Manufacturers' Monthly February 2014

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

FEBRUARY 2014

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Tiny yet powerful photocells for the food industry

INSIDE CMM probing systems >> The future of automation Lean manufacturing >> What’s new Endeavour Awards >> Air filtering system

SAFETY IN ACTION >> Your survival guide for Melbourne’s 2012 conference and exhibition

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Sweet returns for dessert company.

When the thought of turning on the lights started to leave a bad taste in the mouth, multi-award winning dessert maker, Exquisine Pty Ltd, decided it was time to act. Like many companies the rapidly rising and fluctuating energy costs were severely affecting their bottom line. But as it turned out the solution to their needs was to be found in an overhead, literally.

Their Thornbury based factory has a large north facing roof space that was ideal for solar panels.

So in 2013 Exquisine Pty Ltd commissioned EnviroGroup, a leading commercial installer, to install a 80kW Yingli Solar PV system. They chose Yingli Solar high efficiency polycrystalline panels because of their proven ability to produce ongoing high energy yields under the harsh Australian climate, making them an excellent return on investment. In fact, this large solar PV system will not only offset a significant portion of the company’s electricity usage, approximately 300 kilowatt-hours per day, but will also help reduce carbon emissions by 139.7 tonnes a year.

Exquisine can now invest this energy cost saving back into the company to allow an expansion of production in the future. Sweet!

For more information please visit yinglisolar.com/au or call 1300 309 489.

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Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au Managing Editor: Kevin Gomez Ph: (02) 8484 0976 Fax: (02) 8484 0722 kevin.gomez@cirrusmedia.com.au Editor: Matt McDonald Ph: (02) 8484 0645 Fax: (02) 8484 0722 matthew.mcdonald@cirrusmedia.com.au Journalists: Brent Balinski Ph: (02) 8484 0680 Fax: (02) 8484 0722 brent.balinski@cirrusmedia.com.au Alex Heber Ph: (02) 8484 0884 Fax: (02) 8484 0722 alex.heber@cirrusmedia.com.au Editor-at-Large: Alan Johnson Ph: (02) 8484 0725 alan.johnson@cirrusmedia.com.au Graphic Designer: Louis Santos louis.santos@cirrusmedia.com.au Production Co-ordinator: Mary Copland Ph: (02) 8484 0737 mary.copland@cirrusmedia.com.au VIC/Overseas Sales: Michael Northcott PO Box 3069, Eltham, VIC 3095 Ph: 0448 077 247 michael.northcott@cirrusmedia.com.au NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8484 0868 Fax: (02) 8484 0722 Mobile: 0414 644 664 anthony.head@cirrusmedia.com.au QLD Sales: Sharon Amos PO Box 3136, Bracken Ridge, QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@cirrusmedia.com.au NSW, SA/NT & WA Sales: Cirrus Media Ph: (02) 8484 0868 anthony.head@cirrusmedia.com.au Published 11 times a year Subscriptions $140.00 per annum (inc GST) Overseas prices apply Ph: 1300 360 126

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Inside FEBRUARY 2014

4 Editorial

For daily news visit manmonthly.com.au

The Mount’n Mover was BlueSky’s first 3D printer project.

■ Moving into uncharted territory

6 Industry Comment ■ What manufacturing needs from

Government ■ Lean lessons from Japan ■ How variations affect batch

quality

10 IT@MM ■ Don’t miss out ■ 3D printer shaves development

time ■ Colour added to 3D printer’s functionality

14 HR, Recruitment & Training

18 Automation & Robotics

28 Health & Safety

■ What is the future of automation

■ Keeping on top of machine safety ■ Pipeline supply solutions

in manufacturing?

20 Metalworking & Machine Tools ■ The evolution of CMM probing

■ The top 5 workplace issues

for 2014

systems ■ Portable measurement system ■ Blade measuring system

16 Motors & Drives

24 Materials Handling

■ Synchronous motor or induction

■ 55 years and still on a roll ■ Conveying safety

motor?

■ Decentralized soft starter

reversing motor with motor protection ■ Medium voltage AC drives

Cirrus Media Tower 2, Level 3, 475 Victoria Avenue, Chatswood, NSW 2067, Australia Locked Bag 4700, Chatswood Delivery Centre, NSW 2067, Australia Ph: (02) 8484 0888 Fax: (02) 8484 0633 ABN 80 132 719 861 ISSN 0025-2530 www.cirrusmedia.com.au © Copyright Cirrus Media, 2013 Average Net Distribution Period ending Sep’13 17,385 Printed by Bluestar Print 83 Derby Street, Silverwater, NSW 2128 Ph: (02) 9748 3411

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26 Endeavour Awards ■ Last chance to enter the

Endeavours

■ Long-range safety sensors

31 Test & Measurement ■ Filor adds scanner to 3D offerings ■ Weidmuller expands its

ACT20M range

33 What’s new ■ Portable marking machine ■ Air filtering system ■ Signal processor ■ Cable protectors

38 The Last Word ■ Shoni Even-Chaim speaks with MM

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

FEBRUARY 2014

Tiny yet powerful photocells for the food industry

Print Post Approved PP100007882

MA0214_003.pdf

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CMM probing systems >> The future of automation Lean manufacturing >> What’s new Endeavour Awards >> Air filtering system

SAFETY IN ACTION >> Your survival guide for Melbourne’s 2012 conference and exhibition

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Sensing range is independent of characteristics and colour of the object being detected. The 06 is housed in stainless steel with high protection rating IP 68/IP 69 K. The transparent black housing cover provides good contrast for the integrated LEDs, making them clearly visible. The coated front pane consists of resistant, shatterproof plastic. www.ifm.com/au

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Manufacturers’ Monthly FEBRUARY 2014 3

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Comment

KEVIN GOMEZ – Managing Editor

Moving into uncharted territory

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NEXTISSUENEXTISSUE • Management: Exporting • Compressors & Pneumatics • Laser Technologies & Applications • Fasteners & Adhesives • LED Lighting • 3D Printing • Forklifts & Attachments •M Bearings, Gears A0 2 1 4 _& 0Lubrication 0 0 _ BOC

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One stumbling block is the federal or many reasons, I’m glad to government’s decision to block see the end of 2013. It was a venture capital investors from challenging year, with dismal getting the same tax breaks as manufacturing related news capturing public companies. a lion’s share of headlines.

But there is hope — the According to the Australian government has promised to look at Industry Group’s Performance of changes to the tax system and make Manufacturing Index, the sector it easier for entrepreneurs to get finished 2013 in contraction, funding and tax breaks. consistent with most of the year.

While we have been focused on But there’s a new government in the travails of the auto industry, place, one that does not believe in there are sectors that have been subsidies, and this may well force a experiencing success — quietly and cultural and structural change upon without any fanfare. our industry.

Australia has over 500 companies in The Federal Government is calling the medical products manufacturing for input into the allocation of the sector boasting a combined turnover $100 million growth fund aimed of $10 billion. at transforming the states most In fact, the Ausbiotech chief affected by the impending exit of executive has even called on Holden and Ford. displaced automotive workers to The objective is to transform move into pharmaceutical and the sector from heavy industry medical device manufacturing. manufacturing to higher, valueThat will, of course, require added production. reskilling the workforce.

Given the mountain of a challenge Future manufacturing jobs that confronts us, $100 million is a relatively modest sum but there will be in the areas of creative is at least an acknowledgement design, robotics, 3D printing and that we face a major challenge and machine optimisation. need to act.

There has been a lot of publicity As a country, we tend to punch surrounding 3D printers. Most above our weight when it comes to local manufacturers we speak with, generating good ideas and inventions. look at them as nothing more than 1 However, 2 0 1 4all - 0 1 -turns 0 9 to T 0mud 9 : 5 3 : 2prototyping 9 + 1 1 : 0tools.

0 this when it comes to commercialisation.

But they are entering mainstream

manufacturing. Siemens, for instance, will be using 3D printing to produce spare parts for gas turbine engines.

This technology presents an opportunity for local manufacturers to penetrate low-volume markets but we need to get in early and ride the technology as it evolves.

If we are to transition to a high-technology manufacturing environment, it will need industry, government and educational institutions working together. No doubt, it can be done.

We are seeing evidence of local innovation in the entries that are trickling into our office for the Endeavour Awards. This is the 11th year for Manufacturers Monthly’s well supported awards program to celebrate professional excellence.

The Awards gala dinner will be held on May 14 or 15, during NMW in Sydney, and it promises to be a fantastic event.

All finalists get two free tickets so hop onto www.manmonthly.com.au/ awards, download the simple entry form and send in your entry today.

As always, the team at Manufacturers Monthly would love to hear from you, so do drop us an email, follow us on Twitter and join the discussions on Facebook and Google+. kevin.gomez@cirrusmedia.com.au

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© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. All other logos, trademarks or service marks used herein are the property of their respective owners.

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Answers for industry.

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Industry COMMENT

Innes WIllox – Chief Executive, Australian Industry Group

What manufacturing needs from Government While governments must be prudent and accountable, not all public assistance can be dismissed as “corporate welfare”. As Innes Willox writes, well targeted government programs are part of what manufacturing needs in 2014.

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or many manufacturers it business directions and the right industry – will be necessary in 2014 almost goes without saying that policies from federal and state and beyond if we are to continue 2013 was a very tough year. governments to encourage a new to ensure a strong and dynamic The industry battled against phase of investment and innovation. industrial sector in Australia. the considerable headwinds of the As well, the new Government Among the most urgent priorities strong dollar, intense competition in Canberra faces intensifying for the year ahead are the from emerging economies, a industrial restructuring and the repeal of the carbon tax and the legacy of low productivity growth, Australian Industry Group will implementation of its replacement a growing unit labour cost continue to argue for strategies and policy; further workplace relations disadvantage and considerably policies that promote a balanced reform to allow greater flexibility higher energy prices. and diversified growth path – one and to boost productivity; defining a With the dollar closing the year that reduces the risks to national credible path for getting the federal about 16% off the high points of wellbeing associated with our heavy budget in order; and improving our 2013 and hopefully some further reliance on the export of a handful falls to come, manufacturers will of commodities to a handful of be in more of a position to take countries. advantage of the opportunities As General Motor’s recent ahead of us, particularly in the decision to cease manufacturing in growing decisive M A 1 markets 0 1 3 _ 0of1Asia.

6 _ GTo R make A 1 Australia 2 0 1 3 has - 0 emphasised, 9 - 2 3 T1 1 : 0 8 : 4 5 + 1 0 : 0 0 the most of this will require new action – both from Government and

Among the most urgent priorities for the year ahead are the repeal of the carbon tax and the implementation of its replacement policy.

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6 FEBRUARY 2014 Manufacturers’ Monthly

tax system to help industry invest and contribute to new employment growth.

The current budgetary difficulties make it even more important to look very closely at all areas of public sector expenditure and to eliminate wasteful or inefficient programs.

Expenditure directed to businesses and business programs should not be shielded from rigorous assessment.

In this regard, Ai Group does not support “corporate welfare” if that refers to handing out taxpayers’ funds without proper justification and transparency.

At the same time it is too easy, and indeed it is counter-productive to lump all expenditure and tax expenditures related to business in the “corporate welfare” bucket.

The research and development tax incentive is a case in point as it has a very strong policy rationale behind it. Similarly, government funding of, and incentives for,

workforce training initiatives are well supported by very good policy arguments.

The same can be said for programs like the federally funded Enterprise Connect program that is proving to be very successful at lifting the productivity of small and mediumsized businesses. Measures that address the failure of financial markets to provide early-stage capital are similarly well-supported.

In the end, in place of ideological positioning, it must come down to a careful evaluation of the communitywide costs and benefits and the alternative uses of the funds. This assessment must take into account the inefficiencies associated with taxation as well as any benefits that flow to the broader economy as a result of the spending programs.

One very topical area is the programs that assist in redirecting Australia’s manufacturing efforts as the industry itself undergoes rapid restructuring. As mentioned, the benefits of well-targeted and carefully designed programs in this area include reducing the exposure of the economy to what has become an excessive reliance on commodity exports.

Broad economy-wide benefits can be achieved if programs can assist in the more rapid development of the new sources of industrial strength than would occur if we relied purely on market forces to deliver us a diversified and balanced growth and to provide opportunities for employees ‘liberated’ in the course of restructuring.

It is critical, both at the political level and in our own businesses, that we get these tasks done. The Australian Industry Group intends to continue to take a leading role and will consult widely to meet our objectives of working in the best interests of our members, the manufacturing sector and the strength of the broader economy. manmonthly.com.au

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Industry COMMENT

Lean lessons from Japan

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In November, Shinka Management, in conjunction with the Australian Industry Group, conducted a lean manufacturing study tour of Japan.

The tour provided industry leaders with first-hand experience of world-class lean implementation.

Dr Paul Smith writes.

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ean manufacturing is a “Particularly with the recent production philosophy events affecting manufacturing in that has evolved out of Australia, the need to strengthen our practices made famous by Japanese productivity improvement capability industry over the past several is more apparent than ever. The decades. During the week-long Australian Industry Group Lean study tour, participants learned Japan Tour provides the opportunity about the implementation of lean to learn from the decades of lean manufacturing and continuous management innovation and knowimprovement practices in some of how that has been developed in Japan’s top companies.

Japan,” said Willox.

The tour has been run annually 15 participants attended in since 2007, and originated from November from 10 organisations. the awareness that there has As the manager for Enterprise not been a genuine example of Connect’s Best Practice Unit, Lee lean production principles being Baines participated in the tour with applied in an Australian company an interest in using lessons to assist over an extended period of time.

Australian industry.

Through discussions with company “Australian businesses need every management in Japan, participants weapon at their disposal to help learn how to establish, implement compete in a global market,” said and sustain lean programs.

Baines.

Innes Willox, chief executive of the Australian Industry Group, has been outspoken about the need 1 strengthen 2 0 1 3 - Australian 1 0 - 0 9 T 1 4 : 1 3 : 4 6 + 1 1 : 0 0 to industry competitiveness.

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We have a lot to learn from Japan, a country that has experienced similar challenges to Australia.

“Visiting Japan opens up more ideas and opportunities and is highly recommended to manufacturers, engineering or service related industries.”

Willox and Baines’s comments have become especially relevant as Australia’s manufacturing sector has been grappling with Holden’s recent facility closure announcements. Shortly following the announcement, Prime Minister Tony Abbott and Federal Industry Minister Ian Macfarlane challenged manufacturers to increase competitiveness through lifting productivity and removing cost out of their businesses.

In this regard, we have a lot to learn from Japan, a country that has experienced similar challenges to Australia related to cost of labour and strong currency, necessitating a laser-sharp focus on productivity improvement for their manufacturers to remain

competitive on the global stage.

The tour commenced in Tokyo with a briefing on Japanese customs and business etiquette, and a seminar from the Japan Management Association Consultants on lean manufacturing implementation in Japan.

The group then travelled to Nagoya and spent two days with a Toyota Group lean training facility, learning about the Toyota Production System (TPS) and the elimination of waste, overburden and unevenness from manufacturing processes. In between classroom and hands-on training sessions, visits were held with second and thirdtier suppliers in the Toyota Group, and with Gifu Auto Body’s Hi-Ace production plant and Toyota’s Motomachi Factory. Participants developed an insight as to how TPS enables Toyota’s people to work smoothly and efficiently, and achieve extremely high levels of quality and productivity.

Whilst the Japanese automotive industry can be credited with much of the development and popularisation of lean manufacturing, the production philosophy has been adapted and evolved by a wide range of industries including food and beverage, electronics, pharmaceuticals and the service industry.

In addition to learning about Japanese management philosophy, the tour group spent the week immersed in Japanese culture. A series of briefings are planned for Sydney, Melbourne, Brisbane and Adelaide in February.

The next Lean Japan Tour will be held during the 18th through 24th of May 2014, and in addition to automotive and manufacturing companies will include visits to a food and beverage producer and a logistics facility.

[Paul Smith, PhD, is a Director of lean consulting firm Shinka Management Pty Ltd, working to promote Australian industry productivity through Japanese lean manufacturing practices.]

Shinka Management 08 83940005 shinkamanagement.com manmonthly.com.au

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Industry COMMENT

How variations impact batch quality Batch processes are difficult to control and analyse because each batch is unique.

Understanding how these variations impact batch quality while the batch is running can provide enormous benefits, writes Janice Abel.

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ompanies that utilise batch manufacturing processes for specialty chemicals, food, pharmaceuticals, biotech products and other products can utilise data that is already being collected to make real-time decisions and take appropriate actions.

Real-time batch analytics can help companies gain a better understanding of their processes, minimise variations, and know where to make improvements to the process instantaneously.

Historically, batch processes have been difficult to control and analyse because each batch is unique: batches are not the same length; time lags differ; raw materials can differ, and there are often differences in equipment, operating conditions, and process activity.

Advanced batch controls can be complex. Understanding how these variations impact batch quality while the batch is running can provide enormous benefits.

Manufacturers use batch analytics software to compare batches to help uncover potential problems in real time. One analytics solution of which ARC is aware enables users to compare ideal, “golden” batches to other batches to help better understand how variables affect the current batch.

The supplier calls this “dynamic time warping” (DTW). This aligns the data and can compare many batches’ parameters and accommodate for variable timing differences. The technology helps align the data accurately between batches and match parameters from historical batch data to the variations found in the live batches. The data analytics software can be used to determine how the batch is progressing and predict if a batch will meet specification or have to be re-worked, modified, or even discarded.

Abnormal operations Significantly, the batch analytics software expands the range of manmonthly.com.au

model building process, data for the selected batches is automatically aligned with the correct parameters using dynamic time warping.

Analytics software

processes that can take advantage of advanced process control. The solution can be used to interpret data to help optimise the process in real time. The software analyses comparisons of batch trajectories across different batches to other parameters and variables. The primary multivariate methods

Creating batch process models can be particularly challenging because of the inherent time variability from batch to batch. employed include principal components analysis (PCA) and projections to latent structures (PLS).

PCA provides a concise overview of a data set. It is used to recognise patterns, including outliers, trends, groups, relationships, etc. PCA helps detect abnormal operations. PLS establishes relationships between input and output variables and

develops predictive models of a process for quality predictions.

In addition, the included model predictive multivariable analysis (MVA) software enables users to adjust batch trajectories and predictions for control using a comparative model. MVA helps the engineer look at the batch parameters holistically to be able to identify the interaction of the variables and uncover what is contributing to a particular condition.

The real-time analytics can help determine how all the variables affect the batch.

By drilling down on individual parameters, an engineer can determine if something is out of range or “not quite right,” make decisions about the process, and take appropriate actions. The software can also help predict when problems are beginning to develop so that corrective measures can be taken.

The analysis can examine conditions and measurements that impact product quality. By visualising the data, the engineer can determine if the batch should be used for model generation. It’s critical to compare data from multiple batches to align batch parameters to determine how a batch is doing.

During the data extraction and

By generating models and using the dynamic time warping screens, the manufacturer can determine if a parameter is different from batchto-batch. In the past, it was not easy to access, visualise, and compare data; or generate models to compare parameters “on the fly,” while the batch was running. This technology makes it far easier to do so.

The included model-building application tools can enable workers who are familiar with their process to step through the process.

Users can generate models by selecting which batches should be used to generate models. They can also compare the results with other models and check predictions.

Lab analysis data can be used to validate the models and determine when the model is working well. The analysis can help determine what is working well and what needs to be improved.

A major brewing manufacturer is using this batch analytics software as part of a beta trial to identify process problems. According to one of its engineers, the brewing company used the software to model its Briggs Lauter Tun -- a unit that separates extracted wort (sugar from grains) -- to identify the critical quality parameters during production runs.

The company was also able to use the DTW feature that overlays different batches and matches the parameters to identify abnormal conditions with their pH meters.

The company corrected this problem to increase efficiencies and is now using the technology to identify other challenges.

[Janice Abel (jabel@arcweb.com) is Principal Consultant, ARC Advisory Group.]

ARC Advisory Group www.arcweb.com Manufacturers’ Monthly FEBRUARY 2014 9

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TechnologyIT@MM Don’t miss out Lack of investment in design software means many manufacturers are missing out on essential innovation tools. Alan Johnson reports.

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ucceSSfuL Australian manufacturers learnt many years ago that they can’t compete with china and other low-cost labour countries on price, instead their focus has been on innovation in the design of their products.

However research by Solidtec Solutions, a value-add reseller of SolidWorks software products for the Australia and New Zealand markets, reveals that there are still too many manufacturers not taking advantage of readily available design tools, in particular 3D cAD (computer Aided Design).

While 3D cAD has been around for decades now, Solidtec’s ceO Shane Preston says there are still a high number who haven’t made the move from 2D cAD. “We come across them every day,” he said.

He believes innovation is something Australian manufacturers need to focus on to compete in the global economy they are now operating in.

“That innovation will differentiate them from their local and international competitors,” he said.

In a bid to find out more, Solidtec recently conducted some research on M some and on1 theA 0 of 2 1its4 customers, _ 0 0 0 _ S OU manufacturing sector in general.

10 FEBRUARY 2014 Manufacturers’ Monthly

FASTFACTSFASTFACTS

Design software • Automation of the design process is on the rise.

• 3D CAD is seeing improved technical communications.

• A lack of training is still an issue in the industry.

• Aussie manufacturers need to keep on top of design innovation.

Concurrent engineering tools in 3D CAD allow designers to spend more time actually designing.

“Basically we asked them to describe their business processes; ability to continue to focus on how they went from identifying their innovation within the organisation customers’ needs right through to actually diminished,” Preston told putting money in the bank.

Manufacturers’ Monthly.

“Interestingly, we found that most “for example, I recently visited a customers had a similar serial design ceO of a manufacturing company in process; they waited until they had Melbourne who said exactly that. finished one step in the process “She said the company used to be before moving on to the next one. innovative, but over recent times, “That was very much true for as the company had grown, it had those still using 2D cAD, while those been tied up with its own systems who had invested 3D cAD had the and didn’t spend as much time on ability to do parallel or concurrent innovation as before. engineering.

“She described the company as a “While we found out that many 90/8/2 organisation. What she meant of our customers started off with was the company spends 90% of its an innovative product, with a focus adapting and modifying the niche product in the market, over company’s existing products, 8% on and only 1time, 2 as 0 1their 3 - business 1 2 - 1 1grew T 2 and 0 : 2 2 : 1 continuous 8 + 1 1 : 0improvement 0 became more successful, their 2%, at most, on innovation.

“What was most frustrating for her was that innovation was what won her new customers,” Preston said.

“We have found that if a company has the ability to use 3D cAD then it is able to spend more time on innovation, by doing the serial process items in parallel. “for example, while the engineers are designing, they can also be doing the validating stages such as checking weight, strength, usability, manufacturing ability and user testing.

“With 3D cAD, users are able to do that at the same time as actually doing the detailed design, unlike 2D users who have to finish their design before they can start the validation phase,” Preston said.

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3D CAD advances Recent years have seen a number of advances in 3D CAD technology, but the one that stands out for Preston is the growing role of the automation of the design process.

“It used to be a multi-step design process, but now many of the processes are rolled into one tool.

“We used to talk about ease of use as the number of clicks needed to perform a task, but now ease of use is starting to mean automation of all repeated tasks when operating the design tool,” Preston explained.

He said another area of advancement in 3D CAD is in technical communications, which can be as simple as assembly instructions for the shop floor, or it could be marketing material, guides, instruction manuals, etc.

“Again traditionally, this is done at the end of the detailed design process,” Preston said.

“Interestingly, when we spoke to companies as part of our research, most companies said they allocate a certain amount of time to do that, but nearly always, because of product over-runs, they end up with a really compressed time-line to get that done.

“Whereas in 3D you can start setting out all of that documentation and start working on that at the same time as the design team is working on the new product.”

More training Preston says a lack of training is still an issue within the industry.

It’s often a case of you don’t know

manmonthly.com.au

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what you don’t know.

“What we find is people come out on university, or from another company, with some training, but are reluctant to admit they need further training in 3D CAD.” Preston explained that his company conducts around 18 different training courses, but only four of them are run regularly.

“So this year we introduced an on-line training option which replicates a classroom environment.

Preston says a lack of training is still an issue within the industry. It’s often a case of you don’t know what you don’t know.

“The person can sit in his/her office and see the instructors face and ask them questions one-on-one.

“What that has enabled us to do is conduct niche courses, as numbers are not so critical to make the course viable. We can run a course with just one person,” Preston said.

Design tips He says one of the most common problems he finds with a newer clients is not spending the time to set up their templates, documents and properties as effectively as they could do.

While engineers are designing, they can also be doing the validating stages such as checking weight, strength, usability, manufacturing ability and testing.

“With 3D CAD technology, you can have data flow from a part or an assembly right through to a number of areas, such as drawings or Bill of Materials (BOM).

“I see some customers who don’t take the time to set this up. It’s not a lot of time, but they would get that time back many times over if they spent the time to set up their templates, documents and properties properly.

“As a consequence, they probably don’t get as much return because they haven’t got the information flowing as smoothly as they could,” Preston said.

But for our more established customers, Preston said it’s more an issue of data storage.

“The fact is all 3D CAD systems

generate an enormous amount of files and data.

“One recent report revealed that each CAD user spends 18 minutes a day just looking for data, while another report suggested it was as high as 38 minutes day.

“Whichever is correct, if you multiply that by the number of users in a company, then multiplied by the hourly rate, that’s adds up to a considerable amount of money lost every day of the year.

“So using technology such as PDM systems to manage that data effectively will give companies a substantial productivity boost,” Preston said.

Solidtec 1800 824 883 www.solidtec.com.au

Manufacturers’ Monthly FEBRUARY 2014 11

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Technology IT@MM

3D printer shaves development time

A

SMALL US design company, with strong links to Australia, is now using a 3D printer to slash design costs and reduce the time to market.

Founded in 1997, BlueSky Designs, a product development company in Minneapolis, applies ergonomics and universal design to develop products that address the needs of people with disabilities – at work, at play, and at home.

BlueSky’s products, including the Mount’n Mover – a mounting system that allows individuals in wheelchairs to easily position devices, trays and laptops – make everyday activities simpler and more accessible.

For its first few years of operation, BlueSky produced custom, one-of-a-kind solutions for individuals. Designs were sketched on paper then outsourced for production.

Eventually, M A 0 2 1 the 4 _ company 0 1 2 _ Gevolved RA into a full product development firm

BlueSky Designs was involved in the design of Monash University’s Bionic Eye project which will restore sight by transmitting wireless signals directly to an implant in the brain.

– from developing to manufacturing that could keep up with the speed to selling its products. of our business and allow us to 1 “We 2 0 had 1 4 -a period 0 1 - 1of6 growth T 1 0 : that 0 8 : 4 really 9 + 1 innovate, 1 : 0 0 while not costing a spawned a need for production tools fortune,” said BlueSky founder and president, Dianne Goodwin.

In 2006, BlueSky purchased a Dimension 3D printer to more easily and cost-effectively develop and test concepts.

“Before purchasing the printer,

A prime example of cost and time savings, the Mount’n Mover was BlueSky’s first 3D printer project. we were working with an outside service bureau to prototype.

Because of the high expense, we could only afford to develop a few prototypes at a time,” said Goodwin.

A prime example of cost and time savings, the Mount‘n Mover was BlueSky’s first 3D printer project.

After having spent $23,000 on outsourcing the production of three metal movable-arm prototypes, Goodwin learned she could print eight ABS prototypes in-house using the 3D Printer for just $3,000, while 12 FEBRUARY 2014 Manufacturers’ Monthly

slashing production time by three weeks.

Goodwin also makes a cost comparison to smaller components of the movable-arm prototype production.

For the 36 locking mechanisms each assembly required, an outside service bureau quoted $2,000 per assembly – and that was just to prove the concept and verify functionality.

To test and prototype BlueSky’s two-dozen different locking mechanism designs would have cost $48,000. Instead, with the 3D Printer, BlueSky had the ability to prove out designs for thousands of dollars less before spending the money in the more robust pre-production prototype.

“For a shop of our size – with only a few employees – we never could have done what we’ve done without the 3D printer,” said Goodwin.

“The cost of exploring and producing different designs was prohibitive and we’ve found a way to resolve that.

“With the 3D printer we can develop many iterations before deciding on the ones we machine, which has saved us tens of thousands of dollars in design and manufacturing costs,” she said.

Stratasys www.stratasys.com manmonthly.com.au

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Colour added to 3D printer’s functionality

T

he Stratasys Mojo 3D printer has recently been enhanced with new functions and colour options.

Users will now be able to add a dash of colour to their prototypes and models, with nine different colours available.

In addition, the printer’s new sparse interior fill option allows for faster printing using less building and less support material saving time and money.

The printer is powered by Stratasys Fused Deposition Modelling (FDM) Technology, and can build accurate functional concept models, rapid prototypes, and product mock-ups in different coloured ABS plus thermoplastic.

According to the company, the printer is easy to use, can fit right on the user’s desk and will

reinvent how the user designs and creates.

The 3D Print Pack contains the model and support materials that build the 3D printed parts. With every material change, the printer’s engine installs a fresh print head to ensure optimum print quality.

The snap-in print head is also easy to use and fast to change. each foil bag contains 80 cubic inches of material, which means fewer material changes and more uninterrupted printing.

Tasman Machinery 03 9584 8355 www.tasman3d.com.au

The printer is powered by Stratasys Fused Deposition Modelling Technology.

3D design in a browser

Customers can access full-fledged 3D design and M A 0 work 2 1 4 _ 0 0 0 _ ELE engineering in a browser.

manmonthly.com.au

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1

Autodesk’s customers are now be able to access Autodesk Inventor, and other 3d design tools via a web browser.

According to the company, it is now possible to access 2 0 1 4 - 0 1 - 1 0 full-fledged T 0 9 : 3 83d: design 2 9 + and 1 1 : 0 0 engineering work in a browser

without sacrificing performance, power or functionality.

Continuing to build on Autodesk’s collaboration with Amazon Web services, this new capability debuts as a tech preview and is an expansion of the remote access capabilities

provided through Autodesk Remote software. With this new capability, developers can access 90-day trials of Autodesk Inventor, Revit, Maya and 3ds Max software.

Autodesk Australia www.autodesk.com.au

Manufacturers’ Monthly FEBRUARY 2014 13

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HR,RECRUITMENT + TRAINING The top 5 workplace issues for 2014 As we enter the first working weeks of the New Year, law firm Justitia examines what will be the workplace issues in focus for 2014.

1. The effect of the updated workplace bullying laws The amendments to the Fair Work Act 2009, which focus on workplace bullying, started operation on 1 January.

These changes introduced the first individual right of recourse of workplace bullying in any jurisdiction, Justitia explained.

“Workers who reasonably believe that they have been bullied at work may apply directly to the Fair Work Commission for an order to stop the bullying,” Justitia said.

“The Commission will be required to start dealing with an application to stop bullying within 14 days of the application being made.

“It may do so by taking steps to inform itself of the matter, conducting a conference or holding a formal hearing. In the process, the Commission will consider the outcome of any other investigation into the matter and any other procedure that is available to the worker to resolve the grievance.

“While it cannot make an order for re-instatement or the payment of a pecuniary amount to address the bullying, the Commission can, amongst others, order an individual or group to stop the bullying behaviour, or require an employer to implement anti-bullying policies and training. A breach of an order made by the Commission will attract a maximum penalty of up to $10,200 for an individual or $51,000 for a body corporate.”

However, there are some employers that will be exempt from these new laws, such as State government and unincorporated 14 FEBRUARY 2014 Manufacturers’ Monthly

bodies like sole traders, partnerships, and not-forprofit associations.

Justitita describes the new amendments as a quick and relatively inexpensive mechanism to resolve workplace bullying issues.

“We think it will prove a popular option for aggrieved employees and their union representatives to get the attention of their employer,” it said, adding that “consequently employers should be preparing for these changes by reviewing their workplace bullying policies, complaints procedures and relevant training programs”.

2. Unconscious bias Is an unconscious lack of objectivity damaging your company’s performance and harming your workforce?

According to Justitia, an “unchecked unconscious bias in an organisation’s management team can result in a failure to recognise high-potential employees or even lucrative business opportunities”.

It is predicted that this year some companies will be taking radical steps to overcome this issue.

The Business Council of Australia (BCA) has announced plan to fight unconscious gender bias amongst its members, as current biases have created a “male-gendered concept of merit-based assessment” in a number of companies.

To reverse this trend BCA is proposing an interventionist checklist, which includes measures such as regularly testing CEOs and

It is estimated nearly half of all Australian workers are in insecure employment. board members for bias, and the development of female-only hiring short lists.

“Some organisations are already offering training to managers and recruitment staff on how to tackle unconscious bias in the workplace,” it said.

“Unconscious bias training has been described by some as a ‘light bulb moment’ when senior employees begin to understand the potential in a diverse range of people. We predict that the focus on unconscious bias in the workplace will intensify in coming months and that more and more organisations will be taking up initiatives like those announced by the BCA. “For this reason, unconscious bias is set to become a hot topic for HR managers in 2014, particularly in the areas of recruitment and talent management.”

3. Reporting to the Workplace Gender Equality Agency In 2012 the Equal Opportunity for Women in the Workplace Act 1999 was replaced by the Workplace Gender Equality Act 2012, which introduced a new reporting and compliance framework focused on improving equality.

Any company with 100 plus employees now have to submit a public report that addresses the six specific Workplace Gender Equality indicators.

As it came in 2012, the grace period for reporting has ended, and there is a flurry of activity expected as the May 31 deadline approaches and workplaces adapt to the broader reporting obligations.

These obligations are in line to become even more extensive next year. manmonthly.com.au

MA0214_015.pdf

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From April this year employers will be set minimum standards (which are yet to be published) related to measurable outcomes or evidence of action taken to improve outcomes.

4. Insecure employment

15

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Future’ campaign to support these workers.

Part of this is through expanding the definition of employers and employees, giving Fair Work more power to make orders, and expanding the existing National Employment Standards.

However Justitia stated that this push may be reined in by business demands for more workplace flexibility or labour market deregulation.

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Productivity Commission review into the operation and impact of the Fair Work Act 2009,” Justitia said.

“It is expected that the Coalition will initiate this review in 2014, with

As non-standard employment such as irregular and unpredictable job hours with little security increases, the issue of insecure employment is rising.

This is being seen through the hiring of casual workers instead of permanent staff, placing staff on short fixed term contracts, relying on interns or apprentices, and having extensive contract arrangements in place.

It is estimated nearly half of all Australian workers are in these forms of employment.

To fight this, the Australian M A of 0 9Trade 1 3 _Unions 0 1 2 _(ACTU) ECI Council

The spectre of WorkChoices is still haunting the political and business landscape.

Abbott’s current government had a requirement that the Productivity promised that it would refrain from Commission provide recommendations pursuing IR legislation change, but on how to improve the operation of it has now stated it will carry out a the Fair Work Act 2009.” series of ‘reviews’ that may lead to The findings of the Commission changes in a second term. will probably form the pillar of any 1 “A 2 key 0 1 3 - 0 8 -of1the 3 T 1 0 : 4 7 : 3 new 7 + workplace 1 0 : 0 0 relations policies by element

is pushing its ‘Secure Jobs, Better

foreshadowed reviews was a

5. Workplace Law reviews

The spectre of WorkChoices is still haunting the political and business landscape.

the Coalition.

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While these five issues will garner much of the focus of businesses in this new year, Justitia stated that there are a number of other, smaller issues and reviews that will key this year, including: • A review by the Law Reform Commission into workplace relations laws’ “encroach upon traditional rights, freedoms and privileges” – for example, the reverse onus of proof in adverse action laws is a likely candidate; • A Royal Commission into the home insulation programme, which will look at workplace health and safety arrangements in that scheme; and • A mooted Royal Commission into union misconduct, which may impact on registered organisations and those who deal with them.

Justitia 03 8621 4500 justitia.com.au

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manmonthly.com.au

Manufacturers’ Monthly FEBRUARY 2014 15

MA0214_016.pdf

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Motors& DRIVES Synchronous motor or induction motor?

Each motor type offers unique advantages and it is important to understand the design, fabrication, installation, operation and maintenance of both solutions, writes Amin Almasi.

E

lectric motor drivers generally use a Load Commutated Inverter (LCI) converter associated with a synchronous two-pole electric motor.

However, Voltage Source Inverter (VSI) technology and induction motors are becoming a popular option. As such, a comparisson of two technical solutions for electric motor drivers - LCI (synchronous motor) technology and VSI (induction motor) technology - follows.

It is important to consider the footprint, the torque pulsations on train shaft, harmonics and initial price. In addition, lessons learned from design, fabrication, installation, operation and maintenance of both solutions are presented.

Because of the reactive power consumption of its thyristor bridge, an LCI system cannot naturally power an induction motor. If this is the case, the forced commutation circuits would have to be added, resulting in a very complex, costly and less reliable solution.

motor torque (using a modern fast switching device), an appropriate PWM and a sinusoidal output filter.

There is a constant Power Factor (PF) on the network side >0.95 with no need for an additional PF compensation system. There is a very low harmonic content, particularly when using 24-pulse arrangement on the network side.

Lowest cost A variable speed drive panel for a large VSD electric motor.

available with different topologies MW, with some isolated cases above (2, 3, 4, 5 levels, etc.) and different 30 MW) for around 15 years. electronic power components (GCT, 2. LCI technology generates torque IGBT, etc). They can feed medium pulsations. A harmonic filter is and large voltage electric motors for power ratings up to around 50 MW (higher power levels are under study).

A well-known VSI arrangement is a 12-pulse VSI with two network serial bridges associated with a 3-level Pulse Width Modulation (PWM) motor inverter.

When comparing Load Different topologies Commutated Inverters (LCI) vs.

The VSI stands for “Voltage Voltage Source Inverters (VSI), Source Inverter” using a capacitive the following factors should be DC link with self-commutation considered: semiconductors. It can supply a 1. LCIs have been used for more lagging and leading power factor load. than 30 years (since the early 80s) for A VSI can power both induction high-power synchronous motors. On M A 0and 2 1synchronous 4 _ 0 0 0 _motors.

DAT 1 the 2 other 0 1 4 hand, - 0 1VSIs - 0 are 7 T more 1 5 : recent 4 1 : 3 1 + 1 1 : 0 0 motors At present, the VSI systems are and have been used (mainly up to 30 generally required. Because of the speed excursion of the variable speed drive application, it is mandatory to implement a comprehensive torsional WHEN YOUR SYSTEM LETS YOU DOWN study (the torque analysis) of the complete train.

Control Systems — When you need an upgrade and / or retrofit ...

3. Because of multiple pulse rectifier configurations, VSI network Servo and VS Drives When you need repairs and / or retrofits ... diode bridges reduce the harmonic Computer Touch Screen Panels When you need repairs and / or retrocurrent level emission. Depending on the network short circuit level, using PLC Programming and Documentation a 12, 18 or 24 pulse rectifier topology For fast, professional service; we work with all major brands; can result in the elimination of Siemens, Allen Bradley, ABB, Emerson (Unidrive and Unidrive harmonic filter(s) in practice.

SP, Mentor), Mitsubishi, Panasonic, Bosch and many others.

An induction motor (using VSI technology) provides robustness and simplicity. There is a very Call now: 03 9874 7737 ww.datafactory.com.au low harmonic content on the

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16 FEBRUARY 2014 Manufacturers’ Monthly

Because of the speed excursion of the variable speed drive application it is mandatory to implement a comprehensive torsional study of the complete train.

There is also a smaller footprint, mainly due to the absence of a harmonic filter. Typically the VSI solution requires only 70% of the footprint compared to a LCI option with the same rating. The VSI solution is also cheaper. An induction motor is cheaper compared to a synchronous motor for the same application.

There are few references to the operation of induction motors with powers higher than 30 MW. There are also few references to the operation of PWM-VSI technology with power levels greater than 30 MW. The choice of the induction motor (VSI) solution is recommended for use in situations where at least one successful reference is available, but with a proper de-risking plan. A de-risking plan should be carefully implemented. The main factor is a full-load test of the induction motor with its VSI. A string test of the complete machinery train should also be considered. Induction motors are simpler to fabricate and install (compared to the synchronous motors). They are also simpler in terms of the performance tests, startup and operation.

Put simply, the selection depends largely on application.

[Amin Almasi (amin.almasi@ymail. com) is a rotating machine consultant in Australia. He specialises in rotating machines including centrifugal, screw and reciprocating compressors, gas turbines, steam turbines, engines, pumps, condition monitoring and reliability.] manmonthly.com.au

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Medium-voltage AC drives

Decentralized soft starter and reversing starter with motor protection Nord Drivesystems presents a motor-mounted starter with an extended performance range for the economicly distributed implementation of soft start and reversing functions, for motors from 0.25 to 7.5 kW. The compact SK 135E integrates motor overload protection through PTC thermistor monitoring, mains and motor phase failure monitoring, I²t monitoring, and magnetizing current monitoring.

The electronic, wear-free switching technology replaces motor circuit breakers, reversing contactors, and brake rectifiers, thus rendering entire control cabinets unnecessary in large facilities.

When the drives are ordered complete and wired with gearbox, motor and starter, any assembly effort is reduced to simply tightening the screws and establishing the electrical connection, which is optionally with plugs.

The soft start function reduces mechanical stress, preventing shocks during start-up and braking. A voltage boost can be programmed for applications requiring high break-away torques.

M A 1braking 0 1 3 modes _ 0 0 0are_ available.

P I E -The starter 1 2 0 1 Various features four potentiometers and four DIP switches

In contrast to Vacon’s current low-voltage products, these medium-voltage AC drives typically operate on voltages of several kilovolts and at power levels of several megawatts.

Vacon is a full-scope AC drives company which focuses on AC drives. It offers products from small powers to multi-megawatt solutions. The global medium-voltage AC drives market is growing, and therefore the company is expanding its range.

According to the company, the medium-voltage technology in AC drives is a natural extension for Vacon, since the power levels of machines and systems have increased over the years.

Industries that typically use medium-voltage drives include marine and offshore, mining, metals and oil and gas. Some examples of applications for these drives include propulsion, pumps, fans, conveyors and hoists.

The first deliveries of the medium-voltage AC drives are scheduled to take place in 2014.

Vacon Pacific 08 9227 9651 www.vacon.com

The soft start function is intended to reduce mechanical stress. for adjusting the most important parameters. LEDs signal the operating status.

Parameterization and diagnosis can be carried out via parameter boxes or via a PC, using NORD CON software.

Nord Drivesystems 3 - 0 9 - 1 2 T 1 4 : 5 3 : 3 5 + 1 1300 0 : 050 0 0347 www4.nord.com

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Manufacturers’ Monthly FEBRUARY 2014 17

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Automation& ROBOTICS What is the future of automation in manufacturing?

The rise of innovative automation systems in manufacturing is not bad news for workers. The worforce of the future will simply move from manipulating matter to playing with information and ideas. Jim Pinto writes.

S

OME three decades ago, had not been taken into account.

FASTFACTSFASTFACTS when American automakers Today, reduced headcount and felt threatened by Japanese increased leisure are not options; the The manufacturing competition, they had a vision of remaining employees are working of tomorrow beating their rivals with “lights out” harder than ever.

• Manufacturing is entering a dynamic manufacturing - highly automated As Yogi Berra said, “It’s deja vu new phase. factories with robots left to build all over again.”

• Machines will still need people to design, program and service them. cars on their own.

Many of the new production • Old ideas about training and seniority But manufacturing will always methods in the next manufacturing will become obsolete. need people. revolution will require fewer people • Next generation robots will be When lights-out automation was working in factories, and some cheaper and easier to set up. still a dream, it was imagined that lights-out manufacturing is now work weeks would be reduced and possible.

Editor: Watch out for Industry 4.0 people would have much more Manufacturing will still need updates in the forthcoming M Atime.

0 2 1 4 _ 0 0 0 _ F A N 1 - people, 1 2 0if 1not 4 so - 0many 1 - 0in9the T 1factory 5 : 2 4 : 3 0 + 1 issue 1 : 0of 0Manufactures’ Monthly. leisure But competitive globalisation itself. Automated machines need

people to design, program and service them.

As manufacturing transforms into a high-tech workplace, the new generation of process and automation engineers and technicians will be completely different - they will have grown up with the Internet, smartphones and video games.

Old-fashioned ideas about training and seniority will quickly become obsolete as the fast-growing skills shortage generates high demand for skilled engineers and technicians. Tech power will trump everything else.

FANMASTER Here at FANMASTER our goal is.........

To Protect Australian workers 1300 900 345 www.fanmaster.com.au 18 FEBRUARY 2014 Manufacturers’ Monthly

manmonthly.com.au

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Future workplaces - the equivalent of factories - will be bright and stimulating places where people enjoy working and jobs are challenging and rewarding.

Knowledge workers don’t need time cards, defined working hours or staffsergeant supervisors.

Today’s young people are smart, and even brash. They want to work; but unlike their parents, they don’t want work to be their lives. If they can be attracted, they are the ones who will be the automation engineers and technicians of tomorrow.

Technology shifts There will be some super high-tech factories that make smaller quantities of highly specialised products. But there will also be millions of small and medium-sized businesses that will benefit from new materials, cheaper robots and 3D printers that can economically produce a wide variety of products in small numbers.

For smaller companies, robots are generally too inflexible and require too much financial investment. But the next generation of robots will be

automation systems: productivity, meaning improved efficiency and reduced manufacturing costs; steady product improvement in smaller batches; optimum asset utilisation; integrated factory and information technology; production flexibility, making it easy to expand, with high redundancy, self-recovery and rapid reconfiguration; integrated control, safety, security and information systems; network standardisation; standards for products and systems interoperability; web-based software, data exchange and integration; robust wireless everywhere; self-diagnostics and predictive maintenance; and health, safety and environmental responsibility.

In my view, conventional deterministic control architectures will fade away and will steadily be replaced by distributed, robust, modular, adaptive, non-hierarchical, fault-tolerant autonomous control systems.

A report from the McKinsey Global Institute, Manufacturing the Future: The Next Era of Global Growth and Innovation, presents a clear view of

Conventional deterministic control architectures will...be replaced by distributed, robust, modular, adaptive, non-hierarchical, fault-tolerant autonomous control systems. cheaper and easier to set up, and will work with people rather than replace them. There will be a proliferation of smarter software and an abundance of cloud-based services.

The continuing manufacturing drive will be to make more with less - pack more information and knowledge into less matter using less energy while making more effective products.

Jobs will keep moving from manipulating matter to playing with information and ideas, as priorities continue to shift toward design, programming, finance, logistics, marketing, production and repairs, and into making sure that the continuously changing combination of human and automation investments performs optimally.

Manufacturers will demand several capabilities from future manmonthly.com.au

how manufacturing contributes to the global economy today and how it will probably evolve over the coming decade.

The report states that manufacturing is entering a dynamic new phase and will continue to grow globally.

As a new global consumer class emerges in developing nations and innovations spark additional demand, global manufacturers will have substantial new opportunities.

Innovative automation systems will be the core of future manufacturing growth.

[Jim Pinto is a US-based industry analyst and commentator, writer, technology futurist and angel investor. His areas of interest are technology futures, marketing and business strategies for a fastchanging environment, and industrial automation with a slant towards technology trends.]

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Pressure sensors & SSwitches it

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UV Light DistribuƟon Film

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Inclinometers

x

Tilt sensors

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Accelerometers

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Signal condiƟoners

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Digital panel meters

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Package leak tester

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UTMs

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Wireless sensors

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Colour sensors

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InerƟal gyros

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Data loggers & DAQ

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Enquiry@bestech.com.au www.bestech.com.au Manufacturers’ Monthly FEBRUARY 2014 19

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Metalworking& MACHINE TOOLS The evolution of CMM probing systems Stationary and portable metrology probing systems have evolved from traditional single point tactile probes to advanced scanning laser probes capable of reliable, high speed metrology of a wide range of materials in the most demanding of environmental conditions.

Ian Martin writes.

T

HE aim of metrology is quite simple: to ensure that the items manufactured match the original intent of the designer.

Metrology is accomplished by gathering as much mathematical information about the physical dimensional characteristics of the “as built” parts and comparing them against the designer’s specifications.

Over time, the ability to do this has become increasingly sophisticated.

Initially, metrology was limited to measuring in just one dimension at a time; height, length, or depth. It was not until the late 1960’s when the first true three-dimensional Coordinate Measuring Machine (CMM) debuted in the market.

A CMM can be used in manufacturing and assembly processes to test a part or assembly against the design intent. By precisely recording the X, Y and Z coordinates of the target, points are generated which can then be analysed via regression algorithms for the construction of features.

The typical “bridge” CMM is composed of three axes, an X, Y and Z. These axes are orthogonal to each other in a typical three dimensional coordinate system. Each axis has a scale system that indicates the location of that axis.

Touch probes The machine will read the input from the touch probe, as directed by the operator or programmer. As the probe touches the surface of the component, 20 FEBRUARY 2014 Manufacturers’ Monthly

FASTFACTSFASTFACTS

CMM Probing Systems • Metrology was once limited to measuring in one dimension at a time.

• In the late 60s the first threedimensional CMM appeared.

• Portable CMMs usually take the form of an articulated arm.

• Non-contact scanning is now advancing quickly.

programmed to repeatedly measure identical parts.

More recent innovations are touch probes that drag along the surface of the part taking points at specified intervals, known as scanning probes.

This method of CMM inspection is often more accurate than the conventional touch-probe method and can be many times faster as well.

Portable CMMs

The typical portable CMM is composed of three axes, an X, Y and Z. the stylus deflects and simultaneously sends the X,Y, Z coordinate information to the computer.

These points are collected by using a probe that is positioned manually by an operator or automatically via Direct Computer Control (DCC) which can be

Portable CMMs are different from “traditional” CMMs in that they most commonly take the form of an articulated arm.

These arms have six or seven rotary axes with rotary encoders, instead of linear axes. Portable arms are lightweight - typically less than 10kg - and can be carried and used nearly anywhere.

The inherent trade-offs of a portable CMM are manual operation and overall accuracy is in general less accurate than a bridge type CMM. Non-repetitive applications such

as reverse engineering and large-scale inspection of low volume parts are ideally suited for portable CMMs. In addition, if parts are too large or heavy or if they have to be inspected whilst still in the fixture, a portable CMM that can be brought to the part is often the only solution.

Non-contact scanning The next generation of scanning probes, known as non-contact scanning, is advancing very quickly.

This category includes both point and line scanning probes.

Optical probes - particularly line scanners – work many times faster than the most advanced touch scanning probes to create very large data sets which, due to their large size, are called ‘point clouds’.

These point clouds can be used to not only check size and position, but, due to the high density of point information compared to contact probes, to create a full 3D image of the part as well.

Optical scanners are most suited to complex freeform parts where the shape is not easily represented by simple prismatic entities, examples being car, aerospace, motorcycle bodies, trim and seats; many consumer products, medical components and blade shapes such as those used for power generation.

They have created a whole new range of solutions to common customer problems. Typical applications include: Target Inspection/Validation - In manmonthly.com.au

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this application, measurement of specific features contained within the point cloud can be made for the purpose of dimensional inspection or GD&T and the results compared against nominal values.

This latter step could of course be performed using conventional tactile measurement but for larger parts where tolerances can be up to 0.5mm or more, an optical scanner is often faster since non-contact measurement is more tolerant to large deviations of the part from nominal.

In addition, due to the high density of information contained in the point cloud, the whole cloud can be compared against the full CAD surface model to give a ‘colour map’ of the deviations across the whole part. Such a tool is extremely powerful for first article inspection and production line tuning processes.

Typically a customer will just measure parts but in many cases the tool that produced the part will also be inspected.

Optical scanners are most suited to complex freeform parts where the shape is not easily represented by simple prismatic entities.

Reverse Engineering - Reverse Engineering is the process of taking a physical part, measuring it to determine its size and creating a CAD design from these measurements. This is most often used in cases where the product design process has significant manual operation, such as automotive design.

Despite the advances in CAD, many designs still start life as a physical model which then needs to be turned into electronic form.

In other applications legacy parts, for which engineering drawings no longer exist, are unavailable or out of date may need to be scanned in order to generate a CAD model to make tooling for replacements. manmonthly.com.au

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Non-repetitive applications such as reverse engineering and large-scale inspection of low volume parts are ideally suited for portable CMMs.

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semi-finished, stamped, forged, casted and painted metals, sand cores, wax, carbon fibre, plastics, clay, rubber, wood, ceramics) and be used easily on a range of different part sizes Reliable – must work under a wide range of environmental conditions Easy to use – minimal operator training is desirable Accuracy - must meet the needs of the application M A 0 2 1 4 _and 0 2portable 1 _ M T I CMM 1 2 0 Stationary probing systems have evolved over

the years and the unique technology in the CMS106 and CMS108 scanners now produces an accurate, fast non-contact probe capable of measuring a wide range of materials in demanding environmental conditions whilst being repeatable, reproducible, flexible and easy to use.

[Ian Martin is Managing Director of Hi-Tech Metrology] Hi-Tech Metrology 1 4 - 0 1 - 1 4 T 1 1 : 5 0 : 1800 0 6 +283 1 1095 : 0 0 www.hitechmetrology.com.au

In both these cases, point clouds can either be processed by special software packages to create 3D CAD models or transferred directly to CAD software where a full working 3D model is created.

Replication (copying/scaling) For applications where a one-off replica of a part is needed it may not be necessary to create a full CAD model. In this case the point cloud may be turned directly into a polygonal mesh which is a basic form of a 3D model. This mesh can be edited, for example, scaled or a half model can be mirrored to create the desired electronic part.

From this final mesh a physical replica can be created using standard manufacturing techniques like milling or Rapid Prototyping.

Typical copying applications include cultural heritage, for example, buildings where a façade has eroded over time and needs restoration or replication of sculptures in different scales.

Summary The applications described above cover a very wide range of objects with different materials (metal, plastic, clay). Thus the key customer requirements for an optical probe are: Repeatability – for series measurement, the results must be highly repeatable Reproducibility – independent of the operator programming or running the system, the results should be the same Flexibility – the probe should be able to measure a wide range of materials (for example, machined, MTI122x210.indd 1

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Metalworking & MACHINE TOOLS For a stronger, lighter, and more sustainable world.

Portable measurement system

SSAB is the world’s leading manufacturer of quenched and tempered steel, marketed under the well-known brand names of Hardox® wear plate, Weldox® high strength steel and Domex ® high strength steel.

High strength steel made by SSAB is sold all over the world. The high strength steels contribute to lighter weight of the end product, as compared to the use of ordinary steel.

SSAB product is well-known for its high uniform and precision properties as well as its workshop friendliness. They are available in a wide range of thicknesses, widths and lengths to cater to different customer needs. You can find SSAB high strength steel product grades ranging from 0.7mm to 160mm.

For more information, refer to SSAB complete product program at www.ssab.com.

Because you ask a lot of your equipment, get the wear plate preferred around the world - HARDOX, the number one choice in abrasion resistant steels.

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22 FEBRUARY 2014 Manufacturers’ Monthly

Brisbane Phone: +61 7 3891 3533

The new HDR (High Dynamic Range) Mode lets users scan materials with contrasting colors (i.e. black and white) simultaneously.

FARO Technologies has released the new Laser Line Probe for Edge, which when combined with the flexibility of the FaroArm is said to create the smallest, lightest, contact/non-contact portable measurement system, the FARO Edge ScanArm ES. The new system is the latest advancement in the company’s Laser Line scanning sensors, featuring EST (Enhanced Scanning Technology).

EST is the combination of multiple hardware and software improvements designed to boost performance by improving the ability to scan challenging surfaces. Materials with dark or reflective optical qualities can now be scanned with less effort and without the need for sprays or surface coatings.

According to the company, scanning is becoming a big part of the metrology world and the improved

performance of the ScanArm ES minimises the challenges of capturing data on surfaces with less than ideal optical qualities.

New and improved filtering algorithms automatically adjust and optimise the scanning parameters for plastic, metal, or a variety of surface finishes and colours. The new HDR (High Dynamic Range) Mode of the Edge ScanArm ES lets users scan materials with contrasting colors (i.e. black and white) simultaneously.

The Edge ScanArm ES is said to be the ideal tool for product development, inspection, and quality control and offers capabilities such as point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling.

FARO Technologies www.faro.com

Cermet grade Seco designed its new cermet grade TP1030 to consistently deliver premium threading performance and maintain tool life in high-production thread turning operations that involve steels and stainless steels.

The grade maintains tight tolerances in combination with high surface finishing demands in a broad cutting speed area, especially when used in conjunction with Seco HD threading holders.

Available in an S-type insert to ensure a uniform-profile edge line, the grade is an ultra fine grain cermet substrate that increases productivity and achieves excellent surface finish. When compared

to carbide, it offers improved crater wear resistance and reduces the risk of builtup edge.

A TiSiAIN nanolaminate PVD coating further protects the edge and is intended to further improve performance.

The grade complements Seco’s CP500, CP300 and CP200 PVD-coated carbide threading inserts as a specific optimisation grade for steels and stainless steels. It is offered in the most common external and internal profiles and pitches, such as ISO 1.0-3.0 mm, UN 20-8 TPI and W 19-11, as well as 60-degree partial profiles.

Seco Tools www.secotools.com/au

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Blade measuring system

Indenting machinery Tronics has launched the Technomark range of indenting machinery from Europe.

According to the company, it can produce a high quality mark and is very versatile. The Technomark Multi 4 indentor is able to be configured in four configurations; it may be handheld, bench mounted, a combination bench and handheld configuration or fully integrated on to a production line.

Oscillating at 3000 cycles per minute using electro-magnetic excitation, the carbide tipped indentor is said to be capable of making high quality marks on all surfaces with a Rockwell hardness of up to 63HRC, including most metals, titanium, copper, brass and plastics.

The indentor has Ethernet and RS232 connectivity, and also has I/O ports for machinery integration. With no consumables, and a simple electromechanical design, it is a very cost effective indenting machine to own and operate.

Tronics 1300 661 222 www.tronics.com.au L M0 2 1 4 _ 0 0 0 _ B A C 1

BAC Workplace Systems

RENISHAW has developed a family of hardware and software products for CMM (Co-ordinate Measuring Machines) that are specifically designed to aid the measurement and manufacturing of aerospace blades.

The products complement the Revo 5-axis measurement system and include ApexBlade planning software for Revo sweep scanning and DMIS programming, Modus airfoil analysis for the calculation and reporting of blade section profile and airfoil characteristics, and SurfitBlade to aid reverse engineering of the complete airfoil.

Historically blades have been measured in sections due to the limitations of measurement techniques. Now, the new system enables the whole blade to be inspected quickly and accurately allowing unlimited section or full surface analysis based on high precision contact probe data.

ApexBlade is a software package designed to quickly generate collision free programs that drive the Revo measurement system to carry out complex ‘sweep scans’ that will collect point cloud data from across the complete blade surface.

The CAD model is imported into the virtual Revo CMM environment prior to the automatic generation of the measurement plan. Both transverse and longitudinal scans are supported and each sweep can be split, which is useful for edges where the actual position is expected to be 2significantly 0 1 4 - 0 different 1 - 1 0 from T 0 8the: nominal 0 4 : 4CAD. 1 + 1Once 1 : the 0 0user is happy with the program, a DMIS file is generated that can

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The system allows the whole blade to be inspected quickly and accurately. be executed within Renishaw’s Modus metrology software.

A key advantage of the new Renishaw approach to blade measurement is that a cloud of tip centre data points is generated over the entire airfoil and root surfaces. The Modus Point Cloud Sectioning (MPCS) functionality then allows ‘on surface’ sections to be constructed by intersecting any defined plane with the captured point cloud. This can be carried out at the time of measurement, or in the future if further sections at different locations are required, without the need for re-measurement of the blade.

The Modus airfoil module then allows the user to take the nominal aerofoil sections available from the CAD model and the actual sections from the MPCS to provide blade fitting functionality for the reporting of blade section profile and aerofoil characteristics.

Renishaw 03 9521 0922 www.renishaw.com

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Visit our Website at www.bacsystems.com.au to order the latest BAC Catalogues

manmonthly.com.au

Manufacturers’ Monthly FEBRUARY 2014 23

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Materials HANDLING 55 years and still on a roll Despite the hardships currently being felt in the Australian manufacturing sector, 2013 was a good year for Richmond Wheels and Castors. And, as Brent Balinski writes, the company and its six stores are confident they can continue their success.

“

Probably in the eight years we’ve been here, we’ve quadrupled the amount of sales that we do,” said brett Thompson, the manager of richmond Wheels and Castors’ Wa store, which opened in 2005 and which he joined in 2006.

“When we started, the materials handling industry was quite competitive and people obviously took notice of us, but not seriously. “and now we’re probably public enemy number one to every wholesaler in Perth.”

The Welshpool store – along with outlets in four other australian cities and one in auckland – are part of the richmond organisation.

In what will likely be remembered as a less than brilliant year for manufacturing, the company enjoyed continued success in 2013, as well as its 55th anniversary.

The third-generation familyowned business, founded by Frank Winslow, began in the Victorian suburb it takes its name from in 1958. It relocated to the industrial hotspot of Clayton, south-east Melbourne, in 1963, where it still manufactures its products.

In its very earliest days it worked in steel fabrication for the building industry. richmond acquired a materials handling company in 1961, and sold materials handling products under the liftnMove brand.

Materials handling solutions still contribute a significant part of the company’s business, but wheels and castors – which became the focus of the company when Winslow retired in 1987 – make up the bulk of its sales.

“That’s our bread and butter at richmond in Perth,” explained Thompson. “you could say that for any state. We also deal with material handling and stack-style trolleys and appliance trolleys and platform trolleys and pallet trucks and electric

24 FEBRUARY 2014 Manufacturers’ Monthly

Richmond has designed and manufactured a castor and mounting kit for fixed containers.

and manual stackers… right down to plastic tubs and so on. you’d have to say that probably about 70 per cent of our earnings would be from wheels and castors.”

The company’s wheels, castors and rollers are put to use in a variety of industries, from hospitals to huge infrastructure projects (such as the Victorian regional rail link project) to the resources industry.

Thompson gave an example of richmond’s engineering know-how being used to greatly reduce leadtimes for a major mining engineering company through custom-making a product.

The well-known company was looking to source pipe-rollers for a project from Germany, however richmond was able to provide an alternative. “[The engineering company] said ‘can you do these, we can’t get our hands on these for about three

months; we need them in about three weeks,’” recalled Thompson.

Some drawings of the German product were made, a quote was provided in a day, and richmond’s engineers went to work.

“The customer’s response to this custom job was absolutely ecstatic,” said Thompson. “and this is what keeps those customers coming back. If it’s going to cost you an arm and a leg and it’s going to take so much time we to get... we can do it at probably half the price and in only a tenth of the time.

“That’s one of the custom jobs, but that’s just one of many.”

Thompson said that his state’s remoteness meant some businesses are used to long lead times and have been forced to become patient. a quick turnaround and effective service through richmond’s network has been able bring about

a better result than some clients had previously been used to.

However, keeping appropriate stock levels is a constant challenge.

“It’s hard to have all the stuff here, everything that you do here in the one place,” the store manager said. “and a lot of things have to be stored in our existing warehouses, so getting things over fast enough and being able to serve the customer fast enough is also a challenge,” he said.

When asked of other regular challenges, Thompson said that protecting the dominance in the state that the company had established was foremost.

“There are a lot of challenges, but the biggest is staying number one in the market,” he said. “over here we’re pretty much number one.”

Richmond Wheels and Castors 1300 682 300 www.richmondau.com manmonthly.com.au

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Conveying safety

Emergency stop systems are one way to combat one of the most common accidents around conveyors - tripping.

Conveyors belts can be dangerous. But, according to Kinder & Co, there are steps that can be taken to improve the chances that all your workers go home in one piece.

T

he Australian mining industry is, without a doubt, a potentially dangerous one. The unfortunate series of incidents that occurred in early December only demonstrates how seriously safety should be taken on all mine sites.

All aspects of the site are at risk, and in the ten year period between 2000 and 2010, 30 miners were killed in conveyor belt related accidents alone.

Conveyor manufacturing company Kinder & Co. CeO Neil Kinder explained that “if you consider the huge number of rotating parts, nip points, suspended counterweights, rotating couplings, and myriad other issues typically seen on a conveyor alongside human beings then it’s surprising that this figure is not higher”.

“Conveyors need to be designed with safe access, for regular inspections and maintenance work.

“AMsafe A 0 means 8 1 3 _must 0 0 be 0 _provided T S U so - that 1 2 0 1 3 personnel are not exposed to any danger from the

conveyor or surrounding areas when conducting their work.” he went on to say that even when there has not been an incident, we must remain vigilant on site, as “every time someone gets hurt, or worse, they are not going home to their family in the same condition that they left”.

So how can a site effectively protect its workers around conveyors?

Machine guarding and safety switches are two ways to prevent accidents.

Guarding is a reliable way to prevent roller pinch point injuries. emergency stop systems are also another way to combat one of the most common accidents around conveyors - tripping.

Kinder said pull wire switches provide the simplest 0 7 - 1 1option T 1 0for : 3initial 3 : 2setup 9 + 1and 0 :adjustment.

0 0 he gave a four point plan for operators to

follow to avoid accidents when working around conveyor belts.

• Firstly - Stop. Don’t work or travel near the conveyor while it is operating • Secondly - De-energise. Turn off all power to the conveyor belt and disconnect the electrical circuit at the break panel or motor control centre.

• Thirdly - Lock and tag. After disconnecting the power, lock and tag to ensure the conveyor belt cannot be reactivated whilst working around it.

• And lastly - Block from motion. Secure the belt to prevent unintended motion such as belt movement caused by stored energy.

By following these basic steps, operators can ensure they are a little safer over the summer.

Kinder & Co 03 9587 9244 www.kinder.com.au

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Manufacturers’ Monthly FEBRUARY 2014 25

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EndeavourAWARDS Enter online at manmonthly.com.au

Last chance to enter the Endeavours

– don’t miss out

Open to all manufacturers, Manufacturers’ Monthly’s Endeavour Awards program is the ideal vehicle for Australian manufacturers to highlight their recent successes and achievements. Alan Johnson reports.

W

ith the Australian dollar slowly moving down to a more sustainable level against the greenback, manufacturers are increasingly optimistic about 2014 and are in turn being encouraged to enter this year’s Endeavour Awards. however, Manufacturers’ Monthly’s Managing Editor, Kevin Gomez, advises readers to start the nomination process as soon as possible as the deadline for nominations is fast approaching COB February 27th.

“While the nomination process is not arduous, it’s important companies don’t miss the deadline.

Simply go to www.manmonthly.com. au/awards for more information and the nomination form. it’s as simple as that, and is free to enter,” Gomez added.

“And by entering the 2014 Endeavour Awards, it shows the rest of the manufacturing industry that your company has survived the tough times and is now in a good market position,” Gomez said.

Proudly sponsored by BlueScope Steel, the Endeavours are the only awards program designed specifically for Australia’s manufacturing industry, and are now in their 11th year.

Designed to celebrate Australian manufacturers’ achievements and inspire innovation and success, the Endeavour Awards are open to all manufacturers, large and small, including engineering companies, food processors and chemical companies.

New category Enterprise Connect has been a proud sponsor of the Endeavour awards for a number of years now, but for 2014, in conjunction with Manufacturers’ Monthly, the organisation has 26 FEBRUARY 2014 Manufacturers’ Monthly

developed an exciting new category called the Business transformation Award.

Gomez says the Award is all about recognising an Australian SME manufacturer that has successfully transformed its business, by increasing productivity, innovation and competitiveness as a result. “the Australian manufacturing industry is highly dynamic with many unsung companies making a valuable contribution to Australia’s economic output, with product innovation, support of local employment and training our future stars. “this is your opportunity to

have your business and those that have played an important part in the transformation success to be recognised. “if your business has gone through a transformation you’re proud of, we want to hear about it.”

Gomez said there are a number of benefits for manufacturers entering the Business transformation Award, which include: • Attending the Endeavour Awards gala dinner for a night of celebration, with Enterprise Connect covering accommodation and flights for the winner of this category.

Manufacturer of the Year for 2013: Pat Boland, director of ANCA (right) being congratulated by Steve Gregson from overall sponsor BlueScope Steel.

• Receiving recognition by your industry through independent endorsement and establishing market leadership, increasing business profile and increasing sales.

• Building strong moral within your business through recognition of team effort, improved processes, culture and sustainability.

Categories for 2014 the Endeavour Awards program, sponsored by BlueScope Steel, now includes 11 categories: * Technology Application of the Year Award - for successful applications of new technologies (sponsored by ifm efector); * Environmental Solution of the Year Award - for successful implementation of solutions to reduce the environmental impact of manufacturing (sponsored by Atlas Copco); * Safety Scheme of the Year Award - for implementation of schemes to improve safety in manufacturing (sponsored by Sick Australia); * Exporter of the Year Award - for excellence in developing an export market (sponsored by EFiC); * Global Integration Award - for manufacturers who have successfully engaged in international supply chains (sponsored by iCN); * Business Transformation Award (new for 2014) - for Australian SME manufacturers (less than 200 employees and less than $100m annual turnover) that have successfully transformed their company, and increased productivity, innovation and competitiveness as a result; (sponsored by Enterprise Connect); * Australian Consumer and Trade Product of the Year for innovative new products for use by consumers/trades; * Australian Industrial Product of the Year - for innovative new products for use by industry (sponsored

by BOC);

* Australian Innovative Steel Award - for products or projects using Australian-made steel that demonstrate innovation, plus deliver competitive advantage for users; * Most Innovative Manufacturer Award - recognises a manufacturer in Australia that has thought ‘outside the box’ to implement a new business idea (sponsored by SEW-Eurodrive); * Young Manufacturer of the Year - for the rising stars of Australia’s next generation of manufacturers; * Lifetime Achievement Award - recognises an individual who has made an outstanding personal contribution to his or her manufacturing business and the wider manufacturing community; plus the overall * Manufacturer of the Year Award - awarded to a winner from one of the above categories.

With only weeks to go until nomination entries close, Manufacturers’ Monthly encourages all readers to take the opportunity to become Australia’s Manufacturer of the Year 2014. the Awards’ gala presentation ceremony and dinner will be held in Sydney on May 14 or 15, 2014.

Entry is free, with information and nomination forms available at www.manmonthly.com.au/Awards.

For more information on the Endeavour Awards call Kevin Gomez on 02 8484 0976 or email kevin.gomez@ cirusmedia.com.au.

manmonthly.com.au

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NOMINATIONS

ARE CLOSING ...

DON’T MISS OUT! NOMINATIONS ARE CLOSING ON THE 27TH OF FEBRUARY 2014 for the 11th annual Manufacturers’ Monthly Endeavour Awards.

Be a part of the national awards program that celebrates the industry and recognises and rewards manufacturing excellence. Join us for Australian Manufacturing’s night of nights by nominating your business or employees.

THE CATEGORIES ARE • Technology Application of the Year • Environmental Solution of the Year • Safety Scheme of the Year • Consumer/Trade Product of the Year • Industrial Product of the Year • Australian Steel Innovation Award • Global Integration Award • Exporter of the Year • Young Manufacturer of the Year • Lifetime Achievement Award • Most Innovative Manufacturing Company • Manufacturer of the Year • Business Transformation Award

VISIT: www.manmonthly.com.au/awards EMAIL: awards@manmonthly.com.au PLATINUM SPONSOR

.

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Health& SAFETY keeping on top of machine safety New technology can mean new safety hazards.

According to Sick, there are steps that can be taken to counter these hazards.

i

n the early days of the industrial revolution labour was cheap and there was relatively little regard for the suffering of injured workers.

But times have changed. These days new guarding systems are developed and incorporated into new and existing machinery.

Pressures of a global playing field and different safety standards around the world make it even more challenging.

Whether he/she is involved in design, production or maintenance, the modern day engineer is faced with increasingly complex machinery that requires increasing levels of protection and existing machinery that needs to comply with today’s relevant laws, regulations and standards.

While this may sound challenging, there are principles and processes that have been developed into regulations and standards. The overriding principle when designing any safeguards for machinery and plant is that it must keep operators safe.

Experience shows the most cost effective way to achieve this is to consider the potential risk of M A 0to2 hazards 1 4 _ 0 during 0 0 _ Pthe RI exposure design phase. This will enable the

FASTFACTSFASTFACTS

Safeguarding machinery • Understand all relevant safety laws, regulations and standards.

• The best safety solution is always to eliminate hazards in the design phase.

• If risk elimination is not possible, then the next step is to minimise risk.

• It is vital that the needs of operators and maintenance personnel are included in planning at the concept level. designer to design out any exposure to hazards, taking into account the need to reduce speed, temperature and pressure to an acceptable level.

What about existing machinery?

The same applies. it is necessary to design a system that also complies with current day legislation.

Presence sensing systems such as safety light curtains and safety scanners should be used when physical guards are not suitable.

and Western Australia have no legislative action, while Victoria is likely to delay legislation.

Harmonisation will happen. it’s just a question of time for the Federal The steps to machine safety Government to provide the necessary The first step is to understand concessions to enable the states to laws, regulations and standards. work towards passing the bill.

The new national harmonised OHS Then there are the regulations laws promise to remove confusion and codes of practice that point us and provide a transparent national towards Australian Standards that legislative framework for industry will ensure we have designed and to follow. currently there are four selected the correct interlocking states that are yet to enact the system based on the risk of exposure 1changes.

2 0 1 Tasmania 4 - 0 1 - has 1 4the T 1bill 0 : 5 2 : 4 to 1 the + 1 hazard.

1 : 0 0 before parliament. South Australia The law requires that risk is

eliminated. if this is not possible, then engineers must minimise risk. in addition, by law, when access to machinery is not necessary, permanently fixed guards must be employed. if access is required during operation or maintenance, it is necessary to provide a guard that is interlocked. An interlock guard is one that is movable or has a movable part. The movement of the guard interacts via a switch connected to the control system which prevents movement of dangerous parts while the guard is open.

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There is still more that needs to be considered. For example, if a switch has been incorporated, how do operators know which switch to use?

Or similarly, how should the control system be designed?

Standard AS4024.1 – 2006 Safety of machinery covers the use of interlocking systems. The standard is divided into six sections covering safety principles, risk assessment, ergonomic principles, design parameters, ergonomics and displays (controls, actuators and signals).

What about a guard that is not welded and is not interlocked? i.e. a fixed barrier that can be removed with tools. In this case, caution is urged. And the tool selected should not be in the possession of the operator.

There is a hierarchy of control which runs from elimination to substitution then to engineer control; and from there to administrative and to personal protective equipment.

Operators M A 0 2 1always 4 _ 0 attempt 0 0 _ S to PE perform their duties in an efficient

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manner and assume the guarding A great example of the use of will protect them. But they presence sensing systems is on entry sometimes manipulate or bypass the and exit of palletisers by using very devices introduced to protect muting sensors to differentiate them. Generally, they do so because between products and humans. they feel the guarding is annoying Using captive key type systems, or badly design. there is the problem of trailing Given this fact, manipulation needs to be considered and it should be as difficult as is reasonably practicable to do.

Where physical guards are not suitable, the hierarchy of control allows the use of presence sensing systems such as safety light curtains, safety scanners, safety mats or bumpers. Even though presence sensing systems are the last step in the hierarchy of control, they are the only solution when where one operator follows another looking at frequent access. into the machine danger zone.

When used correctly, they can This can be prevented by using offer productivity improvements a safety scanner to monitor if the such as the ability to load and operator is in the danger zone of unload machines more efficiently machine. This will avoid unexpected by reducing time taken to open and start ups. Safety scanners are close doors and remove potential also used on AGV’s as an antiuse and for personnel 1hazards 2 0 1introduced 4 - 0 1 - through 1 3 T 0 8the : 3 0 : 1 collision 6 + 1 1 :solution 0 0 of physical barriers. protection.

By law, when access to machinery is not necessary, permanently fixed guards must be employed.

Risk Assessments Where necessary, risk reduction follows a risk assessment by applying suitable protective measures. A new risk shall not result from the application of protective measures.

The repetition of the entire process, risk assessment and risk reduction, may be necessary to eliminate hazards. A collective approach is most suitable in this area.

Otherwise, the engineering department may design a safety system that complies with standards, but doesn’t suit machine operators.

The end result may run the risk of being bypassed and manipulated.

Decision makers in industry are responsible for their employees as well as for cost-effective production.

Only if management makes safety part of everyday business will employees embrace the topic.

It is vital that operators and maintenance personnel are included at the concept level.

SICK 1300 405 807 www.sick.com

Manufacturers’ Monthly FEBRUARY 2014 29

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Health & SAFETY Angled gauge adaptor system EnErpac’s new adaptor kit enhances workplace safety and efficiency by angling widely used high pressure hydraulic gauges (700bar, 10,000 psi) to the ideal position for visibility when undertaking jobs such as lifting, pressing, cutting, crimping, forming and maintenance.

TheGa45Gc Gauge adaptor assembly positions its G series glycerine-filled pressure gauge at 45 degrees to ensure operators get the best readings possible and can easily monitor the system, enhancing safety. according to the company, accuracy and safety are crucial when working with high pressure hydraulics, and this assembly acts as a clear window on a broad range of commonly used systems, where it helps minimise hazards such as overloading.

G series gauges are widely usedFwith N 1 Enerpac 1 1 3 _ hydraulic 0 0 0 _ Stools AF and lift cylinders. The Gauge

The stoppers can be quickly deployed.

The gauge has dual scale readout (bar and psi).

assembly adaptor can also be used with a wide range of compatible high-pressure hydraulic tools, which are widely used throughout industries such as construction and infrastructure; civil, mechanical, production and process engineering; electrical distribution and maintenance; energy production and reticulation; government utility; mining and resources, manufacturing and materials handling, oil and gas, onshore and offshore resources, safety, water and waste water.

1

Pipeline supply solutions

One method of stopping and sealing pipelines that is attracting increasing interest and application in Australasia for maintenance and environmental protection applications involves inflatable pipe stoppers that can be rapidly deployed, easily transported and widely applied in urban, remote, temporary and permanent industrial situations.

“Pipelines are a major component of such a risk management strategy and, while many companies are becoming aware of the issues involved, others have yet to understand them fully,” said James Maslin, national Sales Manager for Air Springs Supply Pty Ltd, which distributes Pronal inflatable stoppers suitable for all types of pipelines.

The common factor with maintenance, testing and emergency situations is that they need stoppers that can be rapidly and securely deployed to provide primary or secondary safety and environmental security as required by both by Safe Work Australia and State environmental Protection Agencies.

“Pronal products are based on more than 40 years of producing specialist pneumatic Enerpac elastomer designs for demanding applications, including government, military, heavy 198: 007 service, sub-sea and exploration” said Maslin.

2 0 1 3 - 1 0 - 1 5 1300 T0 9 2 1 : 2industrial, 2 + 1 1emergency : 0 0 enerpac.com.au Air Springs Supply 1300 385 119 www.pronal.com.au.

EDGES NEW

Long-range safety sensors The Reer Admiral AX-LR Long Range safety light system has been designed for the protection of workers up to 60m away as well as those workers exposed to risks arising from the use of dangerous machines in a range of outdoor applications.

The Admiral AX LR has two safe PNP static outputs and can work without any external control unit, having

Leading the way in high visibility impact protection, New Safepad Edges are designed to cover protruding or hazardous edges. Made from high quality EVA foam, Safepad products are durable and reduce worksite injuries and costs. Typical uses include cornices, flanges, ducting, braces, stairways and beams.

www.safepad.com.au sales@safepad.com.au (+61) 8 9474 6886

30 FEBRUARY 2014 Manufacturers’ Monthly

The sensors comply with International Standard IEC 61496-1-2.

all the safety functions integrated inside the emitter and the receiver.

The system complies with the requirements of the european Standard eN 61496-1 and the International Standard IeC 614961-2 and also integrates the start/ restart interlock function as well as providing external Device Monitoring (eDM).

Features include integration of the main safety functions, including selfmonitoring of the safety circuits and for the AX models, the external device monitoring (eDM) and the Start / Restart interlock functions.

They are said to be reliable in the field, thanks to the rugged construction and to the high level of immunity to external interference.

Treotham Automation 1300 615 110 www.treotham.com.au manmonthly.com.au

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Test&MEASUREMENT Filor adds scanner to 3D offerings With the goal of “closing the gap” in its services, Bunbury-based Filor 3D Services recently invested in a Faro long-range laser scanner.

U

PGRADING from the previous model of Faro Focus, Callum Davies, business development manager at Filor, told Manufacturers’ Monthly that the biggest advantages from the new scanner would be seen in servicing oil and gas clients, though it would be useful in a huge range of applications.

The Faro Focus 3D X330 model (released in October last year) comes with a new 1550 nm, Class 1 laser rating, safe for flammable conditions.

“The laser rating allows us to bring this technology into the oil and gas industry with the full knowledge that it is safe to use,” explained Davies.

“The next great advantage is the range of 330 metres in every direction; this gives us a huge scanned cloud.”

The 330-metre, extra-long range is nearly three times that of previous models, according to Faro. The company also says the X330’s new features include noise reduction of up to 50 per cent, an integrated GPS receiver, the ability to perform

in direct sunlight, and increased portability (it weighs just 5.2 kilograms), and a battery life of 4.5 hours.

“We want this to be used in many settings but we see great advantages to reliability engineering, heritage and archaeology and general engineering,” said Davies.

“Keeping personnel away from large or dangerous equipment and even having the ability to measure without a shutdown, is a bonus to any mine site.”

But, adding to Filor’s equipment such as a portable CMM arm, CAD software and 3D printer, the X330 offers an increased level of service for the company’s industrial clients.

“Last week we scanned a local manufacturing plant just as a test; I see a massive advantage just in virtual fly-throughs so your clients can see your plant and understand processes,” said Davies.

Purchased from metrology specialist vendor Laser & Survey Solutions in Queensland for “around the $100K area”, Davies said Filor was the first Australian company to acquire an X330 scanner.

The scanner offers noise reduction of up to 50 per cent.

While many of us spent the Christmas holiday period playing beach cricket and binge eating, Filor has been getting to know its new scanner.

In only a couple of weeks, Davies has put the scanner to use on the Cape Naturaliste Lighthouse and Ngilgi

Cave, the Bunbury manufacturing facility mentioned above, a construction site and “countless streets and other points of interest as we travel around the state”.

Laser & Survey Solutions 1800 765 542 laserandsurveysolutions.com.au

Weidmuller expands its ACT20M range

The RTD and thermocouple devices are designed for high accuracy.

manmonthly.com.au

THE 6 new models for thermocouple and RTD temperature sensor conversion and isolation, expand Weidmuller’s existing range of 6mm signal isolators and converters.

They are available as thermocouple or RTD standalone units as well as combined RTD and thermocouple models. Users can also choose between isolated and non-isolated models.

All the temperature models are available as output loop powered or 24Vdc powered units. They also

feature a dip-switch selection for zero, the full scale range setting and output selection.

According to the company, the new RTD and thermocouple devices offer a high accuracy reading to within 0.1% of the measuring range. Depending on the unit, the measuring range is from -200°C to +1370°C. The operating temperature range is a broad -25°C to +70°C to ensure the units are suitable for demanding applications. The output voltage is selectable from 0(1)…5V,

0(2)…10V and the current can be adjusted between 0(4)-20mA. The output response times are set at 30ms intervals.

The models measure only 6mm in width, and are quite small and compact. They are recommended for use in industrial, automation and mining applications.

The six new temperature models increase the existing ACT20M range to a choice of 16 models.

Weidmuller 1300 914 822 www.weidmuller.com.au Manufacturers’ Monthly FEBRUARY 2014 31

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Test &MEASUREMENT

EtherCAT I/O system

T

he EP1816-3008 EtherCAT Box from Beckhoff has two integrated 3-axis acceleration sensors and 16 digital inputs.

According to the company, the I/O module is easy to install and is suitable for use in harsh environments.

It can be used to implement cost-effective vibration and shock/oscillation monitoring directly in the field. The machine-mountable device also enables tilt monitoring in longitudinal and transverse directions.

It features two integrated 3-axis, 16-bit acceleration sensors with resolution options of ±2 g, ±4 g, ±8 g and ±16 g. The sampling frequency is 1 Hz to 5 kHz. These so-called MEMS (microelectronic mechanical systems) are based on forked silicon structures, which have movements or vibrations that result in a capacitive change and a corresponding signal value.

AM 1 1 1 3 _ 0 0 0 _ FLI 1 A typical application for the 3-axis

Digital guage The guage meets AMS Instrumentation & Calibration’s electromagnetic Noshok 1000 Series Digital Gauge compatibility requirements allows local digital indication of (EMC) to EN 61326. pressure in place of mechanical gauges, and provides 4,000 hours of battery life.

Precision, reliability and mechanical durability make the NOSHOK 1000 Series Digital Gauge ideal for pressure measurement in a variety of applications, including machine construction, apparatus monitoring, hydraulics & pneumatics, and mobile test equipment.

Standard pressure ranges are available from 0 psig to 30 psig, to as high as 0 psig to 10,000 psig. Compound ranges are also available from 30/30 psig through 30/600 psig.

The I/O system supports acceleration and angle The display on the NOSHOK 1000 Series Gauge has an integrated measurement directly in the field. bar graph with a trailing indicating pointer to show the trends in a acceleration box is vibration and shock/ working pressure system, and an additional display provides a direct oscillation monitoring of machines and readout of the peak value, tare and other functions. buildings. For example, vibrations of robot Optional features include tare function, password protection, min./ arms can be monitored exactly and with no max. memory, internal lighting, 300° rotatable base, and a rubber great effort via the measured accelerations. case protector.

Beckhoff AMS Instrumentation & Calibration 1300 316 970 2 0 1 3 - 1 0 - 1 4 T 1 6 : 2 2 : 4 41300 + 1321 1 058 : 0 0 www.beckhoff.com.au www.ams-ic.com.au

Make GAS visible!

FLIR GF-Series Thermal imaging cameras for gas detection and industrial applications Conventional leak detection equipment such as a Volatile Organic Compound meters (or sniffers) mean that the operator must visit and test each potential leak site.

Using a FLIR GF-Series thermal imaging camera you get a complete picture and can immediately exclude areas that do not need any action. This means you can achieve enormous savings in terms of time and personnel.

Another advantage is that systems do not have to be shut down during the inspection.

Depending on the model, a wide variety of gas can be detected.

All FLIR GF-Series thermal imaging cameras are dual-use systems. They not only allow the user to detect gases, they can also be used for industrial maintenance inspections.

www.flir.com FLIR Systems Pty Ltd. VIC: 03 9550 2800 NSW: 02 8853 7870 WA: 08 6263 4438 Free Call AU: 1300 729 987 NZ: 0800 785 492 Email: info@flir.com.au Disclaimer: Images for illustrative purposes only. The images displayed may not be representative of the actual resolution of the camera shown. ISO No. FLIR20870

32 FEBRUARY 2014 Manufacturers’ Monthly

Captured gas leak

Electrical inspection

Gas leak

manmonthly.com.au

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What’sNew

Brought to you by

See more new products at manmonthly.com.au

The new air filtering system has just 16 components compared to 115 with the previous version.

Grade offered in single, double-ended inserts, widths from 3 mm to 10 mm.

Multi-directional turning for super-alloys Air filtering system NeDerMaN has released its third generation FilterBox air filtering system. It is designed to capture airborne particles, filter them out, and create a cleaner and safer work environment.

The company’s development team has created an air filtering system where the number of components has been reduced radically, from 115 to 16 compared with the previous version.

The third generation FilterBox is also 27% lower in weight as a consequence of less material used, now 102kg, and includes an automatic start/stop function so the system only operates when needed.

The team continuously asses a product’s environmental impact during the product’s development process, and strive to minimise each product’s impact during its life-cycle, from raw material, manufacturing, distribution, use, maintenance to disposal and recycling.

For example, this third generation FilterBox air filtering system is modular and can be upgraded instead of thrown away, plus it is manufactured at three different production plants depending on where it is to be sold, meaning reduced transportation and carbon dioxide emissions. as well, the product’s software allows service personnel to remotely troubleshoot and update the product, leading to a reduction in travel required.

Other features of the new FilterBox include a 3m easily manoeuvrable extraction arm, dust free emptying of the dust bin, polyester filter cartridges with 99% separation efficiency, an integrated LCD display, an automatic damper minimising dust leakage during pneumatic cleaning and third party approval for welding fumes, category W3 eN 15012.

Nederman 03 8720 3700 www.nederman.com.au

manmonthly.com.au

SeCO believes that its CP200 has long been an excellent grade for parting-off and grooving operations involving challenging materials. To further increase the versatility of its PVD product, the company has now made it available for MDT (multi-directional turning) applications.

While primarily intended for superalloys, including Inconel, hastelloy and Waspaloy, as well as highstrength steels, the new CP200 for MDT is also highly productive when cutting cast iron with low hardness and martensitic stainless steels. The latest inserts feature an optimised micrograin and sharp, periphery-ground cutting edge that allows them to excel in high-speed

operations and maintain a high resistance to plastic deformation.

In general, the CP200 grade complements Seco’s uncoated 883 grade, and can be paired with the company’s Jetstream Tooling to further enhance chip control, productivity, surface finish and overall component quality. Jetstream Tooling delivers highpressure coolant directly to the cutting edge to remove heat from the cutting zone and facilitate higher cutting speeds.

Seco Tools Australia www.secotools.com/au

Portable marking machine

The marking machine may also be used on vertical or inclined surfaces.

The XM700 micro-percussion portable marking machine is designed to meet identification and traceabilty requirements.

It facilitates the easy identification of machinery, assets, tooling, construction equipment, and metal structures.

The unit produces deep identification marks on the hardest surfaces. Fully portable, it is powered by battery or mains. It doesn’t need to be plugged in and requires no PC, no control unit, and no keyboard.

It has an ergonomic design and is easy to use on vertical or inclined surfaces. It offers flexible connectivity for easy data exchange with a PC, a code reader or a USB key.

It includes an intuitive touch-screen interface which can even be used while wearing a glove and features large navigation icons to provide direct access to desired functions with a finger or a stylus.

The user can mark each item individually with references, serial numbers, batch numbers, date, 2D codes.

The marking machine comes with a range of accessories, including a support column, a side handle (right or left-handing), a barcode reader, and a water-proof suitcase on wheels.

Gravotech 02 9684 2400 www.gravotech.com

Manufacturers’ Monthly FEBRUARY 2014 33

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What’sNEW

Brought to you by

Polyamide cable protectors TREOTHAM Automation offers cable protectors made from TPE and Polyamide 66 UL approved material and IP54 protections.

These PACOF cable protectors may be opened and closed in longitudinal direction any time. They offer the option of using PMA standard nominal widths with all PMA fittings, and trouble-free retrofitting.

Free from halogens and cadmium, these easy installation, self-extinguising protectors have a temperature range of –40°C to +105°C; short-term to +160°C. New cables can be added without the need for re-wiring or re-threading within the building of machines and installations.

They are suitable for use in vehicle manufacturing and building construction.

Treotham Automation 1300 615 110 www.treotham.com.au

The cable prtectors have a temperature range of –40°C to +105°C.

Safety air guns with extensions

M A with 1 0 914 1 3 mm _ 0 and 4 2 1829 _ GR A Available mm extension pipes.

1

COMPRESSED Air Australia’s Super Blast Safety Air Guns from EXAIR provide high quality performance for blowoff, drying or cleaning requirements.

These are now available with 914 mm and 1829 mm extension pipes. These CE compliant Super Blast Safety Air Guns with extension pipes provide strong blowing force to clean large areas quickly and the extensions allow the reaching of areas not easily accessible.

Extension pipes are designed to provide a safer way to blow off hard to reach areas, while allowing compliance 2 0with 1 3OSHA - 0 9noise - 2 (29 3 TCFR 1 1 1910.95(a)) : 0 8 : 0 and 9 + dead-end 1 0 : 0 0(29 CFR 1910.242(b)) regulations. Supplying compressed air

closer to the affected area can decrease air consumption and increase results; adding an extension can reduce excessive bending and reaching.

Super Blast Safety Air Guns use engineered air nozzles for high performance – designed to maximise entrainment of room air while minimising compressed air consumption. They range in force from 3.2 to 23 pounds (1,451 to 10,433 grams) measured 305mm from target at 80 PSIG (5.5 BAR).

Compressed Air Australia 1300 448 246 www.caasafety.com.au

Send your part, see the mark Scan barcode to see video demonstration 34 FEBRUARY 2014 Manufacturers’ Monthly

manmonthly.com.au

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What’sNEW

Brought to you by

Robust signal processor BAlUFF claims that its signal processor BiS V is an ideal choice to support the company’s robust RFiD data carrier. it not only supports all the features found on new data carriers, but also significantly simplifies hardware and installation for users. The controller in the metal casing with iP 67 protection fulfills all requirements for industryoriented design and comes equipped with USB as a service interface to Pcs. Balluff offers the device with a choice of Profibus, ethercAT, ethernet/iP or cc-link interface. especially positive for users: up to four HF read/write heads (13.56 MHz) in accordance with iSo 15693 and iSo 14443 or lF read/write heads (125 kHz) can be connected in the front with plug-in connectors and are then automatically recognized. in addition, the RFiD controller is the only device on the market to offer an io-link master port for direct connection of io-link-compatible sensors or actuators.

Balluff-Leuze M A 1 1 1 3 _ 0 3 7 _ B1300 I N653-893 1 balluff.com.au

Metal casing with IP 67 protection.

The conveyor can be configured with single/ multiple inlets.

Tubular cable conveyor Flexicon has expanded its FlexiDisc line of tubular cable conveyors with the addition of a 15 cm diameter system, more than doubling the capacity of its recently introduced 10 cm diameter conveyor.

The conveyor is intended for the gentle transfer of friable materials including virtually all beans, cereals, coffees, dried fruits, frozen vegetables, grains, nuts, beans, pet foods, seeds, snack foods, spices, teas and other 2 0 1 3 - 1 0 - 2 3 T 1 1 : 0 3 : 0 0 + 1fragile/friable 1 : 0 0 food products. Typical non-foods include bulk chemicals,

minerals, prills, chopped fibreglass, microspheres, regrind, pellets of all types, tobacco and other fragile products. low-friction, high-strength polymer discs slide materials gently, quietly and dust-free through smooth stainless steel tubing, which can be routed horizontally, vertically or at any angle, through small holes in walls or ceilings, over short or long distances.

Flexicon Corporation (Australia) 1300 353 942 www.flexicon.com.au

EWR. Weld more efficiently Maximise your cost savings!

Optimal use of all resources is essential for an economic and efficient welding process, be it manual or robotic.

However, options for shielding gas consumption are often given too little consideration. The EWR (Electronic Welding Regulator) system can save up to 60% of shielding gas and at the same time provide superior gas coverage during the welding process.

Contact us for a trial today!

Contact Us: Ph: (03) 9580 6500 Fax: (03) 9580 4896 Email: sales@binzel.com.au www.binzel.com.au manmonthly.com.au

Manufacturers’ Monthly FEBRUARY 2014 35

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What’sNEW

Brought to you by

Small BLDC motor controller MAXON MOTOR’S new brushless DC motor controller has miniature dimensions of only 43 x 11mm, but is still able to perform robustly.

The brushless DC servo controller range has just received a new entry that features an OEM plug in style form factor for easy integration into new equipment designs.

Supporting existing controllers that require the motor to have a minimum of 3 hall sensors to operate, this new motor controller can now be used with

brushless motors that are not fitted with either hall sensors or an encoder.

Despite this lack of feedback from the motor, the smart controller is still able to provide a closed loop speed control between the motor and control unit.

12 Amp of peak current is available for up to 30 seconds on top of a continuous current rating of 4 Amp. The voltage level accepted is anything between 10 and 50 VDC which is particularly helpful in motor control applications with rapid deceleration

rates and high levels of back fed energy.

It is also able to self-limit the amount of current the motor is allowed to draw from the motor control unit which allows a motor to even be driven to stall without burning out.

Maxon Motor Australia 02 9476 4777 www.maxonmotor.com.au

Protected against winding short circuits.

Overmolded M40 powerfast connectors

Connectors feature a MA 0 2 1 4 _ 0 0 0 _ T a n j a n t G u i d e s protection rating of IP67.

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1

Offering a more robust connectivity solution than field-assembled versions, overmolded M40 powerfast connectors are factory tested to ensure optimal performance in harsh industrial automation applications.

The powerfast connectors feature both power and signal capabilities within the same connector, and are capable of up to 35 amps. The line offers male or female, straight connectors, standard and custom lengths 2 0and 1 4pigtails - 0 1 or - extensions.

1 4 T 1 0 For : 3 a4complete : 5 5 + 1 1 : 0 system, the powerfast line also provides mating

receptacles, cordsets, splitters and a jumper plug.

According to the company, they are reliable and durable. In comparison to traditional fieldassembled connectors, these connectors are designed to provide a more cost-efficient, tamper-proof solution with ingress protection in demanding applications, including automotive, conveyor OEMs and material handling.

TURCK Australia 1300 132566 0 www.turck.com.au

Affordable, Accurate & Rapid

Work Assembly Systems

BuildPro Welding Tables are the key to serious time saving in any metal fabrication workshop.

Tanjant Tool Co. Pty Ltd is the sole Australian importer for these tables & modular tool kits.

Please visit our website or telephone us on (03) 9872 6222 for a catalogue and price list.

www.weldingtables.com.au

36 FEBRUARY 2014 Manufacturers’ Monthly

manmonthly.com.au

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What’sNEW

Brought to you by

Double and triple-scissor lift tables

7” tablet with Windows 8.1 Pro

ACTISAFE has introduced to the Australian market double and triple-scissor lift tables with two-tonne load capacities.

These can be custom designed and manufactured to meet exact requirements in the manufacturing, handling, retail and food sectors.

These are not people-lift items of equipment; rather they are designed to lift or lower product and/or equipment up to and from a selected height.

For example, such as to a gangway where an employee may be selecting various stockkeeping units for an order.

Made durable for all types of warehouse and logistics conditions, Actisafe double and triple-scissor tables are provided with highly visible safety-yellow markings.

Customisation is possible on most aspects of the equipment including bellows, roller tops, ball tops, while rails and auto-levelling M A 0 2 1 4 sensors _ 0 0 0can _ FbeAadded N2 on request.

PANASONIC AUSTRALIA will launch a seven-inch rugged tablet in April 2014, following the product’s unveiling at the 2014 International CES trade show in January.

At the time of its unveiling, the Toughpad FZ-M1 was the thinnest and lightest rugged seven-inch fanless tablet with a 4th generation Intel Core i5 processor. Running Windows 8.1 Pro, it can be easily incorporated into enterprise and government environments.

According to the company, the tablet is unique in that it offers all the functionality of a computer without any compromises. It has the capability to run any organisation’s existing Windows software in a completely rugged, customisable and mobile form factor.

As such, it is said to be suitable for broad range of business uses and applications. The tablet is designed to improve productivity and efficiency in a host of professional scenarios, including customer service, inventory management and asset tracking, maintenance, eForms, route delivery, eCitations, electronic medical records, inspections, mobile point-of-sales and geographic information system (GIS).

Panasonic Australia 02 9986 7746 www.toughbook.com.au

Cost-effective alternative to manual handling.

These scissor tables have been designed to provide a complete means of solving any materials handling problems.

Units are nominally supplied with a powder coated finish as standard but can be received in galvanised finish for added durability, stainless steel (for sensitive food handling areas), or in a range of colours, with pallet disks or U-shaped top.

Actisafe 1 2 0 1 4 - 0 1 - 0 9 T 11300 5 : 852 4 2397 : 4 7 + 1 1 : 0 0 www.actisafe.com.au

7”

The tablet weighs just 540g.

FANMASTER COOLING HEATING VENTILATION FANMASTER HAS A SOLUTION FOR YOUR APPLICATION- “JUST ASK”

1300 900 345 www.fanmaster.com.au manmonthly.com.au

Manufacturers’ Monthly FEBRUARY 2014 37

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The lastword Productivity gains through real-time feedback OFS is an Australian company specialising in the development of productivity improvement software for the manufacturing industry.

The company’s MD Shoni Even-Chaim spoke with Hartley Henderson.

What was the vision behind the development of OFS-Go and how is it different to OFS-X ?

O

perations Feedback Systems (OFS) recently launched OFS-Go – a web based overall equipment effectiveness (OEE) solution designed to enable manufacturers to make rapid, responsive decisions. Manufacturers’ Monthly spoke with Shoni EvenChaim who established OFS in 2006.

What was the prime motivation for establishing OFS? The original goal of our software was to improve DIFOT (delivery in full, on time) for the manufacturing industry by providing real-time feedback about production orders to planners and their scheduling systems. DIFOT certainly began to improve, but in particular we noticed that productivity was soaring – the first plant increased its capacity by an outstanding 30 percent within a few months.

Now, our focus is on software that helps operators, supervisors and managers to maximise the speed of production by eliminating unplanned stops and wastage through the application of OFS-X and OFS-Go. A key element of this is to give voice to people on the factory floor to identify and put a stop to inefficiencies and unplanned downtime by providing feedback in real-time.

Most manufacturing businesses don’t have an instant scoreboard - the score only goes up the next day, or even later. By engaging and empowering operators, pressure is put on middle and upper management to address inefficient areas.

With most industries averaging an OEE measure of 30-40 percent, there are clearly significant gains to be achieved.

38 FEBRUARY 2014 Manufacturers’ Monthly

Our vision with OFS-Go was to bring an economical, robust OEE solution to the table, and to be able to have an installation up, running and getting results – in as little as one day.

With OFS-Go, we wanted to be able to quickly deliver an OEE solution to any kind of industry without having the time and cost associated with needing to ‘wire’ everything up.

This is the main difference between OFS-X and OFS-Go. We typically install OFS-X onto a mainline industrial machine, such as a printing press, or a filling line, where there are inputs readily available for us to collect automatically. We might count units in and units out, allowing us to calculate real-time wastage, as well as monitor the up-time of inline components, such as tray-packers, wrappers and robots.

OFS-Go does the same thing, but we’ve designed an easy to use, intuitive, touch display where the operators ‘tap in’ this sort of information, rather than automatically harvesting it from the process, as we do with OFS-X. The major advantage of OFS-Go is, because we don’t have the need to do any wiring and electrical integration work, it can be up and running extremely quickly and for less cost than OFS-X. This also means that OFS-Go can be hosted internally or clients can choose to take advantage of an OFS-Go Cloud solution.

How is OFS different to SCADA? Well, our audience is different and as a result our functionality is also different. The users of OFS are operations and management, focusing on productivity and efficiency. The users of SCADA are typically more engineering

based, focusing on parameters and diagnostics. Put another way, OFS engages both people and process, placing a high importance on input and feedback from workers, which is different to SCADA’s data, tags and symbols approach.

Because of this difference, we find that the take-up of SCADA by operations and management is usually quite poor, as these systems

We have a strong focus on continuing product development with the aim of producing four software releases per year - Even-Chaim. are designed for engineering users and can be very intimidating for less sophisticated users. On the other hand, we have invested significant resource into making sure that OFS software is extremely easy to use for both our operations and management audience.

Consequently, we have found the take-up and use of OFS software to be fast and extensive.

How broad and successful are your OFS industry applications?

OFS is ‘generic’, which means that it will operate equally well on all machines and processes. This is really useful when a business wants to use a common benchmark and reporting methodology across different types of manufacturing machines. From a best practice and continuous improvement perspective, software like OFS is really the only way to compare and contrast plants and divisions.

Today, over 2,500 operators are using OFS technologies, OFS-X and OFS-Go, in a range of industries including printing, packaging, labeling, cereals, confectionary, beverage, chemical, and blow moulding.

By measuring productivity in real-time, these installations are really out-performing, and we’ve seen some outstanding results with OEE gains of 30 percent or more. Examples include blue-chip companies like Visy Industries, Heinz/Golden Circle and Brickwood Holdings.

Smaller businesses are also benefitting from OFS products.

Our solutions are quite scalable, meaning that OFS works just as well on a single machine shop as it does in a company with multiple sites and hundreds of production lines.

What are your projections for the future development and uptake of OFS? We forecast a huge future for OFS-Go as testing only started in July 2013 and it is now rapidly gaining traction with some outstanding results being delivered.

In particular, it is evident that this technology can be successfully applied to a wide range of industry types beyond manufacturing industry. For example, OFS-Go will soon be used to monitor teams of workers in real-time laying broadband cable in the ground for the NBN Co. We have a strong focus on continuing product development with the aim of producing four software releases per year.

Potential opportunities are being identified to utilise OFS to improve the efficiency of supply chains in the future.

Operations Feedback Systems 03 86 849 859 www.ofsystems.com manmonthly.com.au

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Vaculex TP Express Parcel Handler

Safe Manual Handling at Distribution Centres

Express parcel handling with the revolutionary Vaculex TP Express - Good ergonomics is good economics...

Vaculex TP Express – is a unique, brand new vacuum lift, specially designed for express parcel, package & carton handling type of work. They are extremely versatile because they can handle a great variety of item sizes, shapes and weights. They are suitable for any workplace where fast, safe, consistent & effective throughput is required. Clients in the transport, postal, food, meat works, warehousing and many other diverse industries are experiencing the real productivity gains from using the Vaculex TP Express.

Vaculex TP Express is very user-friendly and does not require any training downtime to operate. It is so light and easily managed that working speed and productivity are maintained or in many cases increased, which is usually the contrary when using a lifting aid.

Ergonomic to use All control functions are built into a compact, ergonomic handle with a suction cup that can rotate 3600 and swivel sideways by 900 to pick parcels from the side to fit where needed. There is no effort during the lifting process. The single handed control of the unit enables the user to move freely whilst using their free hand for manipulation of the load. Lifting fast in poor posture does not require heavy weights to cause pain and strain injuries but this is now all in the past with the Vaculex TP Express.

Distribution Centres Situation: The main areas in a Distribution Centre are the receiving dock, the storage area, the picking area and the shipping dock. Manual work in all these areas might cause problems with repetitive strain injuries due to bad postures and heavy manual lifting that are performed with a high intensity.

Solution: Materials Handling P/L, together with our partner Vaculex, have developed specialized solutions to solve these problems in most of the areas in a Distribution Centre. In addition to the reduction of work related injuries Vaculex solutions usually also improves productivity and worker satisfaction.

Vaculex solutions for Distribution Centres include solutions for: • Unloading or loading containers and trailers • Order picking in picking areas • Palletizing • De-palletizing

Vaculex WORKING WITH EASE

De-palletizing

Order picking in picking areas

Unique in its versatility! We offer you a lifting system that is so flexible and user-friendly that nothing beats it. Shape, surface, gripping angle or the need to rotate the load or the lift is no problem for Vaculex TP Express.

Palletizing

This large furniture & home wares distribution uses thirty two (32) Vaculex TP Express units suspended off our MechRail aluminium light crane systems to quickly, safely & easily store & retrieve stock

The 444 page Materials Handling Pty Ltd, se...

Working with eaee to fr is e, gu catalo wish organizations that ace pl rk to improve wo , safety, productivityd efficiency an est profitability. Requ w. no py your co Unloading or loading containers and trailers

Our website: www.materialshandling.com.au Phone us: 1300 65 00 35 Fax us: 1800 68 68 96 Email us: sales@materialshandling.com.au MM1402MH

Australia Wide Service

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Making things right Industry 4.0

Success of manufacturing in Australia? … let’s drink to that.

Making things right – The future of manufacturing is Industry 4.0 www.siemens.com.au/futureofmanufacturing

The world is entering the fourth industrial revolution – known as Industry 4.0.

Countries like Germany and the US are quickly starting to embrace and prepare for this industrial revolution and Australia needs to do the same or we‘ll be left behind.

There’s a difference between making things and making things right. Our technology is helping many of Australia’s food and beverage manufacturers make things right. Making things right, means making the right kind of progress. It means understanding that decisions today will affect tomorrow. That’s why Siemens is redefining manufacturing, making it more nimble, adaptable, intelligent; from design to prototype to production – in rapid innovation cycles.

So factories can perform faster, better and produce more with fewer resources.

Are you ready for a successful future of manufacturing for your business? Scan QR Code for more and a white paper on Industry 4.0 or contact Siemens: manufacturing.au@siemens.com Call 137 222 and ask about Industry 4.0

Answers for Industry.

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