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WALKINSHAW GROUP A global leader in the design, engineering, development, and marketing of performance vehicles

Marija Dukovska-Pavlovska, General Manager of Makstil, speaks about the company’s environmentally-friendly steel production practices

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Produce delivered from paddock to plate

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Smooth cruising for European manufacturing

Behind the global tech powerhouse of the world’s Smartest City

The suite life of the hotel industry

World-class medical diagnostics for Africa

T R AV E L GUIDE

COCA-COLA SABCO MOZAMBIQUE Iconic and impactful brands and beverages

SYRAH RESOURCES LTD

Putting Mozambique on the map for global EV development

CYPRUS

GENIE ENERGY LTD

BATCHFIRE RESOURCES

Mediterranean escapism in the Land of Aphrodite

Advancing the solar generation

F E AT U R E

MOELLER AEROSPACE

PACTIV EVERGREEN

VAN MOER LOGISTICS

On a trajectory of expansion, Batchfire Resources is the low-fugitive emission energy coal producer pursuing plans for Net Zero

Sustainability and innovation in food and beverage packaging

Gideon Burger, CEO of Axiology Labs discusses providing top quality laboratory products for life science solutions across Africa

quality laboratory products for life science solutions across Africa Gideon Burger, CEO of Axiology Labs discusses providing top

Innoquest Diagnostics is moving forward as one in pursuit of transformative healthcare. Ginny Foo, CEO, gives us the details

Donavan Hutchinson, MD of SHI UK, tells us how how organisations are being empowered to adapt to changing business models and workplace strategies

LTD RESOURCES SYRAH

transformative healthcare. Ginny Foo, CEO, gives us the details Innoquest Diagnostics is moving forward as one in pursuit of

empowered to adapt to changing business models and workplace strategies Donavan Hutchinson, MD of SHI UK, tells us how how organisations are being

brands and beverages Iconic and impactful

MOZAMBIQUE SABCO COCA-COLA

RESOURCES BATCHFIRE

From quaint fishing village to bustling resort getaway

EVERGREEN PACTIV

AEROSPACE MOELLER

RE S US

We go Behind the Lens with culinary storyteller, Karolina Wiercigroch

VALLARTA PUERTO From quaint fishing village to bustling resort getaway

gas turbine technology discovery in air travel and industrial Ascending to new heights of

beverage packaging innovation in food and Sustainability and

TRAVEL GUIDE

PUERTO VALLARTA

We go Behind the Lens with culinary storyteller, Karolina Wiercigroch

of modern infrastructure investment Expert Eye, Amanda Li, discusses the unsustainable nature

LOGISTICS MOER VAN

pursuing plans for Net Zero is the low-fugitive emission energy coal producer On a trajectory of expansion, Batchfire Resources

Charting cleaner waters for the Adriatic

Expert Eye, Amanda Li, discusses the unsustainable nature of modern infrastructure investment

leading sustainable logistics in Belgium Founder and CEO, Jo Van Moer, discusses

EV development on the map for global Putting Mozambique

YACHTING’S SUSTAINABLE REVOLUTION

Ascending to new heights of discovery in air travel and industrial gas turbine technology

Founder and CEO, Jo Van Moer, discusses leading sustainable logistics in Belgium

waters for the Adriatic Charting cleaner

REVOLUTION SUSTAINABLE YACHTING’S

GUIDE TRAVEL

F E AT U R E

solar generation Advancing the

Land of Aphrodite escapism in the Mediterranean

ENERGY LTD GENIE

CYPRUS GUIDE T R AV E L

diagnostics for Africa World-class medical

AFRICA LANCET CERBA

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European manufacturing Smooth cruising for

INHA WORKS

ZERELLA FRESH

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WELCOME FROM THE EDITOR

Fresh Off the Production Line

EDITORIAL Head of Editorial: Jack Salter jack.salter@outlookpublishing.com Editor: Lucy Pilgrim lucy.pilgrim@outlookpublishing.com Editor: Ed Budds ed.budds@outlookpublishing.com Junior Editor: Rachel Carr rachel.carr@outlookpublishing.com

It is my pleasure to introduce you to our inaugural issue

Junior Editor: Lauren Kania lauren.kania@outlookpublishing.com

PRODUCTION Production Director: Stephen Giles steve.giles@outlookpublishing.com Senior Designer: Devon Collins devon.collins@outlookpublishing.com Junior Designer: Louisa Martin louisa.martin@outlookpublishing.com Production Manager: Megan Cooke megan.cooke@outlookpublishing.com Digital Marketing Manager: Fox Tucker fox.tucker@outlookpublishing.com Web Editor: Oliver Shrouder oliver.shrouder@outlookpublishing.com Social Media Executive: Jake Crickmore jake.crickmore@outlookpublishing.com BUSINESS CEO: Ben Weaver ben.weaver@outlookpublishing.com

of Manufacturing Outlook – the new multi-channel brand launched by Outlook Publishing, bringing you the very latest developments from the manufacturing industry. Today, manufacturing organisations worldwide are confronting unprecedented change, embracing technological innovations, and incorporating critical environmental sustainability agendas. Therefore, now more than ever is the time to showcase the strides being taken throughout this dynamic realm in a dedicated, sector-specific title.

Managing Director: James Mitchell james.mitchell@outlookpublishing.com

The cover star of our first edition is Walkinshaw Group, a global leader in the

Chief Commercial Officer: Nick Norris nick.norris@outlookpublishing.com

design, engineering, development, and marketing of performance vehicles that

Regional Director: Joshua Mann joshua.mann@outlookpublishing.com

is working tirelessly to become Australia’s biggest automotive manufacturer.

HEADS OF PROJECTS Callam Waller callam.waller@outlookpublishing.com Deane Anderton deane.anderton@outlookpublishing.com Eddie Clinton eddie.clinton@outlookpublishing.com Josh Hyland josh.hyland@outlookpublishing.com Ryan Gray ryan.gray@outlookpublishing.com BUSINESS DEVELOPMENT DIRECTOR Thomas Arnold thomas.arnold@outlookpublishing.com TRAINING & DEVELOPMENT MANAGER Marvin Iseghehi marvin.iseghehi@outlookpublishing.com SALES AND PARTNERSHIPS MANAGER Donovan Smith donovan.smith@outlookpublishing.com

PROJECT MANAGERS Cameron Lawrence cameron.lawrence@outlookpublishing.com Dennis Morales dennis.morales@outlookpublishing.com Jack Belton jack.belton@outlookpublishing.com Jordan Levey jordan.levey@outlookpublishing.com Kierron Rose kierron.rose@outlookpublishing.com Kyle Livingstone kyle.livingstone@outlookpublishing.com Liam Pye liam.pye@outlookpublishing.com Nicholas Kernan nicholas.kernan@outlookpublishing.com Poppi Burke poppi.burke@outlookpublishing.com Taylor Green taylor.green@outlookpublishing.com ADMINISTRATION Finance Director: Suzanne Welsh suzanne.welsh@outlookpublishing.com Finance Assistant: Suzie Kittle suzie.kittle@outlookpublishing.com Finance Assistant: Victoria McAllister victoria.mcallister@outlookpublishing.com

CONTACT Manufacturing Outlook Norvic House, 29-33 Chapelfield Road Norwich, NR2 1RP, United Kingdom Sales: +44 (0) 1603 363 631 Editorial: +44 (0) 1603 363 655 SUBSCRIPTIONS Tel: +44 (0) 1603 363 655 jack.salter@outlookpublishing.com www.mfg-outlook.com Like us on Facebook: facebook.com/manufacturingoutlook Follow us on Twitter: @outlookpublish

Our exclusive interview with CEO, Ryan Walkinshaw, delves into the group’s strong racing pedigree as it combines to take on supercars through Walkinshaw Andretti United, in an alliance of both technical expertise and commercial prowess with two other global powerhouses of motorsport. “This exciting announcement sent chins wagging, as fans around the globe pondered what these three teams could potentially achieve together,” he tells us. From automotive to automation, we also learn about the solid reputation that AWC Incorporated has built as the authorised local sales, support, and service partner for leading manufacturers of automation and control systems across the US. The company’s position remains “to provide customers the indispensable support necessary to achieve their business goals in a safe and efficient manner,” explains CEO, Kirk Goins. At the forefront of environmentally-friendly steel production practices, meanwhile, is Makstil, a regional leader in the production of hot rolled heavy plates based in North Macedonia. A true example of the transition towards cleaner production processes, Makstil encapsulates the active change currently being undertaken in the European steel industry. “As steel is an industry that has historically been associated with large amounts of emissions, I am very happy to say that is now in the past,” states General Manager, Marija Dukovska-Pavlovska. With a multitude of other manufacturing success stories to be found throughout, from the likes of SAFE Boats International, BBS Automation, Aerosonic and more, we hope you enjoy the first of many issues to come. Jack Salter Head of Editorial, Outlook Publishing Manufacturing Outlook Issue 1 | 3

CONTENTS REGULARS

6 NEWS Around the Manufacturing sector in seven stories

8 EXPERT EYE 6

Elevating global manufacturing solutions

B U S I N E SS I N S I G H TS

10 Swap and Go Revolutionising road transport fleets

14 Believe the Hype The ultimate hypercar breaking boundaries

TO P I C A L F O C U S

18 Opening Doors for Future Makers Celebrating National Manufacturing Day 2023

MANUFACTURING OUTLOOK CONTENTS

F E AT U R E S

22 SHOWCASING LEADING COMPANIES

Tell us your story and we’ll tell the world

AS IA PACIFIC

24 Walkinshaw Group Hardwired Automotive Passion Driving in the DNA

38 BBS Automation Sustaining Cutting-Edge Solutions Forward-thinking automated assembly and testing systems

94 Aerosonic

128

Precision Flying At the forefront of air data systems

102 Leach International Corporation Power Distribution Prowess Designing and manufacturing missioncritical parts

EU R OP E A N D M I DD L E E AST

108 Makstil Transforming Traditional Industry

46 PWR Advanced Cooling Technology High-Performance Cooling World leaders in thermal management

Moving towards cleaner, greener European steel

120 Trymax Semiconductor Equipment B.V. When Plasma Matters The industry’s most trusted semiconductor partner

Steel plate manufacturing in the face of adversity

136 Vítkovice Steel European production of the most recyclable material in the world

The Pride of Australia Driving success for commercial vehicles

142 Höganäs Borgestad New Age Industry

NO RT H AMERICA

Sustainability-centric refractory products in European manufacturing

60 AWC Incorporated The Trusted Partner

150 Marelli

Passionate people winning together

Changing the Automotive Dynamic

74 SAFE Boats International

Transforming the future of mobility

You’re Going to Need a Safer Boat

AFRICA

Securing safety at sea

156 SIPH

86 Nortek Global HVAC Accessible heating and cooling for all

Steely Resilience

Perpetual Steel

52 JOST Australia

Making the World Breathe Easier

128 Metinvest Trametal

Conserving a Crucial Commodity

120

Spearheading African sustainable rubber production

Manufacturing Outlook Issue 1 | 5

NEWS

Around the manufacturing sector in seven stories…

NORD WAY FORWARD SECTOR

NORD DRIVESYSTEMS (NORD) is expanding its Polish site in Wiechlice. Tripling the size of one of its two locations, where the innovative IE5+ motor is produced, the company is extending the existing factory hall and installing a new geothermal system. Construction began in April 2023, and the extension is expected to be open in Q2 of 2024. The workforce of 220 employees will also significantly increase. NORD’s second Polish production site was only established in 2019 but already requires additional space. Demand for the IE5+ and other electric motors is increasing, making the original extension necessary.

INFLUENTIAL ANNUAL EVENT DUBAI WORLD TRADE Centre (DWTC) has announced that this year’s edition of Gulfood Manufacturing, the world’s most important food and beverage event, will occur from 7th to 9th November. It will bring over 2,000 exhibitors together, including the most prominent global food and beverage production brands, to fill 15 halls. The themes of artificial intelligence

(AI), robotics, and automation will feature heavily and explore how the digitalisation of the food and beverage manufacturing sector is spurring an evolution in efficiency. A focus area of this year’s event will be Dubai’s Green and Sustainable Manufacturing initiative. Attendance is free, and registrants will have access to all four events with a single pass.

BAYER CELL OUT BAYER HAS OPENED the first cell therapy manufacturing facility to advance regenerative medicines on a global scale. The 100,000 square foot (sqft) building advances Bayer’s sustainability efforts as it is the first fully electric plant in its pharmaceutical manufacturing network. The USD$250 million plant will help 6 | Manufacturing Outlook Issue 1

SECTOR

produce transformational cell and gene therapies and help break the industry-wide bottleneck in manufacturing capacity for regenerative medicine. The new cell therapy manufacturing facility is part of a transformation at the company’s dedicated biotechnology site in Berkeley, California, and it will supply the material required for late-stage clinical trials.

SECTOR

EPLAN FOR PARTNERSHIP

SECTOR

DIGITAL TRANSFORMATION IN manufacturing can only become a reality with networked systems, end-to-end data, and close cooperation between manufacturers. Subsequently, EPLAN founded the Partner Network in 2020, which currently has 65 manufacturers as members. One of the newer additions is the international technology company, Dassault Systèmes. Both parties have now entered into a technology partnership whereby, working together, the interface between the EPLAN platform and the

HAVING CREATED A bipedal robot named Digit, with a humancentric design, Agility Robotics (Agility) is now opening RoboFab, the first robot manufacturing facility to mass produce humanoid robots. The factory in the US state of Oregon will have the capacity to produce 10,000 robots annually. RoboFab will employ more than 500 workers at the new site alongside Digit, who will move, load, and unload totes, similar to its capabilities at Agility’s customer sites. Digit is designed from the ground up to go where people go and to do practical work safely in spaces meant for humans, and is expected to cost around USD$250,000.

FOURJAW TO THE MANUFACTURING FLOOR INTERNET OF THINGS (IoT) start-up FourJaw has secured £1.8 million to enhance its machine monitoring platform. The UK company is looking to boost productivity, sustainability, and profitability in the manufacturing industry. The platform acts as a fitness

THE SIX DIGIT DOLLAR MAN

Dassault Systèmes 3DEXPERIENCE platform will be expanded. The goal is to seamlessly integrate electrical engineering and fluid-power technology in the context of product development. SECTOR

tracker for machines, monitoring vital signs such as machine utilisation and energy usage. It is already used by 120 manufacturers worldwide in sectors ranging from aerospace and automotive to energy and food production. The funding will help FourJaw accelerate its vision to maximise manufacturing productivity across the globe, according to co-Founder and CEO, Chris Iveson, which in turn will help elevate lives, communities, and society.

SECTOR

BRUDERER PRESSING ON WITH NEW FACILITY THE WORLD-LEADING MANUFACTURER of high-speed presses, Swiss-based Bruderer, is opening a new state-of-the-art, 48,000 sqft factory and showroom in Shropshire. This reinforces its 55-year commitment to the UK by announcing the significant investment in the Hortonwood site – a stone’s throw away from the industrial revolution. Construction work on the bespoke facility started this month. It will include a dedicated competence centre capable of servicing new and pre-owned machines, restoring legacy presses, and a modern showroom with new models, ancillary equipment, and turnkey solutions. Manufacturing Outlook Issue 1 | 7

DRIVING THE PRODUCT LIFECYCLE FORWARD As greater global demand creates a pressure to produce products quickly, Hooi Tan, President of Global Operations and Supply Chain for Flex, explains how advanced manufacturing technology helps shorten time to market Written by: Hooi Tan, President of Global Operations and Supply Chain, Flex

ransforming an idea into a product is complicated, so doing it on a large scale is a huge challenge. From ideation to prototyping, engineering, assembly, reverse logistics, and everything in between, mass manufacturing is a complex process. However, according to the most 8 | Manufacturing Outlook Issue 1

recent Eurostat data, production of manufactured goods continues its upward trend with a five percent increase in 2022, following an eight percent increase in the previous year. Similar trends span the globe, with consumer spending and interest in durable goods increasing in many countries, especially during busy seasons. Surprisingly, it’s not just consumer demand that’s making an impact; the COVID-19 pandemic showed how quickly health systems can request highly regulated medical devices like ventilators and oxygenisers. To keep up with the increasing demand, manufacturers are accelerating time to market with quicker ramps, less waste, and greater efficiency. However, this task becomes even more challenging for certain product categories. The product life cycle for consumer goods is already short, with rapid changes happening annually and

sometimes even monthly. While highly regulated industries, such as medical and automotive, move slower, they are also in high demand. Many leading manufacturers are investing in Industry 4.0 technologies to address these challenges and help create smart, efficient, and sustainable factories. For organisations looking for support in every facet of the product life cycle, there are some ways advanced manufacturing technology can help.

INNOVATE AND IDEATE Turning a vision into a viable product requires a mix of art and science. Before moving forward, organisations need to consider design plans, production strategy, and materials. Simulation and modelling technology are two innovations that can help check for product viability and potential pitfalls during these early stages. By modelling

EXPERT EYE FLEX

Additionally, the use of additives enables teams to quickly test the design before it goes into mass production, where potential errors can be detrimental.

BUILD, PRODUCE, AND DELIVER

and simulating the product virtually, organisations can improve on the time and money required to build and test the product in the real world. This type of innovation can also help identify high-risk components or parts before a product even exists. The next step is to shorten the time to market with a working prototype. This step requires the right mix of know-how, advanced software, and production capabilities. Additive manufacturing solutions have become incredibly important in this stage. Rather than leveraging legacy production solutions, which often require the removal of materials through milling, carving, or other means, additive manufacturing enables engineers to quickly create a prototype leveraging computeraided design (CAD) software or 3D object scanners. 3D printing and rapid prototyping serve as an incredibly cost-effective and fast way to deliver a product in its first tangible form.

Once a product is ready for prime time, the factory must be too. Ensuring a facility is using the latest automation and digitisation solutions can reap massive benefits in the long run. Smart automation and robotics can help streamline repetitive assembly tasks, reduce variability, and lower the possibility of errors, while increasing safety and freeing up human workers for more valuable work. These machines can also exchange information using machineto-machine (M2M) communications to improve coordination, thereby boosting performance, lowering downtime, and raising productivity while reducing costs. With production running at full steam, organisations come to the final leg of the product journey, where the focus shifts to fulfilment, distribution, logistics, and aftermarket support. At this stage, keeping up with constantly changing dynamics, shortages, and repairs can be one of the more complex steps. Real-time visibility in transport networks, orders, and returns becomes paramount at this stage; therefore, a strong digitisation plan is fundamental. Distributed digital technologies are used by leading manufacturers to act as a 24/7 decision-making system on factory floors around the world. These systems can integrate feeds from various sources, including factory machines, supply chain feeds, and even global news media, turning insights into actions to navigate a crisis. While this overview provides a high-level snapshot of what it takes to create a product at scale, it is not

always this simple, as challenges can pop up on any line at any time. Industry 4.0 technologies represent a much-needed step forward that helps alleviate costly mistakes that can delay production. However, the real importance will always be the knowledge of the workers and managers on the factory floor. Technologies can free up time, increase safety, and improve decisionmaking. Still, it’s the real-time, humanlevel problem solving that drives the most value and ensures that deadlines are met, products are produced, and contracts are fulfilled.

ABOUT THE EXPERT Hooi Tan is President of Global Operations and Supply Chain at Flex, the manufacturing partner of choice that helps a diverse customer base design and build products to improve the world. In his role, he is focused on scaling Flex’s manufacturing excellence through leading-edge, advanced manufacturing capabilities to drive quality, efficiency, and productivity for the company. Tan has held many leadership roles in his 22 years with Flex, including Senior Vice President of Global Operations, running more than 130 facilities across 30 countries and ensuring a safe and healthy work environment for all. Prior to Flex, he worked at Solectron, an electronics manufacturing company for original equipment manufacturers (OEMs). Over his career, he has held a variety of leadership roles in operations, programme management, business development, and government affairs.

flex.com

Manufacturing Outlook Issue 1 | 9

Janus Electric’s next-generation exchangeable batteries are revolutionising road transport fleets. Lex Forsyth, CEO, informs us about this breakthrough technology Writer: Jack Salter

A Lex Forsyth, CEO, Janus Electric

10 | Manufacturing Outlook Issue 1

technology breakthrough that utilises existing electrical infrastructure has created a world-first zero-carbon solution to electrify road transport fleets in Australia. This ground-breaking battery technology has been developed by Janus Electric (Janus), dedicated to providing Australian road transport businesses with a smarter, safer, and cleaner alternative. “We identified a need for the electrification of heavy vehicles and

established that the batteries need to be exchangeable. Hence, the Janus solution was born,” opens CEO, Lex Forsyth, who launched Janus in 2020 together with fellow co-Founder, Bevan Dooley. Aiming to electrify the trucking industry, Janus has developed a patented exchangeable battery system that negates the need for lengthy recharge times. As the company’s revolutionary batteries are exchangeable, they are not permanently fixed to the truck

JANUS ELECTRIC ENERGY & UTILITIES

Swap and Go and can therefore be removed and charged in just four minutes at any Janus Charge & Change station. “With most plug-in vehicles, you have to wait for the vehicle to charge, whereas with the Janus solution, you just swap the battery and keep moving; that’s the key difference,” Forsyth states. Utilising renewable energy sources such as solar, wind, and hydro, Janus’ Charge & Change stations provide a three-way system – grid to battery, battery to battery, and battery to grid. This creates demand for renewable energy during the day and means better utilisation of the national electricity grid, offering utility

providers and governments a significant return on green technology infrastructure. It also enables renewable energy to be fed back into the grid, minimising surges and outages. “Our Charge & Change stations act as a battery energy storage system, so you’re able to use the battery that’s in the station as a microgrid to help support infrastructure, logistics parks, and grid-style assets,” explains Forsyth.

CONVERTING EXISTING FLEETS The impossible has been made possible by Janus, as the company

can convert prime movers from existing fleets into electric vehicles (EVs). Janus converts diesel engine trucks due for a rebuild or replacement with a new electric motor, at a cost comparable to rebuilding an existing diesel motor. “Existing vehicles already produced for fleets can be reutilised by replacing diesel engines with electric motors,” Forsyth outlines. The daily management of operating costs and margins is at the core of every transport and logistics business. Fleet electrification will revolutionise existing operating costs and deliver significant, proven savings to the Manufacturing Outlook Issue 1 | 11

JANUS ELECTRIC ENERGY & UTILITIES

bottom line over a vehicle’s lifetime. It’s estimated that converting existing diesel-powered trucks to Janus’ technology can reduce maintenance and operating costs by up to 70 percent over the vehicle’s lifespan, therefore significantly reducing the need for capital investment in completely new EVs. Indeed, electrification means no oil changes, oil filters, air filters, or fuel filters, whilst reduced levels of heat extend the life of brakes and tyres. Operationally, fleets are also cheaper to run as the cost of electricity per kilometre (km) is cheaper than diesel. “The environmental benefits are simply a by-product of the solution. It’s about how we put returns back into logistics supply chains, increase their margins, reduce their operating costs, and still give them the same efficiencies that they experience with their current vehicles,” emphasises Forsyth. Fleet owners are also not locked into one type of battery cell, such as lithium-ion, as Janus’ batteries have been created to be fully upgradable with emerging technologies.

EXPANDING PRODUCTION In Melbourne, the company recently converted seven trucks for Cement Australia to the Janus solution, the last of which was delivered in August 2023. Another converted truck belonging to Janus’ long-standing customer, Fennell Forestry, has now travelled in excess of 42,000km and completed around 180 battery swaps. It’s undeniable proof of where the technology is going, and very shortly, Janus will also have the world’s largest electric truck operating for Qube which is capable of hauling up to 175 tonnes. “We have trucks heading to California into the ports of Los Angeles and Long Beach with a customer that has come on board there, and we’ve a lot of enquiries coming out of New 12 | Manufacturing Outlook Issue 1

Lex Forsyth, CEO, test driving an electric truck

OZ Minerals electric truck trial event with Janus Electric and Qube crews

“ W I T H M O S T P L U G - I N V E H I C L E S , Y O U H AV E T O WA I T F O R T H E V E H I C L E T O C H A R G E , WHEREAS WITH THE JANUS SOLUTION, Y O U J U S T S WA P T H E B AT T E R Y A N D K E E P M O V I N G ; T H AT ’ S T H E K E Y D I F F E R E N C E ” – LEX FORSYTH, CEO, JANUS ELECTRIC

Zealand, Mongolia, South Africa, and other regions,” notes Forsyth. With the UK and Europe equally starting to show a lot of interest, Janus is expanding production and looking to roll out a further 30 electric trucks by June 2024 in Australia as well as the US. “It’s about where we position the

business and open up production and conversion centres in key locations and areas across the world,” Forsyth concludes.

www.januselectric.com.au

SUBSCRIBE NOW TO THE DIGITAL MAGAZINE

A production-line of exclusive content, delivered straight to your inbox Building on the global success of its regional titles – Africa Outlook, EME Outlook, APAC Outlook, and North America Outlook – Outlook Publishing is proud to introduce a digital magazine and web platform dedicated to the manufacturing sector. As manufacturing organisations worldwide confront unprecedented change, embracing technological innovations and incorporating critical environmental sustainability agendas, now more than ever is the time to showcase the strides being taken in this dynamic sector. A multi-channel brand, Manufacturing Outlook brings you the positive developments driven by organisations across the global manufacturing industry through its various platforms. Discover exclusive content distributed through our website, online magazine, social media channels, and dispatches delivered straight to your inbox with a bi-weekly newsletter. Through this compelling new venture, we foreground the movers and shakers of the industry. To participate as a featured company and join us in this exciting endeavour, contact one of our Project Managers today.

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ASTON MARTIN FEATURE

Aston Martin is geared up to enter the 24 Hours of Le Mans in 2025 with a prototype of the Valkyrie, which is set to become the first hypercar to simultaneously compete in both of endurance racing’s most prestigious series Writer: Jack Salter

BELIEVE T P

erformance is the driving force behind Aston Martin, and motorsport is the ultimate expression of this pursuit of excellence. Harnessing the emphatic, breathtaking performance that Aston Martin is known for is the Valkyrie – the definitive hypercar. Supported by Heart of Racing (HoR), Aston Martin’s invaluable championship-winning endurance 14 | Manufacturing Outlook Issue 1

racing partner raising money for Seattle Children’s Cardiology Research Fund, at least one Valkyrie will be entered into the Hypercar class of both the FIA World Endurance Championship (WEC) and the IMSA WeatherTech SportsCar Championship (IMSA). As a result, the prototype will participate in three of the most prestigious events in sportscar racing – the 24 Hours

THE HYPE of Le Mans (Le Mans), the Rolex 24 at Daytona (Rolex 24), and the 12 Hours of Sebring (Sebring). When a racing prototype of the Valkyrie carries Aston Martin into the fight for victory at Le Mans, it will take on the challenge it was born for and return the iconic ultraluxury British sports car manufacturer to the pinnacle of endurance racing.

ANNIVERSARY ANNOUNCEMENT

This year marked the 100th anniversary of Le Mans, a century on from the inaugural running of the world’s greatest endurance race in 1923. The Aston Martin name is synonymous with endurance racing glory, with the brand’s Le Mans debut coming in 1928, just five years after the race was first run. Manufacturing Outlook Issue 1 | 15

Since then, cars adorned with the famous wings of Aston Martin have clinched no less than 19 class victories at Le Mans, including overall triumph in 1959 with the iconic DBR1. Over the past 95 years, more than 240 drivers have raced for Aston Martin at Le Mans in 27 different chassis and engine combinations through virtually every era. No other venue has given Aston Martin as much success as Le Mans, and just as the world-famous event is celebrating a milestone year, 2023 likewise marks the 110th anniversary of the iconic car manufacturer. It therefore made perfect sense to announce the brand’s return to the world’s greatest endurance race for the first time since 2011, with the most potent hypercar ever devised.

PROTOTYPE VERSION Originally designed and developed to meet Le Mans Hypercar (LMH) regulations, Aston Martin Performance Technologies (AMPT) has begun the task of developing and homologating a prototype version of the Valkyrie for racing within a pre-defined aerodynamic and power performance window. AMPT is situated in the newly built AMR Technology Campus, co-located with the Aston Martin Aramco Cognizant Formula One Team headquarters in Silverstone. The complex knowledge base that Aston Martin is building through its Formula One team can likewise be harnessed by AMPT to further enhance the capabilities of the Valkyrie. A race-optimised carbon fibre chassis and a modified 6.5-litre naturally aspirated V12 Cosworth engine will be used by the hypercar, which as standard produces over 1,000 brake horsepower. To incorporate the critical Balance of Performance (BoP) requirements of the Hypercar class, the Cosworth power unit will be further enhanced and developed to withstand the

ASTON MARTIN FEATURE

relentless rigour of long-distance endurance racing. HoR will spearhead both of Aston Martin’s WEC and IMSA programmes once the Valkyrie has been homologated, as it becomes the first purebred hypercar to participate in both championships and the only one among its rivals whose origins can be traced back to an existing production car. Having earned Aston Martin’s first IMSA GT Daytona (GTD) class championship title in 2022, HoR recorded the brand’s maiden class victory in this year’s Rolex 24 and finished seventh on its Le Mans debut in June. With big ambitions in endurance racing, it’s the right time for HoR to make the step into WEC and IMSA’s top classes and compete for honours.

COMPETING AT ALL LEVELS The Valkyrie’s entry into the Hypercar class ensures that Aston

Martin will have a presence in all aspects of endurance racing. Not only that, but following the additional announcement of Aston Martin’s commitment to building and preparing all-new GT3 and GT4 cars, it will also be the only manufacturer competing at every level of sportscar

and GT racing (from Hypercar to GT4) and the FIA Formula One World Championship. Taking Aston Martin back to the top tier of sportscar racing, the Valkyrie has the potential and performance capabilities to compete alongside benchmark machinery in its class. Doing so in cooperation with a proven championship-winning operation such as HoR provides a competitive platform for Aston Martin. As the only hypercar in the class with direct synergies to its road car counterpart, the Valkyrie is a fascinating concept that was always destined to break boundaries. Now, Aston Martin has the chance to demonstrate what this impressive feat of engineering can achieve on the track.

Manufacturing Outlook Issue 1 | 17

O DOO F M

18 | Manufacturing Outlook Issue 1

TOPICAL FOCUS NATIONAL MANUFACTURING DAY 2023

OPENING ORS FOR FUTURE MAKERS

Manufacturing is one of the UK’s most diverse and crucial industries. Guy Opperman, UK Minister for Employment, and Stephen Phipson, CEO of Make UK, highlight how National Manufacturing Day 2023 celebrates and cultivates job opportunities Writer: Lucy Pilgrim

Photographed as part of National Manufacturing Day, championed by Make UK

or centuries, the manufacturing industry has been a significant indicator of modernisation. Indeed, the Industrial Revolution that took place in the 1700s heralded a new age of manufacturing, and by the 19th century, the UK had become known as the workshop of the world, due to its dominance in international trade as the world’s largest manufacturer. Today, the UK manufacturing industry spans a vast range of sectors, steadily increasing by 1.4 percent every year since 1948, sparking a transition from low to highproductivity goods, advancements in automation and technology, and producing a highly-skilled workforce. Held in September, the mission of this year’s National Manufacturing Day (NMD) was to bolster the many available employment opportunities, as the celebration called upon jobseekers to consider the valueadded benefits of this vital industry. Manufacturing Outlook Issue 1 | 19

TOPICAL FOCUS NATIONAL MANUFACTURING DAY 2023

Photographed as part of National Manufacturing Day, championed by Make UK

First established by Make UK in 2022, NMD showcases the best of British manufacturing, as businesses across the UK present a range of proficient job opportunities across hundreds of factory sites, celebrating a plethora of manufacturing sectors such as automotive, food and beverage, aerospace, defence, medicine, chemical, and more. Businesses that took part in this year’s NMD include Lush, RNLI Lifeboats, and Siemens, who all opened their doors to let the general public take a peek behind the scenes and witness the multitude of options available for career development. “This is a really exciting day where the whole manufacturing sector comes together to celebrate the innovative things Britain designs and makes,” Stephen Phipson, CEO of Make UK states. “Our companies are at the forefront of global renewable technology 20 | Manufacturing Outlook Issue 1

“ T H E M A N U FA C T U R I N G S E C T O R I S A K E Y P A R T O F O U R P L A N T O G R O W T H E E C O N O M Y, D R I V I N G I N N O VAT I O N A N D P R O D U C T I V I T Y ” – G U Y O P P E R M A N , U K M I N I S T E R F O R E M P LOY M E N T

development and some of the most groundbreaking engineering developments seen anywhere in the world.”

THE KEY TO GROWTH At this year’s NMD, the UK Minister for Employment, Guy Opperman, called upon employers in the manufacturing industry to take advantage of the free support available from Jobcentre Plus, as it is key to accelerating the UK economy. In fact, manufacturing is one of the most significant growth areas which the government has committed to supporting in job creation, as it aims

Photographed as part of National Manufacturing Day, championed by Make UK

TOPICAL FOCUS NATIONAL MANUFACTURING DAY 2023

to strengthen the UK’s competitive advantage in the global market. “Manufacturing is a key part of our plan to grow the economy, driving innovation and productivity as well as playing a vital role in upskilling and futureproofing the UK workforce,” Opperman comments. To further build the national sector, the government has engaged in programmes such as Made Smarter, the Aerospace Technology Institute (ATI), and the Automotive Transformation Fund (ATF). Indeed, the government pledged £350 million to the ATF in accordance with its 2021 Net Zero Strategy. Alongside this, the government has also announced £500 million of funding in the 2020 Ten Point Plan, to support the creation of an internationally competitive electric vehicle (EV) supply chain, further stimulating growth. “I am proud of the Department of Work and Pensions’ (DWP) record of linking firms up and down the country with jobseekers looking to move into the sector. I encourage both employers and individuals to reach out to their local Jobcentre Plus teams to make the most of the opportunities and talent in their areas,” Opperman adds.

BUILDING OPPORTUNITY FOR ALL To commemorate NMD 2023, employers and local manufacturing

Photographed as part of National Manufacturing Day, championed by Make UK

businesses held tours and programmes for all ages and abilities. One particularly engaging scheme managed by Jobcentre Plus is the Sector-based Work Academies Programme (SWAP), which provides trainees with comprehensive fasttrack training to learn new skills and obtain relevant work experience, as well as offering the opportunity of a job interview with the employer at the end of the programme. Therefore, NMD is a catalyst for positive change in the industry, as it places the multitude of diverse job opportunities at the fore, whilst nurturing and influencing the next generation of innovative British manufacturers.

THE UK MANUFACTURING INDUSTRY – FACTS AND FIGURES •

2.5 million jobs created

•

Provides 12 percent higher wages than the rest of the UK economy

•

Goods produced comprise 51 percent of the UK’s total exports

•

UK ranked 10th in the world for export of goods

•

15 percent of total UK business investment

Manufacturing Outlook Issue 1 | 21

Tell us your story and we’ll tell the world MANUFACTURING OUTLOOK is a quarterly digital publication and media brand showcasing the latest innovations, industry insights and corporate stories from across the international manufacturing sector. Its world-class team collaborates with the biggest and most exciting brands to craft engaging and authoritative content for a global audience of industry players. As manufacturing organisations worldwide confront unprecedented change, embracing technological innovations and incorporating critical environmental sustainability agendas, now more than ever is the time to showcase the strides being taken in this dynamic sector. The expertise of our in-house design and production teams ensures delivery to the highest standards, as we look to promote the latest in engaging news, industry trends and success stories from the length and breadth of the global manufacturing sector. As a multi-channel brand, Manufacturing Outlook reaches an international audience through various platforms, with exclusive content distributed through our website, online magazine, social media channels, and bi-weekly newsletter. Through this compelling venture, we intend to foreground the movers and shakers of the industry. To participate as a featured company and join us in this exciting endeavour, contact one of our Project Managers or our Managing Director, James Mitchell, today.

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WALKINSHAW GROUP ASIA PACIFIC

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Issue 1

WALKINSHAW GROUP A global leader in the design, engineering, development, and marketing of performance vehicles

H A R DW I R E D AU TO M OT I V E

PA S S I O N

Utilising its first-class expertise, Walkinshaw Group is a global leader in the design, engineering, development, and marketing of performance vehicles, with significant motorsport interests in Australia and the UK. We learn more with CEO, Ryan Walkinshaw Writer: Ed Budds | Project Manager: Thomas Arnold

I think the biggest misconception about the Australian manufacturing industry in 2023 is that it doesn’t exist, which is simply incorrect.” The defiant opening statement from Ryan Walkinshaw, CEO of Walkinshaw Group (Walkinshaw), perfectly encapsulates the prominent standing of the company, as it has worked tirelessly to become Australia’s biggest automotive manufacturer and second-largest caravan manufacturer. More broadly, it also highlights the often-underrated strength of the nation’s vast manufacturing industry. “A huge portion of what we manufacture internally or source through our range of suppliers is made in Australia,” he affirms. Growing up at racetracks around the world meant that an incredibly strong connection with the automotive and racing industry was forged for Ryan at an early age. “Racing and the process of creating automobiles has always been a great passion of mine. When my father passed away in 2010, I took over the business in Australia at the ripe age of 22 years old, and here we are today, 13 years later.” Today, Walkinshaw is headquartered in Clayton, Victoria, producing over 12,000 vehicles per year. The business encompasses five key areas: Walkinshaw Automotive Group, the automotive manufacturing arm, which also offers manufacturing and engineering options outside of the automotive industry; Walkinshaw Performance, which deals with the company’s high-performance products; New Age Caravans, the second largest caravan business in Australia; Walkinshaw Sports, a key golf and sporting goods distribution company that works with some of the biggest brands in the industry; and finally, the company’s racing team, Walkinshaw Andretti United, who competes in the top level of Australian motorsport, the Supercars Championship. Manufacturing Outlook Issue 1 | 25

Marija Dukovska-Pavlovska, General Manager of Makstil, speaks about the company’s environmentally-friendly steel production practices

www.mfg-outlook.com/work-with-us

Marketi ng Oppo rtunity

H A R DW I R E D AU TO M OT I V E

PA S S I O N

WALKINSHAW GROUP ASIA PACIFIC

HISTORY OF SHAMIC SHEETMETAL Shamic Sheetmetal (Aust) Pty Ltd commenced operations in 1978 as a fully Australian-owned and managed small family business, manufacturing sheet metal products. Under the leadership of Managing Director, Eric Woodgate, the company quickly gained a reputation for manufacturing high-precision and high-quality sheet metal bracketry and parts for a range of customers, from small producers to large national and multinational companies in various sectors including automotive, telecommunications, racking, rolling stock, industrial lighting, electrical cabinets, and much more. In 1985, we began manufacturing wood heaters. We acquired the rights to a range of well-known heater brands between 1998 and 2001. Gas heaters were added to the range in 2001. In 1998, the company moved to larger, purpose built premises in Croydon South, Victoria, and since that time has developed into a modern, computerised sheet metal and home heating manufacturing and warehousing facility. We now manufacture and distribute the full range of HeatCharm, Arrow and Coonara wood and gas heaters in all states through a network of over 150 distributors.

WELCOME TO OUR FAMILY Shamic Sheetmetal (Aust) Pty Ltd is an ISO 9001 certified manufacturer of specialised sheet metal components and products for leading businesses around the country, a noteworthy case being Shamic Sheetmetal’s long-standing relationship with Walkinshaw Group across 25 years of manufacturing automotive components for their range of vehicles.

inbuilt and freestanding gas log fires which have a 4.6 to 5.1 energy star rating. Our heating products are available through a national network of over 150 authorised retailer stores. Our commitment to quality, research, design and the latest production innovations across sheet metal and heating products has seen Shamic Sheetmetal (Aust) Pty Ltd sustain its growth and development. We have been listed as a TOP 500 Victorian private company and we take pride in being an Australian-owned and managed company using state-of- the-art automated machinery to produce top-class quality steel components at globally competitive price points.

Our clients benefit from having a highly automated, local manufacturing partner and supplier with the experience to understand their needs and flexibility to meet specific requirements and make timely changes, as required. We utilise the latest advances in integrated design and manufacturing technology across our manufacturing services that include CAD design, automated CNC punch and laser cutting, automated NC folding, robotic and manual welding, paint and powder coating, modern warehousing and despatching functions. As well as being a world-leader in sheet metal manufacturing, Shamic Sheetmetal is a market leader in wood and gas home heating and we offer an unparalleled range of stylish heaters in colours to suit any decor and home heating requirement. Our industry certified indoor gas heaters offer up to a 5- star energy rating with powerful heat output and our wood heaters are fully tested to Australian standards for power output, efficiency, and emissions. Along with the Hermitage, Mystique, and Chateau, our recent innovations include the Mosman and Yarra linear gas heater, and Royal

sales@shamic.com.au | shamic.com

WALKINSHAW GROUP ASIA PACIFIC

Ryan Walkinshaw, CEO (back row, second from right) with the Walkinshaw team

In total, Walkinshaw employs over 1,200 people across the entire group, which continues to grow year-onyear. “Without oversimplifying it, our people and our legacy continue to set us apart,” acclaims Ryan. “We have a fantastic mix of experience in our business, some of our employees have spent decades here, and others have experience in the broader industry, whilst we also have the strength of youth coming through,” he sets out.

WALKINSHAW’S WORLD-CLASS VALIDATION Australian driving conditions are widely recognised by many original equipment manufacturers (OEMs) as some of the toughest in the world. To directly counter the harsh terrain, Walkinshaw has developed the world’s best practice automotive design validation (ADV) procedures that deliver ultimate durability and reliability to its customers. The company’s ADV plans are developed to ensure the simulated, physical component level, and vehicle level testing is strategically timed to ensure that learnings are carried into subsequent phases of development. Walkinshaw’s full vehicle level testing facilities are state-of-the-art, with its in-house structures lab housing a full vehicle shaker rig.

MOTORING TO SUCCESS Walkinshaw’s automotive business has rapidly evolved in recent memory, as the company is successfully becoming a highly diverse operation 28 | Manufacturing Outlook Issue 1

This shaker rig can be used for vibration testing of individual components all the way up to sub-assemblies and the full vehicle, to ensure that products are at the correct standards of endurance and safety.

Creating a Home Away From Home Designed for your next adventure

WALKINSHAW GROUP ASIA PACIFIC

1,000th Chevrolet Camaro built

“WHEN HOLDEN CLOSED, THE EASY THING F O R U S T O D O W O U L D H AV E B E E N T O F O L L O W S U I T A N D T U R N T H E L I G H T S O F F, B U T I N S T E A D , O U R H U G E LY TA L E N T E D A N D T E N AC I O U S WO R K FO R C E H AS R E I N V E N T E D W H AT W E D O ” – R YA N WA L K I N S H AW, C E O , WA L K I N S H AW G R O U P Ryan Walkinshaw, CEO

that works with a range of OEMs around the globe. The company was built off the back of Holden Special Vehicles (HSV), working with a single OEM in Holden, creating its core range of aspirational, high-performance vehicles. “When Holden closed, the easy thing for us to do would have been to follow suit and turn the lights off, but instead, our hugely talented and tenacious workforce has reinvented what we do,” recalls Ryan proudly. On the automotive front, the 30 | Manufacturing Outlook Issue 1

company is currently working with five OEMs, including General Motors, Toyota, and Volkswagen, with more to come in the future, as well as operating across a number of industries and projects that Walkinshaw never would have considered possible five years ago. This progression has not only reinvented what the company does, but it has simultaneously helped Walkinshaw to truly thrive within the industry. This reinvention was kickstarted through the remanufacturing of large American trucks, from

left-hand drive to right-hand drive, with the company subsequently expanding much further. “For context, in the largest HSV production year in 2008, we produced just under 5,000 units with 450 staff. Last year alone, we did over 12,000 units amongst our 1,200 staff, with projections indicating that number will again rise by the end of this year,” he shares. In this way, the company continues to bring exciting products to market, which is core to Walkinshaw’s central beliefs and values.

MASTERS IN MANUFACTURING Walkinshaw’s business has now successfully pivoted to a contract manufacturing and engineering company for multiple customers. “We can apply our whole organisation’s expertise and experience to help deliver first-class results for our customers, as is evident most recently with our success and growth in the full-size truck market,” Ryan tells us. “We look forward to helping our customers continue to grow, and to further invest in our community by providing more employment opportunities,” he adds. Over the years, this has diversified into the realms of off-road vehicles, performance light commercial vehicles, full-size commercial vehicle remanufacturing, and caravans. Now, the company’s expert team 32 | Manufacturing Outlook Issue 1

“ W I T H O U T O V E R S I M P L I F Y I N G I T, O U R P E O P L E A N D O U R L E G ACY CO N T I N U E TO S E T U S A PA R T ” – R YA N WA L K I N S H AW, C E O , WA L K I N S H AW G R O U P

of 65 across engineering, computeraided design (CAD), and fabrication also support external services. These services cover, but are not limited to, simulated structural testing utilising finite element analysis (FEA), structural component testing in the fully-equipped structures lab, and ground-up design, development, and validation of all automotive components across mechanical, electrical, and software systems. “We have a core group of experts who specialise in all disciplines across the automotive component

spectrum. Their experience brings innovative solutions to complex problems and a ‘never say die’ attitude when tasked to deliver on tight deadlines.” At present, Walkinshaw’s expertise in design, simulated testing, and physical testing for the world’s best practices is unmatched in the southern hemisphere. “The company’s engineers share a passion for automotive engineering. They love what they do, and it shines through in every faction of their work,” Ryan enthuses.

WALKINSHAW GROUP ASIA PACIFIC

Empowering Australian manufacturers since 1984.

TCL Hofmann is a provider of best-in-class additive manufacturing equipment, materials and services to the design, engineering, medical and manufacturing industries. Our end-to-end solutions encompass the full suite of metal, polymer and ceramic technologies and materials from leading global manufacturers.

P: (03) 8586 2900 | E: sales@tclhofmann.com.au www.tclhofmann.com.au | www.tclh3dprinting.com.au

PROUDLY SUPPORTING LOCAL MANUFACTURING. NAPA Auto Parts provides a comprehensive range of automotive aftermarket products for all types of vehicles, to keep your workshop moving. For more information visit napaparts.com.au

Manufacturing Outlook Issue 1 | 33

WALKINSHAW GROUP MANUFACTURING

From left to right: Zak Brown, CEO of McLaren Racing, Michael Andretti and Ryan Walkinshaw

“ W E W E R E T H E FA C T O R Y H O L D E N R A C I N G T E A M F R O M 1 9 9 0 R I G H T T H R O U G H TO 2 0 1 6 , B U T M U C H L I K E T H E AU TO M OT I V E B U S I N E S S , W E H A D T O R E T H I N K H O W W E O P E R AT E D W H E N HOLDEN CLOSED” – R YA N WA L K I N S H AW, C E O , WA L K I N S H AW G R O U P

STRONG RACING PEDIGREE What is now an esteemed racing history in Australia started when Ryan’s father came to race in Bathurst, New South Wales (NSW) with his TWR Jaguar XJS, and he loved the place so much that the company has been present there ever since. Furthermore, racing is in the very DNA of Walkinshaw as a business. “We were the factory Holden Racing Team from 1990 right through to 2016, but much like the automotive 34 | Manufacturing Outlook Issue 1

business, we had to rethink how we operated when Holden closed,” Ryan recollects. “Of course, we could have packed up the team and moved away from racing, but that’s not what we do.” In 2018, Walkinshaw Andretti United was born, combining Walkinshaw Racing, Andretti Autosport through Michael Andretti, and United Autosports through Zak Brown. Racing relates closely to each company and reflects everything that

Walkinshaw does, encompassing innovation, technology, and high performance. To date, Walkinshaw Andretti United has had eight Bathurst 1,000 wins and eight Supercars Championship drivers’ titles across its storied history. With nearly three decades of experience and a wide range of in-house capabilities and expertise, the company’s racing business can provide its clients with exactly what is required to compete and win.

WALKINSHAW GROUP ASIA PACIFIC

Mercury Mufflers has been the trusted name in Mufflers, Exhausts and Accessories for over 70 years • Mercury Mufflers is an Australian-owned and operated company established in 1951 • We are the Australian manufacturers of the Outlaw Performance Exhaust • We specialise in the manufacture of Performance Exhaust Systems and the conversion of left-hand drive automotive components to right-hand drive for aftermarket and original equipment • Nationwide coverage with branches in QLD, NSW, VIC and WA distributing a full range of automotive exhaust products and accessories • National distributor for Trailboss Towbars

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WALKINSHAW GROUP ASIA PACIFIC

Walkinshaw’s initial venture into the vast sports business started out in golf product distribution, and has grown rapidly. Having worked with some of the biggest and most recognisable brands in the world, while additionally manufacturing bespoke products such as golf buggies and balls, the company is now expanding into other sporting sectors. “Our roots as a company are in high-performance, which applies perfectly across these industries,” Ryan affirms.

THREE ICONIC ORGANISATIONS The three organisations that bring together Walkinshaw Andretti United cover the entire globe, with Walkinshaw Racing based in Australia, Andretti Autosport in the US, and United Autosports in Europe. The diverse pedigree they all bring is unrivalled in Australia. From Bathurst 1000 and Indy 500 wins to Supercars Championship and Global Rallycross titles, their respective motorsport résumés are more than impressive. Now, they have combined to tackle

Australia and take on the mission of supercars. The announcement unveiling Walkinshaw Andretti United took place at the most iconic circuit in Australia, Bathurst, on the eve of the biggest race of the 2017 season, the Bathurst 1000. “This exciting announcement sent chins wagging, as fans around the globe pondered what these three teams could potentially achieve together,” Ryan comments. Naturally, it didn’t take long for the

WALKINSHAW GROUP ASIA PACIFIC

+61 3 9703 2626 info@hispecgroup.com.au www.hispecgroup.com.au

Tell us your story and we’ll tell the world

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first win to be achieved through Scott Pye’s famous victory at the Australian Grand Prix, with five further podiums coming in the first season. “This partnership is not only beneficial on the track, but off it as well. Andretti Autosport brings a wealth of technical knowledge and experience across a broad range of categories and cars, while Zak Brown, the co-owner of United Autosports alongside Richard Dean, is also the CEO of the McLaren Formula 1 team,” he continues. Brown is now universally regarded as one of, if not the, best commercial operators in motorsport.

DESIGNED TO PERFECTION Elsewhere within the company, Walkinshaw Design has a rich history of delivering world-class, niche products and always strives to transform its clients’ visions into reality. “We put our customers at the centre of our design process, collaborating with our clients to

A specialist manufacturer of fluid carrying products. Our range includes brake, AC, water, air, oil and fuel pipe assemblies. We are a complete systems supplier with CAD, engineering, prototyping and production capabilities.

create uniquely tailored products that can enhance their brand and create genuine excitement in the marketplace,” Ryan reveals. Walkinshaw Design is where the company’s creativity and its customers’ vision meet. It’s about realising dreams and aspirations as Walkinshaw is highly passionate and experienced in delivering world-class solutions to individual and specifically tailored briefs. “We have full design studio capabilities including theme sketch development, clay modelling, full size or scale milling, 3D Alias surfacing, scanning, and scale vehicle modelling for assessment or aero testing.” Alongside this, Walkinshaw offers broad capabilities in the styling and design of exterior surfaces and components including fascias, lighting, sheet metal, trim or fibreglass parts, wheels, and spoilers. Another key competency is the company’s ability to develop designs from 2D

concepts through to clay models, CAD, 3D print, and finally, tooling. Furthermore, Walkinshaw is highly experienced in interior material and trim standards. To date, the company has expertly designed, engineered, and manufactured numerous different interior parts including IP, consoles, binnacle gauges, seat trims and foams, electronic systems, and ornamentation. To date, the company has been involved in some incredible products and moments across its journey, but now finds itself in an exhilarating new chapter which is equally exciting for everyone involved and promises to keep delivering success far into the future.

www.walkinshawperformance.co.uk Manufacturing Outlook Issue 1 | 37

S U S TA I N I N G CUTTING-EDGE SOLUTIONS BBS Automation’s forward-thinking automated assembly and testing systems are providing cutting-edge solutions, as Andreas Foerster, General Manager for Southeast Asia, tells us Writer: Jack Salter | Project Manager: Poppi Burke 38 | Manufacturing Outlook Issue 1

BBS AUTOMATION ASIA PACIFIC

talent readiness is relatively high, and demand for Industry 4.0 solutions is steadily increasing. “Everyone is striving to achieve or implement Industry 4.0, and there are several impressive success stories related to these initiatives in Southeast Asia,” notes Andreas Foerster, General Manager for Southeast Asia at BBS Automation (BBS). However, like any industry, there are challenges to overcome, including supply chain disruptions, regulatory changes, and increasing competition. “Nevertheless, I believe the manufacturing industry in Southeast Asia offers exciting prospects for those willing to navigate this dynamic landscape,” says Foerster, who holds a bachelor’s degree in engineering and a master’s degree in professional technical management.

GLOBAL FOOTPRINT

etting up manufacturing plants in Southeast Asia was once driven by lower labour and operational costs. However, the region’s growing manufacturing industry is currently undergoing a significant transformation, with Southeast Asian governments actively competing to invest in infrastructure development and technology adoption to improve the overall business environment. In Malaysia specifically, facilities are well-established, most of the population is proficient in English,

BBS caters to major manufacturing players across a variety of sectors, including automotive, electronics, life sciences, renewable energy, energy storage, consumable parts, and the optical industry. Since the 31st of August 2023, BBS has been part of the Dürr Group, a global capital goods company headquartered in Germany. The core competencies of BBS and its 2,700 employees include assembly and testing solutions, software development, testing systems, winding technology, foundry automation, and build-toprint projects. “In Penang, we have a 35-year history of specialising in design-build systems and build-to-print projects,” Foerster informs us. “Additionally, we have a dedicated department specialising in niche and precise leak testing using helium.” Penang, often dubbed the Silicon Valley of the East, has been home to BBS’ Malaysian manufacturing plant since 1988, complementing the company’s German headquarters and

worldwide network of 23 locations spanning Asia, Europe, and North America. This extensive global footprint makes BBS stand out as one of the leading players in automation with a vast network of sites worldwide. The cooperation between these global locations contributes to a more comprehensive project portfolio, especially for international projects in a wide range of industries. “Our teams work cohesively and collaboratively, ensuring efficient communication and cooperation across all locations,” states Foerster. As a result, BBS is well equipped to provide exceptional support and service, especially to customers with a global presence, with dedicated design engineers, skilled software developers, and builders at every site. BBS follows a lean management system, facilitating close interaction between General Managers such as Foerster and CEO, Josef Wildgruber, a streamlined approach that allows for effective and efficient decision-making. “From our German headquarters, we maintain a centralised technical team that provides crucial support to every plant, ensuring a consistent and high level of technical expertise across the organisation,” he outlines.

CUSTOMISATION TO MEET UNIQUE REQUIREMENTS As a customised equipment manufacturer and a solutions provider across various industries, every project is naturally fascinating to BBS and comes with a unique set of challenges. It all begins with a deep understanding of the customer’s product, processes, and specific requirements. A dedicated team collaborates closely with the customer to precisely define specifications, immerse themselves in the customer’s standards, and develop the most suitable concept. Manufacturing Outlook Issue 1 | 39

MANUFACTURING OUTLOOK: CAN YOU TELL US MORE ABOUT YOUR CAREER PATH TO DATE?

BBS Automation’s manufacturing plant in Penang

Andreas Foerster, General Manager for Southeast Asia: “My career journey has

When it comes to project execution, BBS’ project management, engineering, and procurement teams work hand-in-hand to address critical issues, manage risks, and adapt to changes, ensuring the successful delivery of each project. “In the automotive sector, for instance, we offer an extensive array of automated assembly and testing solutions for keyless entry systems, steering switch panels, electrical oil pumps, DCUs and ECUs, speedometers, car seats and tracks, condensers, radiators, and much more,” details Foerster. In build-to-print, BBS has successfully manufactured over 20 testing chambers for radar systems deployed worldwide, established multiple assembly and testing lines for heavy-duty industrial fans, and crafted specialised dip coater machines utilised in the medical sector. “If I were to speak about one standout project, it would be the 40 | Manufacturing Outlook Issue 1

been driven by my passion for cutting-edge technology. It all started when I began as a mechanical technician in Germany with a well-known mechatronic systems manufacturer. “As I progressed, I transitioned into a process and quality engineer, which brought me closer to the world of machines and equipment. My career then took a significant turn when I moved into procurement, allowing me to combine my technical knowledge with a deep understanding of the business side of operations. “After several years, I made the deliberate choice to transition into the equipment manufacturing field because I discovered that delivering the right customised solutions to customers is a rapidly evolving market that continually presents new challenges. This was a pivotal moment in my career as it allowed me to take on a leadership role in the automation industry, which I’ve found incredibly exciting and fulfilling.”

automotive sensor production line with a three-second cycle time per part,” Foerster highlights. “We are constructing more than 10 lines for this project, spanning multiple locations across Asia, Europe, and North America. The equipment

we’ve designed and built for this project is estimated to produce a staggering 80 million parts annually.” As a systems integrator, establishing strategic collaborations with industry leaders is of utmost importance to ensure top-notch

BBS AUTOMATION ASIA PACIFIC

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Manufacturing Outlook Issue 1 | 41

BBS AUTOMATION ASIA PACIFIC

quality and precise control. For example, BBS has cultivated a strategic partnership with Kistler, streamlining the integration of an electromechanical system into their servo press operations, harnessing the benefits of a well-proven monitoring system, and further bolstering their commitment to exceptional quality and performance.

EV REVOLUTION One area that particularly excites the company is its involvement in development and innovation within the electric vehicle (EV) sector. “We are excited about the transformation of components used in EVs and eagerly anticipate playing a role in this revolution,” Foerster tells us. BBS has implemented several EV solutions globally and is capable of providing a wide range of EV components. In Penang, BBS also offers leak testing solutions for various EV products, such as battery trays and coolers, from its manufacturing plant.

EXCITING INNOVATIONS As new technologies continue to emerge, increasingly innovative consumer products are being introduced to the market. Everyday items such as hair dryers, shavers, and various electronic devices each require specialised assembly and testing solutions. “We stand ready to collaborate with our customers and are always ready to contribute to these exciting innovations,” says Foerster. As an example, having specialised in manufacturing equipment for the optical industry, including applications for medical glasses, contact lenses, and standard eyewear over the years, BBS has recently extended its expertise to participate in an R&D project for virtual reality (VR) glasses. Another avenue in the pipeline 42 | Manufacturing Outlook Issue 1

“ W E ’ R E A LWAY S O N T H E L O O K O U T F O R I N N O VAT I O N S A N D A C T I V E LY S U P P O R T P R O D U C T D E V E L O P M E N T, P A R T I C U L A R LY I N T H E E V E R - E V O LV I N G T E C H N O L O G Y M A R K E T. S TAY I N G AT T H E F O R E F R O N T O F T E C H N O LO GY A N D T R E N DS CO N T I N U E S TO F U E L O U R PA S S I O N A N D C O M M I T M E N T TO I N N O VAT I O N ” – A N D R E AS FO E R ST E R , G E N E R A L M A N AG E R FO R S O U T H E AST A S I A , B B S A U T O M AT I O N

that has gained BBS’ interest is the expansion of its engagement in medical projects with the acquisition of Italy-based Kahle Automation, having actively contributed solutions for high-speed needle assembly, insulin pumps, and medical sensors. Medical products are now undergoing a remarkable phase of innovation and experiencing a surge in the development of new items, including various types of sensors, devices, and components. “We look forward to offering comprehensive solutions in this dynamic and evolving field,” Foerster shares.

“We’re always on the lookout for innovations and actively support product development, particularly in the ever-evolving technology market. Staying at the forefront of technology and trends continues to fuel our passion and commitment to innovation.”

PROCUREMENT STRATEGY BBS’ global procurement strategy focuses on sourcing components and services globally to optimise quality and cost-efficiency. As such, the company views its suppliers as partners because its ultimate goal is to develop the right solutions.

“Without the right partners and their solutions, we can’t guarantee the success of our projects,” emphasises Foerster. As a systems integrator, it is crucial that BBS works closely with its global suppliers, especially for components, as delays in delivery can likewise lead to project delays. For instance, in a recent project working with Omron, BBS deployed a total solution equipped with multiple stations and robotic arms. BBS’ success in this venture hinged on the prompt support and close cooperation it received from Omron, for which the company is sincerely grateful. “Building strong relationships with our suppliers is vital to our success. We’ve developed several cooperation strategies with them, understanding that the quality of products is paramount,” Foerster affirms. Indeed, whilst cost management

is important, BBS prioritises quality as, in the long run, a lower-cost product can be unreliable and result in malfunctions that ultimately incur higher costs and resource consumption. Equally, collaborating with suppliers for innovative solutions also keeps BBS at the forefront of automation technology. “This commitment to innovation drives our ongoing success.”

SYNERGY OF SKILLS From suppliers to employees, teamwork is at the core of solutions providers such as BBS and plays a vital role in ensuring the smooth execution of projects. With everyone bringing their own unique expertise, the synergy of these skills leads to the successful completion of projects. From a leadership perspective, it is about showing respect and compassion as BBS strives to create

a working environment that offers stability and growth opportunities for staff. “Empowering our team members is not just a philosophy; it’s a practice,” states Foerster. “We believe in working hard and having fun together. We regularly organise events that bring our employees together. Whether it’s a barbecue, traditional food preparation, or exciting activities, we create opportunities for our team to bond beyond the confines of work. “Sometimes, we surprise them with food trucks, ice cream, or doughnuts – simple gestures that create a strong foundation for team unity,” he adds. BBS intends to build strong foundations of trust and camaraderie within the team by valuing relationships that go beyond work-related interactions and creating a workplace where everyone feels like they belong. Manufacturing Outlook Issue 1 | 43

BBS AUTOMATION ASIA PACIFIC

In a world of customised equipment where flexibility is key, BBS also encourages its team members to embrace challenges and solve problems with courage, critical thinking, and creativity. “It’s inspiring to see the team take ownership, dedicate themselves, and contribute in unique ways to turn the seemingly impossible into reality,” Foerster admires. “Together, we face challenges head-on, guided by a mindset focused on unity and achieving successful project outcomes.” People are, therefore, the backbone of success at BBS, who takes great pride in empowering and recognising their invaluable contributions.

Malaysia’s multicultural environment is also something that BBS values highly by celebrating major ethnic holidays and conducting activities that promote each culture, with the goal of fostering an inclusive environment where everyone feels appreciated and cherished.

POSITIVE IMPACT In addition, BBS is very particular about its safety regulations, aiming to create a safe workplace for staff. A dedicated team regularly reviews and implements the company’s safety standards, such as personal protective equipment (PPE) requirements when entering the production area. BBS is also an organisation that takes corporate social responsibility

(CSR) seriously, as evidenced by its Penang plant in Malaysia which is an environmental pioneer in the region. The company invested in solar panels more than 15 years ago at a time when environmental issues were not discussed as urgently as they justifiably are today. These panels generate around 30 percent of the electricity at the facility and demonstrate the value that BBS places on the sustainable development of its business activities. “The solar panels were originally a customer project. We had the chance to work closely with them to develop a complete solution for solar panel assembly and testing lines, and the panels on our roof were produced by our own equipment. We were one

of the pioneers of solar energy solutions at the time,” reveals Foerster. In recent years, the company has increased its efforts to give back to the community, having participated in volunteering programmes such as food fairs for the blind and blood donation drives. The enthusiastic response from team members has been heartening, and BBS is eager to engage in more impactful activities. “These experiences have enriched us and deepened our connection with our community. I believe our commitment to CSR extends beyond our business operations; it’s a reflection of our values and our dedication to

making a positive impact on the world around us.”

DEDICATION TO STATE-OF-THEART TECHNOLOGY Foerster is optimistic about the company’s future, as the recent acquisition and future integration into the Dürr Group has significantly increased BBS’ size and expertise, enabling it to better meet the evolving needs of its customers. The company is currently in the process of developing a machine optimisation programme that will enhance the efficiency and productivity of BBS’ equipment, resulting in reduced operational input, lower energy consumption, and cost savings. Staying ahead of trends such as Industry 4.0 is another future priority for BBS, emphasising the interconnectivity of equipment and the pivotal role of monitoring devices to achieve this. “We work closely with partners like IFM, leveraging their various sensors and systems to monitor different machine components and facilitate

communication between hardware, making Industry 4.0 a reality,” concludes Foerster. Nevertheless, to stay at the forefront of the artificial intelligence (AI) revolution, utilising AI is also a key factor. In fact, some of the company’s solutions already incorporate smart manufacturing systems with deep learning and AI control logic, showcasing BBS’ commitment to advanced technology integration as it strives to strengthen its capabilities in this area. There will undoubtedly be challenges in the global landscape, however, Foerster has great confidence that the innovative spirit and commitment of BBS to delivering quality solutions will allow it to excel in the future.

Tel: +49 89 8560 7354-0 info@bbsautomation.com www.bbsautomation.com Manufacturing Outlook Issue 1 | 45

PWR ADVANCED COOLING TECHNOLOGY ASIA PACIFIC

HIGHPERFORMANCE COOLING When it comes to thermal management, PWR Advanced Cooling Technology is a world leader. Andi Scott, General Manager of Advanced Technology, highlights the company’s cooling solutions in the automotive, aerospace and defence sectors Writer: Jack Salter | Project Manager: Kierron Rose

or three decades, the Weel family have been deeply involved in manufacturing products to serve the automotive cooling industry. PWR Advanced Cooling Technology (PWR) was founded in 1997 by Kees Weel and his son Paul, to fulfil the growing demand for highquality, lightweight, performance aluminium cooling products. “The market was ready for a product that was measured by its performance and backed up by a flexible manufacturing facility capable of designing and adapting cooler configurations to custom specifications,” opens PWR’s General Manager of Advanced Technology, Andi Scott. 46 | Manufacturing Outlook Issue 1

Andi Scott, General Manager of Advanced Technology

With Kees still heavily involved in the business as CEO, PWR services many different sectors and has grown to become the technical partner of choice for leading motorsport teams, original equipment manufacturers (OEMs), and aerospace and defence customers around the world. “You will find PWR’s product range across motorsport categories including Formula 1 (F1), NASCAR, IndyCar, the World Endurance Championship, the World Rally Championship, MotoGP, motocross, and off-road racing,” Scott tells us. “In the OEM space, we supply many renowned brands such as Aston Martin, Mercedes, BMW, Porsche, Bugatti, Koenigsegg, Ford, McLaren, and Pagani,” he adds.

PWR Advanced Cooling Technology bar and plate products

Manufacturing Outlook Issue 1 | 47

PWR ADVANCED COOLING TECHNOLOGY ASIA PACIFIC

PWR set up its new aerospace and defence division less than three years ago, and it has already achieved significant success in a short space of time. This is best seen in the electric vertical take-off and landing (eVTOL) aircraft market, where engines are being replaced by heavy battery packs. Initially, the additional mass of battery packs for any significant flight time would stop the aircraft from generating enough lift to get off the ground. This caused a rethink of the technology used for this purpose, not only for the batteries but also for lightweight thermal management systems.

WORLDWIDE PRESENCE PWR’s headquarters in Queensland, Australia, and additional manufacturing sites in Indianapolis (US) and Rugby (UK), are vertically integrated to complete all processes from raw material acceptance to the finished deliverable product. Now publicly listed on the Australian Stock Exchange (ASX), PWR currently has a global complement of over 500 staff, 350 of which are located in Australia, 130 in the US, and 40 in the UK.

PWR facility

48 | Manufacturing Outlook Issue 1

MANUFACTURING OUTLOOK: DO YOU PARTAKE IN ANY CORPORATE SOCIAL RESPONSIBILITY PRACTICES? Andi Scott, General Manager of Advanced Technology: “PWR has a developed environmental, social, and governance (ESG) roadmap in support of our environmental and social impacts. “We actively promote a circular economy for our waste aluminium materials and are in the process of reviewing all packaging to assess recycling opportunities at each of our global sites.”

The company also has a range of valuable certifications, holding AS9100, ISO9001, IATF16949, ISO14001, and NADCAP accreditations across its three manufacturing sites, and takes great pride in seeing its products exported around the world. For example, PWR has enjoyed healthy growth in defence material exports to the US market, ranging

from cooling components for highpower electronics systems used in ruggedised avionics and radar systems, through to large thermal solutions used in heavy land vehicles. “It is quite easy for other countries to think Australia is too far away to get anything designed or manufactured, but I certainly think PWR is a great example of breaking that thought process as we export over 85 percent of the products we manufacture in Australia to the rest of the world,” acclaims Scott. “Australia is a quiet overachiever, in my opinion, when it comes to manufacturing. The skillsets and capabilities I have witnessed across multiple businesses in our network have shown time and again that Australia can and does manufacture world-class parts, often in combination with a refreshing can-do attitude.”

VARIETY OF TECHNOLOGIES There are many fantastic companies around the world providing novel and efficient cooling solutions, which provides healthy competition for PWR.

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“ O V E R M A N Y Y E A R S , P W R H A S B U I LT A T R U S T E D N E T W O R K O F S U P P L I E R S F O R VA R I O U S A S P E C T S O F O U R O P E R AT I O N S , AND WE HOPE THEY GROW WITH US” – A N D I S C O T T, G E N E R A L M A N A G E R O F A D VA N C E D T E C H N O L O G Y, P W R A D VA N C E D C O O L I N G T E C H N O L O G Y

Manufacturing Outlook Issue 1 | 49

PWR ADVANCED COOLING TECHNOLOGY ASIA PACIFIC

The main attribute that sets the company on a different trajectory is the fact that it is not limited to one technology or manufacturing method. Instead, PWR’s approach is that of an R&D division, investing in and utilising a wide variety of new and existing technologies to broaden its manufacturing capabilities and generate valuable IP. “We are able to look at a complete thermal problem with our eyes wide open and choose the best matching manufacturing methods for individual components of the thermal system, to best meet or surpass our customers’ needs,” Scott outlines. “Other companies may focus on one technology or manufacturing method, and consequently they are forced to develop a solution within

the limitations of that equipment or technology.” PWR continuously strives to improve in all areas of thermal systems design, manufacturing, and validation to keep ahead and match new customer platform needs. Proof of this is seen in PWR’s internal simulation and wind tunnel calorimeter facility. Using both empirical test data and predictive methods, the company has been able to create its own software to help guide the best technology and solution required for every aspect of the system. In addition, PWR is able to use this predictive data to test products in a simulated environment before manufacturing prototypes. “The software prediction is then

“ W E E X P O RT OV E R 8 5 P E R C E N T O F T H E P R O D U C T S W E M A N U FA C T U R E I N A U S T R A L I A TO T H E R E ST O F T H E WO R L D ” – A N D I S C O T T, G E N E R A L M A N A G E R O F A D VA N C E D T E C H N O L O G Y, P W R A D VA N C E D C O O L I N G T E C H N O L O G Y

validated by physical testing of the actual product once complete, therefore closing the loop on our predictive information to continuously improve our process,” states Scott.

AUTOMOTIVE PERFORMANCE Current F1 cars are a fantastic feat of engineering, generating over 1,000 horsepower from a 1.6 litre turbocharged internal combustion engine (ICE). F1 cars also benefit from hybrid power, which is harvested through an energy recovery system during braking. This complexity means a typical F1 car will have cooling systems for the engine water, engine oil, intercooler, energy store, hydraulics, gearbox, and electronics. PWR engages with its customers to support their needs for a bespoke holistic cooling system; as with any sport, there are various requirements from customers to achieve the best possible performance. “This means we are always faced with different thermal conditions, loads, and geometry constraints,” explains Scott. “We specialise in these freeform geometry heat exchangers, which all make efficient use of the available space inside the complex aerodynamic shapes of the modernday F1 car.” The company has also just completed a series production run in which cooling systems were delivered directly to Ford’s production line in the US for use in a new variation of the Mustang GT. The bespoke cooling system used in the Aston Martin Valkyrie road car, meanwhile, is also currently in production. “I had the pleasure of working on this project before I emigrated to Australia, whilst I was still at Red Bull Racing. The car was designed by Adrian Newey, and I was lucky enough to be part of a small team working

on the Valkyrie as it came to fruition,” Scott reveals. “After moving to Australia, I then had a second opportunity to support the Valkyrie project, this time from PWR’s side, where we designed the complete cooling system to meet the demands of the engine and drivetrain. All the while, PWR is continually growing its global manufacturing footprint, capabilities, and customer base. With all the various propulsion systems, such as ICEs, turbine engines, battery electric, and hydrogen fuel cells, there is one common factor – they all have considerable thermal management to contend with. “As power density increases, the ability to remove heat from engines, motors, fuel cells, inverters, and graphical processors becomes more

challenging, and therefore provides the opportunity for PWR to continue its journey.”

THE DRIVING FORCE As people are the driving force that allows PWR to be as successful as it is, the company works hard to train, support, and retain its staff. PWR is focused on its people and ensures they have access to learning and development opportunities. “We have various apprenticeships and graduate programmes to help expose our staff to the various departments and create a pathway for progression,” Scott says.

PWR has many trusted suppliers that are also key to its success and likewise need to be reactive in order to keep up with customer needs. “Over many years, PWR has built a trusted network of suppliers for various aspects of our operations, and we hope they grow with us.” Equally, PWR wants to continue to focus on sensible and sustainable growth, to ensure the brand continues to expand for decades to come.

PWR ADVANCED COOLING TECHNOLOGY Tel: +61 (0)7 5547 1600 info@pwr.com.au www.pwr.com Manufacturing Outlook Issue 1 | 51

JOST AUSTRALIA ASIA PACIFIC

THE PRIDE OF AU S T R A L I A JOST Australia is a leading supplier of parts and components to the nation’s transport industry. We learn more about its high-quality products suitable for a range of applications with Managing Director, Guy Locke Writer: Ed Budds | Project Manager: Kierron Rose

he Australian transport industry is currently experiencing some very exciting times and growth, however, there are also many challenges being faced by the sector, as the industry contends with ongoing shortages in local labour, delays and inconsistencies in the supply chain, alongside the rising costs of doing business. This, however, is also providing great opportunities for businesses that embrace these challenges and manage to find innovative ways to develop solutions, and the ones that overcome these challenges will be in a strong position to capitalise on the current growth in the industry. Manufacturing Outlook (MO): What is your take on the industry in Australia and New Zealand at the

moment? Is it an exciting space to be working in, and have you noticed any recent trends developing? Guy Locke, Managing Director (GL): We are definitely seeing a trend of more open communication between suppliers and customers to help manage stock demands and inventory controls due to the extended lead times being faced through component supply. Across the sector, there is also a continued increase in demand from customers looking for improved innovation around safety and ease in the use of equipment. With the shortage of labour, the fleet operators are looking for any way to improve safety and productivity with their drivers and reduce the risk of an incident. Manufacturing Outlook Issue 1 | 53

JOST AUSTRALIA ASIA PACIFIC

Guy Locke, Managing Director

MO: Please can you introduce us to JOST Australia? GL: JOST Australia is a fully owned subsidiary of the global business JOST-Werke (JOST), located in Neu-Isenburg, Germany. Backed by its European parent company and supported by JOST facilities in multiple locations around the world, the company is a leading supplier in the Australian transport industry, providing a comprehensive range of advanced technology components that are engineered to the highest standards, quality, and are suitable for a wide variety of transport applications. JOST is a leading global manufacturer and supplier of safetyrelated systems for the commercial vehicle industry. Under the JOST umbrella brand, which includes JOST, Rockinger, Tridec and Quicke, our extensive product portfolio is divided into systems for both road and 54 | Manufacturing Outlook Issue 1

agriculture. Today, the JOST brand includes fifth wheel couplings, landing gears, ball bearing turntables, king pins and container locks as well as components for alternating systems. Truck and trailer axles are also sold under the JOST brand. The tradition-steeped ROCKINGER brand comprises the core components of towing hitches, drawbar eyes and drawbars for transporters and trucks. TRIDEC offers steering systems and axle suspensions for trailers. ROCKINGER products are also used in agricultural applications, whilst Quicke has been part of the JOST family since February 2020 and specialises in agricultural front loaders and equipment. JOST currently employs over 3,600 people worldwide, has sales and production facilities in over 20 countries on all five continents, and listed on the Frankfurt Stock Exchange.

JOST Australia currently operates from six company locations in Victoria, New South Wales, Queensland, South Australia, Western Australia, and Auckland, New Zealand, employing more than 90 staff across a range of roles and functions. Within these locations, JOST maintains strong stock levels in all product categories and also produces, assembles and customises its portfolio of fifth wheel product options to suit the local markets and demands, including having full-time engineers employed to stay in front of regulatory and industry changes. Undoubtedly, JOST prides itself on being backed by a global business, while operating at a local level to ensure that it can serve market and customer requirements. This has held the company in good stead by having the capacity and capability to provide a one-stop shop for customers when it comes to sourcing their product demands such as fifth wheels, landing

Quality Parts Manufacturing is Sevaan Group Australia-based Sevaan Group is a contract manufacturing firm that employs about 50 staff and specialises in the precision manufacturing of metal parts and products for OEMs in a range of industries including defence, mining, agriculture, gaming, space, robotics, electronics and transport.

and welding and finishing. “Our ability to offer customers a one-stop shop for all their parts manufacturing means that we can ensure quality control and the integrity of their parts, in addition to timely delivery and cost-competitiveness,” explains David Green, CEO, Sevaan Group.

Established in 1997, Sevaan Group has gone from strength to strength. Today, Sevaan Group’s smart manufacturing plant is based upon LEAN production principles and compliance to ISO quality, environmental, health and safety management standards. Its unique and highly integrated operation consists of sheet metal fabrication, machining and finishing at scale.

According to David, the demand for high-quality precision parts in the APAC region has surged. “Both Australian and overseas firms are placing more and more emphasis on the need for the production of precise and high-performing components in increasingly shorter lead times. This is partly because the components are critical to the overall performance of the end product, partly because firms are more environmentally aware and require components that provide durability and longevity, and partly because long-term they can be more cost-effective.”

The company produces parts and products in a range of materials including steel, stainless steel, aluminium, nickel, copper, and brass. Its end-to-end capability means it offers customers component and product design, production, finishing and assembly under the one roof at its state of the art facility in Sydney. Its operational processes include CAD/CAM controlled laser cutting, bending, folding, punching, machining,

To continue to deliver quality components, the group is investing heavily in technology in all areas of production to ensure it has the ability and capacity to efficiently serve customers.

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We are Sevaan Group an Australian manufacturer of complete end-toend metal components for OEMs. Using our proven capability and considerable expertise, Sevaan Group produces high-performance components in an extensive range of metals at scale. This, fused with our integrated in-house design, cutting, machining, bending and folding, welding, and finishing and assembly capabilities, provides you with real choice, cost-competitiveness, quality-control and peace of mind. For high-quality metal parts call Sevaan Group on +61 2 9824 5555 or email: marketing@sevaan-group.com.au

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JOST AUSTRALIA ASIA PACIFIC

gears, ball bearing turntables, king pins, container locks, towing hitches, drawbar eyes and drawbars for either their transport or agricultural needs. In relation to fifth wheel supply, JOST specifies, customises, paints, installs and completes the mandatory certification of the product and installation ready for vehicle registration for the customer, which makes dealing with JOST significantly easier, on top of the peace of mind of knowing the product is designed and engineered with German excellence and quality. Serving all segments of the transport market across the industry, 56 | Manufacturing Outlook Issue 1

including truck and trailer OEMs, trading segment customers, and just as importantly the fleet operator themselves, has had a major emphasis on JOST being extremely close to the end user. MO: What, for you, separates and differentiates JOST Australia from the competition? GL: Having localised operations spread across Australia and New Zealand, such as in Melbourne, Sydney, Brisbane, Adelaide, Perth and Auckland, along with access to international markets, provides the

company with the opportunity to remain close to customers to ensure it is not simply meeting their needs but exceeding them. JOST has the unique ability to customise fifth wheel product requirements for our customers in any of these locations, along with supplying any other product from our portfolio, and has become a one-stop shop to make the job of sourcing a product for its customers, or their respective customers, as easy and as integrated as possible. The company’s state offices are supported by national teams in engineering, operations, finance,

“ O U R S TA F F A R E O U R B I G G E S T A S S E T A N D T H E M O S T I M P O R TA N T C O G I N T H E M A C H I N E ” – G U Y LO C K E , M A N AG I N G D I R E C TO R , J O ST AU ST R A L I A

sales, and a highly trained, nationwide customer service team that operates with extended hours to cover all time zones across Australia to ensure we exceed market expectations and stay close to both customers and markets. Each employee, regardless of their role, is empowered and responsible for delivering the JOST’s goals and vision to each and every customer, and these state locations have their own operational capabilities to deliver stock off the shelf quickly or even custom build something faster than our competitors. Our sales teams are highly experienced in working with our products, with many staff holding long tenures at JOST and in the industry, helping to support customer

needs through deep knowledge and providing genuine advice, which ensures that they get the right product for their specific application. Backing this up, the JOST sales teams all provide support through specification guidance, conducting training across customer workshops, fleet operator driver training, and parts interpreter training. Furthermore, JOST’s customers know they can call on any of the resources within JOST for expert help. MO: What ongoing or recent projects would you like to showcase? GL: The recent Brisbane Truck Show held in May at the Brisbane Convention Centre allowed JOST to show

its support for the industry and the launch of many sector-leading innovative products. During the show, JOST had a large presence of experts and displays to allow current and potential customers to interact with the products and see them first-hand. With the growing interest of sensor technology in the fifth wheel coupling process, which can also allow for this function to be fully integrated into the prime mover’s dash displays, is allowing for greater use and increased demand for our sensor technology units. JOST sees this trend only growing as the industry continues to strive for the improved operational safety of its fleets and driver comfort. This includes a fully operational simulator for the JOST KKS, the first of its kind to be released which facilitates the fully automatic operation of the coupling and decoupling procedure for a truck and trailer combination with a fifth wheel coupling attached. Manufacturing Outlook Issue 1 | 57

JOST AUSTRALIA ASIA PACIFIC

The driver is guided through the entire coupling process, with sensor technology providing live information on the KKS remote control throughout every step of the process. Climbing out of the cabin to manually open the fifth wheel, cranking down the landing gear and manually connecting the spiral cable, air and brake connections are all a thing of the past for drivers. Time, comfort and safety gains are made possible with just one product. A further innovative product, the Drawbar Finder, was launched from the ROCKINGER product range, which allows for safer and easier tow coupling connection for the driver via either an integrated or dash mounted camera display enables the driver to see in real time a guidance system 58 | Manufacturing Outlook Issue 1

and visual display during the coupling process, eliminating the need to continually do manually checks, reducing coupling time, and lowering the risk of damage to the equipment or operator. We also launched our Loc Lite device that allows for an audible and visual alert to a second or subsequent coupled trailer on a combination, again to support the safe and accurate coupling of trailers to each other. MO: How do you empower your staff and recognise the valuable contributions that they make? GL: A vital aspect of the business for JOST is the development and growth opportunities provided to the company’s people.

Our staff are our biggest asset and the most important cog in the machine, so without them we have nothing and no way of getting our product to the market. We place a large emphasis on development roadmaps for our staff, regardless of what role they are in. In this way, JOST wants to continue creating a strong inclusive culture of “One JOST” and has therefore developed processes and initiatives for staff training and development locally through talent identification programmes and the local JOST Academy programme. Now that this initiative is underway, JOST provides a higher level of intense training and development opportunities across the business to provide a cross-functional mindset.

All these initiatives help to retain and reward staff, as the company wants its people to be long-term employees and advance through the business if they have the desire and determination required to thrive. MO: Do you partake in any corporate social responsibility practices? GL: We are placing a greater focus on corporate social responsibility efforts in this space to ensure we implement genuine and realistic actions that will allow us to be mindful of our impact on the environment, social responsibilities, and retain a high level of governance across the business. These range from reducing waste, looking at implementing solar photovoltaic systems on some sites,

to supporting local social causes that are important to our people, and maintaining strong processes for monitoring and reporting on any initiatives. JOST is firmly committed to the United Nations Agenda 2030 which sets global targets for sustainable global development. The company will contribute to its implementation through its corporate strategy and by engaging with sustainability issues.

JOST AUSTRALIA Tel: 1800 811 487 sales@jostaustralia.com.au www.jostaustralia.com.au Manufacturing Outlook Issue 1 | 59

THE TRUSTED PA R T N E R 60 | Manufacturing Outlook Issue 1

W wh of A pos pro Writer:

AWC INCORPORATED NORTH AMERICA

with a simple mission: to help local refineries optimize and standardize their operations. Nearly 60 years later, the business has grown exponentially, evolving to become an invaluable support partner to titans utilizing Factory Automation and Process Technology. This is reflected by its near nationwide reach, as AWC’s customers now span 11 US states across 32 regional support offices. “Our team embodies a ‘Winning Together’ culture in which our employee-owners, customers, and technology partners collectively succeed because we strive to ‘out know, out care, and out serve’ others in our space,” introduces Kirk Goins, CEO of AWC.

NO ORDINARY DISTRIBUTOR

We speak to CEO Kirk Goins, ho discusses the importance AWC Incorporated’s valuable sition as an all-round service ovider in the automation and control industry Lucy Pilgrim | Project Manager: Kieron Harvey

he automation and control industry incorporates a plethora of technical services, from information technology (IT) to mechanical systems. To cater to such a multitude of products and brands, AWC Incorporated (AWC) has built a solid reputation as the authorized local sales, support, and service partner for leading manufacturers of automation and control systems. AWC was founded in 1965 by three engineers as a local manufacturing representative in the Baton Rouge Kirk Goins area of Louisiana,

AWC is uniquely positioned to deliver customers significantly more value with expert support and dedicated engineering services. As an authorized distributor and service partner of products and solutions to customers across a broad geographic area, AWC supplies innovations from the world’s leading technology factory automation and process technology companies like Siemens, Phoenix Contact, Honeywell, Farris, Valmet, and many more. AWC’s driving mission remains “to provide customers the indispensable support necessary to help them achieve their business goals in a safe and efficient manner,” Goins explains. This explains why the company’s customer base spans many verticals, including oil and gas, pulp and paper, automotive, water and wastewater, food and beverage, and many other industries. Manufacturing Outlook Issue 1 | 61

That was easy Expand your automation freedom with PLCnext Technology from Phoenix Contact. PLCnext is an open industrial automation platform with limitless possibilities that expand the use of a PLC in ways that have changed the future of automation. Open with Linux, PLCnext is IIoT ready, offering multiple cloud connection options. Explore programming capabilities with the potential to be networked for easy monitoring. With apps available on the PLCnext Store to save programming time and PLCnext Engineer software available as a free download, it’s easy to implement into your control system. It’s a proven technology that many of our customers have already adopted. Visit www.phoenixcontact.com/open to learn more about what you might be missing out on.

Build your control cabinet with confidence Industrial solutions from sensor to cloud Control cabinet designers must constantly rethink their processes to remain competitive. Since its founding in 1923, Phoenix Contact has collaborated with customers across nearly all industries to improve the reliability and efficiency of industrial applications. Today, Phoenix Contact provides comprehensive solutions to optimize processes and save time. The COMPLETE line perfectly coordinates hardware and software to streamline processes, giving you the peace of mind and competitive edge needed to succeed in today’s highly complex manufacturing world.

Power reliability No other function in your control cabinet impacts overall system performance more than reliable power. Phoenix Contact has all the necessary components to reliably protect, convert, monitor, and distribute low-voltage power within your system. High-performance surge protection and circuit breakers protect equipment from transient overvoltage and overcurrent disturbances. Transmission of those disruptive events to a “cloud” enables preventive maintenance. Redundant solutions or batteries supplement the DC power supply when needed, safeguarding low-voltage power, even in critical situations. In addition, future-proof monitoring systems save energy in the overall system. Innovative solutions for AC or DC potential distribution reduce space requirements and installation times in the control cabinet.

Connectivity Connections in the cabinet, through the cabinet, and in the field are the bridge between the field-based sensors and logic controlling a system. The automation and control level reads inputs and drives outputs. These devices must be connected by secure discrete wiring or through networks. These same devices must be reliably powered, which requires efficient distribution and marshaling to energize and balance loads. Loads can range from small milliamp signals to high-horsepower motor connections. Analog signals often require special functionality at the connection point, such as testing, measurement, or fusing. Specialty terminal blocks support these functions. When >>>

Build your control cabinet with confidence Industrial solutions from sensor to cloud

system complexity and I/Os increase, networking field signals outside the enclosure is often a more efficient way to integrate larger systems than point-to-point wiring.

Signal switching and conditioning Every signal has a specific purpose, and not all signals are the same. Sometimes along the journey, signals may need to be isolated, amplified, or converted to serve their purpose. Ensuring the signal’s mission is accomplished can be as simple as choosing a universal product, or it might require digging deeper and allowing the application to dictate product selection. The COMPLETE line system has numerous options to transmit signals reliably. From controller and connectivity solutions to sensors and motors, this group of products ensures the right switching at the right time.

Safety Functional safety management starts at the top and should encompass an entire company strategy. In application, safety is applied in two major areas: machine and process..

Automation and control The heart of your control cabinet is the logic platform. For OEMs and control engineers alike, it has never been easier to build smaller, smarter machines fast. This lets builders free themselves from using controllers and equipment based solely on prior familiarity or specifications. Industrial PCs/HMIs and scalable controllers can streamline functionality, reduce equipment and costs, and usher in the next generation of intelligent machine automation. Control systems can range from simple, single-function control to real-time SCADA applications.

Networking The modern factory, driven by the Industrial Internet of Things (IIoT) and big data, must handle increased network traffic and the possibility of internal or external vulnerabilities. Phoenix Contact networking and security products support many technologies, so you can design and implement scalable, reliable, and high-functioning systems.

Machine safety can be as simple as a single safety sensor tied to a safety relay controlling a motor, or as complex as multiple fail-safe PLCs with distributed safety I/O networked throughout a factory. No matter how large your system, it will always have three pieces: inputs, outputs, and logic.

Ethernet infrastructure devices provide everything from basic connectivity to advanced managed switches, with options that include powering end devices, field-wiring connectivity, and converting between physical media. Network security can properly separate the IT and OT networks and protect critical assets.

Process safety is usually larger in scope, making it inherently more complex. In addition to controlling inputs and outputs, some signals from the field come from explosive areas and need to be properly conditioned. Over-voltage protection and power redundancy also become necessities in a continuous process.

Cellular remote connectivity powers communication with devices around the globe. The increasing capabilities of cloud services provide the support and data management needed for IIoT. Wireless technology enables convenient, reliable, and cost-effective communication, either on the factory floor or to remote sites miles away.

Shop floor productivity

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Time is money. The tools and resources used to build your control cabinet are key to controlling costs. Design software, marking systems, industrial tools, wire management, and cabinet accessories are often overlooked. Careful consideration of these products reduces errors and production time, translating directly to the bottom-line profitability of any shop floor.

Phoenix Contact stands behind its products with the industry’s most comprehensive Limited Lifetime Warranty. The LLW is our promise to you that the products you install in your control cabinets are built to last.

All aspects of your cabinet design and build will require tools and equipment on the shop floor. Wires and components in and around the cabinet will need to be processed, organized, and identified. This family of products ensures the production of a high-quality cabinet.

Trusted partners in industrial automation

Phoenix Contact and AWC work together to bring innovative products and world-class service to customers in the automation and control industry. From connectivity to control, Phoenix Contact gives you the confidence you need in your production systems.

Your trusted partner for the control cabinet and beyond Intuitive circuit breaker system From connectivity on the machine to through-panel and in-cabinet wiring, Phoenix Contact gives you the confidence you need in your production systems. CAPAROC is your customizable electronic circuit breaker system for overcurrent protection in 12 V to 24 V DC applications. The CAPAROC system uses data-driven power modules to customize overcurrent protection. With numerous feed-in power modules, circuit breakers, potential distribution modules, and current rails, CAPAROC makes it easy to design an intelligent communication system. Learn more at www.phoenixcontact.com/us-caparoc

AWC INCORPORATED NORTH AMERICA

“WE LIVE BY OUR MISSION OF EMPOWERING PEOPLE T O M A K E T H E G R E AT E S T P O S S I B L E I M P A C T O N T H E C O M M U N I T I E S A N D FA M I L I E S W E S E R V E T O G E T H E R ” – K I R K G O I N S , C E O , AW C I N C O R P O R AT E D

For example, AWC is particularly proud to be a key partner in the success of the U.S. Navy Fleet Oiler (T-AO) Program. This fleet of oilers for the U.S. Navy is designed to transfer fuel and cargo to its carrier strike groups operating at sea. AWC was tasked with designing, building, and implementing critical power and control components of the lead ship in the class (T-AO-205), named in honor of Rep. John Lewis (D-Ga.). The oilers feature the capacity to carry 162,000 barrels of oil, a significant dry cargo capacity, aviation capability and a speed of 20 knots. The first ship was successfully delivered, with Ship 2 (USNS Harvey Milk) ready for final delivery to the US Navy, and Ship 3 (USNS Earl Warren) preparing for Sea Trials later this year. As the company approaches Ship 9, the Navy has already committed to procuring 16 vessels in the T-AO(X) 66 | Manufacturing Outlook Issue 1

Class, and excitement is building for future projects. “Supporting and servicing customers with diverse challenges across multiple industries provides rewarding experiences and outcomes for our automation and controls experts and customers. It also allows us to remain strong during economic downturns or if one segment grows/ falls disproportionately to others,” recalls Goins. However, in the present economic environment, AWC is experiencing a strong demand across all sectors, and the company is anticipating positive impacts from emerging advances in the Internet of Things (IoT) and artificial intelligence (AI). “We are beginning to turn a corner in the ongoing global supply chain disruptions and workforce challenges affecting lead times and availability in the manufacturing and industrial parts

industry,” says Goins. AWC is looking forward to seeing how the significant trend in reshoring manufacturing plays out in the North American market. Such trends and changes in the industry make for a dynamic and forward-thinking environment for AWC.

WINNING TOGETHER A dependable and connected supply chain is fundamental to the successful operations of AWC’s customers, therefore, technical partner relationships are the most important component of the company’s “Winning Together” mantra. Despite facing recent headwinds in supply chain operations, the close collaboration with technical partners has carried AWC through the storm, so it can diligently continue to help its customers achieve success.

It’s an exhilarating time for industrial enterprises. The US is seeing considerable growth from reshoring and infrastructure projects are thriving. Although inflation and labor shortages are introducing new stresses, that pressure is accelerating the uptake of new optimizations and automations. The most momentous change, however, is artificial intelligence (AI). The pressure’s on for industrial businesses to digitally transform and harness AI to forge ahead in the modern industrial landscape. Seizing the moment will bring added precision, clarity, and foresight to business decision-making to maximize production and value. The baseline for those discoveries is, of course, data.

INDUSTRIAL DATA UNLOCKS THE PROMISE OF DIGITAL TRANSFORMATION

INDUSTRIAL DATA FOR A NEW ERA OF PRODUCTIVITY For many industrial companies, this is where the dream of digital transformation dissolves into a series of question marks. The predominant question is: “How can we get data from our industrial systems?” Those who run small-to-medium-sized operations have far-reaching goals, but the stakes are high. No matter how much capital there is to play with, digital transformation is a substantial investment. For industrial leaders, digital transformation is a messy business. It’s not ones and zeros, instant uploads, and seamless connectivity. There’s the physical world to contend with. Industrial equipment might be bolted to factory floors in isolated regions or scattered through remote areas plagued by extreme weather. A single operation might encompass hundreds of pieces of legacy equipment in manufacturing facilities dotted across the country. Industrial companies are eager to embrace data and leverage digital tools to grow, learn, and scale. But, they need no-nonsense ways of extracting data from operational technology (OT) to succeed. TACKLING THAT TREACHEROUS FIRST MILE As with most significant change opportunities, the first mile is the hardest mile. It’s a challenge to access industrial data platforms from remote and rugged field sites. Any system worth the investment needs to be robust and resilient to survive those conditions and derive and deliver data. Furthermore, a lot of perfectly well-functioning industrial and manufacturing processes have evolved over decades. Old machines that have stood the test of time are fixed to plant floors alongside state of the art equipment. That wild mix of legacy and new technology is commonplace but complicates data extraction. Industrial companies need simple data access solutions that can speak across their systems, however varied, unique, or outdated. Without them, data stays locked away. ACCESS, CONNECT, VISUALIZE Many enterprises consist of decentralized assets. To derive insights, they need to access equipment installed on site and securely bring data to a central location. That might involve access to older controllers and remote field sensors actuators and integration with multi-vendor environments. Whether it’s robots in an automotive plant or wind turbines across a vast geographical area, those assets need to connect. Installations need ruggedized networking solutions and industrial Ethernet switches to direct and secure outgoing data without interruption. Once that reliability is achieved, those can plug into analytics engines and optimization programs to drive industrial efficiency. Finally, companies need to visualize data, to make it actionable on site and beyond. Operators need durable and flexible industrial panels to integrate data across multiple devices, protocols, and the cloud.

OUT-OF-THE-BOX SOLUTIONS TO BRIDGE OT AND IT Access, connectivity, and visualization devices might seem like separate elements, but together they form the critical bridge between operations and information. OT and IT departments have traditionally had different priorities and strengths, but the right hardware and software configurations put them on the same path. Red Lion has worked with industrial systems and data for 50 years. We’ve seen IT emerge, and we understand the evolving needs of both IT and OT audiences. For OT and IT to serve each other, enterprise connectivity solutions need to be simple to use, resilient, intuitive, and secure. They need to be durable and deployable right out of the box. Companies like AWC Inc., have helped businesses transform and thrive with Red Lion’s FlexEdge® Intelligent Edge Automation Platform. As a networking router, protocol converter, advanced

ABOUT RED LION: Red Lion is focused on being THE Industrial Data Company™. We empower industrial organizations around the world to unlock the value of data by developing and manufacturing innovative products and solutions to access, connect and visualize their information. Red Lion’s global manufacturing and support facilities serve customers in factory automation, alternative energy, oil and gas, power and utilities, transportation, water and wastewater industry segments. We provide scalable solutions for cloud connectivity, edge intelligence and asset management, industrial Ethernet switches and industry leading panel meters and operator panels, to make it easy for companies to gain real-time data visibility that drives productivity. Red Lion is part of Spectris plc, the experts in providing insight through precision measurement.

Industrial Internet of Things (IIoT) gateway, and scalable edge controller, it’s an all-in-one platform that bridges OT and IT – connecting assets, delivering data, and improving productivity at the edge. DATA ISN’T MAGIC – IT’S AN INVESTMENT Companies across sectors are seizing the moment by investing in digital technology to make operational improvements. The way industrial companies can get results from those investments is through data. People who’ve worked in the industrial space for as long as we have are hardwired for different kinds of challenges and solutions. We’re entering an amazing new era of AI-powered productivity, but no matter how dazzling it might seem, data isn’t magic. Industrial companies need someone who understands the particularities of industrial data and can traverse that treacherous

first mile. They need someone who can access data in hardto-reach spaces and from legacy technology that works well for a reason. They need someone who knows how to deliver that information efficiently, securely, and intact, to different communities of users. They need a trusted partner to unlock the promise of digital transformation to maximize value from that investment. We are that partner. We are THE Industrial Data CompanyTM. To discover how Red Lion products can help you securely access, connect, and visualize your industrial data, visit www.redlion.net.

Worldwide Headquarters: 1750 5th Avenue, York PA 17403 USA T +1 (877) 432-9908 | info@redlion.net

AWC’S MAIN SERVICES “When we work together, we achieve amazing results,” Goins highlights. “Through hard work, our processes and relationships will be even stronger when the supply chain is restored to pre-COVID-19 levels of reliability and robustness.” AWC’s comprehensive network of people and technology partners sets it apart from other manufacturing entities in the North American market. The company is committed to its customers, partners, and employeeowners to create a collective focus on achieving its objectives and reaching success. Moreover, as an employee-owned company, team members are the core of AWC, and as such have an unshakeable dedication to the business. “We know this makes a difference as our teams are empowered to creatively problem solve for the benefit of our customers and technical partners,” Goins continues. 70 | Manufacturing Outlook Issue 1

Technology Partnerships: Building unmatched technology insights and expertise as the local business partner for global technology manufacturers. Applied R&D: AWC’s “Thincubators” allow engineers to continuously evaluate new automation and controls technology to find cost-effective solutions to industry challenges. Digital Technology Labs (DTLs), meanwhile, provide a safe place to test new ideas, validate technologies and work through integrations. Consulting: The AWC consultancy team can highlight new opportunities in programmable logic controller (PLC) automation, flow control, electrical power, and much more. Workforce Optimization: AWC ensures clients have the team they need (internal and external) to effectively design, build, operate, and support their customers’ automation and control systems. Distribution and Logistics: AWC’s supply chain team make sure clients have the right products at the right time and place. Systems Integration: The engineering, design and project management teams can fill technical resource gaps in either an a la carte or turnkey approach with internal and certified partner resources. Life Cycle Optimization: The technical support and services teams provide proactive and responsive support.

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“ W H E N W E WO R K TO G E T H E R , W E AC H I E V E A M A Z I N G R E S U LT S ” – K I R K G O I N S , C E O , AW C I N C O R P O R AT E D

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AWC INCORPORATED NORTH AMERICA

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The team structure guarantees efficiency and streamlines operations for swifter responses and more nimble, customized solutions. Another core belief of AWC is its wider responsibility to the communities in which it operates. “At AWC, we feel it is critical that we are responsible members of the communities in which we live, work, and conduct business. As such, we live by our mission of empowering people to make the greatest possible impact on the communities and families we serve together,” Goins comments. As AWC rapidly expands its workforce, it is positioned to continue enriching the lives of even more communities. “We have the best team in our sector, and we want to ensure continued investment in hiring, development, and training.” To facilitate this, AWC continues to invest in tools and technology in support of safety, quality, and

efficiency. In recent months, several exciting initiatives have been launched, including specialized manufacturer-led training, investments in STEM programs and projects, plus a robust college-level engineering internship program.

GREEN INNOVATIONS Beyond community-centric activities, AWC is a vital part of industries shifting towards a greener future. AWC’s technologies and services are becoming increasingly critical, particularly for aiding customers in the adaptation and conversion to electric capabilities via innovative energy technologies. AWC is on the front lines of several innovative developments which will incorporate its vast portfolio of Factory Automation and Process Technology services and capabilities. One such initiative utilizes hydrogen as the green energy of the future

to create portable power units for customer equipment, vessels, and remote facilities. AWC’s experts are harnessing the newest technologies to marry together the chemical and electrical segments to create a holistic solution within the context of green energy. Other innovative green projects AWC is currently working on include an electric vehicle (EV) manufacturing and charging station design, space exploration initiatives, and 3D home building technology, all designed to amplify the work the customers are making in green energy.

AWC INCORPORATED 24/7 Hotline: (800) 411-8400 websupport@awc-inc.com www.awc-inc.com Manufacturing Outlook Issue 1 | 73

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SAFE BOATS INTERNATIONAL NORTH AMERICA

YO U ’ R E G O I N G TO N E E D A S A F E R B OAT Delivering durable vessels and riding the wave of change that continues to ripple throughout the maritime industry, is SAFE Boats International. We drop anchor and find out more from CEO, Richard Schwarz Writer: Ed Budds | Project Manager: David Knott

he US maritime space is undergoing rapid expansion and finds itself at the helm of a tremendous technological transition. Vessel construction for both commercial and government customers has been increasing and there is a wealth of significant new opportunities on the horizon, with much of this being driven by emerging industries such as offshore wind. Although offshore wind is a fairly mature industry in Europe, it exists in its infancy throughout the US. Despite this, the continent possesses ambitious plans to develop offshore

wind as a key component of its clean energy strategy and this continues to create demand for an entirely new fleet of vessels to support the construction and servicing of new offshore wind turbines. Across North America, craft operators are also scrutinizing alternative energy options for powering vessels of all sizes, meanwhile hybrid and all-electric vehicles (EVs) are already achieving mass market acceptance. The demand for greater efficiency and lower carbon intensity in maritime operations is inspiring designers and

builders to innovate, which will no doubt usher in significant changes to the industry. Within this, there has been a steady increase in the use of other technologies in the marine space, including control and perception systems designed for the autonomous operation of vessels. Poised to effectively capitalize on this seismic change in the industrial landscape is SAFE Boats International (SAFE Boats), as the company innovatively develops strategies to address each of these emerging trends.

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“So far, it seems likely that autonomous systems will be used primarily to augment and enhance crew safety and efficiency, but the technology is clearly advancing towards a future which will include greater reliance on true autonomous operations,” introduces Richard Schwarz, CEO of SAFE Boats.

DELIVERING ELITE VESSELS Every fraction of the business at SAFE Boats starts with the company’s mission, “We provide professional mariners with the most capable boats, allowing them to complete their mission, save lives, and protect freedom around the world.” 76 | Manufacturing Outlook Issue 1

Adhering to this goal, SAFE Boats designs and builds highly reliable and extremely durable aluminum vessels that help keep military, law enforcement, first responders, and commercial mariners safe as they carry out their duties, protect citizens and work to save lives. Founded in 1996, today the company is headquartered just outside Seattle, Washington in the city of Bremerton, with a second location, the Large Craft Facility, based in nearby Tacoma. The company was named for its pioneering wraparound collar design, ‘Secure Around Flotation Equipped’. “We currently have 250

employee-owners but are growing rapidly and expect to be closer to 300 by the end of the year,” affirms Schwarz. To date, SAFE Boats has impressively delivered more than 2,500 vessels to the federal government, international customers in 70 countries, and more than 160 state and local agencies throughout the US. Utilizing a dedicated team of designers, engineers, project managers, builders, craftsmen and trainers, SAFE Boats works as an integrated team to build every vessel. Many of these specifically chosen professionals have extensive field experience, making them perfectly

SAFE BOATS INTERNATIONAL NORTH AMERICA

SAFE BOATS IMMEDIATE PRIORITIES FOR 2023 • Continue to adapt to supply chain and inflation pressures that caused disruption in 2022. SAFE Boats has been implementing strategies to mitigate the impact of material and component shortages to bring more predictability for its production team and ultimately for its customers. • Complete reactivation of the company’s Tacoma Large Craft Production Facility. This process includes continued hiring as well as investments in equipment and infrastructure for the facility. • Complete production on the first two Mk VI Patrol Boats for the Ukrainian Navy. • SAFE Boats’ longer-term objectives include the further diversification of its customers and products. This is alongside a continued emphasis on providing quality vessels to professional mariners worldwide.

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primed to continually deliver the company’s now world-renowned premium levels of service. In addition to delivering highperforming and durable vessels, SAFE Boats also provides customers with outstanding warranty, service and parts support, as well as direct access to a comprehensive in-house support network of trainers, technicians and logisticians.

PREVALENT PRODUCTION PARTNERSHIPS Representing a key portion of its burgeoning portfolio, SAFE Boats has started production of the Mk VI Patrol Boat for the Ukrainian Navy. The US Navy is procuring the vessels as part of an assistance package for Ukraine, consisting of 16 boats authorized by the US Congress. “We have two boats in production in our Tacoma facility and expect to have a third by the end of May. We will complete the first two vessels this year and will deliver additional vessels in 2024 and 2025,” Schwarz tells us. SAFE Boats has expertly executed

Experience unparalleled ballistic protection with Iten Defense, the only American company that manufactures both opaque and transparent armor products proven to keep maritime vessels, ground vehicles, and aviation platforms protected, along with the people on them. Our commitment to excellence is embodied by our motto, “Performance Under Pressure.” With decades of involvement in the armor industry, our team of experienced professionals know what it takes to deliver reliable, effective solutions. Our products are made from the highest-quality materials and rigorously tested to ensure they meet the highest standards of durability and performance. At Iten Defense, we understand the importance of safety and security in theater. That’s why we are dedicated to providing the best possible solutions, products, and services to our customers. We provide opaque and transparent armor solutions that can be tailored to fit the budget and threat requirements for any new or existing maritime, ground, or aviation platform. Our products are designed to withstand the toughest conditions and provide superior protection. So if you’re looking for the best in armor protection, look no further than Iten Defense. Our commitment to Performance Under Pressure means you can rely on us to keep you and your crew safe, no matter what.

Contact us today at info@itendefense.com or visit at ItenDefense.com to learn more about how we can help you protect your people and assets with our industry leading armor solutions.

SAFE BOATS INTERNATIONAL NORTH AMERICA

“ T R A N S I T I O N I N G T O A T O TA L LY E M P L O Y E E O W N E D C O M P A N Y C R E AT E S T H E F O U N D AT I O N TO B E CO M E A T R U E N O R T H W E ST L E G ACY ” – R I C H A R D S C H WA R Z , C E O , S A F E B O AT S I N T E R N AT I O N A L

a strategy of partnering with other vessel designers and builders around the world. These carefully constructed relationships provide access to other markets for SAFE Boats’ products and also give the company the ability to bring world-class designs and capabilities to the US market. These relationships include Diverse Marine in the UK, and Stormer Marine in the Netherlands. “We look for companies that share a culture and business philosophy that is similar to ours and develop longterm relationships that benefit both organizations.”

MASTERING A VAST FOOTPRINT The product of tireless work to expand and develop, SAFE Boats has now established a significant 80 | Manufacturing Outlook Issue 1

international footprint and has increased its focus on international markets in recent years. SAFE Boats has provided crafts to international customers through Foreign Military Sales (FMS) contracts

with the US Government, as well as direct sales to foreign governments. As a result of this, the company now boasts significant brand recognition around the world and is continuing to leverage its reputation and the ability

to provide global support to expand its international customer base. Furthermore, SAFE Boats has also formed strategic partnerships that respond to the need to address the pressing economic and social pressures facing many of its international customers. “We are working with customers to implement the co-production of SAFE Boats as well as licensing SAFE Boats’ designs when customers require greater local production. This is all part of a strategy that looks at opportunities around the world, whether or not they conform to the way the company has historically conducted business,” explains Schwarz. Elsewhere, SAFE Boats is ramping up production at its Large Craft Facility in Tacoma. “This is where we are building the Mk VI Patrol Boats for the Ukrainian Navy. We have the first two boats out

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of the initial eight vessel contract in production and are continuing to hire as we increase to full-rate production,” acclaims Schwarz. Workforce development is becoming one of the most important areas of focus for the company. In the past, SAFE Boats was able to find the skilled workers it needed within the labor market, however, the entire

industry is now facing a shortage of talent which is expected to worsen as the current workforce ages. To counteract this dilemma, SAFE Boats is working with local and regional partners and investing in workforce development in order to ensure that it has the skilled craftspeople who act as the backbone of the company’s success. It is

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the expectation that SAFE Boats’ employee ownership model will provide a unique and new way to attract and retain its team.

EMPOWERING PEOPLE Now 100 percent employeeowned through an Employee Stock Ownership Plan (ESOP), all SAFE Boats employees have the opportunity and the obligation to be engaged and active as owners of the company. Scott Peterson, one of the company’s original founders,

previously described how, “It has always been our dream and our vision to make SAFE Boats about our team and the community we live in. “Transitioning to a totally employee-owned company creates the foundation to become a true Northwest legacy. This allows an incredibly talented and dedicated SAFE Boats team to continue supporting the men and women in uniform around the world for generations to come.” The company hopes that its staff

will ask questions, solve problems, and challenge themselves and SAFE Boats itself to create a real culture of employee ownership that drives performance, adds value and creates opportunities for the entire team. Complementing its ownership model, SAFE Boats is committed to creating a diverse and inclusive environment and is increasing its outreach to the community. “We are working with high schools and technical colleges throughout the region that focus on developing

“ W E A R E L I V I N G A N D D O I N G B U S I N E S S I N A N U N P R E D I C TA B L E WORLD, AND WE WILL SURVIVE AND THRIVE BY BEING FLEXIBLE A N D C R E AT I V E ” – R I C H A R D S C H WA R Z , C E O , S A F E B O AT S I N T E R N AT I O N A L

and creating opportunities for the next generation of maritime workers,” continues Schwarz. Frequently described as a missionfocused company, SAFE Boats also knows that its customers deserve the best and that it can deliver world-class products and services that merit their ongoing loyalty and support. “I am grateful to work with an

incredible team and I’m confident that our transition to employee ownership respects and builds upon the company’s legacy of leadership and integrity,” Schwarz enthuses. “If the past three years have taught us anything, it is that we are living and doing business in an unpredictable world and we will survive and thrive by being flexible and creative.”

SAFE BOATS INTERNATIONAL Tel: 360-674-7161 info@safeboats.com safeboats.com Manufacturing Outlook Issue 1 | 85

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Frigidaire Split System Installation

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MAKING T H E WO R L D B R E AT H E EASIER

ith over 100 years of experience in the heating, ventilation, and air conditioning (HVAC) manufacturing business, Nortek Global HVAC (NGH) has set the standard for quality, consistency, and innovation from the get-go, with the priority always being optimizing and simplifying the customer experience. Philip Windham, President and CEO of NGH, had his entrepreneurial spirit ignited from a young age after watching his father make a successful living as an HVAC sales manager and eventually open up a representative firm in the 1970s. “Right out of the gate, I need to state that this is an amazing industry. I have been fortunate to work for great people in great companies over the course of my career. I have been a representative, worked in wholesale distribution, and worked for component manufacturers, but I found a home for my career at NGH,” opens Windham.

The modern HVAC business is about more than just manufacturing, as Philip Windham, President and CEO of Nortek Global HVAC, tells us Writer: Lauren Kania Project Manager: Kieron Harvey

With ample experience in the industry and utilizing the dedication and drive that all those within the company bring on a daily basis, NGH designs and builds HVAC equipment and parts for residential homes of all styles. “Our segmented approach to business allows us to focus on different subsets of our customers and includes the residential, national accounts, manufactured housing, and parts markets,” Windham adds. Additionally, NGH markets with a diverse set of brands. In residential, household names including Frigidaire, Maytag, and Gibson are prominent; in manufactured housing, NGH specifically designed and engineered the Intertherm and Miller brand for the unique needs of the manufactured home. Manufacturing Outlook Issue 1 | 87

We have the infrastructure, experience and technology that your project requires. Our philosophy Plastiexports is the leading Mexican company in plastic injection projects for various industries. We have 35 years of experience in the sector, in which we have demonstrated a sense of adaptation to the needs of our environment. Our projects satisfy the industrial evolution of sectors such as household appliances, electronics or the specialized automotive industry. Plastiexports entered the US market in 2020, with the acquisition of an industrial plant in Erwin, Tennessee. In 2021. Plastiexports reaffirmed its growth in the United States with a new headquarters in Charlotte, North Carolina (2021). Our headquarters in USA provides an opportunity to meet the regionalization needs of the clients we already work with, as well as a new business vision that arises from necessities of a world in constant transformation.

Our daily work revolves around the mission, vision and values that have made us an excellent company.

Excellence We base our work on the continuous improvement of our processes, products and services to achieve the highest level of global quality.

Respect

We treat all our employees equally. We recognize the value and potential of each person, since our employees are the cornerstone of our success.

Ethics We comply at all times with the laws and regulations set by the authorities; doing the right thing no matter who is watching.

Commitment We are committed in the creation of innovative solutions that exceed the expectations of our customers and partners.

Teamwork

We are all part of the same team and unite knowledge, effort and passion for what we do to be a leading global company.

AN AVANT-GARDE COMPANY

Plastiexports has more than 20 years serving the export market. Therefore, we have assured the inclusion of state of the art technology in each of our processes.

plastiexportsusa.com

NORTEK GLOBAL HVAC NORTH AMERICA

NGH Employees with Unit in Sound Lab at Corporate Headquarters

NGH FACILITIES AT A GLANCE • Headquarters in O’Fallon, outside of St. Louis, Missouri (MO), that houses testing labs and NGH’s primary R&D facility • Largest manufacturing facility in Saltillo, Mexico, featuring two plants and one distribution center, with equipment manufactured for the residential, manufactured housing, and national account segments • Main distribution center in Poplar Bluff, MO, serves as a warehouse and plays a critical role across all segments • Plant in Dyersburg, Tennessee, where packaged units, coils, and fabricated parts are manufactured • Research and design lab in Shanghai, China, which doubles NGH’s testing capabilities globally

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MADISON INDUSTRIES ACQUISITION NGH has been better able to serve its customers since it was acquired in 2021 by Madison Industries (Madison), which has helped breathe fresh air into the business. “Madison supports growth, innovation, and building something truly remarkable that long outlasts us,” notes Windham. By fostering an 80/20 operating system and building it into the DNA of NGH, Madison helped establish principles that allow for an accelerated focus on solutions for customers through segmentation. “The privilege of focus that our segmented approach gives us allows our teams to become experts within their vertical so we can deliver the highest degree of customer support and the best products to serve that slice of the industry.” With dedicated teams serving a variety of customers, the company’s teams develop deeper relationships with key clients, helping them solve their business challenges collaboratively and with greater ease.

This helps create a workplace where communication and new ideas thrive.

CUSTOMER EXPERIENCE AT THE CORE NGH recognizes that one size does not fit all and that each and every customer is unique. “We are committed to the relentless pursuit of supporting our distribution and OEM customers through a focus on exceeding their expectations,” Windham states. The strategic approach that NGH takes in regard to key partner development is a collaborative process with the end goal of ensuring that everyone is provided with a level of customer care that fits each unique business need. With contractors, NGH focuses on working together to understand their business and create a personal growth plan. Additionally, through the voice of customer research, they design their equipment to be easy to install and service for the contractor, making their life easier. By working together as true partners, a mutual value that allows both companies to grow is formed.

Creating Components You Can Count On

SSW AT A GLANCE OUR VALUE – Superior design, leading innovation for surface technologies, optimized local and reliable manufacturing.

An Innovative Technology Solutions Partner

TRACK RECORD - Over 75 years of

Providing our customers innovative, engineered products that enhance lives through safety, convenience, comfort, and efficiency in their homes and businesses.

solutions in fabrication, finishing, and

market leadership in engineered metal and glass components serving the appliance and HVAC industries. INNOVATION & EXPERTISE – Robust engineering and innovation capabilities deliver industry best products and engineered coatings. PRODUCT LIFECYCLE SUPPORT – Supporting our customers through the entire product lifecycle, providing full-service R&D design, product development, and large-scale

sswtechnologies.com

manufacturing and delivery across North America.

NORTEK GLOBAL HVAC NORTH AMERICA

NGH has adapted to become an agile and nimble organization over the years, adhering to every regulatory and compliance change that larger companies make while still providing that personal touch that others are unable to compete with. “We have all the operational and go-to-market capabilities that the ‘big four’ in the residential space have, but we have to do it better to compete. We have a bias for action, an entrepreneurial spirit, and the trust of our customer base. This gives us large company capabilities with a small business feel.” No business, no matter how enthusiastic, is able to find growth

without the loyalty and support of its consumers and key vendors. NGH not only recognizes this factor, but prides itself on truly fostering those relationships within the community it serves. “We are fanatically focused on our customers; it is literally called out in our long-term strategic plan – overserving our priority customers so we can grow together,” Windham emphasizes.

MAKING A DIFFERENCE Windham notes that a lot has changed over the past few years at Nortek Global HVAC, and that human nature has an aversion to change.

MANUFACTURING OUTLOOK: WHAT DIFFERENTIATES NORTEK GLOBAL HVAC AND ITS HVAC EQUIPMENT FROM THE COMPETITION? Philip Windham, President and CEO: “The difference starts with a simple mission – making the world breathe easier. “We help homeowners breathe easier by keeping their homes comfortable throughout the year. We help contractors breathe easier by designing equipment that is safe, easy to install and service. We help our distribution partners breathe easier because we focus on partnership. “We’re ultimately looking to grow our partners’ business, convert more contractors into buyers, and provide constant support. By providing a “return on air” to key stakeholders, the potential that NGH offers to those looking to find a reliable and time-tested company passionate about their industry cannot be replicated.”

Blower Wheel

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“That’s why we show up every day and celebrate the hard work, the small wins and the large ones with our teams. Trust, mutual accountability, inclusion, and respect permeate the make-up of all our teammates.” Not only did NGH embrace these changes, but it paved the way for company standards, earning it the title of one of St. Louis’ Top Workplaces for 2023. “This achievement is a testament to everyone’s hard work and dedication to our culture, our customers, and one another. It is hard to imagine a better group to have as a work family,” comments Windham. In addition to ensuring the well-being of its employees, NGH recognizes the importance of working to help the local community and creating positive change through its teams and products. One such program is NGH Gives, in which all employees receive one paid community service day each year at an organization of their choice. They can do this by themselves, with a team of employees, or with family and friends. NGH also recently donated a 16-SEER Mini-Split system to Diamonds in the Ruff Rescue Organization (DITRRO), a nonprofit, foster-based animal rescue organization, for use in a new facility, and contributed to a St. Jude’s charity, a non-profit medical corporation which focuses on children’s catastrophic diseases, in August 2023.

NORTEK GLOBAL HVAC NORTH AMERICA

www.100revolutionsstrong.com “The event featured an auction, raffle, dinner, and a special appearance by a St. Jude family. During the event, a 14.3 SEER2 heat pump and air handler was auctioned off,” Windham reveals. “We have also routinely supported Make-a-Wish, United Way, Homes for Heroes, Wounded Warrior Project, Habitat for Humanity, the Josie Foundation, and Toys for Tots.”

THE FUTURE OF HEATING AND COOLING As any major industry can attest, rules and regulations are constantly changing with new science, laws, and customer needs. In preparation for the federally mandated transition from R-410A refrigerant and introduction to A2L refrigerants, like R454B, in 2025, NGH has met this project head-on. To ensure that things are done right to prepare distributors and contractors for this change, NGH will

be introducing an entirely new lineup of A2L refrigerant products ahead of the mandate. Along with this new federal regulation, Section 25C of the Inflation Reduction Act is shaping the future of the HVAC industry by making high-efficiency heat pumps a smarter choice for homeowners and offering tax credits to homeowners with a tax liability through 2032. In addition to the segmented market model NGH offers, the company has created a team dedicated to the sole purpose of improving the customer experience from order entry to customer service. “Our Customer Experience (CX) team has decades of experience between them, so they know the industry inside and out. The goal is to listen; if our customers have any pain points, the CX team will work with internal and external stakeholders to improve processes and alleviate concerns so that NGH is the best

manufacturer to partner with,” notes Windham. Ultimately, NGH’s key priorities are to continue making the safe, quality products that contractors and homeowners rely on every day, while strengthening its commitment to driving increased effectiveness in selling techniques, marketing materials, and prospecting. “We want to continue focusing on what really matters to the business. We want to make NGH an exciting and rewarding place to work by investing in our employees, and overserving our customers to drive their success so that we can all profitably grow together,” Windham concludes.

NORTEK GLOBAL HVAC Tel: 1-800-422-4328 communications@nortek.com www.nortekhvac.com Manufacturing Outlook Issue 1 | 93

AEROSONIC NORTH AMERICA

The next generation of air data systems are being developed by Aerosonic to further enhance the safety of aircraft operations. We delve into these safety-critical systems with the company’s leadership team Writer: Jack Salter | Project Manager: David Knott

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PRECISION F LY I N G

Photo: KF21

rom ubiquitous satellite connectivity to more electrical aircraft and advanced air data systems, aerospace is ripe with more opportunities than ever. Having recovered from the significant disruption caused by the COVID-19 pandemic, the need for new game-changing solutions to meet the requirements of the North American aerospace market are once again being driven by regulatory changes and increasing demand. “As we move to flying higher, faster, and with better fuel economy, there isn’t a better time to be part of aerospace. It’s a very dynamic industry with many opportunities and new development projects such as unmanned aerial vehicles (UAVs) and electric vertical take-off and landing (eVTOL) aircraft,” opens Alexandre Lebeau, Vice President of Sales and Marketing at Aerosonic. Manufacturing Outlook Issue 1 | 95

AEROSONIC NORTH AMERICA

Timeless design and superior craftsmanship are just a few of the reasons why pilots have relied on Aerosonic to provide accurate, reliable flight data for 70 years. Founded in 1953, Aerosonic’s expertise in air data is the core competency that has enabled it to develop products that facilitate safe aircraft operations and meet the ever changing needs of the industry. The company, whose first product offerings were mechanical instruments such as airspeed indicators and altimeters, began by serving the military market and expanded to civil aviation in the 1970s before acquiring Avionics Specialties, Inc. in 1993, adding new customers, products, processes and talent to the organization. “The acquisition brought the first generation of Integrated MultiFunction Probes, Angle-of-Attack (AoA) sensors, and Stall Warning Transmitters,” outlines Rachel Kosmin, President of Aerosonic.

“A S W E M O V E T O F LY I N G H I G H E R , FA S T E R A N D W I T H B E T T E R F U E L E C O N O M Y, THERE ISN’T A BETTER TIME TO B E PA R T O F A E R O S PAC E ” – ALEXANDRE LEBEAU, VICE PRESIDENT OF SALES AND MARKETING, AEROSONIC

CONSOLIDATED PRODUCTS Aerosonic was then purchased in 2013 by TransDigm, a leading manufacturer of highly engineered components for the commercial and military aerospace industries. Multiple product lines were consolidated into Aerosonic over the past 30 years, broadening the company’s skillset and portfolio to cover all aerospace air data needs and supporting all phases of aircraft development and operations. With this consolidation of air data products into the company, Aerosonic is now an air data system center of excellence, designing, qualifying/ certifying, manufacturing and supporting safety-critical systems for all types of commercial and military aircraft, anywhere in the world. This long history of acquisitions and organic growth made Aerosonic one of the top three suppliers of air data systems to the aerospace industry 96 | Manufacturing Outlook Issue 1

Photo: Mark Wagner

worldwide, today employing 120 highly skilled employees co-located at a single facility in Clearwater, Florida. “Our comprehensive product portfolio includes an extensive range of static ports and pitot probes for all kinds of aircraft platforms, as well as FAA-PMA (Federal Aviation Administration – Parts Manufacturer Approval) pitot and pitot-static probes for commercial aircraft,” shares Lebeau. “Additionally, we offer specific air data test booms to support flight test activities, trailing cones, lightweight

pitot and pitot-static probes, and outside air temperature sensors.” The company’s portfolio also encompasses the associated safetycritical air data computers, to feed the aircraft computer and provide the necessary inputs to the cockpit. “We have expanded our probes and air data computer product lines to develop the next generation of Integrated Multi-Function Probes and Integrated Static Ports for the latest military fighter and trainer jets,” reveals Greg Van Bemden, Vice President of Engineering.

ABL Machining Inc. 37925 6th Street East #105 Palmdale CA 93550 Phone: (661)272-0340 Fax: (661)272-0370

AEROSONIC NORTH AMERICA

Photo: M-346

NEXT-GEN PROBES Integrated Multi-Function Probes developed and introduced to the market by Aerosonic provide all air data system functions to military aircraft within the most optimized package from a size, weight and power standpoint. Aerosonic’s next generation of Integrated Multi-Function Probes leverage patented technology to extend the mission capability of fighter and trainer aircraft, by implementing an independently operated bank of heaters to keep the probe free from ice during flight. The technology developed for these next-gen Integrated MultiFunction Probes will be extended to a product line of smart, Design Assurance Level A (DAL A) fixed air data probes intended for UAVs, eVTOLs, regional and business aircraft. “Our new line of fixed Integrated Multi-Function Probes will offer a range of smaller, lighter, and power-optimized solutions that are more easily integrated into 98 | Manufacturing Outlook Issue 1

space-constrained electrical aircraft,” explains Kosmin. The company is also nearing PMA issuance from the FAA for an updated icing-compliant probe for commercial aircraft application, which will allow Aerosonic to work with select partner airlines on flight trials prior to full global distribution. It follows heavy investment in far-reaching and unique R&D testing capabilities by Aerosonic, as well as production acceptance testing of its products. Thus, the company now owns two high-speed wind tunnels in its new SonicWorks™ R&D facility, along with two low-speed wind tunnels for production acceptance testing. “Our R&D wind tunnel capabilities go up to Mach 0.8, and we partner with a local university for transonic and supersonic test development,” Van Bemden informs us. Aerosonic continues to invest in its production capabilities and capacities to meet growing demand in the aviation market, heavily automating its operations as a result.

AEROSONIC - 2023 TARGETS • Progress with the development of next-generation Integrated Multi-Function Fixed Air Data Probes for UAVs, eVTOLs, business and regional jets. • Expand pitot and pitot-static probes portfolio to provide the safest and most reliable probes to airline customers. • Further automation of manufacturing processes to consistently provide high-quality and highly reliable products to OEMs and operators. • Retain highly-skilled engineers and technicians and expand its talents to meet growth expectations.

RS Hughes

AEROSONIC NORTH AMERICA

MANUFACTURING OUTLOOK: WHAT MAKES AEROSONIC A SOCIALLY RESPONSIBLE ORGANIZATION? RACHEL KOSMIN, PRESIDENT: “Aerosonic is committed to reducing our global environmental impact, supporting the health and safety of our employees,

Photo: TA-50 group in ROKAF airbase; ROKAF 2011

increasing the diversity of our workforce, and fostering mutually beneficial relationships with our communities, among other things. “Additionally, we are dedicated to conducting business in a legal, ethical and socially responsible manner. We maintain a consistent focus on innovation and value creation to benefit our stakeholders and customers with continued regard for the advancement, health and safety of our employees and the communities in which they operate. “The development of our new Integrated Multi-Function Probes also supports decarbonizing aviation as it offers lighter size and weight, which translates into fuel savings as well as lower Line Replaceable Unit (LRU) counts onboard the aircraft, thus optimizing the overall logistics chain from aircraft manufacturing to aircraft in-service support and providing best-in-class TCO.”

Last year, for example, the company automated 60 percent of its induction brazing work, with the addition of a second robot set to automate the remaining 40 percent in 2023. Two robots are likewise being added by Aerosonic to automate the entire polishing process for 80 percent of its fixed air data probes, complete with scanning systems for automated in-process inspection. “We also added a new fiveaxis CNC lathe and CNC grinder in 2022 to increase our ability to run a larger envelope of complex machine components in-house,” Nick Mancinelli, Vice President of Operations, adds.

INTELLECTUAL CAPITAL

Photo: Aram Grigoryan, Business Unit Manager, Aerosonic

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A large catalog of existing products provides great pedigree for Aerosonic, as the company aims to focus on its new product portfolio and build on the technologies that add

AEROSONIC NORTH AMERICA

® Delivering excellence in the quality of services we provide and the relationships we build with our clients in an environment of pride and individual responsibility. MRO Aerospace provides a broad range of military aircraft component repair capabilities and factory distribution. Located near Tampa, Florida, we are equipped to repair and overhaul a vast array of military aircraft components – from fighters to heavy transports. We specialize in: • Inertial Navigation Systems • Avionics • Instruments • Accessory Maintenance • Repair • Overhaul services

mroaerospace.com Photo: Aram Grigoryan, Business Unit Manager, Aerosonic

value for customers and provide the best total cost of ownership (TCO). Aerosonic is proud to serve hundreds of unique customers worldwide, from recognized commercial aircraft manufacturers to systems integrators, airlines and all kinds of operators. Though significantly smaller than its closest competitors in the air data systems space, it means Aerosonic is nimble, agile and reactive to customer demands and the market whilst enjoying strong financial backing. “Our experienced leadership team has focused and reshaped our new product offerings, through best practices in product life cycle management as well as our extensive intellectual property portfolio,” Lebeau tells us. A lean operating model equally empowers Aerosonic’s team members to take action and be accountable with minimal

bureaucracy, ensuring company processes are actually serving its employees and not the other way around. Waste is tracked and purged by Aerosonic on a daily basis, to equip its highly skilled engineers and technicians with the tools and means to keep focusing on what matters for customers. Heavily invested in the success of customers’ programs, every level of the organization plays a critical role in the company’s success and truly cares about bringing value. “Aerosonic would not have been successful for 70 years without our most important resource, our employees, who are true experts in our field and the engine that continues to drive us forward,” concludes Kosmin. “Air data is not taught in school; many of the processes and procedures were developed through

years of experimentation and analyses.” Whilst new entrants have struggled to break into the air data systems market because of their complexity and the safety-critical function they provide, Aerosonic’s immense intellectual capital and trade secrets have kept the company at the forefront of air data systems development, manufacturing and testing.

AEROSONIC Tel: +1-727-461-3000 aerosonic.com Manufacturing Outlook Issue 1 | 101

LEACH INTERNATIONAL CORPORATION NORTH AMERICA

P OW E R

DISTRIBUTION P R OW E S S Leach International Corporation has been a leader in power distribution for over a century. With new leadership, we look to the next 100 years with Vice President of Sales and Marketing, Elijah Dobrusin Writer: Jack Salter | Project Manager: David Knott

erospace, military, rail, space and high-end industrial applications worldwide are found in the most severe environments. For thousands of these applications, equipment and components are designed and manufactured by Leach International Corp (Leach). “We’re on aircraft platforms, missile systems, satellites – for flight-critical, mission-critical needs, you come to Leach,” begins Vice President of Sales and Marketing, Elijah Dobrusin. “Our clients make electrical systems, from major OEMs and aircraft manufacturers such as Boeing, Airbus, and Bombardier to tiered manufacturers like Collins, Safran, and GE Aerospace.” The company was founded by Val Leach, a young World War I radio operator. He was frustrated by the two-way technology available at

the time because it prevented a telegraph operator from breaking into or stopping a sender’s transmission, often leading to misinformation or the need to resend a message. Having seen these communication errors cost lives during the war, he invented the break-in relay, a device that revolutionized telecommunications, leading to the launch of Leach in 1919.

More than 100 years later, Leach is headquartered in Buena Park, California with an additional manufacturing site in Tijuana, Mexico. The company combines leading-edge components with unique design and manufacturing capabilities to provide custom AC/DC power distribution assemblies, including a large catalog of off-the-shelf relays and contactors. “We produce everything you need for the power distribution in your electrical system needs,” Dobrusin says. “Because we’re making important, critical, and complicated parts, we have a relatively small list of suppliers whose support is crucial,” he adds. “We’ve worked closely with those suppliers the past several years to mitigate the impacts of the COVID-19 pandemic on the supply chain. Producing Leach’s components requires rare alloys, ceramics, and difficult to manufacture Manufacturing Outlook Issue 1 | 103

LEACH INTERNATIONAL CORPORATION NORTH AMERICA

subcomponents. Our supply chain has worked closely with us to ensure we can keep delivering to our crucial customers, even when parts are difficult to source.” In addition to Leach’s key suppliers, the company has partnered with two franchise distributors that ensure parts are readily available so commercial flights can take off safely and the US military can be mission ready. “BJG Electronics, recently acquired by FDH Aero, and AAR Corp, have been two incredible distributors supporting all of our customers.”

CUSTOMIZED SOLUTIONS Not only does Leach have 3,000 active parts and the largest power distribution catalog for aviation and aerospace, but it also provides heavily customized and bespoke products for customers. Indeed, with endless customization opportunities, many of the products and systems developed by Leach have been driven by specific customer needs. “We provide unique engineering and development services so 104 | Manufacturing Outlook Issue 1

customers can co-develop products and ask Leach to produce a custom solution to meet their needs,” reveals Dobrusin. With customers being a top priority, Leach components and equipment have become synonymous with reliability and high-quality performance over the course of a century. As the company continues to contribute to mission-critical industries, Leach is inherently proud of its commitment to quality. “Quality and performance are some of our biggest differentiators. People come to Leach when things have to work; we are known for outstanding quality and industry leading performance,” acclaims Dobrusin. As aviation embraces electrification, however, there needs to be a fundamental shift in the way products are designed and systems are created. It’s one of the biggest shifts the power distribution industry is going to see for quite a while, according to Dobrusin, which makes it both an exciting and challenging market to work in.

LEACH INTERNATIONAL CORPORATION NORTH AMERICA

“Aircraft are becoming more electrified, from hybrid and fully electric propulsion to passengers increasingly wanting to use electronics and have more screens onboard,” he notes.

HIGH-VOLTAGE FUTURE As the aviation industry continues to adopt electrified aircraft, greater power and higher voltages will be necessary. In response, Leach is working on a number of 270 volt (V) power distribution systems and components to deal with the increasing power demands of electrified aircraft, including the development of a hybrid contactor.

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“We will be bringing that to 1,000V and 1,000 amps shortly, so we’re very excited about this project,” Dobrusin smiles. “Many customers have said they’re ready and excited for us to complete this innovation, so we know there is interest in the market; that’s the next big development for us.” Another major advantage of increasing voltage and power levels is that wires can be thinner and lighter. This provides the ability to reduce weight on aircraft. Weight is paramount to fuel burn, which equates to emissions and range. By reducing the weight of its products and enabling higher powered systems, Leach is

making aircraft more efficient and environmentally friendly. “We’re continuing to develop the next generation of high-powered products and solutions. That’s really where the future is,” outlines Dobrusin.

FRESH LEADERSHIP A bachelors and masters graduate in mechanical engineering from Carnegie Mellon University, Dobrusin’s career is firmly rooted in the aviation industry. While Dobrusin is a relative newcomer to power distribution, he comes with more than a decade of executive experience in aviation manufacturing. “I’ve always had the mind of an

LEACH INTERNATIONAL CORPORATION NORTH AMERICA

MANUFACTURING OUTLOOK: HOW IMPORTANT ARE PEOPLE TO LEACH? ELIJAH DOBRUSIN, VICE PRESIDENT OF SALES AND MARKETING: “People are critical. If you walk around our factory, it’s incredible how many at Leach have been here for 20, 30, or even 40 years. “That’s an incredible amount of tenure, and people are proud to be part of the great legacy at Leach. I’m relatively new to the organization, but I am proud to be part a team with this level of ownership, passion, and pride.”

“ W E ’ R E O N A I R C R A F T P L AT F O R M S , M I S S I L E S Y S T E M S , A N D M I L I TA R Y TA N K S . W H E N Y O U H AV E F L I G H T- C R I T I C A L O R M I S S I O N - C R I T I C A L N E E D S , YO U C O M E TO L E AC H ” – ELIJAH DOBRUSIN, VICE PRESIDENT OF SALES AND MARKETING, L E A C H I N T E R N AT I O N A L C O R P O R AT I O N

engineer with an acute interest in how everything around me works. When I had the opportunity to join Leach, I was excited about what was going on in the electronics market and helping to bring this 100-year-old company – with its incredible legacy and history within aviation – to the next level,” says Dobrusin, who has now been at Leach for three-and-a-half years as part of the company’s new leadership team. Under this new leadership, Leach is committing to exceptional customer service and coming together as a team to ensure growth, evolution, and innovation to meet the future of power distribution. In 2023, Leach also announced the appointment of Jamie Davy as President, an experienced senior

aerospace executive, and Victor Melendez as Vice President of Operations, who has been with Leach for nearly two decades. “It’s great to see growth from within as we elevate the future leaders of Leach,” emphasizes Dobrusin. Combined with a modern rebrand, the new leadership demonstrates Leach’s renewed commitment to its power distribution legacy and the future of aerospace innovation. Leach has made a number of investments that coincide with this change in leadership, including additional testing and engineering capabilities as well as facility and equipment upgrades. “There was a lot of equipment that had been ageing, so we focused on putting money back into the business

to ensure that we continue to produce the highest quality products that we’re known for,” Dobrusin concludes. As Leach steps into the next 100 years, it looks to its reputation and respect for quality, and is proud to continue its legacy of providing the best in power distribution.

LEACH INTERNATIONAL CORPORATION Tel: +1 (714) 736-7598 Relayed@leachcorp.com https://leachcorp.com/

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TRANSFOR TRADIT IND

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MAKSTIL EUROPE & MIDDLE EAST

Makstil is at the forefront of environmentally-friendly steel production practices. We speak to General Manager, Marija Dukovska-Pavlovska, about industry changes and challenges in North Macedonia and beyond

RMING TIONAL DUSTRY

Writer: Ed Budds | Project Manager: Nicholas Kernan

Makstil finds it extremely exciting to showcase itself as a true example of having transited towards cleaner production processes, and we work hand in hand with the Ministry of Environment to reach our goals.” The words of Marija DukovskaPavlovska, General Manager at Makstil, encapsulate the active change currently being undertaken in the European steel industry. Majority-owned by the Swiss company Duferco, Makstil is a North Macedonian regional steel industry leader with a headcount of approximately 1,000 employees that operate across two production sites,

namely the Steel Shop and the Plate Mill. Makstil’s Steel Shop consists of an electric arc furnace (EAF) to produce liquid steel, a ladle furnace for secondary refining, and three continuous casting machine lines to transform liquid steel into slabs, with the company’s production capacity amounting to more than half a million tonnes per year. The Plate Mill makes up the production side of the business, where produced slabs are reheated in a pusher furnace and rolled into plates in a high reversing mill, levelled, then cooled on cooling beds and mechanically cut or flame cut to the ordered size. Manufacturing Outlook Issue 1 | 109

HARNESSING THE POWER OF CHEMISTRY Speaking to Tim Saxon, Chief Marketing Officer for Resonac Graphite, we learn about the vital role of graphite electrodes in the production of steel, and how the company is shifting in a more environmentally conscious industry. Can you briefly describe your business and how you support Makstil? Resonac Graphite (Resonac), formerly known as Showa Denko Carbon, manufactures ultra-high power (UHP) graphite electrodes which are critical components used in the remelting of steel scrap. To produce its steel plates and slabs, Makstil owns and operates an electric arc furnace (EAF). When using an EAF to produce steel, a high-powered electric arc is used to melt and recycle steel scrap into new steel. The electricity used to melt the scrap is transferred solely through the graphite electrode. In 2022, approximately 30 percent of the world’s steel (or approximately 565.5 million metric tonnes) was produced via EAFs – making steel the most recycled material in the world.1 As of 1st January, 2023, Showa Denko Carbon officially became Resonac Graphite BU. Why the change? We like to say, “New look. Same values.” Showa Denko Carbon has a very strong name in the global steel industry, but our parent corporation has undergone a substantial transition over the past three years. In 2023, after acquiring and completing the integration of Hitachi Chemicals, the Showa Denko Group officially became Resonac – a company whose mission is to change society through the power of chemistry. The name “Resonac” was chosen to convey the desire to RESONATE with Chemistry. Much like our business unit which

literally transforms carbon into graphite, we recognise that the world is also undergoing fundamental change. As a global community, we must place a priority on sustainability and responsibility, recognising our obligation to future generations. We know our purpose is not just to simply manufacture and sell a product. As a business unit and corporation, it is Resonac’s responsibility to co-create innovative technologies and services with partners inside and outside of our business. With these synergies, we want our combined solutions to be more than just the sum of its parts. Fortunately, the “new” steel industry provides a multitude of opportunities for co-creation. Speaking of increased focus on sustainability in manufacturing, how do you see your business changing? The increased focus on sustainability and environmental stewardship is having a meaningful impact on the graphite electrode industry. As mentioned earlier, recycling steel via EAF only accounts for approximately 30 percent of the world’s production, but that method of production also results in approximately 75 percent less carbon emissions than other methods of steelmaking.2 As more steelmakers focus on sustainability, the industry is seeing a considerable increase in the construction of electric arc furnaces, which will significantly increase the demand for graphite electrodes. Given that, how does Resonac plan to address those issues? The graphite electrode industry, much like the steel industry, is a cyclical one. Both industries also require significant capital investment and face major threats from offshore competition – particularly by government-subsidised producers who are not required to adhere to safety or sustainability standards. Despite these threats, Resonac has a very strong history of investment in the global EAF steelmaking industry. The company (then Showa Denko) produced its first graphite electrode in Omachi, Japan more

than 85 years ago. Over the next several decades, Resonac grew the graphite electrode business as the EAF steel industry grew. In 1988, it purchased the Ridgeville, South Carolina facility in the US, and in 2017, purchased the A Coruña Spain, Steeg Austria and Banting Malaysia facilities from SGL Carbon. Resonac is now the world’s largest manufacturer of UHP graphite electrodes with plants strategically located to meet regional demand with regional supply. Our most recent and perhaps most exciting investment, is the acquisition of Automation (AMI), which was announced in June 2023. AMI is an industry leader in providing innovative process control and automation technology that improves customer operating efficiency. AMI’s Meltshop Division is at the forefront of EAF automation and optimisation and has the largest group of EAF specialists in the world. The Industrial Systems Division is a prominent supplier of customised automation and power control systems for steel, paper, cement, oil and gas, transportation, and mining. As an industry leader and vital part of the EAF steelmaking supply chain, Resonac is in a unique position to use our innovative technologies, our products, and our services to help in the transition from traditional methods of steelmaking to new, safer, cleaner, more efficient, and more flexible production. While we understand that business philosophies and practices are ever-changing, we are happy that we have ongoing projects and co-creative efforts with various partners around the world. Does this include Makstil? Yes, of course! While both companies historically maintained a very professional “buyer/seller”

Tim Saxon, Chief Marketing Officer for Resonac Graphite

relationship in the past, Resonac’s strong partnership with Makstil was solidified during the most extensive graphite electrode crisis to date. In late 2017, after years of (ex-China) graphite electrode production rationalisation, the Chinese Blue-Sky Initiative forced the immediate stoppage of approximately 40 percent of its graphite electrode capacity.3 Almost instantly, global EAF steelmakers were left without a way to melt the steel they were dependent on producing for their survival. Even if available, prices for electrodes increased by approximately 10 times in three months, which turned out to be a small price to pay for the ability to produce product and fill customer commitments. Needless to say, the crisis found different suppliers and different consumers negotiating various, creative ways to withstand the predicament and keep the electrode supply lines open. Some of those solutions turned out to be less advantageous in the longer term, but proved necessary for the survival of several steel businesses. During this tumultuous time, Resonac worked diligently to develop true “win-win” partnerships that will ensure our industry not only survives… but thrives during the next crisis. The framework of these partnerships was the foundation for Resonac’s Volume Supply Partnership (VSP), which was recently renewed by Maksil, as well as our Strategic Supply Partnership (SSP). We are now excited to start “co-creating” with selected partners on a new

Optimisation Supply Partnership (OSP), but more to come on that endeavour. Makstil has discussed some projects and ambitious plans for continued diversification and expansion in the coming years, so you are confident Resonac can help them achieve their goals? Absolutely. Although names can change, a company’s purpose and legacy lie in its DNA. At Resonac Graphite, supporting our partners in the electric steelmaking industry is exactly what we do. World Steel Association (worldsteel.org) Steel Manufactures Association (steelnet.org) 3 Industry estimates 1 2

MAKSTIL EUROPE & MIDDLE EAST

The steel plates are used for applications such as shipbuilding, pressure vessels, bridge construction, mining and industrial machinery, and windmill structures, all of which require high quality and high strength. The Plate Mill gives Makstil the opportunity to offer its clients rolled plates with various dimensional ranges adapted to their needs. This represents the company’s trademark and is recognised by Makstil’s clients across Europe. “As steel is an industry that has historically been associated with large amounts of emissions, I am very happy to say that is now in the past. We express pride in confirming that we are causing no direct harm to the environment through our production activities, and we have clear visibility on the impact of the Carbon Border Adjustment Mechanism (CBAM),” explains Dukovska-Pavlovska. Makstil traditionally serves its domestic regional market and neighbouring countries, such as Bulgaria, Croatia and Serbia, with the majority of its sales in the markets of the European Union (EU), which North Macedonia is foreseen to join in the next decade according to the government’s

predictions. Moreover, for DukovskaPavlovska, the market seeing the biggest growth of late is Turkey, where Makstil’s customers take advantage of the geographical proximity and availability of the company’s final production output. Makstil’s distinctive adaptability towards its clients’ needs is also recognised across the pond, as the company exports non-negligent quantities towards the US and Canadian markets. However, Makstil’s operation in the steel industry has not come without its challenges. “The steel industry is facing particular issues linked to the availability and sourcing of the raw materials and ensuring the uninterrupted supply chain needed in our production processes. In addition, it must confront the volatility and unpredictability in terms of prices,” elaborates Dukovska-Pavlovska. “This can create confusing ground for us, as we want to maintain optimal prices for our clients, but we also need to fulfil the various commitments that Makstil has. This includes transitioning to a more resource-efficient production process, having the least possible environmental impact, and contributing to and supporting the

local communities where we operate. We also want to be at the forefront of circular economy practices, not only within the North Macedonian industry, but also regionally.”

SCRAPPING OLD STEEL By design, Makstil is a mini steel mill. Unlike the integrated mills that produce new steel from iron ore in a blast furnace (BF), mini steel mills such as Makstil melt, refine and recycle scrap metal by using EAF technology. By using this technology, Makstil belongs to the 30 percent of steel producers in the world leveraging this more environmentally-friendly method compared to BF. Furthermore, as an active participant and supporter of the circular economy, Makstil only uses scrap metal as an input material for the production of slabs and hot rolled plates as a final product. “Makstil is focused on saving the resources we use in our production processes (natural or otherwise). We actively support the concept of the circular economy by encouraging the rational use of secondary raw material (steel scrap) as well as the reduction, reuse, and recycling of waste,” says Dukovska-Pavlovska.

MANUFACTURING OUTLOOK: COULD YOU TELL US ABOUT YOUR DRIVE TO BRING INCLUSIVE CHANGE TO THE STEEL INDUSTRY? Marija Dukovska-Pavlovska, General Manager: “As a female leader who has progressed throughout my career by working within organisational development, finance and human resources in various industries, being offered the opportunity to lead one of the largest steel industrial companies in our region was obviously an enormous challenge for me, not least because of the perilous and complicated times we live in. “I intend to use my time at Makstil not only to confirm and strengthen our position as a market-leading specialised steel producer, but also to prove that a woman can successfully thrive in what is often considered a masculine work environment and serve as an example for generations of girls and young women that they too can indeed succeed in fields where their success isn’t necessarily guaranteed from the beginning.”

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An industrial metrology

WWTECH provides its clients with a complex way of problems resolving, offering them three-dimensional coordinate measurements and a full 3D documentation. Due to accurate measuring devices FARO (Laser Tracker, Measuring Arm) WWTECH makes it is possible to carry out uniquely accurate, fast and non-contact measurements, the results of which can be analysed in a real time.

Service

Fully functional equipment is fundamental to the company’s success. Every machine has precision elements, bearings, and a number of other parts, that enable its efficient operation. Those main elements, which ensure correct machine operation, require specific solutions in case of a breakdown. Leaks, cracks and grooves are issues that have to be eliminated to ensure proper operation.

Safety

In all undertaken activities, WWTECH gives priority to safety. The health of our staff, society, and respect for the environment are the factors which determine our whole team’s activities, and other aspects of our work, such as transportation or cooperation with a third parties. www.wwtech.com

MAKSTIL EUROPE & MIDDLE EAST

“ M A K S T I L F I N D S I T E X T R E M E LY E X C I T I N G TO S H OWC AS E I TS E L F AS A T R U E E X A M P L E O F H AV I N G T R A N S I T E D T O WA R D S C L E A N E R PRODUCTION PROCESSES, AND WE WORK HAND IN HAND WITH THE MINISTRY OF ENVIRONMENT TO R E AC H O U R G OA L S ” – M A R I J A D U K O V S K A - P AV L O V S K A , G E N E R A L M A N A G E R , M A K S T I L

“All metal waste generated during the production process, and part of the refractory waste, is returned to the very same production process. The remaining waste that cannot be recycled is further selected and disposed of, to be handed over to authorised and trusted partners for their own use downstream.” According to Dukovska-Pavlovska, any inert and non-hazardous waste, such as slag from an EAF, through the process of crushing and separating, is divided into fragments and is transformed from waste into raw material where it can be fully used as a buffer for road construction, as well as a foundation for an asphaltic or concrete pavement, cement, and various cement products. This circular economy is designed to save natural resources and energy, creating added value and ultimately a healthier and cleaner environment with new employment opportunities. On top of this, it improves product competitiveness, focuses on positive society-wide benefits, and provides increased earnings that contribute to the sustainable development of modern civilisation and an economy fit for the challenges of the years ahead. “At Makstil, we are proud to take the lead on these initiatives and believe we are setting an example not only for other fellow companies in our industry, but also towards those working in fields very different from our own,” Dukovska-Pavlovska adds. “I am especially humbled by Makstil being awarded as the most environmentally friendly company, 116 | Manufacturing Outlook Issue 1

granted by the municipality where we are based (which is also home to other heavy industry actors). The Green Agenda award from the Economic Chamber of North Macedonia further confirms Makstil’s contribution towards safeguarding the environment as well as our commitment to zero waste.”

LEADING GREEN Despite its size as a mini steel mill that produces steel plates from recycled scrap, Makstil is present in the markets of more than 40 countries and collaborates with approximately 500 customers, reaching trading destinations in several continents and meeting the needs of the most demanding clients. Makstil prides itself on offering a 45-day delivery window, with the flexibility to provide specific materials necessary for projects at the exact requested time, and answers to complicated specifications with no limitations in terms of the number of ordered pieces, dimensions, and qualities within the company’s product range. “We are recognised for our excellent after-sales service with a prompt response time, yet one of our key features of business for clients is our dedication to practices that are more environmentally friendly,” Dukovska-Pavlovska says. “One of our leading environmental protection activities, Photography ©Viktor Mácha from both a technical and financial aspect,

Manufacturing Outlook Issue 1 | 117

MAKSTIL EUROPE & MIDDLE EAST

MANUFACTURING OUTLOOK: CAN YOU ELABORATE ON THE COMPANY’S OPTIMISATION AND HEALTH AND SAFETY DEVELOPMENTS? Marija Dukovska-Pavlovska, General Manager: “During the last five years, Makstil heavily invested in the field of health and safety for all its employees. Our Board of Directors and management commitment is of paramount importance for stepping up and leading the whole process by example through the top-down approach. “Our commitment to the ISO 45001 occupational safety and health management was integrated during the last year at all levels of the company. I would like to underline that in addition to achieving the highest quality production and financial results, the company has maintained an optimal level of health and safety of our employees and improvement of the working

was the installation of the Dedusting System in the Steel Plant (Filter Plant – FP) carried out back in 2015. Thanks to this investment, we succeeded in almost completely absorbing the dust particles emitted during the melting process. This dust is then packed, and we get further value from it as we collaborate with verified external partners for its collection and distribution outside Makstil. “For more transparency with our stakeholders, Makstil continuously monitors the dust emissions in the air and on a quarterly basis publishes the results that are fewfold lower than allowed by local and EU norms. Makstil continued the practice of publicly announcing the emissions of solid particles emitted from the production chimneys during the operation of the factory, which once again confirms the company’s commitment to promoting full transparency in its business operations.” Makstil is the first company in the country to obtain an Environment Product Declaration (EPD) for hotrolled plates. With the EPD, Makstil confirms its commitment to protect and preserve the environment

Viewing itself as the frontrunner of environmental improvements in the heavy industry sector in North Macedonia, Makstil is following a vision to produce steel plates that satisfy the needs of its customers in an environmentally sustainable way

conditions. “We should not forget that this

by continually reducing the environmental impact of its products. The declaration provides an overview of the objective, verified, and comparable environmental performance of the hot-rolled plates manufactured on the company’s production site.

industry is one with a high risk, and we continuously work on process and equipment improvement to enhance workplace safety. In parallel with that, we continuously increase awareness of all employees to identify potential risks and to participate in developing countermeasures.

A LOW CARBON VISION

Monitoring the trends in the industry, we are following many indicators related to health and safety, and our strategic goal fully encourages, motivates, and obliges us to be a company that has a “zero by choice” approach.”

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The environment and employee well-being are the twin pillars of Makstil’s vision. Regarding the latter, the company has achieved significant results in employee retention and satisfaction through renewed and innovative solutions aimed at better engagement and fair reward systems and plans for its workers. Yet the

business’ operational focus is set on the continued sustainability-centric mission to help alter the industry for the good of the planet. “Overall, the industry is dealing with different sets of specifics; regulatory, environmental, availability of raw materials, or qualified staff – you name it,” Dukovska-Pavlovska tells us. “Adjusting an entire robust steelmaking organisation with traditional business practices to new production process trends is a challenging enough activity for a female leader, especially with the new challenges regarding the transformation of production towards green steel. It is an industry environment where personal resilience and the ability to

innovate is critical to staying ahead while fully satisfying and retaining the loyalty of our clients. Nevertheless, Makstil has successfully proven that this is an achievable goal despite the challenges posed.” Viewing itself as the frontrunner of environmental improvements in the heavy industry sector in North Macedonia, Makstil is following a vision to produce steel plates that satisfy the needs of its customers in an environmentally sustainable way, and it has already started with activities related to the decarbonisation process that it will continue moving forward. “Decreasing greenhouse gas (GHG) emission levels requires the

introduction of some changes in all production aspects as well as delivering goods and services. In this context, Makstil has already introduced investments in renewable energy and carbon-free sources,” Dukovska-Pavlovska concludes. “We are proud of what we have achieved thus far, and we thoroughly follow the European Commission’s goals of reaching net zero by 2050.”

Tel: +389 2/3287 023 https://makstil.com Manufacturing Outlook Issue 1 | 119

TRYMAX SEMICONDUCTOR EQUIPMENT B.V. EUROPE & MIDDLE EAST

120 | Manufacturing Outlook Issue 1

WHEN

PLASMA M AT T E R S

As the company boasts some of the most advanced equipment in the industry, CCO Peter Dijkstra discusses how Trymax Semiconductor Equipment B.V. has achieved this unique position Writer: Lucy Pilgrim | Project Manager: Nicholas Kernan

mongst many titans of the manufacturing industry in the Netherlands, Trymax Semiconductor Equipment B.V. (Trymax) is the company of choice for the design, manufacture and marketing of plasmabased processing and equipment solutions. Trymax was first founded in 2003. Its name stands as a re-lettering of the Matrix plasma asher machines that are widely regarded in the industry.

“Our mission was clear, to provide service and support for European customers who depended on Matrix-like machines,” Peter Dijkstra, CCO of Trymax begins. As time went on, the company faced new challenges; between 2007 and 2009, it realised that the ageing Matrix machines had exceeded their serviceability limits, prompting Trymax to start manufacturing its own equipment.

Manufacturing Outlook Issue 1 | 121

TRYMAX SEMICONDUCTOR EQUIPMENT B.V. EUROPE & MIDDLE EAST

This signified a major transformation, as it shifted from a service-orientated provider to a cutting-edge manufacturer. “This strategic move allowed the organisation to adapt to the evolving semiconductor landscape and stay at the forefront of technological advancements,” Dijkstra tells us.

PRECISION PERFORMANCE Trymax’s headquarters, situated in Nijmegen, has an impressive total capacity of 4,200 square metres (m2), which includes a manufacturing cleanroom, a state of the art demo lab, an engineering and manufacturing area, and a logistics, storage, and technical area, with an equipment build capacity of up to 250 toolsets per year. When situated within the wider network of facilities, Trymax is proud to be the number one European semiconductor equipment cluster, with one of the strongest supply

THE TRYMAX TEAM “Trymax is like one big family. We go above and beyond to employ a talented team of experts in the field of low-temperature plasmas, subsequently ensuring best-inclass plasma sources and solutions. Therefore, all positions are important to ensure that we supply quality performance and agreed upon equipment on time.” - Peter Dijkstra, CCO

chains. This position is bolstered by the fact that Trymax does all its final assembly and testing in-house, ensuring streamlined operations and maximum efficiency across its entire production. The company’s service offering entails diligent plasma solutions in ashing, descumming, etching, surface preparation, and ultraviolet (UV) curing and charge erasure. To achieve this, Trymax provides an industryleading product line known as NEO, which is designed to address a wide range of applications throughout the semiconductor manufacturing process. All platforms found in each NEO can handle two or more substrate types and sizes simultaneously without any hardware changes. Furthermore, each product has a strong focus on all types of substrate handling, catering to substrate sizes from 77 millimetres (mm) up to 330mm, with a focus on 150mm,

Industry Leader in Custom Built PTFE, FFU, AMC, HEPA Fan Filter Units TES-CleanAir Systems and Airflotek are the leading supplier of standard, non-standard and custom engineered fan filter units (FFU), for semiconductor process tools, equipment front end module (EFEM), pharmaceutical restricted access barriers (RABS), Pharmaceutical battery powered transfer carts, Nuclear HEPA fan units, nuclear bag-in/bag-out HEPA filtration units, OEM memory, and various mini environment applications. For more than 30 years in business, we have grown to be an industry leader by building strong relationships with multiple vendors, cleanroom product providers, manufacturers, and customers. These collaborations have helped to grow our knowledge base so we can identify the exact needs of our customers and find a solution that is the right fit for each unique application. As a proud supplier to Trymax Semiconductor Equipment B.V. since 2009, our long-standing partnership proves our dedication and commitment to our mission of Reliable Product Unmatched Service - Satisfied Customers. For more information, please visit us at: www.tes-cleanairsystems.com and www.airflotek.com

TES-CleanAir Systems 242 W. Larch Road, Suite F Tracy, CA 95304 510-656-5333 www.tes-cleanairsystems.com Airflotek 1075 Highway 124 Building 300, Suite 400 Hoschton, CA 30548 678-475-9800 www.airflotek.com

FIVE DIFFERENT PLASMA SOURCE TECHNOLOGIES COMMERCIALISED BY TRYMAX • Reactive Ion Etching (RIE) • Microwave

“ W E R E C E N T LY O P E N E D A S A L E S A N D SERVICE OFFICE IN THE US. AS SUCH, O U R TA R G E T I S T O I N C R E A S E S A L E S , B U T W I T H O U T L O S I N G Q U A L I T Y, P E R F O R M A N C E A N D I N N O VAT I O N ” – P E T E R D I J K S T R A , CCO, T RY M A X S E M I CO N D U C TO R E Q U I P M E N T B .V.

• Dual Source (DS) • Directly Coupled Plasma (DCP) • Capacitively Coupled Plasma (CCP) Depending on the number of wafers a customer prefers to run, Trymax has platforms for: • 100 wafers per hour (single chamber system) • 150 wafers per hour (double chamber system) • 240 wafers per hour (four chamber system)

124 | Manufacturing Outlook Issue 1

200mm and 300mm. Further features include platform flexibility with five different process modules, alongside a detailed system configuration based on the application specification budget. With a global network of processing chambers, Trymax puts its burgeoning success down to the precision of its NEO products, as its equipment sets the company apart with its ability to process two different wafer sizes simultaneously. This feature proves particularly valuable in a transitioning market, such as the LED industry, in which Trymax’s

machines can process wafer sizes from 150mm to 200mm, outrunning older machines that need extensive modifications to accommodate new wafer diameters. “By already accommodating varying wafer sizes, Trymax’s machines mitigate the risks associated with equipment reconfiguration,” elaborates Dijkstra. “An additional feature is the machine’s automatic recognition of wafer size and the ability to handle it seamlessly, streamlining production processes and enhancing efficiency.” At the peak of Trymax’s innovative

TRYMAX SEMICONDUCTOR EQUIPMENT B.V. EUROPE & MIDDLE EAST

Microwave Plasma Sources The smart, efficient and service friendly plasma source technology Scope of Application: • Photoresist stripping • Isotropic etching • Surface cleaning and conditioning Typical etching rates are: • Photo resist 5µm/min • Silicon 3µm/min • SiN and BPSG 1µm/min • Thermal Oxide 250nm/min eeplasma produces microwave plasma sources for Trymax for the photoresist strip and isotropic etching processes for semiconductor production. • The plasma sources have a maximum power of two or three kilowatts (KW) and the plasma chamber can be equipped with quartz, ceramic or sapphire tubes. • The plasma source is characterised by its very compact design, its high level of service friendliness and its very large process window.

Manufacturing Outlook Issue 1 | 125

solutions, it deploys a sophisticated robot arm that can be equipped with several specialised substrate gripping tools, designed for a diverse range of uses, whilst greatly advancing the organisation’s product line.

CONTRIBUTING TO A BETTER WORLD Correlating with the technical innovations of the company, Trymax is honoured to participate in a multitude of projects that facilitate a better and more sustainable future. Projects like SMART Photonics, for example, allow a much higher data exchange rate by using optical communication. This offers a vital aid to hospitals, providing significantly important components to a vast range of medical equipment. Additionally, the power management integrated circuits (power IC) markets in each NEO have recently had a renewal, as the silicon 126 | Manufacturing Outlook Issue 1

TRYMAX SEMICONDUCTOR EQUIPMENT B.V. EUROPE & MIDDLE EAST

From design to production: your partner for high-quality solutions.

Innovation based on proven technology

INFICON is a leading provider of innovative instrumentation, critical sensor technologies, and advanced process control software that enhance productivity and quality in sophisticated industrial vacuum processes.

www.ara-aalten.nl +31 (0)543 47 25 01 info-request@ara-aalten.nl

was replaced by short interval control (SiC) material. “Industry leaders have made a calculation that suggests if we replace all silicon material for power applications by SiC, we can skip 880 nuclear power plants worldwide, making a huge impact,” Dijkstra informs us. Furthermore, as a key support to the company, Trymax’s logistics supply chain is essential for streamlined operations. Receiving all components and materials on time results in shorter lead times. “We work very closely with all our suppliers. A good example of this was during the COVID-19 pandemic when a major German customer ordered several ashing tools. We couldn’t supply all the tools on time, due to missing an essential component from a German company. “Following our customer’s intervention, who purchased the

These analysis, measurement and control products are essential for gas leak detection in air conditioning/refrigeration and automotive manufacturing and aftermarket.

missing component, we managed to reduce the delayed shipping time, providing an indispensable helping hand,” he recalls.

QUALITY AND QUANTITY As the year continues, Trymax is focusing on increasing its market share in the manufacturing industry. It has much to look forward to as the semiconductor sector expands its capabilities, including new UV curing technology. To be a proactive part of the industry shift, the company brings to the fore the NEO 2000UV tool, an advanced UV curing and charge erasure system which utilises a single UV bulb. The new equipment acts as a bridge tool for two wafer diameters and is specifically designed for applications from three to eight-inch substrates, enabling greater accuracy. Consequently, due to its highly ultra-modern technology and

influential presence in the industry, Trymax has experienced market recognition from many major automotive suppliers to the German, South Korean, North American, and Japanese car industries. “We’re currently number one in Europe and number two in China. Additionally, we recently opened a sales and service office in the US. As such, our target is to increase sales, but without losing quality, performance and innovation,” Dijkstra closes.

TRYMAX SEMICONDUCTOR EQUIPMENT B.V. Tel: +31 24 350 0809 info@trymax-semiconductor.com www.trymax-semiconductor.com Manufacturing Outlook Issue 1 | 127

S T E E LY RESILIENCE Despite significant regional and global disruption in recent years, Metinvest Trametal has resolutely overcome adversity to remain at the forefront of steel plate manufacturing, as Managing Director, Roberto Re tells us Writer: Jack Salter | Project Manager: Nicholas Kernan

METINVEST TRAMETAL EUROPE & MIDDLE EAST

taly is a leading industrial hub in Europe, with a high concentration of enterprises active in the construction, machinery, transport, and energy sectors. Many leading Italian, and indeed European industrial players, are customers of Metinvest Trametal (Trametal), one of the continent’s foremost steel plate manufacturers located in San Giorgio di Nogaro. “We serve more than 700 industrial customers, and our core sales markets are Italy and Germany, the two main steel consumption regions in Europe,” states Managing Director, Roberto Re. Founded in 1985 and part of the Metinvest Group (Metinvest) since 2008, Trametal rerolls semi-finished steel slabs into plates according to the final use requirements of various projects, such as bridges and other big structures, ships, specialised machinery, vessels for liquids and gases, and more. The company’s steel plates have been used as the structural core for many iconic projects in Europe and beyond, namely the San Giorgio Bridge in Genoa, the sarcophagus of the Chernobyl Nuclear Power Plant in Ukraine, and the Hudson Yards Cultural Centre in New York to name a few. Trametal’s production process comprises three main phases, the first of which preheats semi-finished steel slabs to temperatures exceeding 1,100 degrees Celsius. The slabs are then passed through a rolling strand that consists of four vertically aligned rolling cylinders, reducing their thickness from 250-300 millimetres (mm) to just 12-100mm. This phase not only forms the plates in the required dimensions, but also guarantees the mechanical properties of the material, such as strength and toughness. Manufacturing Outlook Issue 1 | 129

METINVEST TRAMETAL EUROPE & MIDDLE EAST

In the third and final phase, the rolled plate goes through the necessary final procedures. Additional reheating, for example, can improve the internal structure of the plate, which is especially important for use in heavy duty structures. “Other final procedures may include levelling, surface treatment, trimming plate edges or cutting the plate into the initial shape, and various testing techniques,” adds Re.

DISRUPTION TO PRODUCTION With a state of the art production facility, the company is responsible for around five percent of total steel plate production in Europe, equating to around 550,000 tonnes per year. However, production has been impacted by a number of disruptive regional and global events in recent years. The onset of the COVID-19 pandemic led to the temporary halt of industrial activity in Italy, affecting Trametal’s output in Q2 2020 before the gradual reopening of the economy allowed it to recover and perform strongly in 2021.

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Further significant disruption in the European steel market has since been caused by Russia’s full-scale war in Ukraine, and subsequent sanctions introduced by the EU against Russia have drastically shifted the market balance for Trametal’s products in Europe. “More than three million tonnes of Russian finished steel was banned from the EU, and Ukrainian imports were significantly reduced due to interrupted production and the blockade of seaports,” Re explains. The spiralling energy tariffs caused by these sanctions, and supply interruptions for natural gas and crude oil, resulted in European production costs increasing by up to

30 percent. Although energy tariffs gradually went down by early 2023, the inflationary spike is still out of control and interest rates will remain elevated in the near term. In such conditions, credit availability is significantly restricted, especially for smaller businesses, negatively influencing the confidence of industrial buyers in terms of customer relations, steel purchasing, and the level of service. “Our customers in downstream industries such as machine building and construction are currently living through a crisis of confidence caused by the lack of credit and geopolitical turmoil,” acknowledges Re.

“ E V E N D U R I N G T H E WA R I N U K R A I N E , T H E C O M PA N Y R E M A I N S A S T R O N G A N D R E L I A B L E PA R T N E R F O R O U R K E Y C U STO M E R S I N E U R O P E ” – R O B E R T O R E , M A N A G I N G D I R E C T O R , M E T I N V E S T T R A M E TA L

METAL FABRICATION

- A constantly growing reality; - 20 years of experience in the iron and steel industry; - Certiﬁed UNI EN ISO 9001 IAF 17, UNI EN ISO 9001 IAF 18 and UNI EN 1090 company; - Construction and installation of metal structures in medium-heavy carpentry; - Assembly, disassembly and demolition of industrial plants.

www.cromes-srl.it Information: info@cromes-srl.it Phone: +39 030 6381678

METINVEST TRAMETAL EUROPE & MIDDLE EAST

MANUFACTURING OUTLOOK: CAN YOU TELL US ABOUT YOUR INVESTMENTS IN CUTTING AND MILLING MACHINERY? Roberto Re, Managing Director: “Over the last five to 10 years, we have observed more of the initial processing of steel, such as large format cutting, shift from final customers upstream to intermediaries or directly to plate mills. Moreover, plates with trimmed edges are the format of choice for many customers in Europe, and we were facing a limited capacity to process the required volume of material. “After a detailed assessment of market requirements, in 2020 we completed an investment into a new cutting centre. We have enlarged the working area of the mill, and installed an advanced high productivity plasma-cutting machine. “The new equipment enables us to process customised plate formats including pre-worked shapes and edges for welding operations. We have also de-bottlenecked our regular edge trimming operations, allowing us to produce material according to prevailing customer requirements.”

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SWITCHING SUPPLIERS Prior to the war, Trametal was fully integrated in the Metinvest supply chain and was getting all its core raw materials – steel slabs – from sister companies in Ukraine. This integrated production chain meant that Metinvest was controlling the quality of products and reliability of delivery, from the extraction of raw materials (iron ore and coal) through to steelmaking and finished steel manufacturing. Sadly, an attack on Mariupol, which is the site of Metinvest’s two key steel mills, Azovstal and Ilyich Steel, meant that Trametal lost captive slab supply of around 600,000 tonnes per year. “We certainly plan to recover our captive slab supply, which would restore the standing of Trametal as an integrated supplier,” Re affirms. Thanks to the exceptional resilience of Metinvest and its willingness to protect its European business, Trametal has managed to switch the

procurement of slabs from group sources in Ukraine to independent suppliers in Europe and other regions, mainly Asia and India. After the initial period of crisis management, Trametal has thus temporarily shifted to its “standalone” business model of working as an independent reroller. “Even during the war in Ukraine, the company remains a strong and reliable partner for our key customers in Europe. “Maintaining our customer base through this challenging period, and providing the required level of service and product quality, has been an extraordinary achievement,” emphasises Re. The shift in suppliers became an enormous challenge for Trametal, as the regularity and reliability of supplies had changed and the production team had to switch rapidly to new specifications compared to

METINVEST TRAMETAL EUROPE & MIDDLE EAST

Projetman for company more thanspecialised 40 years on Projetman Macchine Macchine S.r.l. S.r.l.,operates an Italian in domestic the design, and international in order to supplyand its technological customers machines and development and Markets construction of machines systems, has technological plants. operated for more than 40 years on domestic and international markets. Projetman stands beside beside the the customer, Customer acting in the as design, Projetman Macchine Macchine S.r.l. S.r.l. stands a “partner” development andofconstruction of machines machines and and technological technological plants. systems, for the creation “tailor-made” acting as a "partner" for the creation of "customer tailored" solutions.

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the previous 15 years. “In the transitionary phase of the next two to five years, we may prioritise suppliers with a lower carbon footprint in order to improve our product portfolio and be economically sound once the Carbon Border Adjustment Mechanism (CBAM) comes into force in 2026.”

GREEN TRANSFORMATION Despite the near-term challenges posed in particular by the war in Ukraine, Trametal sees exciting prospects for its products in the longer run due to the European Green Deal and the future transformation of industries and infrastructure. The green transformation requires additional renewable energy equipment, such as the construction of wind farms and the dynamic growth of electric transport and its related charging infrastructure. Finally, and most importantly, new

standards and regulations aiming for improved environmental footprints at the construction and utilisation phases will be introduced over the next two or three decades. “For us, all these changes mean the emergence of new projects based on steel plates, produced to the most advanced environmental standards,” outlines Re. As a European producer, Trametal was involved in discussing and shaping local and imported steel regulations amid the EU’s ongoing green transition. Among other things, the company has also formally assessed its carbon footprint, which is low considering the nature of its rerolling operations, and issued its Environmental Product Declaration in 2023, which is the current industry standard in terms of footprint assessment. The majority of the emissions embedded in Trametal’s products

currently arise from the level of steelmaking in the various regions where it now procures slabs. “Ideally, we will strive for the usage of low-emission slabs as a feedstock in the next five years and the longer run,” Re shares.

MARKET CONSOLIDATION Meanwhile, Trametal plans to consolidate in the shipbuilding and industrial infrastructure markets, where it is a leading player. Fundamental changes have been brought to the former in the last 20 to 30 years, as the manufacturing of tankers and cargo ships has completely relocated from Europe to Asian hubs such as Japan, South Korea, and China. However, the most lucrative highvalue segments of shipbuilding, passenger vessels, and specialised niche vessels such as Arctic explorer ships have remained in Europe. Manufacturing Outlook Issue 1 | 133

METINVEST TRAMETAL EUROPE & MIDDLE EAST

MANUFACTURING OUTLOOK: HOW WERE YOU INTRODUCED TO THE STEEL PLATE INDUSTRY? Roberto Re, Managing Director: “During my youth, I met perhaps the most important person in my personal and professional life, Bruno Spotorno. We were neighbours, and attended the same university where I received my engineering degree. “After around six years of working in telecommunications, Bruno offered me the opportunity to join him at a steel company. He was looking for a young specialist with sales skills, a lot of energy, and a willingness to take on challenges, so he could dedicate himself to the technical and production side of the business. “Initially I was not too excited about the prospect. It seemed like an “old economy”, but my curiosity convinced me to pay a visit to Trametal’s production site in late 1998. After this visit, on the back of my trust and respect for Bruno and in view of the strong support from the Malacalza family, who owned Trametal at that time, I decided to take the step. “It was and still is a fantastic journey, even if I strongly suffered from the loss of Bruno who died in a tragic accident in December 2016, which remains my personal tragedy today.”

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“Several players in Europe, such as Fincantieri Group in Italy and Meyer Weften in Germany, are dominating the global cruise ship market with long, high-value order books. These companies are among the key customers for Trametal and our strategy has always been to provide the best possible products and services to big shipyards.” As a specialised producer of steel plates for the shipbuilding industry, Trametal is able to produce both wide (3,000mm) and thin (4-8mm) plates that are required for certain parts of ships. Such material has to be fully certified by shipbuilding societies including DNV GL, Bureau Veritas, and Lloyd’s Register. “Certification is a complex process of production site inspections and quality assurance for each delivered batch of material,” Re informs us. There are also some additional customer requirements related to the

basic preparation of material before delivering it to shipyards, such as surface cleaning and painting, which the company is able to provide. Trametal was built with niche segments such as shipbuilding in mind, and in time has become a supplier of choice for many key players in Europe. “Over the years we added equipment and processes to fulfil the most complex requirements in the shipbuilding segment.” The situation is similar in the industrial infrastructure market, where Trametal works with several leaders in the manufacturing of bridges and large structures in Italy and across Europe. To guarantee the long-term reliability of industrial infrastructure projects, Trametal’s steel plates must correspond with very strict requirements in terms of dimensions, strength, and the quality of the internal structure.

“ W E C E R TA I N LY P L A N T O R E C O V E R O U R C A P T I V E S L A B S U P P LY, W H I C H W O U L D R E S T O R E T H E S TA N D I N G O F T R A M E TA L A S A N I N T E G R AT E D S U P P L I E R ” – R O B E R T O R E , M A N A G I N G D I R E C T O R , M E T I N V E S T T R A M E TA L

STRATEGIC AND OPERATIONAL INVESTMENT In sectors such as shipbuilding, construction fabrication and specialised machinery, Trametal has demonstrated its flexibility and customer orientation over the years through a number of strategic partnerships. Indeed, the company’s core competitive advantage is the ability to tailor its production and service to the needs of key customers. “We are also proud to have one of the most competent sales networks among Italian producers, with specific competencies in our target industries,” adds Re. Trametal likewise continues to upgrade its equipment in order to provide state of the art products and services to customers. The majority of current investments

are operational rather than strategic, however, the company is always in dialogue with customers in order to assess emerging opportunities. There is an extensive project pipeline related to the post-war reconstruction and modernisation of Metinvest assets in Ukraine, including investment in the group’s iron ore mining facilities to expand the production of direct reduced iron ore pellets, a key raw material for European green steel. “We also plan to upgrade our steelmaking equipment in Ukraine to bring it up to date with the evolving requirements for low-emission steel in Europe,” Re says. This ties into Trametal’s objective for the remainder of 2023, which is to ensure competitive service, quality and prices for customers in order to reach target production and profit levels.

Looking further ahead, the company expects the market climate to significantly improve on the back of economic recovery and the emergence of various steel-intensive public and private projects in Europe. “We aim to expand our existing strategic contracts in Europe and acquire new ones, mostly in our core segments of steel construction, shipbuilding and energy, and to guarantee quality products independent of raw material market disturbances,” concludes Re.

METINVEST TRAMETAL Tel: +39 010 576 2911 trametal@trametal.it metinvestholding.com trametal.metinvestholding.com Manufacturing Outlook Issue 1 | 135

P E R P E T UA L STEEL There are few materials as reusable as steel. We speak to Radek Strouhal, CEO of Vítkovice Steel, about the company’s commitment to quality metal production and the wider community in the Czech Republic Writer: Ed Budds | Project Manager: Nicholas Kernan

VÍTKOVICE STEEL EUROPE & MIDDLE EAST

teel is a unique alloy. A compound of iron combined with carbon and additional minerals, it is highly versatile as a material for construction, manufacturing and a multitude of other industries. Historically, steel has been a defining discovery for civilisations, as both expensive to produce and made only in limited quantities. Steel was therefore saved as a luxury commodity, forged to form durable tools for specialist trades or blades for banquets and battlefields. Today, steel cutlery is no longer reserved for lords and ladies of the court but is found as a staple of every house in Europe thanks to modern means of mass metal production. What makes steel truly special is its unlimited service life and status as the most recyclable material in the world. Based in the Czech Republic, the promotion of steel production and reuse to help turn the globe green is exactly what Vítkovice Steel (Vítkovice) sets out to achieve. “Throughout our whole lives we are surrounded by products which are vital for our civilisation because their properties and use are simply irreplaceable,” introduces Radek Strouhal, CEO of the company. “Such are the products that Vítkovice has been producing since the 19th century.” Vítkovice is a leading European manufacturer of heavy plates and one of the last producers of sheet piles. Its main products are used in a wide range of industries, including construction, energy, transportation, and engineering. Vítkovice transforms steel into heavy plates, shaped cutouts and sheet pilings, which are in turn used as parts of major bridges, various buildings and high-performance machines. With two mills in the northeast city of Ostrava and employing around 850 people, Vítkovice’s mission is to provide its customers with high-quality steel products and services that meet needs and exceed expectations. Manufacturing Outlook Issue 1 | 137

VÍTKOVICE STEEL EUROPE & MIDDLE EAST

This industry-leading position is born from an extensive history in steel production. Vítkovice began in 1828 in Ostrava and continues to this day as a traditional, prominent manufacturer of hot-rolled heavy plates, sheet piles and cut shapes in Europe. Since its establishment, the company’s mission has always been to help build the country.

Radek Strouhal, CEO, Vítkovice Steel

“The traditions and achievements of our predecessors commit us at Vítkovice to provide quality work and services for our customers,” Strouhal tells us proudly. “We connect society with quality products. For example, our heavy plates make bridges which are a focus area for us. “Sheet piles are used for steel and bridge structures or as structures for water management and flood

DID YOU KNOW...? Steel has a deep and rich history. Its qualities have been discovered and exploited across the globe with the oldest recordings of steel production and use being those of Anatolia (most of present-day Turkey) in approximately 1800 BCE, as well as mass steel production in China during the 3rd century CE. This global acknowledgement of steel has also led to unique workings, methods and processes when it comes to producing, shaping and strengthening the material. There are multiple historical examples of the Bessemer Process having been used, which involves the use of blasts of air to remove impurities in molten steel. When it comes to warfare, steel has been used as the most innovative metal for centuries, able to be morphed to form larger blades that retain their shape and durability in the heat of combat to a greater extent than iron. The versatility of steel gave rise to plate armour that reinvented feudal warfare. Japanese “jewel steel” was folded many times over and refined to create the iconic katana - the weapon of the Samurai – as well as the famous technique known as “Damascus Steel”, a form of pattern-welded steel. Knowledge of this particular technique was passed from the Middle East or India, eventually making its way as far as Scandinavia, where Vikings believed (and proved on the battlefield) that such pattern-welded swords were magic.

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protection. We burn our cut shapes on the most modern equipment, which is also why they are often used for machine parts where a high level of precision is required. Quality control of products is carried out in our own accredited testing laboratories, which are equipped with the most advanced testing facilities.”

CARBON COMMITMENT The Czech Republic has a long history of producing high-quality steel products and has a well-developed infrastructure to support the industry. The country is also strategically located in the heart of Europe, making it an ideal destination for exporting products to customers in the region and beyond. For Strouhal, the metal manufacturing industry has always been intriguing. “I became interested in the steel industry after graduating from college with a degree in economics,” he shares. “I began working for a steel, iron and ferroalloy trading company where I quickly became CFO. After a few years I moved to help to save Tatra, the heavy vehicle manufacturer, firstly as CFO and later as CEO. After five years I got the opportunity to come to Vítkovice as CFO and now, as the CEO of a heavy plate mill, I am proud to lead a dynamic and innovative company in this exciting industry.”

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VÍTKOVICE STEEL EUROPE & MIDDLE EAST

Vítkovice is constantly exploring opportunities for increasing the quality of its services, decreasing the negative impact on the environment and delivering higher value to its customers. Despite this, the company has no plans to enter new markets, but instead focuses on utilising its proximity to customers and high product range to cover all client needs with swift delivery and the highest quality. Primarily focusing on in-house development, Vítkovice has undertaken internal upgrades such as the renewing of its lighting systems across all facilities. It is one of many actions taken by the company’s internal environmental, social and governance (ESG) team which is dedicated to improving Vítkovice’s profile in the environmental and social field. “We recently upgraded the lighting systems across all our company facilities as part of our commitment to sustainability and reducing our environmental impact,” Strouhal says. “The new LED lighting systems are more energy-efficient and have a longer lifespan than traditional lighting, reducing our energy consumption and maintenance costs while also improving the working conditions for our employees. “Vítkovice is also committed to sustainability and reducing its environmental impact. We are constantly exploring new ways to improve our operations, reduce our carbon footprint, and increase our value for society. We are proud to be a leader in the steel industry in this regard.”

FORGING A COMMUNITY FOUNDATION Moving ahead into 2023 and beyond, Vítkovice’s key priorities for the coming year are to continue to improve its production capabilities and increase its efficiency and productivity. On top of this, the

Exterior of the Ostrava plant

“ T H E C I T Y O F O S T R AVA I S N O T O N LY T H E P L AC E W H E R E W E WO R K , B U T A L S O W H E R E WE LIVE, AND WE HELP THE PEOPLE AROUND US” – R A D E K ST R O U H A L , C E O, V Í T KOV I C E ST E E L

company is also focusing on developing new products and services that meet the changing needs of its customers as well as expanding its presence in key markets. “We simply focus on keeping up the pace with our customers and their needs so they can fully rely on us and our products,” Strouhal comments. While productivity is core to the company’s focus, there is a greater aspect of the operation that Vítkovice is passionate about – people and the community sit at its heart and are the forethoughts of the business. Vítkovice keeps track of social, cultural and sporting events and is actively involved wherever needed, with employees engaged in fulfilling social responsibilities. The company’s Vítkovice Steel Foundation Fund also

helps those with social or medical needs. “The city of Ostrava is not only the place where we work, but also where we live, and we help the people around us,” Strouhal elaborates. “We are not indifferent to what goes on in our surroundings. We care about the environment, we believe that it is important to give back to the communities where we operate, and we are committed to supporting disabled or seriously ill people in our area. Our company set up its foundation many years ago and through it, we do our best to support people to better their lives.”

Tel: +420 595 696 077 www.vitkovicesteel.com Manufacturing Outlook Issue 1 | 141

HÖGANÄS BORGESTAD GROUP EUROPE & MIDDLE EAST

N E W AG E INDUSTRY We speak to Hanna Landell, Managing Director of the Production Unit at Höganäs Borgestad Group, about the company’s collaborative impact in making manufacturing a greener industry across Europe and beyond Writer: Marcus Kääpä | Project Manager: Nicholas Kernan

or almost 200 years, Höganäs Borgestad Group (Höganäs Borgestad) has mastered the design of refractories, materials highly resistant to heat and critical to a multitude of industries within the manufacturing space. Headquartered in Sweden, the company is a small but key player in the field of refractory production, working with companies of all sizes across Europe, helping drive forward industrial sustainability practices from Nordic countries. Höganäs Borgestad understands that designing refractories is an art that has developed through the centuries, where material composition, grain size and density are combined with precision. Meanwhile, thermal conductivity, permeability, abrasion resistance and thermal expansion are measured meticulously, as necessary for operational needs. This is something that the company has perfected over the years. Indeed, since the industrial revolution, customers have turned to Höganäs

Borgestad for their most challenging requirements, and together with such customers, the company has developed turnkey solutions. “Making refractory materials may seem simple, but there is much more to it; they are the result of engineering, experience, innovation and passion,” introduces Hanna Landell, Managing Director of the Production Unit at the company. “Through close partnership with our customers, we know that cement and steel producers, along with other industries around the world that require top-notch refractories, are not actually looking for shaped or unshaped solutions. They’re looking for something else - something that will support their profitability and efficiency ambitions, and something that will deliver value longer than any other refractory.” In light of this, customers turn to Höganäs Borgestad for turnkey solutions. Moreover, the company works closely with them all the way from design and installation to support, maintenance and beyond. Manufacturing Outlook Issue 1 | 143

HÖGANÄS BORGESTAD GROUP EUROPE & MIDDLE EAST

LEADING FROM THE NORDICS Höganäs Borgestad is a traditional Nordic producer with a main market presence in the Nordic region, but also a global presence with customers in more than 70 countries. This international market penetration has been achieved through following customers abroad to deliver global production units as the company has in the Nordics. “It is very exciting to work in the Nordics at the moment,” says Landell. “There are so many big initiatives in various industries and all of them with a focus on reducing CO2 emissions and being fossil fuel free.” According to Landell, the Nordics represent a small yet impactful market, in many ways driving development in the industry. Refractory technology itself is also seeing continual advancement with innovative ways being discovered that minimise the environmental impact of refractory production. Within this, there exist new materials and new technologies in order to make the refractory process more sustainable. “In the past, refractories have sometimes been seen as commodities, but now more than ever they are being viewed as high-value products that need to be durable, high performance and green,” Landell continues. “This sustainability-centric view is becoming increasingly important for

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MANUFACTURING OUTLOOK: CAN YOU TELL US ABOUT YOUR INTRODUCTION TO REFRACTORIES AND HÖGANÄS BORGESTAD? Hanna Landell, Managing Director - Production Unit: “The first time I encountered refractories was in 2009 during my studies. I wrote an essay at the installation company Macon, which was part of Höganäs Borgestad. Before this, I didn’t know anything about refractories. “After my studies, I continued consulting in the company for around 18 months before I entered the steel industry. In 2016, I got the opportunity to come back to Höganäs Borgestad and the refractory industry and have been here ever since. It is a very interesting space!”

us as well as the customers we serve, and it is the direction that we – and much of the industry – is headed.” For Landell, the refractory and manufacturing space in Europe is equally interesting as it is challenging. The steel industry, for example, is

a strong sector and one in which continual advancement and innovative initiatives are being driven forward, with its future geared towards going green and away from a reliance on fossil fuels. Of course, this then has its own impact on the refractory space; new production methods require new designs, new materials, and production adjustments, making the space full of busy developments. “A lot is happening! We are seeing a great deal of interest regarding secondary raw materials – which can be used in manufacturing processes in place of or alongside virgin raw materials – as well as circular business models,” Landell explains. “This level of change shows that sustainable production methods are on everybody’s agenda.”

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This is an area in which the Nordics boast a foremost position, far ahead of other countries in Europe and leading the drive with their industry initiatives.

GREEN PRODUCTION This environmental drive is showcased in Höganäs Borgestad’s own production methods. The company utilises recycled materials and applies a greener production process, for example having the option of using electricity generated by hydropower, with furnaces running on natural gas. Höganäs Borgestad has used recycled materials in the core of its products for many years now, but the company’s aim is to constantly increase the amount used and is planning investments in production equipment to increase this scope. However, it is Höganäs Borgestad’s collaboration with its customers that sees the company make a truly greater and better impact on the environment. “We have been working with businesses on reducing energy consumption for many years, but now there are other initiatives on top of this, and these only provide more opportunities for us to help companies make such an impact,” Landell affirms. “Höganäs Borgestad is working on a number of projects. In the cement industry, for instance, one of our recent and ongoing projects revolves around the refractory design and linings, and this is aimed towards decarbonising the sector overall.” In the automotive space, Höganäs Borgestad is utilising its production facility and its knowledge of materials to reduce CO2 emissions in automotive production. Each of these kinds of developments further impacts the refractory industry, leading players such as Höganäs Borgestad to think outside of the box and seize opportunities when it comes to production development, utilising 146 | Manufacturing Outlook Issue 1

HÖGANÄS BORGESTAD GROUP EUROPE & MIDDLE EAST

industry knowledge to the advantage of partnering businesses and the environment. “Höganäs Borgestad is quite a small company, but we work with a large variety of industrial players,” Landell tells us. “We can also be quite specific in our offerings when it comes to delivering customer needs and making specific developments for such clients. “This is the strength of having R&D and production in place because we can cater to different companies of different sizes with various needs.” Not only does Höganäs Borgestad boast professional R&D and production teams, but the company also has its installation department that tries to install the materials directly. This level of combined capability makes Höganäs Borgestad a strong partner in the market to go to, the primary advantage of being a smaller and more flexible provider.

COLLABORATION IN THE INDUSTRY It is because of Höganäs Borgestad’s reliability and professionalism that it has been chosen as a partner to multiple European industry players. At the end of 2021, Höganäs Borgestad made the strategic decision to cease the production of standard bricks in Sweden and instead become more specialised in the market. The company subsequently entered a partnership with German firm Refratechnik Holding GmbH (Refratechnik), revolving around sourcing those types of specialised products to Höganäs Borgestad. Today, Höganäs Borgestad produces unshaped products, special bricks and hand-rammed products at its plant in Bjuv (Sweden) with the other bricks coming from Refratechnik, as Höganäs Borgestad is now Refratechnik’s chosen partner in the Nordic countries. Höganäs Borgestad also cooperates on some projects

“ O U R V I S I O N O F “ S E T T I N G N E W S TA N D A R D S ” M E A N S T H AT W E A R E S E T T I N G T H E L I N E . O U R V I S I O N I S TO O F F E R T H E M O ST E F F E C T I V E H I G H -T E M P E R AT U R E S O L U T I O N S T H AT I N C R E A S E T H E P R O D U C T I V I T Y A N D CO M P E T I T I V E N E SS O F O U R C U STO M E R S . O U R M A I N G OA L I S TO O P T I M I S E YO U R B U S I N E S S A N D W E ST R I V E TO S E T N E W I N D U ST RY S TA N D A R D S ” – H Ö G A N Ä S B O R G E S TA D G R O U P

Manufacturing Outlook Issue 1 | 147

HÖGANÄS BORGESTAD GROUP EUROPE & MIDDLE EAST

“ C O M B I N I N G O U R K N O W L E D G E A B O U T C E R TA I N I N D U S T R I E S A N D M A R K E T S M A K E S O U R PA R T N E R S H I P S V E R Y P O S I T I V E , E F F E C T I V E A N D I M PAC T F U L” – H A N N A L A N D E L L , M A N A G I N G D I R E C T O R - P R O D U C T I O N U N I T, H Ö G A N Ä S B O R G E S TA D G R O U P

outside this territory. The quality of Refratechnik’s products meets high standards regarding technology and sustainability and for both companies, their combined knowledge is a strong competitive advantage. “Refratechnik has a lot of 148 | Manufacturing Outlook Issue 1

developments and production in Europe as well as outside of the continent, and it is also close to where we operate which is very helpful strategically,” Landell says. “But importantly, Refratechnik already makes use of recycled

materials and has a very sustainabilitycentric approach to its operations and business, as well as innovative thinking. “Combining our knowledge about certain industries and markets makes our partnerships very positive,

effective and impactful.” Moving ahead, Höganäs Borgestad is looking towards a green future. Sustainability is the foundation of the company’s strategy, and it hopes to launch some new products this year geared towards helping customers reduce their environmental impact. Decarbonising various industries will require innovation and investment; to do so, Höganäs Borgestad constantly challenges existing solutions in the pursuit of something better and finds new ways to solve the challenges of

today and tomorrow. “We aim to take the next step to increase recycling and improve energy efficiency in our own production,” Landell concludes. “We have always strived to design and produce high-value products that are durable, high-performing, and green. “We are also looking into what we need when it comes to production facilities for continued development. Of course, this means using more secondary raw materials and

increased processing, and looking into what we can do with what we have, or if we will need to work with additional partners to achieve our vision.”

HÖGANÄS BORGESTAD GROUP Tel: + 46 42 855 00 info@hoganasborgestad.com www.hoganasborgestad.com Manufacturing Outlook Issue 1 | 149

Marelli and its Ride Dynamics division are co-creating the future of mobility. President of Marelli Ride Dynamics, Antonio Ferrara, discusses the suspension and shock absorber solutions providing comfort, safety, and performance Writer: Jack Salter | Project Manager: Kierron Rose

CHANGING THE

AU TO M OT I V E DY N A M I C M

obility – the movement of people and goods – is undergoing a transformational shift. The future of mobility is being driven by disruptive technologies and trends such as autonomous and electric vehicles (EVs), with far-reaching implications for the way we live. With a strong and established track record in innovation and manufacturing excellence, the mission of Marelli is 150 | Manufacturing Outlook Issue 1

to transform the future of mobility through working with customers and partners to create a safer, greener, and better connected world. One of the world’s leading global independent suppliers to the automotive sector, Marelli employs around 50,000 members of staff and enjoys a global footprint that includes 170 facilities and R&D centres across Europe, Asia, Africa, and the Americas.

MARELLI EUROPE & MIDDLE EAST

“Marelli’s approach is based on co-creating the future of mobility with its customers, suppliers, and leading technology partners,” outlines Antonio Ferrara, President of Marelli’s Ride Dynamics division. Serving all major carmakers at a global level and focused on advanced technologies around vehicle personality and performance, Marelli helps customers shape a unique driver experience and differentiate their vehicles of the future.

MARELLI EUROPE & MIDDLE EAST

COMFORT AND SAFETY Marelli Ride Dynamics is a global player and one of several divisions that Marelli operates through, responsible for the realisation of suspension components and shock absorbers. The company also provides advanced technologies for a range of other key automotive product areas, including automotive lighting and sensing, electronic systems, interior experience, electric and internal combustion powertrains, green technology solutions, thermal solutions, and motorsport. Marelli Ride Dynamics in its current configuration was created in 2019, as a merger between the existing company’s shock absorber and suspension system business units, the latter of which Ferrara joined as CEO in 2014 before being appointed to lead the newly created division. “We have the capabilities in both ‘souls’ of the division (suspension

RIDE DYNAMICS DIVISION – CORE COMPETENCIES • Development and production of chassis components with a focus on lightweighting and durability targets. • Flexibility in the different materials selection to achieve the best cost/performance compromise (high grade steel, aluminium, composite, cast iron). • Focus on shock absorber tuning definition to achieve customers’ requirements in terms of comfort and performance. • Implementation of advanced technology in order to guarantee excellence in terms of quality and automation.

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Antonio Ferrara, President, Marelli Ride Dynamics

and shock absorbers) to develop and industrialise solutions for the customer that not only reach the requested carmaker’s expectations,

but give them added value for the final user, improving the driving experience,” he says. The ride dynamics of a motor vehicle are determined by the forces generated by the contact between the tyre and the road surface. Shock absorbers help to control the impact and rebound of a vehicle’s springs and suspension. Along with smoothening out bumps and vibrations, the key role of the shock absorber is to ensure the vehicle’s tyres remain in contact with the road surface at all times, ensuring the safest control and braking response. With a deep knowledge of active and passive solutions, lightweight materials and product durability, Marelli Ride Dynamics develops solutions focused on the tuning definition in order to achieve the comfort, performance and safety requirements of customers. “Within Marelli, the Ride Dynamics division develops a huge variety of

MARELLI EUROPE & MIDDLE EAST

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Marelli at CES Las Vegas 2023

Manufacturing Outlook Issue 1 | 153

MARELLI EUROPE & MIDDLE EAST

suspension and shock absorber solutions for a wide range of customer-oriented applications, to ensure a remarkable and safe driving experience,” Ferrara tells us.

E-MOBILITY OPPORTUNITIES In the suspension field, there are opportunities in e-mobility for Marelli Ride Dynamics due to the increased complexity of the chassis structural components that must sustain the new weight balance of vehicles. “The car market is increasingly moving towards EVs and this represents a significant challenge for suppliers of underbody components such as Marelli Ride Dynamics, but also an opportunity with the technological and engineering that can be offered to customers,” observes Ferrara. “Obviously, this requires continuous investment in R&D to

THE MARELLI ATTRIBUTES Drive results – Marelli is determined to achieve impactful and sustainable results. Entrepreneurial – Taking the lead to invest in the future with an outside-in view. Innovative – The company is willing to do things differently to achieve better results. Accountable – Marelli takes responsibility for its actions and results. Inclusive – Engaging the hearts and minds of a diverse team to achieve stretch goals. Aware – Conscious of the impact of its behaviours and authentic in its interactions.

154 | Manufacturing Outlook Issue 1

always be present in the market with the best and most innovative solutions.” The challenge of remaining competitive is hugely exciting for Ferrara, and thanks to Marelli Ride Dynamics’ engineering team, considered best-in-class in such design and development, the company is improving its competitive position in the market. The Ride Dynamics division is currently working on the evolution of its electronic shock absorbers, in order to have an even wider portfolio for its customers. These range from the two-mode switchable damper (Dual Stage Valve) and continuous variable shock absorber (Smart Damping Control (SDC) System) to the new, sophisticated Double SDC. “These are all “semi-active” shock absorbers, but Marelli Ride Dynamics

is also developing a “fully active” solution that enables a suspension system capable of smoothly levelling the vehicle in almost all driving conditions, obstacles, turns and road surfaces,” reveals Ferrara. Another connected future mobility trend is the rise of Advanced Driver Assistance Systems (ADAS), which is increasing the market share and diversifying the customer base of Marelli’s electronic shock absorber technologies. In order to optimise such investments in technology and shorten the time to market in a fast and dynamic world, it is integral for Marelli to find and develop good partners and suppliers. “We are proactively acting on this, continuing to differentiate our supplier panel and introducing local players that are showing very high levels of quality and are ready to play in the global market,” Ferrara says. “We are also working to take some existing technical partnerships a step forward to catch new market demands, parallel to building up new partnerships that will increase our ability to grow and diversify our customer portfolio in emerging markets, particularly China and India.”

Marelli Ride Dynamics production process

DESIGN FOR SUSTAINABILITY Marelli has chosen a very clear path towards sustainability, and Marelli Ride Dynamics is developing disruptive solutions that will be capable of achieving carbon neutrality. The division is strongly committed to achieving its ESG 2025 objectives for a more environmentally friendly product offering, through both the evolution of internal transformation processes and interaction with its main raw materials suppliers. “We have started to develop a fully active electromechanical rotary damper suspension, an oil-free electric actuated solution providing outstanding comfort and handling for an unprecedented riding experience,” shares Ferrara. “This active suspension solution is able to regenerate the energy it requires by capturing the vertical movement of the car caused by the asperity and roughness of the road.” The company’s sustainable approach permeates every project under development, and in Q2 2023,

“ M A R E L L I ’ S A P P R OAC H I S B AS E D O N C O - C R E AT I N G T H E F U T U R E O F M O B I L I T Y W I T H I TS C U STO M E R S , S U P P L I E R S , A N D L E A D I N G T E C H N O LO G Y PA R T N E R S ” – A N T O N I O F E R R A R A , P R E S I D E N T, M A R E L L I R I D E D Y N A M I C S

all new projects will begin from the initial concept design phase by calculating the carbon footprint involved. Designers will have access to a database of materials and subcomponents, where they can select the best solution with the lowest carbon footprint. “In other words, we will effectively apply a “design for sustainability” procedure,” Ferrara elaborates. As well as aiming for the most sustainable solutions, Marelli is targeting rational production capacity utilisation and customer diversification at its various plants in the coming year. On the product side, meanwhile, the launch of a complete and innovative

portfolio of fully active suspensions, both hydraulic and electromechanical, will be customised for different segments and vehicle needs as Marelli and its Ride Dynamics division continue to co-create the future of mobility.

www.marelli.com

Manufacturing Outlook Issue 1 | 155

SIPH AFRICA

CONSERVING A CRUCIAL COMMODITY SIPH’s unwavering mission is the production and marketing of natural rubber from its plantations and partner smallholders across West Africa. We learn more about this indispensable resource with Marc Genot, the Managing Director Writer: Ed Budds | Project Manager: Poppi Burke

frica is a land of excellence for natural rubber, a crucial raw material for sustainable mobility. The consumption of natural rubber is inextricably linked to the development of the automotive industry and tyre production. This vast consumption is driven by growth in many emerging markets across Africa, including China and India. Natural rubber demonstrates characteristics that give it a competitive advantage over synthetic rubber: a lower heat generation and a great capacity to recover its original shape. Such qualities are essential for tyres, especially for heavy goods vehicles, agricultural vehicles, aircraft, and for use in civil engineering. The African natural rubber industry has witnessed monumental expansion and tremendous growth throughout the last two decades. Historically, rubber

manufacturing started in the Amazonian region of South America in the 19th century before extending to Asia, where about 90 percent of its total production is still recorded today across Thailand, Indonesia, Vietnam, China, India, and many other nations. Closely following this, Côte d’Ivoire has risen through the rankings, currently reaching the position of thirdworld producer, with an expected 1.5 million tonnes of rubber this year, an

impressive figure that was less than 300,000 tonnes 20 years ago. Across the African continent, Ghana has also made promising improvements to its rubber agricultural output, now producing nearly 100,000 tonnes per year. Today, 95 percent of the world’s natural rubber is produced by small farmers with an average farm size of four hectares each. Part of this vast, expansive industry, SIPH is located in West Africa and almost exclusively involved in natural rubber production and processing. Part of SIFCA, a large Ivorian group that produces palm oil, cane sugar, and rubber, SIPH is now moving into the renewable energy sector. Having spent most of his career in West Africa ensconced in various sectors such as tyre manufacturing, car distribution, and general trade, Marc Genot, Managing Director of SIPH, now finds himself involved in the rubber plantation and processing business. Manufacturing Outlook Issue 1 | 157

Sphere Corporation Sdn Bhd

Global Suppliers and Specialists in the Design and Fabrication of Crumb Rubber Machineries ISO 9001:2015

Established in 1977, Sphere Corporation Sdn Bhd (Sphere Corporation) is a highly reputable company that specialises in the design of processing facilities and factories for the crumb rubber industry, design and manufacture of crumb rubber machineries and installation and commissioning of crumb rubber processing facilities. As a global supplier of crumb rubber machinery, Sphere Corporation undertakes machinery supply on a turnkey basis apart from selling individual machines. The scope of work includes technical assistance, training and troubleshooting services as and when clients require them. Sphere Corporation skilled engineers have over the years developed a wide comprehensive range of topquality products and provide quality services, supplying to factories in more than 30 countries worldwide.

SPHERE CORPORATION’S EFFICIENT AND ECONOMICAL PROCESSING LINES PRODUCE: • Technical Specified Rubber (TSR 3L/5L, TSR 10/20, TSR CV 50/60) • Ribbed Smoked Sheets (RSS) Mainline Equipment: • Slabcutter • Macerator • Creper • Dry Mode Prebreaker • Granulator • Hammerhill • Mobile Coagulum Crusher • Pelletiser (Coarse, Intermediate, Fine) • Rotary Cutter

• Shredder • Trolley Dryer • Twin Chamber Press • Twin Screw Prebreaker • Homogeniser • Air Scrubber • Trolley Cleaning Station • Rubber Sheeting Battery

TO MEET YOUR RUBBER MACHINERY NEEDS Sphere Corporation is ISO-certified and provides customisation needs with continuous improvement via R&D, offering the following services: • Design of machines and processing system • Fabrication • Installation

• Commissioning • Engineering services • Training services • Advisory services

The all-round services provided by Sphere Corporation: Engineering Services Providing design of processing layout and engineering drawings for in-factory civil works, in factory electrical cabling and water piping. Installation and Engineering Providing experienced and skilled mechanical and electrical supervisors to supervise installation of the processing facility. Commissioning Services Providing experienced commissioning engineers to lead the commissioning of the processing facility. Trouble Shooting Services Providing assistance in solving mechanical and processing problems. Training Providing in-house and on-site training for factory personnel. Turnkey Services Providing full scope turnkey services in design, supply, installation and commissioning of processing facilities and individual machines. Research and Development Working together with customers to understand their needs and continuously perform research and development for further improvement and efficiency of the machines.

Global Suppliers of Crumb Rubber Machineries ISO 9001:2015

Sphere Corporation Sdn Bhd was established in 1977 and is currently located in Pelabuhan Klang, Malaysia. We design processing facilities and factories for the crumb rubber industry. We also design and manufacture crumb rubber machinery apart from installing and commissioning crumb rubber-processing facilities.

Lot 9059, Jalan Udang Gantung/KS10, Telok Gong, 42000 Pelabuhan Klang, Selangor Darul Ehsan, Malaysia T +603 3134 1777 E sphere@spherecorporation.com

sphere.com.my

SIPH AFRICA

Discover SIPH rubber

“I’ve remained interested in the plantation business since 1986 when I was buying rubber for a tyre factory based in Port-Harcourt. However, it took 18 years until I had an opportunity to fully join the industry, first in Ghana in 2004, then in Côte d’Ivoire back in 2011,” he recalls.

HARNESSING HEALTHY PRODUCTION SIPH’s rubber activities currently span Côte d’Ivoire, Ghana, Nigeria, and Liberia, with a total of 60,000 hectares of exploited plantations, 10 processing factories, and a workforce of 11,000 employees. “We are the largest African rubber producer with a total processed rubber nearing 400,000 tonnes this year,” Genot states. “SIPH is a French company headquartered in Courbevoie, near Paris, where our rubber trading activities are hosted. We also have an office in Singapore close to our main customers,” he adds. Natural rubber is produced by rubber trees (hevea brasiliensis), which take six to seven years to start tapping after planting and will continue to produce for about 30 to 35 years if properly managed. A 160 | Manufacturing Outlook Issue 1

MANUFACTURING OUTLOOK: HOW IMPORTANT ARE PARTNER AND SUPPLIER RELATIONSHIPS TO THE SUCCESS OF YOUR BUSINESS? Marc Genot, Managing Director: “Upstream, our supply chain is complex with many farmers delivering their crops to us. We have a close relationship with them, as we provide capacity building programmes and offer various services such as farm management, collection at the farm gate, and payment via mobile money and bank transfer. We operate collection centres in the production areas to be closer to them, and then transport the rubber from there to our nearest factories. “Security for such a complex supply chain is also important to avoid stealing. We have therefore a special partnership with our transporters. “Most of our processing equipment is imported from Asia as per our specifications, with long lead times. This requires excellent communication to maintain our factories on top levels. “Downstream, there is virtually no second transformation for rubber in West Africa, which we regret and hope will change one day! Therefore, our rubber goes out to the world, especially to Europe and the US, as we remain close compared to Asia. African ports are not always as efficient as the rest of the world, and we need to have a very close relationship with shipping lines and port authorities to deliver the right service to our customers.”

healthy rubber tree is tapped every four to six days to extract latex, which contains natural rubber, from the bark. “Our clients are mostly tyre manufacturers and rubber traders as 75 percent of the natural rubber in the world is consumed by the tyre industry.

We deal with market leaders such as Michelin, Bridgestone, and Continental among others,” Genot explains. SIPH is different from many of its competitors as it owns several plantations. The company prides itself as a collective of experts in the

Kam Kit Engineering Sdn. Bhd. (Malaysia) Established in 1979, Kam Kit Engineering is a pioneer and specialises in manufacturing natural rubber processing machinery. Being one of the world largest rubber process machinery suppliers, Kam Kit Engineering delivers multinational clients the finest rubber processing machinery and services. We can: • Provide clients with efficient and effective rubbber machinery (processing line) • Design and manufacture client’s custom-made machineries to fit specific needs • Perfect client’s product qualities • Be a trusted and experienced partner mctang@kamkit.com.my / kamkit@kamkit.com.my www.kamkit.com.my

SIPH AFRICA

“ W E A R E N OT INCREASING OUR S U S TA I N A B I L I T Y BECAUSE GPSNR I S A S K I N G F O R I T, WE ARE DOING IT BECAUSE S U S TA I N A B I L I T Y I S I N O U R D N A” – BERTRAND VIGNES, FORMER M A N AG I N G D I R E C TO R , S I P H

maintenance of rubber trees and, therefore, knows exactly how to take care of them. “We also provide extension services to farmers to build their capacity and run their farms efficiently. Overall, we provide service to about 80,000 farmers.” This service enables SIPH to purchase rubber mostly from the farm gate, without dealing with traders and to deliver the best possible income directly to the farmer. As a result, the company doesn’t have any challenge complying with the new EUDR regulation that imposes traceability to the farm, while most of SIPH’s competitors, who deal with several layers of traders, will now have to review their 162 | Manufacturing Outlook Issue 1

purchasing system to comply. As well as its excellent relationship that has been curated with rubber growers, SIPH has been involved in sustainability programmes since 2007. This is reflected by the impressive ratings SIPH holds with SPOTT and Ecovadis, its d’Ivoire, and and an Integrated Management System which will be completed by the end of the year.

“We are founding members of the Global Platform for Sustainable Natural Rubber (GPSNR) since its inception in 2018 and are currently holding a position in its executive committee where we stand as co-chair,” Genot acclaims. “We are not upgrading our sustainability practices because GPSNR is asking for it, we are doing it because sustainability is in our DNA.”

SIPH AFRICA

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SIPH AFRICA

MAINTAINING SUSTAINABILITY SIPH’s main project in the short term, is linked to the new EUDR regulation and the evolving definition of traceability standards, aimed at ensuring its supply chain is deforestation-free. This initiative is carried out in collaboration with Preferred by Nature and SOCFIN. “We intend to share this standard with our competitors to ensure greater sustainability in our industry. We will be 100 percent ready by the close of 2024 to meet all EU law requirements,” Genot says. The first of several steps that must 164 | Manufacturing Outlook Issue 1

“ W E W I L L B E 1 0 0 P E R C E N T R E A DY BY T H E C LO S E O F 2 024 TO M E E T A L L E U L AW R E Q U I R E M E N T S ” – B E R T R A N D V I G N E S , FO R M E R M A N AG I N G D I R E C TO R , S I P H

be taken to remain compliant is to continue monitoring deforestation and fighting against it. Since 2020, SIPH has partnered with Proparco to implement a satellite monitoring deforestation and bushfires. The key objectives of this programme are to have a clear view of where deforestation happens and to

identify high and low-risk areas. “We can ensure that satellite monitoring alerts are accurate and are trying to share the results with the local authorities and Apromac, the local rubber sector body. We now know where the risks of deforestation are the highest in our area,” he elaborates.

For years, SIPH has been buying directly from smallholders, thus ensuring traceability of the supplied raw material. The company therefore decided to extend the survey by taking the full farm’s coordinates and identifying years of planting. The next step will be to control supplies made by farmers that should not exceed the potential of the farm, and to classify SIPH’s suppliers into high and low-risk categories so that additional controls can be enforced where necessary. Elsewhere, SIPH was involved in the esteemed Rubberway initiative

from its inception, where around 15,000 farmers were interviewed and continue to be interviewed to carry out social and environmental practices diagnosis in the supply chain. This diagnosis was shared in local GPSNR platforms animated by SIPH in Côte d’Ivoire and Ghana to find, with relevant stakeholders, solutions that are shared with the capacity-building networks. Using these sustainable initiatives as a springboard, SIPH aims to provide the market needs, while contributing to socio-economic development through optimisation

of the cultivated farmed areas, together with promoting rubber and smallholder support. In doing so, SIPH continues to thrive as a leader in sustainable management and production efficiency, as well as sustainably growing the company’s agricultural and industrial activities in parallel.

SIPH Tel: +225 27 21 75 76 25 communication@sifca.ci siph.groupesifca.com Manufacturing Outlook Issue 1 | 165

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