain and other vital organs. Exposure to very high concentrations can overcome a person in minutes with few or no warning signs and result in loss of consciousness or even death. The initial symptoms of poisoning are similar to the flu (but without the fever). They include headache, tightness across the chest and shortness of breath, fatigue, dizziness, drowsiness, or nausea. As symptoms worsen the victim may experience
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Silent but
DEADLY BEWARE CARBON MONOXIDE POISONING HAZARDS muscle weakness, vomiting, confusion, losing consciousness and even collapse. The sense of confusion caused by this gas also interferes with the victim’s ability to realize that his/her life is in danger.
Protect your workers Here’s what employers can do to protect workers from CO poisoning: • Install an effective ventilation system that will remove carbon monoxide from work areas. • Maintain water heaters, space heaters and other potential carbon monoxide-producing equipment. • Use equipment powered by electricity, batteries or compressed air. • Use reliable personal and/ or area carbon monoxide
detectors set to alarm well below the exposure limit. Area alarms should give both visual and audible warnings immediately. • Don’t allow the use of gasoline-powered engines or tools in poorly ventilated areas. • Test air quality regularly, and prior to entry in areas where carbon monoxide may be present, including confined spaces. • Ensure employees wear appropriate and approved respirators, such as a full-face piece, pressure-demand self-contained breathing apparatus, in areas with high carbon monoxide concentrations. • Educate workers who may be exposed to carbon monoxide to know the sources and recognize symptoms, how to protect themselves and how to respond in case of an emer-
gency. Employees can help prevent poisoning by reporting any potential hazards, and looking out for ventilation problems, especially in enclosed areas where gases of burning fuels may be released. They should not use gas-powered engines in an enclosed space and emphasize they must report complaints of headache, dizziness, drowsiness or nausea. Vigilance does not end in the workplace. Encourage workers to protect themselves at home by doing the following: • Install carbon monoxide detectors that have both audible and visual alarms. Replace the batteries when the time on clocks is changed each spring and fall. • Never burn anything in a stove or fireplace that isn’t vented. Don’t use an oven as a heat source. • Do not use portable flameless chemical heaters, gas camping stoves or generators inside and never burn charcoal. Never run a car or truck in the garage with the door shut, or in a garage that’s attached to a house. Even idling a vehicle outdoors for a long period can expose occupants to carbon monoxide because of the potential for pulling the gas into the heating system. For more information, visit www.ccohs.ca and search carbon monoxide. The Canadian Centre for Occupational Health and Safety (CCOHS) in Hamilton contributed this article. CCOHS provides information, training, education, management systems and solutions that support health and safety programs and the prevention of injury and illness in the workplace. Visit www.ccohs.ca. Comments? E-mail jterrett@plant.ca.
October 2018
2018-10-05 1:00 PM
LUBRICATION Follow OEM recommendations and these maintenance tips.
Fighting friction with industrial lubes. PHOTO: FOTOLIA
M
aintenance of lubricating oils in critical applications is essential, but many programs lack the basic tools, manpower or budget to keep them within specification. Furthermore, maintenance is often reactive and limited to reducing particulate rather than targeting the causes of failure. This disconnect is costing the Canadian industry hundreds of millions of dollars annually. Mankind has used lubrication to fight friction for more than 4,000 years, so you’d think we’d be better at it by now. Yet statistics published by the world’s leading bearing manufacturers – such as SKF and FAG – suggest less than 5% of bearings reach their engineered L10 lifecycle. Furthermore, they report as much as 80% of bearing failures are directly attributable to poor lubrication practices. Failures lead to costly downtime and missed production targets. With so much at stake, it’s a wonder how such a simple task as injecting grease into a bearing, or choosing the correct oil for an application, could go so horribly wrong. That’s why fluid cleanliness
Managing
FLUIDS
HOW TO KEEP THEM CLEANER management is so important. This subject was dealt with in depth at a recent Education Day seminar, convened by the Society of Tribologists and Lubrication Engineers – Hamilton in a presentation by Olga Minikh. The field technical advisor of Ontario Exxon Mobil Imperial strongly suggests always following OEM recommendations,
properly maintaining filtration systems and regularly draining water from sumps.
Resist deposits Hydraulic fluids must be resistant to the formation of internal deposits, and they must be compatible with all elastomeric materials. A variety of hydraulic fluids – mineral-, synthetic-, bio-
TECH TIP
Keep your eyes open Get insights from visual inspections
W
e seem to rely heavily upon testing technologies and results to prove or disprove the reliability of equipment, says Howard Penrose of MotorDoc LLC. He cited this as a concern in the 1990s with the arrival of new technologies with technicians and engineers becoming more reliant on testing only. He says many people do not realize most of the standards covering electric machines emphasize visual inspections. For instance, electrical testing of a random wound motor will identify flaws and degradation – to a point – in an insulation system. However, it will usually miss quality defects, such as crossed turns, which result in significant electrical potential between conductors, or moveable conductors. Also, in both large and small
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Electrical testing will miss quality defects.
PHOTO: FOTOLIA
machines, testing may not always detect contamination. New testing and methods do provide more insight into the condition of equipment, as well as advances in understanding of the data collected, but visual inspections can provide greater insight into potential problems. Source: MotorDoc LLC newsletter. Visit www.motordoc.org.
degradable or fire-resistant – can be used. Minikh says regular draining of water is necessary for compressor oils; that heat and water are detrimental; and dirt and dust are abrasive to parts. She notes corrosive contamination is to be avoided, and good gas filtration is a must. She also covered engine oils for commercial fleets and off-highway equipment. They must lubricate, clean, seal, cool and protect. Good lubrication management also results in higher productivity and improved environmental sustainability. Well-managed lubricants drive productivity by extending equipment life and oil life, and by reducing energy consumption. Synthetics are more energy efficient and have a better oxygen stability than mineral oils. They also have a lower volatility and low pour point. In a presentation at the same seminar, John Melanson, engineering manager of bearing company SKF Canada Ltd., based in Toronto, outlined what a management program should cover: • Logistics and supply chain • Lubricant selection • Lubricant storage and handling • Lubrication tasks planning and scheduling • Lubricant application procedures • Lubricants analysis and condition monitoring • Lubricant waste handling • Training • Automatic lubrication systems Melanson said a SKF-designed structured program helps identify needed improvements in a lubrication plan. Visit www.skf. ca for more information about the SKF Lubrication Management program. Comments? E-mail jterrett@plant.ca.
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SUSTAINABILITY 3M in Brockville, Ont. where one energy management project saved $350,000 a PHOTO: 3M year.
Save money, save the It’s good for business, the environment and the community. BY ANDREW HEJNAR
M
any manufacturers understand the value of adopting programs and policies to conserve energy, protect the environment and act in a socially responsible way. They realize a robust sustainability strategy is essential to business success, a key driver of new business and an increasingly important influencer of purchasing decisions. It’s also something that many highly talented people look at when choosing where to work. So how do you reduce energy consumption, help the environment and save money? It comes down to three things: establish your goals, set out a policy, then develop and execute a clear strategic plan. Start by setting sustainability goals. Determine what you want to achieve, make sure these goals are specific and measurable, and tie them to a set timeline. 3M goals are to improve energy efficiency indexed to net sales by 30%, increase renewable energy to 25% of total electricity use, and ensure greenhouse gas (GHG) emissions are at least 50% below a 2002 baseline by 2025. This, while growing the business, and helping customers reduce GHGs by 250 million tons of CO2 by using 3M products. The next step is establishing an energy policy. This should come from the most senior ranks and apply to all opera-
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PLANET
HOW TO BUILD AN EFFECTIVE ENERGY MANAGEMENT PLAN tions, clearly stating the company’s commitment and what’s expected of staff. Determine what matters to your organization and state it clearly on one page. You may wish to state your company: • strives to demonstrate good corporate citizenship and sound fiscal management through the reduction of energy use; • aims to appeal to employees – current and potential – who want to work for a sustainable corporation; and • is aligned with customers who prefer, or are mandated to work with suppliers that have a commitment to energy reduction. Mapping out a strategy for implementation follows goals and policy. 3M plans around three key pillars: metering, technology and people. Metering is crucial because you can’t control what you can’t measure. It provides real-time information, so personnel see what’s being used and where. It also provides consumption reporting for tracking use and budgeting. Tracking helps to ensure demand for electricity is kept lower during peak hours by your hydro utility company. Budgeting allows you to determine how much natural gas you’ll need, rather than over- or
under-buying. There are many ways to improve the technology you use to make plants more energy efficient. For instance, switching to LED lighting saves between 60% and 90% of energy use. An added advantage is better quality illumination. Compressed air optimization is another consideration. Despite being a heavy energy consumer – 7 hp of electricity is used to produce 1 hp of compressed air – it’s often used unnecessarily, for such tasks as cleaning workbenches. Instead, use electric blowers and mixers. Also put a preventive program in place to reduce air leaks because most plants waste 20% to 30% of their air.
Identify savings HVAC is another great source of savings. Air conditioning is very expensive – on average $5 per cfm per year – so conduct air balance studies to reduce exhaust and make up air. Look to re-commission existing equipment or use evaporative cooling. The most important pillar of an energy conservation strategy is people. In fact, everyone – including the most senior managers to production workers, sales representatives and front-line customer service agents – should be inspired to embrace
sustainability and energy conservation. Awareness campaigns and regular training, combined with an employee suggestion program and other regular communications, go a long way to helping everyone understand how much they matter to the energy reduction strategy. 3M delivers training on a twoyear cycle to all employees. A quarterly newsletter with its fun energy-awareness comic strip, helps maintain the focus. Also consider implementing the ISO 50001 Energy Management System. This voluntary international standard framework is based on a “Plan-Do-CheckAct” continuous improvement cycle. It leads to improved energy performance and integrates efficiency into management processes. Successful development of goals, policy and strategy requires senior management commitment, expert consultant support and rigorous tracking, but it’s worth the effort. At 3M’s Brockville, Ont. tape facility, energy use between the plant’s busiest production day and non-operating day was compared. On the non-operating day the plant was using 40% of the energy consumed during its busiest operation. By making changes to how and when equipment ran, consumption was reduced to 6% without any capital expense, for annual savings of more than $350,000. But it’s not just costs and savings that matter. A well-developed and executed energy management plan also protects the environment. It’s about doing well by doing good. Andrew Hejnar is the energy manager at 3M Canada, in Brockville, Ont. Visit www.3mcanada.ca. Comments? E-mail jterrett@plant.ca.
October 2018
2018-10-05 1:00 PM
BIOPRODUCTS S2G acquisition broadens the forest product company’s global perspective BY ANNETTE MCLEOD
T
he company that was known as Fortress Paper Ltd. sees itself as more than a producer of paper products. Following a name change to Fortress Global Enterprises in February, the Vancouver-based company in March acquired S2G Biochemicals Inc. Now it’s positioning itself in the bio-refining space. S2G BioChem is a Vancouver-based developer of chemical conversion technologies that makes food ingredients and petrochemical alternatives from cellulosic sugars. In 2016 it partnered with Mondelez International, a global food products company, to produce xylitol, a premium low-calorie sweetener widely used in sugar-free gum. Mondelez makes biscuits, chocolate, gum, candy and powdered beverages (including Oreos, Cadbury milk chocolate and Trident). S2G’s proprietary technology uses renewable feedstock such as wood chips, agricultural and forestry residues to make sugars that are converted into biochemicals such as glycols. The end product can be used as a drop-in replacement for common petroleum-based chemicals such as those used in resins, but contribute far fewer greenhouse gas emissions. S2G entered into an exclusive licence and collaboration agreement with its food company partner to jointly develop the technology to produce xylitol. This new symbiotic relationship with Fortress means the S2G technology will be used to extract and convert hemicellulose from sustainable Canadian hardwood chips used at the Fortress Specialty Cellulose Mill in Thurso, Que. “There’s a really good fit be-
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Sweet
SUCCESS FORTRESS LOOKS AHEAD TO BIOREFINING tween what [S2G does] and what the Thurso mill does,” notes former S2G president Mark Kirby, now president and CEO of Fortress Advanced Bio Products Inc. It’s the special-purpose division formed by Fortress Global following the acquisition. “They produce a dissolving grade of pulp sold around the world and made into rayon, a sustainable clothing material, and they’re proceeding to supply that market and grow capacities,” he says. “Additionally, common to all mills worldwide, they’re looking at how they can get more value out of the biomass, making co-products, transitioning themselves from being pulp and paper to being bio refineries. They need to put in new technologies to do that, which is where [S2G comes] in.” Kirby explains the process: All hemicellulose must be removed from the dissolving grade pulp produced at Thurso, so it’s extracted with steam and water before the pulping process. To get some value from it they mix it with black liquor produced in the pulping process and use it to generate energy for the mill. “But we can create much more
value by making xylitol,” he says. “Plus, they don’t need as much energy as they have in the combined stream. Their capacity is limited by their ability to process that material. They wanted to find ways to offload the recovery furnace.”
Cellulosic sugars Kirby says the S2G technology takes the pre-extracted hemicellulose, cleans it up and converts it into other products. By converting those crude sugars into a valuable product, the acquisition generates more revenue for the mill, and by offloading the recovery furnace, more pulp is produced. There is a range of options for what can be done with the hemicellulose sugars produced by the mill, one of which is converting them into xylitol. This sweetener has a similar taste to table sugar, but offers the health benefits of 40% fewer calories and the ability to actually prevent cavities. Driven by health-conscious and diabetic consumers, world demand for xylitol is expected to reach US$1 billion by 2020, according to market research released last year. The current
Fortress Global’s Thurso Mill digester. PHOTO: FORTRESS
market is estimated at about US$725 million. Demand for xylitol is growing,” Kirby says. “Our partner buys a lot of it and wants more. They want a sustainable, cost-effective supply. We’ve worked with them for a number of years and we think we have a process that’s much more efficient and cost effective than the existing way xylitol is made.” Most of it is produced in China using corncobs as feedstock. The Fortress process is efficient and more environmentally friendly. Because of the lower-cost feedstock, Kirby estimates the advantage over Chinese producers at about 40%. Although Kirby says the goal is to make xylitol for the partner, there are no restrictions on supplying other companies. As Kirby says, bitter experience in processing industries shows it’s wise to go through a demo-scale model before scaling up to commercial, and that’s exactly what Fortress has planned. A Thurso demo plant – by his estimation – will be built by the end of 2020, but he’s restricted in what he can say at the moment, as they deal with the government on funding matters. “The front-end engineering design stuff is kicking off as we speak, and we’d like to get to the point of all financing and investment decisions made by the end
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S2G BioChem engineer making adjustments at the pilot plant.
of the year.” It will run for about a year before they move to construct a commercial plant, which he figures will likely take another two or three years. “It’s a six-year process we have to go through,” he notes. “But that’s the prudent and reasonable way of moving this thing forward.” S2G had previously announced an intention to build the demo plant in Sarnia, Ont., but subsequent conversations with Fortress, it became apparent there was a good fit for the companies, with SG2 in need of feedstock and Fortress seeking better value from its production. “It’s a really exciting step,” Kirby says. “We’ve been working as a Canadian tech company for eight or nine years now, and previously worked in Canada and the US in technology
PHOTO: S2G
demonstration development. We’re pleased we have been able to find a supportive partner/ acquirer in Fortress, which sees the potential of the technology, recognizes the opportunity to diversify the product slate at the pulp mill, and to make this shift to being a bio-refinery. We think it will be a model for Canadian and international forest product companies and we will be in a strong leadership position with the tech development work we’ve done with Mondelez and commercialization at the Quebec mill.”
Saleable material The three-step, extract/condition/convert prehydrolisis kraft process starts there. First, they’ll extract the prehydrolysis liquor, a mix of various wood sugars plus some residual lignin from the wood, other organic mate-
rial and inorganic components. Conditioning removes all the contaminants to create a clean sugar stream. The xylose, or wood sugar, is converted using hydrogen, crystallizing out the xylitol as a food-grade product. The mother liquor that’s left contains residual xylitol and other sugars, a saleable material in the short term. Kirby says down the road the company will make it into additional bioproducts using the basic platform. Bio-glycols can be used as drop-in alternatives that offer sustainability benefits versus oil and gas-derived petrochemicals. But with competitive challenges ahead from low oil and gas prices and large-scale petrochemical production in the Middle East and US Gulf, they need to demonstrate scalability. “As well, we need to show that we can move into investments in large-scale bio-chemical production. We’ll be helped by strengthening oil prices and the price of carbon, but we have to be cost-competitive. There can be no green premium. And we need to demonstrate the technology. It’s logical growth from high-margin, profitable food products into higher volume sustainable chemicals,” Kirby says. The intent is to develop prod-
ucts that allow the company to move into production of bio-glycols over time. The hope is for parallel products but nothing is confirmed. Glycols are used to make everything from countertops and personal care products to Coke bottles, other packaging and clothing fibres. It’s a huge market and there’s a very strong desire to find sustainable alternatives, but they don’t want to pay a premium for that. Nike, Coke and Procter & Gamble will buy sustainable alternatives if they are cost and quality competitive,” Kirby says. As a large producer of agricultural and forest products, recognizing opportunities in Canada’s bio economy requires support from the government, and he says there’s a lot of activity in the public and private sectors to develop and deploy new technologies. “It’s important because it’s key to helping us meet our global greenhouse gas emission commitments,” he says. “It leads to exportable technologies, jobs, investments – all the things we want as a society.” Annette McLeod is a Torontobased freelance writer. Comments? E-mail jterrett@plant.ca.
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October 2018
12/09/2018 10:07:02 AM 2018-09-12 12:58 PM
2018-10-05 1:00 PM
TECHCENTRE MARKING SYSTEMS
SUPPLY LINES
They must be sensitive, data-rich and survive tough conditions.
EXCLUSIVE SALES REP Guardian Telecom, a Calgary manufacturer of rugged, high performance telecommunications equipment, has appointed Impact Technical Products in Mississauga, Ont. its exclusive manufacturer’s rep for across Canada. Guardian is a division of Circa Enterprises Inc., a manufacturer of equipment for the telecommunication, electrical utility and construction industries. Its products are installed across Canada and around the world
BY DARRELL FRIESEN AND DAN STICKNEY
I
ndustrial labels must withstand some exceedingly tough conditions. Changes in moisture, temperature and debris are just a few of the unpredictable factors that affect them. Manufacturers want labels that are attractive and functional in all sorts of exceptional conditions, while holding up well during travel and storage. The demands of Industry 4.0 are making matters even more complicated. As factories digitalize and serialization regulations are enforced in a variety of sectors, the amount and complexity of information included on labels mounts. In addition, as the Internet of Things (IoT) increasingly dominates supply chain operations, smart warehousing is making its own demands. Features such as automated inventory management, RFID solutions and barcode scanning are growing in popularity. Labelling solutions must respond in kind. Many industries, such as oil and gas, industrial chemicals and construction mandate bar codes and fine print to be visible no matter how much information is required. Take MSDS labels: barrel and jug labels, as well as WHMIS and dangerous goods placards, are integral to the safe transport of chemicals. To be both rugged and smart, the technologies used for printing, barcoding, scanning and labelling require careful consideration. Today’s state-of-the-art digital inkjet presses print an array of PMS colours and provide in-line
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NEW ECOXPERTS Printing industrial product labels.
Smart but
PHOTO: JET LABEL
RUGGED WHAT YOU NEED TO KNOW ABOUT MODERN LABELS UV protection and lamination. There are numerous options for label design and applications, and greater durability for extreme environments without yellowing or fading.
Smart warehousing Barcode technology is essential to smart warehousing and supply chain management. Durable labels enable efficiency, automation and speed in the handling of inbound and outbound inventory, all of which has a direct impact on the bottom line. This technological wave started with pharmaceuticals and is now expanding to other industries, such as those benefiting from tighter anti-counterfeiting measures. Key areas of technology
investment include mobile scanning devices, scalable inventory management software, and the ability to apply barcodes both horizontally and vertically on a wide variety of materials. Other solutions include pre-printed LPN barcode labels to track moveable units such as pallets, cartons and cases; tote and shelf labels; and overhead barcode signs or floor plate kits with barcode labels to identify inventory stored in bulk locations. Modernizing equipment is critical. Updated coding equipment ends the practice of hand-applying stickers, which often contain poorly printed date coding, damaging the overall look of packages. Newer equipment prints precise, clear date/pro-
Schneider Electric Canada in Mississauga, Ont. has added new EcoXpert partners. They’re trained by the global specialist in energy management and automation to leverage the latest IoT-enabled technology for power management. The new Canadian EcoXperts are: BARCOL Controls Ltd., Winnipeg; Calderwood Automation Services Ltd., Napanee, Ont.; Cybernetics Control Systems, Langley, BC; Digital Engineering Inc., Thunder Bay, Ont.; The E.A. Group, Toronto; Powercore Engineering Ltd., London, Ont.; Procétech Automation, SainteJule, Que.; and Techno-Contact, Pierrefonds, Que.
CRUSHER ACQUISITION McCloskey International has acquired Lippmann-Milwaukee Inc., a manufacturer of aggregate crushing equipment in Milwaukee. Its products are sold across the aggregate, mining and recycling industries. This acquisition complements McClosky’s product line. The Keen, Ont. manufacturer makes crushers, screeners, stacking conveyors and washing systems. Both companies will maintain their current headquarters and leverage their products across a broader customer base.
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LEADING EDGE Innovative ideas for plants
MONITOR PROCESSES IN 5G
Advanced technology is in development
Sato’s CL4NX industrial thermal printer. PHOTO: SATO
duction codes as labels are dispensed by the applicator. Information is added to a designed-in space – making mission-critical data both aesthetically pleasing and easy-to-read. Scanner manufacturers know speed and accuracy are directly related to workforce productivity, throughput, quality and customer service. Excellent scanners capable of standing up to tough environments are available from many reputable suppliers, including Zebra and Microscan. Zebra’s ultra-rugged scanners capture barcodes in the warehouse and on the manufacturing production line, where every second counts. Label applicators, though fairly rugged by nature, need to be carefully vetted before purchase. Premium brands usually offer better performance in harsher conditions. Thermal printers are also available in rugged versions. SATO offers a line of industrial printers, including its CL4NX, a best seller. Zebra’s ZT400 series is another good choice. For those looking to go beyond barcode scanners, RFID offers a longer scanning range. Systems can be set up so your tag is read without being seen. Advancing your labelling capabilities by automating and streamlining processes will help minimize the downtime of your marking systems. Darrell Friesen is CEO of Jet Label, a manufacturer and printer of labels and printed tape based in Edmonton. Visit www.jet-label.com. Dan Stickney is general manager of sister company Jet Marking Systems. Visit www.jet-marking.com. Comments? E-mail jterrett@plant.ca.
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A collaboration between Fraunhofer Institute for Production Technology (FIPT) in Germany (www.ipt.fraunhofer.de/en), Ericsson (www.ericsson. com) and GF Machining Solutions (www.gfms.com) has led to a 5G manufacturing process monitoring solution that was presented at the IMTS show in Chicago. Current work is aimed at the precision requirements of the aerospace industry, but the technology will eventually be found in a range of applications. When milling parts at high speeds, excessive vibrations lead to surface defects and rework. Real-time process monitoring based on 5G technology (fifth-generation cellular) communicates with sensors and machines to reduce errors. Ericsson’s mobile communications provides real-time monitoring of sensor vibration data, plus better production control, thus allowing for adjustment of the cutting parameters. As for speed, 5G delivers the data in under one millisecond. The three companies aim to further develop this type of wireless sensor connection to ensure adaptive control of production processes with extremely short reaction times. To deliver the power and precision need for such fast reaction, they chose a Mikron MILL P 500 U from GF Machining. It uses highly dynamic direct torque motors as well as a precise gantry with up to 1.7 g acceleration and an accuracy of ±2 µm in the plane. Digitization of production and the application of 5G technology will undergo additional research and development at the International Center for Networked Adaptive Production (ICNAP) in Aachen, Germany.
5G technology communicates with sensors and machines.
IoT in the cloud.
PHOTO: FOTOLIA
MAKING MANUFACTURING SMARTER
VIMANA and Microsoft partner on process analytics VIMANA, based in Emeryville, Calif. (https://govimana.com) and Microsoft are working together to make manufacturing smarter for users of the Microsoft Azure (https://azure.microsoft.com/enca) cloud computing service. VIMANA’s Vision platform provides the analytics and Microsoft contributes its cloud IoT capabilities. Vision provides predictive and prescriptive insights from shop floor data, while integrating data and insights into customer’s own applications. It comes with a range of integration options and can be extended with custom services and algorithms to address proprietary uses. Microsoft, based in Redmond, Wash., is an international software tech company.
October 2018
2018-10-05 1:00 PM
NEW SAAM 3D PRINT MATERIAL
Has fixturing, tooling applications Cincinnati Inc. has developed a new lightweight carbon-fibre resin material for its SAAM (Small Area Additive Manufacturing) 3D printing system that’s impact resistant, and has a high strength-to-weight ratio. Carbon fibre reinforcement makes the material stiff and durable with low warping. The manufacturer of metal fabrication equipment based in Harrison, Ohio says the material’s surface finish makes it suitable for custom tooling applications, as well as assembly, CMM, welding and CNC fixtures. SAAM uses fused filament fabrication technology to 3D-print composite or plastic parts directly from a CAD design, but it also simulates parts produced by non-additive machines. The same CAD file used for a prototype can be
Carbon-fibre 3D printed part.
PHOTO: CINNCINNATI
sent to a laser, a press brake or a shear for metal fabrication. This reduces waste in the design process and accelerates advancement to the production phase. www.e-ci.com
PHOTO: FIPT
BUILDING-IN IOT SECURITY
Blackberry service bakes in protection Blackberry’s thing is guarding against cyber-breaches of IoT-connected devices and enterprises. Now the Waterloo, Ont.-based security specialist is providing a manufacturing service to OEMs of IoT devices that’s the same process used for its own products. Security controls are baked in to protect devices from being exploited, hijacked or misused before they leave the plant. During manufacturing, a BlackBerry Secure Identity Service Key is injected into the hardware and recorded on a secure server. Both at launch and periodically throughout the product’s lifecycle, checks are performed to ensure the two keys match. If they don’t, the device no longer boots. With a BlackBerry Secure license, the OEM gets help implementing remotely managed, secure workstations at each of its manufacturing plants. They’re built on secure web 2.0 architecture, and Blackberry says they require no permanent VPN connectivity. www.blackberry.com
Shields connected devices from cyber-mischief. PHOTO: FOTOLIA
GENIE NANOS HIT WARP 5
High-speed vision data transfer
Faster frame rates.
www.plant.ca
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PHOTO: TELEDYNE DALSA
Teledyne DALSA’s newest Genie Nano cameras have advanced into 5-Gigabit GigE vision territory. The Waterloo, Ont. manufacturer of sensing and imaging technology has added to its lineup eight new monochrome and colour cameras built around SONY image sensors with resolutions from 3.2 to 12 Mpixels. More models will follow before the end of the year, including a 5 Mpixel polarized camera. They’re made for imaging applications that require high-speed data transfer, and replace cameras built into current vision systems that rely on the existing GigE vision interface. Faster frame rates are equivalent to 585 MB/sec., and bandwidth is increased 50%. www.teledyneimaging.com
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PRODUCTS AND EQUIPMENT MATERIAL HANDLING NO-DUST BULK MATERIAL DUMPING The TIP-TITE from Flexicon dumps pails containing high-density bulk solid materials into downstream processing or storage vessels dust-free. The unit accommodates pails of up to 19 litres of powder metals, chemicals, pigments, minerals or other Tips at 45, 60 or heavy, dense 90 degrees. bulk solids, measuring up to 380 mm in height, and weighing up to 340 kg. Dual hydraulic cylinders work in tandem to raise and seat the pail rim against a specially-configured, elongated discharge cone, and then tip the pail to an angle of 45, 60 or 90 degrees with a motion-dampening feature. At full rotation, the discharge cone seals against the inlet of the receiving vessel, creating a dust-tight connection that allows controlled, dust-free discharge through a pneumatically actuated slide gate valve. An optional pneumatically actuated vibrator on the discharge cone promotes complete evacuation of non-free-flowing materials. The pail dumper is constructed of carbon steel with durable industrial finishes, with material contact surfaces of stainless steel. Other models are available in all-stainless steel finished to food, dairy, pharmaceutical or industrial standards. Fexicon Corp. manufactures bulk handling systems in Bethlehem, Pa. www.flexicon.com
DRUMS GET ADDITIONAL LIFT Handle four drums at a time with Liftomatic Material Handling’s LOM-4 forklift-mounted attachments. They don’t require hydraulic or electrical connections. Two units are capable of han-
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dling steel, poly and fibre drums with a total load capacity of 8,000 lb. They come in two configurations. Two configurations. The model L4F handles up to four drums and is useful for mixed loads, single stacking in trucks and trailers and for fill-line movement. Model S4F handles four drums at a time only, for double stacking in trucks and trailers where overall height is limited. Both models have spark-resistant and EE-rated components. Each handles a mixed group of four drums, steel, plastic or fibre at one time, as long as the drum heights are within 1.5 in. of each other. Crane and carriage-mount models are also available. Liftomatic Material Handling Inc., based in Buffalo Grove, Ill., manufactures drum handling equipment. www.liftomatic.com
RITE-HITE WASHDOWN DOOR IS KEEPING IT CLEAN
Heat-sealed vinyl.
The LiteSpeed washdown high-performance door by RiteHite makes cleaning to food operations standards easier. Its PVC vinyl curtain operates on a stainless-steel frame designed without a header and motor shrouds, which are two areas notorious for harbouring bacteria. The completely heat-sealed vinyl and optional urethane stands up to caustic cleaning chemicals used in a typical washdown application. The roll-up design translates into a smaller physical footprint and operates at peak operating speeds of 65 in./sec. It’s powered
by a quiet, 1-hp motor that’s coated to withstand harsh, regular cleanings. And a 7-in. LCD touchscreen graphic user interface handles simple troubleshooting at the door opening. If the LiteSpeed Washdown is bumped or impacted, the TRUE Auto Re-feed feature will automatically reconfigure the door back on its tracks. This eliminates a potential breach in a clean room environment and the downtime and costs associated with repairing a traditional door. Rite-Hite is a manufacturer of material handling based in Milwaukee. www.ritehite.com
PUMPS UNIT DELIVERS PRECISION PUMPING DISPLACEMENT Uses shapememory alloy.
Kinitics Automation’s KPP05 piston pump uses a shape memory alloy to deliver precision displacement, while providing the functionality of a motor, pump and proportional valve in a single compact unit. Driven by the company’s KLA05 linear actuator, the pump allows for displacement or pressure control when additional sensors are used. The pump is compatible with a wide range of fluids and provides a high pressure-to-size ratio. Features include: piston positional accuracy of +/- 5 µm; rated pressure to 10 bar (145 psi); displacement up to 3.3 cc (0.2 cu. in.); flow rates up to 10 lph (2.6 gph); configurable ports; and IP67 environmental protection. The KPP05 also configures with alternate bore sizes when higher pressures or displacements are required. Kinitics Automation manufactures linear actuators and piston
pumps in Richmond, BC. www.kiniticsautomation.com
CABLES CABLES WITHSTAND CONSTANT FLEXING
Cut to length.
igus Chainflex CF30 and CF31 motor supply cables withstand constant flexing, providing a cable service life between 5 million and 10 million cycles. The cut-to-length cables are available with four unshielded (CF30 series) or four shielded (CF31 series) conductors in 16 AWG to 2 AWG sizes. Individual conductors are bare copper and stranded for flexing applications. Conductor insulation is a black TPE mixture that’s sunlight and oil resistant, and flame retardant. And the outer jacket easily strips back from the conductors to the desired length. The cables are supplied by AutomationDirect, a distributor of automation products based in Cumming, Ga. www.automationdirect.com
SENSORS SOFTWARE FOR AGV NAVIGATION OpenIMUTM from ACEINNA is a first of its kind open-source GPS/ GNSS-aided inertial navigation software stack. It’s for autonomously guided vehicles (AGVs) used in industrial Easy to deploy. applications, autonomous cars, factory or industrial robots, drones, ROVs any kind of smart machine that needs to move. Advanced, easy-to-deploy
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localization and navigation algorithms are enabled in a fraction of the time of traditional methods. The stack includes: a FreeRTOS-based data collection and sampling engine; performance-tuned, real-time, navigation-grade GPS/INS Kalman Filter library; free IDE/compiler tool chain based on Visual Studio Code; JTAG debugging for debugging code loaded on IMU; data logging, graphing, Allen Variance plots, and maps; extensive documentation; and a robust simulation environment with advanced sensor error models. ACEINNA Inc., based in Andover, Ma., provides MEMS-based sensing solutions. www.aceinna.com
LASER LASER OPTICS CLEAN CUT COMPOSITE MATERIALS Direct field-replacement CO2 lenses and mirrors from Laser Research Optics fit popular lasers used for cutting comOptimized for 10.6 plex shapes from abrasive microns. composites where edge accuracy is critical. They meet OEM and ISO-10111 specifications and are optimized for use at 10.6 microns. They’re for use with popular lasers to produce clean cuts on abrasive composite materials and phenolics, which are difficult to manufacture by stamping and other fabricating techniques. They come in 0.5- to 1-in. OD sizes with 1- to 7.5-in. focal lengths, and with dual-band, anti-reflective coatings to aid system alignment. Mirrors are 0.5 in. to 10 mm thick and are made from silicon. Laser Research Optics, based in Providence, RI, manufactures CO2 replacement optics for laser engravers. www.laserresearch.net
METAL WORKING NEW FEATURE FOR CNC PILOT 640 A new Turn Plus feature on the HEIDENHAIN CNC Pilot 640 creates a lathe program with a push of a button. The Multitouch operation. contouring control for complex parts allows 5-axis simultaneous machining and combined turn-mill operation, full surface machining with B axis and counter spindle, and up to three channels for asynchronous multi-side machining. Multitouch operation allows swiping and zooming in and out, and high-resolution 3D simulation graphics have been added. Machining operations with one or several setups (multi-channel operation) are programmed separately through structured programming. The maximum number of controlled axes and spindles has been increased to 24 using appropriate options. Two screen formats – 19 in. and 15.6 in. – have up to 25 configurable fields. HEIDENHAIN, based in Schaumburg, Ill., makes motion control feedback solutions. www.heidenhain.us
MOTION COMPACT AUTOMATION AND MOTION CONTROL Festo’s new high performance CPX-E modular control system provides engineers and machine builders with a powerful option for automation systems’ I/O and motion control. Designed as an EtherCAT master and motion controller, it provides a standardized
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ROBOTICS A QUICK CHANGE FOR ROBOT TOOLS OnRobot has a new light compact robots tool changer for collaborative applications developed by Purple Robotics (recently acquired by OnRobot). WeighRepeatability of ±0.02 mm. ing only 200 g, the Quick Changer has a low impact on robot payload. Its compact size also adds minimal distance from the tool
SEW-EURODRIVE INVESTS IN Industry 4.0 Live Laboratory in the Barrett CTI
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platform for stepper and servo motor motion control used in parts handling, assembly systems, palletizing, gluing and dispensing. The CPX-E also controls automation systems, such as packaging machine palletizing units, as well as selective soldering and water handling systems. Its scalable functions include linear and multi-axis movements such as slides and gantries, contour applications and robotics. Individual function modules combine to create an application-optimized automation Standardized platform. platform. The choice of components covers control units, bus modules, digital and analogue input and output modules. Depending on the module
centre point to the robot, which minimizes stress on the joints. The changer releases end-of-arm tools with a click and inserted tools are automatically positioned correctly with a repeatability of ±0.02 mm. Use it on any robot arm, drone, or other equipment with an ISO-9409-1 flange. OnRobot, based in Odense, Denmark, supplies end-of-arm tooling. https://onrobot.com
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CONTROLS
combination, the CPX-E deploys strictly as a remote I/O system with bus module or as a centralized or decentralized control system using a control unit. CPX-E controllers with Codesys V3 software have comprehensive PLC programming functions. The system integrates into the most popular fieldbus networks, EtherCAT, PROFINET and EtherNet/IP. And OPC UA client and server functions ensure it’s Industry 4.0 ready for cloudbased host environments. Festo, is a global supplier of automation technology with a Canadian office in Mississauga, Ont. www.festo.com
MAGNETIC MOUNTS MINIMIZE DOWNTIME
Maximum rpm 6,000.
brake’s power consumption is stepped down to 7 VDC after a split second of 24 VDC for brake actuation. Maximum rpm is 6,000; static friction torque range is 0.044 ft./ lb. to 2.36 ft./lb.; and ambient operating temperature is -10 to 40 degrees C. Additional applications include: end effectors; ball screw actuators; XYZ positioning tables; and 3D printers. Miki Pulley Industrial Brakes, based in Plymouth, Minn., supplies motion control products to industry. www.mikipulley-us.com
BOOST SERVO MOTOR PERFORMANCE Miki Pulley’s BXR-LE electric spring applied brake for small and precise servo motor configurations optimizes performance and efficiency. With its voltage controller, the
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There are several sensors in the stamping dies connected through a multi-conductor, Maximizes productivity. industrial-grade connector to the controller. This connector must be disengaged before pulling the die out of the press. Forklift drivers often forget to do so and rip off the entire assembly causing three to four hours of downtime. Balluff’s magnetic mounts for Q40- and M30-style inductive couplers easily attach or disengage for quick changes. The magnetic mounts also protect the couplers from impact or abrasion in demanding industrial environment. Balluff Inc. in Florence, Ky., supplies networked IO-Link control system architectures. Balluff Canada Inc. is based in Mississauga, Ont. www.balluff.com
PLCS OFFER MORE CONTROLLER OPTIONS WAGO has added 9 PFC200 controllers to its Performance Class PLCs. With Gateways to multiple increased processor fieldbuses. speed and more onboard memory, they offer gateways between multiple industrial fieldbuses and enable data transfer with cloud services and SCADA via the MQTT protocol. An onboard web server provides dynamic HTML5 visualizations for operators and maintenance personnel; and there’s a built-in firewall and VPN for defense-in-depth strategies, but without additional components. They’re programmed with e!COCKPIT software tool that
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provides advanced functions. WAGO, based in Germantown, Wis., is a provider of connecting technologies. www.wago.us
REGULATOR HANDLES HIGH PRESSURE ControlAir Inc.’s Type-3600 regulator safely reduces inlet pressures from as high as 6,000 psig (413 bar) to working pressures ranging between 0 and 225 psig (15.5 bar). This first-cut, high-pressure regulator is made of rugged 316 stainless steel for corrosion-resistance and durability in harsh environments. Designed to meet NACE MR-0175 require- Outlet pressures ments for sour to 225 psig. gases, the non-relieving regulator is used in applications requiring high-pressure reduction for various gases. It’s also used where high-pressure gas must be reduced for use as pilot supply pressure. Outlet pressures to 225 psig (15.5 bar) cover three spring ranges: 0-125 psig (0-8.6 bar), 0-150 psig (0-10.3 bar) and 0-225 psig (0-15.5 bar). ControlAir manufactures precision pneumatic and electro-pneumatic controls in Amherst, NH. www.controlair.com
SCRUBBERS SCRUBBERS GET AN UPDATE Bionomic Industries Inc., a manufacturer of air pollution abatement, product and heat recovery technologies, has a new version of its Series 7000/8000 Meets P10 and P2.5 venturi scrubstandards. bers. The fully integrated pre-engineered package includes recirculation pump, piping networks,
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Plantware instrumentation and automated controls – all factory assembled and tested. They’re low maintenance and meet PM 10 and PM 2.5 particulate emission standards. Units destined for outdoor installation have a freeze protection package for operation in cold weather climates. A variety of materials enable operation on extremely corrosive or erosive gas contaminant streams; and an advanced throat design with diverging section provides high collection efficiencies at reduced pressure drops. Bionomic Industries is based in Mahwah, NJ. www.bionomicind.com
MACHINING HIGH PERFORMANCE ON HARD METAL
torque and power with dynamic machine stiffnessg. Dual ball screws provide feed rates of 45 m/min., and accelerate/decelerate rates of 0.5 G. The bridge and saddle featuring enhanced dynamic stiffness, provide optimum finish and tool life in hard metal applications. The horizontal machining centre handles 5-axis, five-sided complex part manufacturing, combining twin ball screw driven axes in XYZ, an infinite contouring B-axis table, and compact u-frame A-axis tilt spindle. It’s also equipped with hightorque spindle options for hard metal processing and two-speed 6,000 rpm. All spindles have external flood up to 250 psi and internal through-spindle coolant up to 1,500 psi. Fives designs and supplies machines, process equipment and production lines for the world’s largest industrial companies. A US office is in Hebron, Ky. http://fivesgroup.com
CONNECTORS Feed rates of 45 m/min.
REDESIGN IMPROVES MIN CONNECTABILITY
The Five Group’s Cincinnati HMC 800 delivers high-performance to industrial hard metal manufacturing applications that require precision machining. It combines high spindle
Mencom’s redesigned 1 1/8-in. MIN III connectors deliver better connectivity and stability in harsh factory environments. MIN style circular connectors quick-connect limit switch-
EVENTS Physical Asset Management Program U of T Nov. 5-9, Toronto Offered in partnership with the Faculty of Science and Engineering at the University of Toronto, St. George campus. Taught by two world-class instructors. Features fundamental, need-to-know material combined with proven, leading-edge approaches that have shown measurable payoffs. Visit http://learn.utoronto.ca. FABTECH 2018 FMA, SME, PMA, AWS, CCAI Nov. 6-8, Atlanta North America’s largest metal forming, fabricating, welding and finishing event. Sponsored by FMA, SME, PMA, AWS and CCAI. Visit www.fabtechexpo.com.
www.plant.ca
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Old (left) and new designs.
Actin 5 in action at IMTS 2018 in Chicago.
es and pneumatic valves. An enlarged coupling nut makes installation easier by giving a wider knurl area for better gripping, and the connection is more stable. The anodized aluminum coupling nut has been changed to nickel-plated brass, which is resistant to corrosion, salt and weld slag. The nut is also more resistant to high temperatures thanks to a high melting point (870-927 degrees C) for brass, making it more resistant to warping and deforming. Stainless steel versions are also available for extreme chemical conditions. The connectors are UL listed and rated IP67, suitable for harsh environments. Multiple pole configurations include 9, 10, 12 and 19. The cables are made with PVC, PVC TC-ER or rugged PUR jacket material with many standard shelf lengths. Mencom Corp. is a supplier of electrical connection products based in Oakwood, Ga. www.mencom.com
SOFTWARE FOCUSES ON ROBOT TASKS
2018 CME Manufacturing Conference CME Nov. 7, Ottawa The theme of this year’s Canadian Manufacturers & Exporters (CME) Annual General Meeting & Manufacturing Conference is Advancing Innovation for Global Success. The focus will be on strategies to remain globally competitive and scale-up exports through new technologies and skills development. Visit www.cme-mec.ca, Events. ATX Montreal UBM Nov. 14-15, Montreal Automation Technology Expo (ATX) Montreal showcases smart plant design; automation/assembly; robots and robot accessories; production machines and equipment; automation identification controls; integrators; and motion control. Visit https://admmontreal.com/en/atx.
Energid has updated its software development kit with Actin 5. This adaptive motion control software allows robotic system developers to focus on tasks rather than joint movement and paths. It responds in real time to sensory input and directs the robot on the most efficient path while avoiding collisions. The new robot controller development framework is configurable through XML for application on a wide range of platforms, including real-time operating systems. Advanced kinematic control capabilities embed into existing systems with minimal programming, or are used to develop a completely new system from proof of concept through commercial deployment. This dramatically reduces development time. A new EcScript scripting language makes the toolkit easier to use and faster to learn. Motion commands are created with just a few lines of code. Developers can still use C++ for advanced features with the kit’s improved documentation for C++ APIs. A human-machine interface toolkit creates touchscreen- or teach-pendant-friendly user interfaces. It’s built on Qt QML for multi-platform user interface development and provides simple access to Actin features through QML properties. Rendering and visualization tools are also accessible; and reference designs are available for commonly required UI features such as robot jogging controls, work-cell rendering and contextual overlays. Energid, based in Cambridge, Ma., develops advanced real-time motion control software for robotics. www.energid.com
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POSTSCRIPT
Build scale to close the competitiveness gap BY JAYSON MYERS
O
A BETTER WAY OF GAUGING HOW MANUFACTURERS ARE DOING IS TO STEP INTO THE SHOES OF A CFO AND LOOK AT THE FINANCIAL STATEMENTS…
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K, I admit it. I’m an economist and I like statistics. They explain a lot, if the right questions are asked. But sometimes statistics can be misleading, resulting at best in some earnest head scratching, or at worst bad decisions made by businesses and governments. Take, for example, the seemingly endless debate about why Canada’s competitive performance in manufacturing is in decline. In 2000, the United Nations ranked Canada fourth in the world in terms of manufacturing competitiveness. Since then, we have tumbled to fifteenth spot. Investments in research and development and in new machinery and equipment have fallen off dramatically. Our productivity gap with the US, not to mention Germany, Japan and South Korea, has widened. Today, after adjusting for price changes, the value of goods produced by Canadian manufacturers is running at about the same level as in 2002 and 6% lower than the peak, just before the Great Recession. The statistics behind these trends paint a sobering picture of an important industry in trouble. They also underscore the challenges the Canadian economy is currently facing. Our fondness for borrowing on the back of inflated financial and property markets and artificially low interest rates has obscured the reality that Canada’s ability to generate wealth, earn export income and sustain well-paying jobs has been critically impaired by a sputtering manufacturing sector. The seriousness of this situation will become more apparent as interest rates climb higher. But some perspective is in order. The view at the top is not always an accurate indicator of what’s happening at the level of each firm. In fact, when you ask a manufacturer about business, the response is usually fairly positive. A better way of gauging how manufacturers are doing is to step into the shoes of a CFO and look at the financial statements, as well as average operating revenues and costs. The view from this angle is much more positive and instructive, especially comparing Canadian companies to their US counterparts. Financial statistics show Canadian companies are – on the whole – more profitable than those in the US. As a percent of gross output (sales revenue plus changes in inventory valuation), overall labour costs are lower in Canada, while goods and services input costs account for exactly the same proportion of output in both countries. As a
result, gross profit margins are higher in Canada. So too are before- and after-tax profit margins – although US manufacturers do enjoy a growing tax advantage. Another remarkable observation is that over the past 15 years Canadian and US manufacturers have invested exactly the same proportion of their after-tax operating cash in R&D, new machinery and equipment. This helps to explain why stats at a macro-level appear so dismal. Operating cash includes after-tax profits as well as depreciation and amortization costs, which are much higher in the US where operations are typically much larger. Only about 270 facilities in Canada are large enough to employ more than 500 people. There are almost 32,000 in the US. So, what does all this tell us, apart from the fact that more economists should be reading financial statements? It means that scale matters. Bigger companies invest more in innovation, employ more technology and benefit from greater economies of scale and production efficiencies. It also implies declining levels of investment and productivity in Canada can be attributed, at least in part, to the loss of larger manufacturing operations over the past several years. There are lessons here for policy-makers aiming to strengthen economic performance. Any steps governments can take to reduce regulatory compliance costs, accelerate depreciation rates for tax purposes, or otherwise reduce taxes on manufacturers will increase cash flow and boost investment performance. Initiatives that aim to increase the amount of cash companies are willing to invest in innovation, such as supporting technology, production and business scale-up, or that help derisk investment decisions – particularly for smaller companies – should be encouraged. The lesson for manufacturers is the importance of building scale to compete, staying current with technology and capturing new market opportunities. Jayson Myers is the CEO of Next Generation Manufacturing Canada. The award-winning business economist and advisor to private and public sector leaders was president and CEO of Canadian Manufacturers & Exporters between 2007 and 2016. E-mail jayson.myers@ngmcanada.com. Visit www.ngmcanada.com. Comments? E-mail jterrett@plant.ca.
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DIRIS A10 Power Monitors The DIRIS A10 multifunction meter measures and displays electrical values and parameters in low voltage networks and can be utilized for communication and/or output functions. • LCD backlight display • DIN rail mount • Integrated temperature sensor • Integral pulse output allows external accumulation of energy consumption • Direct access keys for currents, voltages, power and energies • Hour meter, temperature and programming menu access pushbutton • Metrological LED (energy metering indication)
DIRIS A20 Power Monitors The DIRIS A20 panel-mounted multifunction meter provides all the measurements required to successfully carry out energy efficiency projects and ensure electrical distribution monitoring. • Large LCD backlight display • Multiple viewing screens display multi-measurement and metering values • Direct access keys for currents, voltages, power and energies • Optional configurable output module and optional Modbus RTU (RS485) communications module
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