Manufacturers' Monthly May 2014

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

MAY 2014

Grant Tinney finds life beyond the auto industry

INSIDE >> 26

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Metalworking How to deal with insert failure

NMW 2014 We preview this year’s event

Automation & Robotics Time to get on board the revolution

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Inside

For daily news visit manmonthly.com.au

MAY 2014

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 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

6 Editorial ■ It’s time to create new industries

8 News & Analysis ■ Big cuts for CSIRO predicted in May budget ■ Procurement – it’s not just about cost-cutting

12 Industry Comment ■ Time to bring award system into 21st century

14 IT@MM ■ Keech plans to lead Australia in additive manufacturing

44

16 Manufacturing in South Australia ■ What will SA’s manufacturing future look like?

■ Why Basetec chose Tonsley ■ Redarc realises the power of investing ■ Exciting things in the pipeline for welding tech company ■ How speed and productivity can keep Clipsal competitive

40 Automation & Robotics ■ Time to get on board ■ Multi-stream loading controller ■ Controller networking and sensor cascading ■ Digitising your factory ■ Automation: the challenges and benefits ■ Transitioning to Industry 4.0

24 Metalworking

50 What’s new

■ Adaptability is the key ■ How to deal with insert failure ■ Waterjet cutting machines

■ Throttle actuators ■ Safety switches

30 NMW 2014 Preview

■ Diesel forklifts ■ MR reach trucks ■ Thermal cameras

54 The last word ■ How to make diversification work

41

■ Sydney, 13-16 May

35 Materials Handling Cirrus Media

■ On the conveyor line ■ Tubular cable conveyor factoryintegrated

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

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MAY 2014

© Copyright Cirrus Media, 2013

A decade ago, nearly all of Grant Tinney’s company’s revenues were from the car industry.

In a decade, he has turned his former mould-and-die-making operation into a highly diverse, high-tech enterprise,

Average Net Distribution Grant Tinney finds life beyond the auto industry

Period ending Sep’13 - 17,385

focussed on developing IP. Precise Advanced Manufacturing’s story should be of interest to hundreds of auto parts businesses who will be forced to diversify or die as Holden, Ford and Toyota close their Australian factories.

INSIDE >> 26

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Manufacturers’ Monthly MAY 2014 5

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Comment

KEVIN GOMEZ – Managing Editor

It’s time to create new industries

A

USTRALIA is fortunate to have a perfect solution for some of the challenges facing manufacturing. It’s just that the ones wielding power are unwilling to act in the interests of our industry.

We’re referring to liquefied natural gas (LNG) and the great promise it holds. Manufacturers around the country are grappling with increasing energy costs while we sit on one of the world’s largest LNG supplies.

In 2013, research from Manufacturing Australia His belief is that new jobs will be created only by reported almost 200,000 Australian jobs could be lost and new industries powered by technology-led intelligence up to $28 billion in economic value wiped out if federal and and connectivity. state governments fail to intervene to ensure competitively What’s interesting is that the drivers for change will not priced gas remains available for Australian manufacturers. necessarily be large companies.

The alternative is indeed scary: a loss of 12 per cent of Recent research from PwC suggests that transforming manufacturing value and 9 per cent of manufacturing jobs Australia’s SME laggards to leaders in their use of caused directly by the shortage of LNG and the price rises technology could increase the country’s GDP by nearly that will inevitably result. $6 billion, increase real wages by 0.5 percent and raise Other gas-rich countries, such as the US, are taking revenue in the economy by $11 billion. concrete steps to ensure that their abundandant energy Between 2010 and 2012, those SMEs that were regarded resources are an asset not a liability. Why can’t Australia do as leaders in the adoption of technology increased revenues the same?

15 percentage points faster and created jobs at twice Western Australia alone seems to have the right idea as the rate of less progressive firms. A key reason is that the state government reserves 15 percent of gas resources the latest wave of technological advances such as mobile from each LNG venture to supply domestic users. However, communications, cloud computing and social media are even in WA, LNG makers have a loophole – floating LNG is giving SMEs access to capability that was previously only exempt from this proviso. And there are a couple of large NEXTISSUENEXTISSUE affordable to large corporates.

FLNG ventures off the WA coast.

• Motors & Drives Manufacturing has to reach a stage where we are It’s time for politicians of all shades to demonstrate the • Waste & Pollution Management focusing less on problems and more on improvement. Our required degree of farsightedness before public opinion • Plant & Machinery Maintenance • Mobile Technology discussions must revolve around Industry 4.0 and treating forces change upon them.

• Materials Handling energy as a managed cost. No doubt, that day will come.

One of the interesting personalities to recently visit • Sensors & Analysers As always, the team at Manufacturers’ Monthly would our shores was the renowned futurecaster Michio Kaku.

• Endeavour Awards: Winners His prediction? Countries that do not better harness their love to hear from you, so do drop us an email, follow us on • Impact of Free Trade Agreements intellectual assets and focus on science-based industries Twitter and join the discussions on Facebook and Google+.

• Manufacturing M A 0 5 1 in 4 Regional _ 0 0 0Victoria _ R_ BOC 1 2 0 1 4 - 0 4 - 0 4 T1 3 : 3 4 : 1 5 + 1 1 : 0 0 would suffer great poverty. kevin.gomez@cirrusmedia.com.au

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Answers for industry.

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News&ANALYSIS Big cuts for CSIRO predicted in May budget

In brief...

3D printed human hearts?

Researchers at Lousiville, Kentucky have bio-printed human heart parts using fat and collagen. The Cardiovascular Institute, a partnership between the University of Louisville and the city’s Jewish Hospital, hopes that it might be able to assemble an entire “bioficial” heart in 3-5 years.

Quickstep wins jet fighter deal Sydney-based aircraft components manufacturer Quickstep has won a deal to deliver carbon fibre components for the F-35 Lighting II Joint Strike Fighter to the US. The deal is worth $US139 million ($A148.55 million) to the company.

Boral, CSR propose JV

THE CSIRO is reportedly preparing for cuts in the next federal budget worth as much as 20 per cent of its annual funding.

Executives at the institute are modelling scenarios where up to a fifth of their $757 million in

Commonwealth funding would be removed. They have an expectation of about a 10 – 15 per cent reduction.

In early April, the research institute confirmed that 300 jobs would be cut across the country, following 400 sackings last year.

What members of our manufacturing community think about possible CSIRO funding cuts...

Rob With a string of manufacturing closures, the polys on both sides have been bleating about becoming “innovative” in what we do, yet here is the Federal Government hacking away at the very source of innovation. Ian Macfarlane, Tony Abbott - what are you thinking!!

Boral and CSR have announced plans to merge their brick-making operations. The proposed joint venture would be 60 per cent owned by CSR and 40 per cent by Boral, and would cover 12 sites in Victoria, NSW, Queensland, South Australia, Tasmania and the ACT.

say we need to innovate!

And these are the same political idiots who are spending $3billion - $5 billion in stopping the boats or >$20billion lost in their failed search for WMD during the Iraqi war... not to mention killing thousands of innocent civilians in the process.

What are they thinking you may ask ? ...they don’t know how to think!

Simon Bella These idiot politicians don’t know anything about innovation or where to begin. Last year gregH these political idiots cut funding Yep, they tell us to be innovative to CSIRO, our biggest science/ and this is the first bl**dy engineering researchers and government that doesn’t even innovators, because they couldn’t have a Science Minister. It is not find a few extra $million to their surprising that Ian Macfarlane, the More help for ex-Holden workers? stingy ~$1billion budget. And this poly now responsible doesn’t even South Australian treasurer Tom Koutyear they have cut funding again have anything to say! santonis wants more assistance from the to way less than $1billion.

Federal Government for former Holden Our researchers and engineers workers. In January, the SA Government JH are becoming retrenched and valuproposed an assistance plan that would Right Simon, without any doubt able invocation halted, destroyed have cost the federal government $333 milthese politician’s are “bl**dy and eventually lost forever and lion. Canberra has pledged just $100 milidiots”. My son is finishing science MA 1 1 1 3 _ 0 0 0 _ T U R 1 2 0 1 3 - 1 0 - 0 9 T1 4 : 1 2 : 1 9 + 1 1 : 0 0 these bl**dy idiots have the gall to lion for workers from both SA and Victoria. at university this year and keen

to continue PhD studies with CSIRO but where are the job and research opportunities? So now he is seriously considering moving overseas and I can’t blame him.

Paul They are cutting funding because there is no money and research has never made any returns.

Editor’s note: These comments are as received. Corrections have been made for spelling and grammar only.

What do you think?

Go to www.manmonthly. com.au and make a comment about this or any other issue.

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Procurement -

it’s not just about cost cutting According to Barry Thomas, these days effective procurement is also about establishing and maintaining valuable business relationships.

T

he perfect storm of a GFC and increasing supply pressures and commodity costs impacted businesses across the globe.

One outcome is that today, in this new age of corporate austerity, procurement plays an increasingly important role in organisational performance.

The challenge for businesses is to ensure that their procurement process is not obsessed with just cost M A 0 5but 1 4 _ 0 0 0 KER reduction, focused on_the creation of enduring business

the organisation and little partnerships which deliver more was expected of greater value in the long-term. procurement than to battle Recently, we have seen a some cost out of the contract tectonic shift in the overarching and then hand the relationship role of procurement – it is no back to the business to manage.” longer only regarded as an Regardless of whether extension of the accounting your organisation has an indepartment that crunches house procurement team or numbers. engages external partners, Indeed, according to the the procurement 2012 KPMG report The Power “middleman” Of Procurement: “Not long ago facilitates much procurement was considered more than sourcing to be an add on service; it -was1the2business 0 1 4 - that 0 4 decided - 0 7 T 1 5 : the 5 6 cheapest : 1 1 + 1 0 : 0 0 suppliers, which suppliers were core to

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News&ANALYSIS

“

receiving externally purchased goods or overseeing orders and approving payments. Procurement is fundamental in providing sustainable business solutions and, in turn, fostering relationships with identified business partners.

With procurement playing such a central role to profitability and performance, organisations need to invest the appropriate level of resource to elevate and empower their in-house or external procurement teams to ensure that corporate expectations are communicated, values are aligned and relationships with partners are enhanced.

Interestingly, Remko van Hoek, a global procurement manager at PWC said that procurement/ partner relationship management is becoming a growing priority; that the focus has moved from a cost centric approach to a larger recognition of the importance of relationships.

InMtandem A 0 5 1with 4 _ this, 0 0 0we B are V P also 1 seeing organisations becoming

training should clearly communicate key corporate expectations which may include striking a balance between prioritising cost reduction targets, while simultaneously engaging partners that reflect organisational values including ethics, reliability and flexibility.

Within a procurement training strategy, it is beneficial to emphasise the importance of investing time and resource for face to face interaction with partners to establish trusted relationships which may subsequently reduce risk in supply more reliant on procurement to chain management. identify the most suitable strategic A robust training program should partners that not only contribute to also include a communications fostering innovation but also help to plan to ensure procurement is maintain a competitive advantage. effectively educating nominated This is especially relevant as more partners about organisational values businesses are outsourcing services and expectations. As part of this, that fall outside of their core each party should be encouraged business remit. to outline their KPIs to encourage As part of a strategy designed to transparency. Procurement will empower and elevate procurement be tasked to measure supplier staff, organisations need to reevaluate up0and 2 0 1 4 how - 0 they 4 - 0set 2 T 9 : train 3 1 : 5 3 performance + 1 1 : 0 0 and effective communication will facilitate their nominated teams. Procurement

...Due diligence is key and businesses should not solely depend on procurement to garner key information.

feedback to ensure that partners can refine their services to meet unique organisational needs.

It is important to consider that while businesses may be increasingly reliant on procurement to identify and engage partners, due diligence is key and businesses should not solely depend on procurement to garner key information.

Employees need to support procurement teams and one way is providing direct feedback. To facilitate this, businesses need to structure their organisation to ensure that internal staff have appropriate access to nominated procurement teams – this will not only elevate procurement’s position, but will also encourage engagement and transparency.

[Barry Thomas is the Vice President and APAC Managing Director of Cook Medical Australia.]

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Comment

INNES WILLOX – CEO Australian Industry Group

editor@manmonthly.com.au

Time to bring award system into 21st century Australia needs an award system that looks after employees but also does away with red tape and excessive union interference in the workplace. Innes Willox writes.

I

T is about time that award provisions reflect the needs of 21st century workplaces. The important issue of annual leave is one such area which desperately needs to be more flexible for both employers and employees.

The Australian Industry Group (Ai Group) has filed proposed new model annual leave clauses for all awards in the Fair Work Commission’s Annual Leave Common Issues proceedings which is part for the Commission’s 4 Yearly Review of Modern Awards.

The model clauses which Ai Group is seeking to have included in all modern awards, cover: • The implementation of a “purchased leave” arrangement by agreement between an employee and the employer. Under “purchased leave” arrangements, an employee has additional annual leave in a year (e.g. 8 weeks) with a corresponding reduction in salary, either: a) For the period of the annual leave – e.g. half pay for twice the annual leave; or b) For the period of the year when the employee is not on annual leave.

• The cashing out of annual leave by agreement between an employee and the employer, provided that at least four weeks’ of accrued leave is maintained; • The granting of annual leave in advance by agreement between an employee and the employer, with the employer having the ability to deduct payment for any leave granted in advance from money owed on termination; • The right of an employer to direct an employee to take annual leave where the employee’s accrued leave is excessive; and • The right of an employer to require employees to take annual leave during a close-down.

Ai Group’s proposals preserve a high level of protection for employ12 MAY 2014 Manufacturers’ Monthly

“

The Australian Industry Group strongly endorses the Federal Government’s submission to the Fair Work Commission’s Four Yearly Review of Modern Awards... ees, while ensuring that employees and employers have access to flexible arrangements to meet their personal and enterprise circumstances.

Each of these matters is of significant importance in every industry and for all occupations. Therefore, it is sensible for each of the matters to be dealt with as common issues during the 4 Yearly Review.

It would not be an effective use of the FWC’s or industrial parties’ resources, for these same matters to be dealt with award by award, with the same arguments heard up to 122 times.

As our recent CEO regulation report found, industrial relations red tape - including restrictions on flexibility - continues to hamper busi-

ness growth. In fact, of 83% of CEOs reporting that the regulatory burden surrounding IR as well as OHS is expected to place the most burden on their business in 2014.

According to the report, union right of entry to workplaces and employees’ claims of unfair dismissal are on the rise and need urgent attention. Based on quarterly reports published by the Fair Work Commission (FWC, formerly Fair Work Australia), there was an average of almost 400 entry permits for union officials issued in each quarter up to September 2013. Quarterly data from the Fair Work Commission show there has been a steady increase in applications to the Commission to hear unfair dismissal disputes, from

around 430 in the September quarter in 2010 to over 690 for the quarter ending September 2013. Both of these issues put an onerous burden on business and productivity.

While awards were largely simplified as part of the Award Modernisation process in 2008-2009, the reality is that many awards still contain restrictions on how employers are to employ and remunerate employees that are not in line with modern employment practices. For example, several awards do not provide for part time employment at all.

The Australian Industry Group strongly endorses the Federal Government’s submission to the Fair Work Commission’s Four Yearly Review of Modern Awards that modern awards need to support job creation and that the softening economic environment and labour market need to be carefully considered during the Review. www.aigroup.com.au manmonthly.com.au

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TechnologyIT@MM Keech has big additive manufacturing plans Third-generation castings specialist Keech prioritises innovation. The company’s Doug Baird tells Brent Balinski about the aim to be a major player in additive manufacturing in Australia.

“

Keech has got the oldest technology in the world - in melting metals - and we’re actually now looking at the newest technology in the world, 3D printing in metals,” said Keech 3D business manager Doug Baird.

The Bendigo-based parent company, which has been busily turning itself from a foundry to an engineering and solutions company under the leadership of ceO herbert hermens, puts itself as the first commercial provider of large-scale additive manufacturing in the central Victoria region. This year it re-named its patternmaking subsidiary Keech 3D, reflecting the role the technology will be playing in Keech’s overall future.

M A 0 5annual 1 4 _ revenue 0 0 0 _ has KEE Keech’s grown to about $50 million, accord-

14 MAY 2014 Manufacturers’ Monthly

To its existing polyjet and FDM ing to the company, with about 7 per machines it plans to add a beefy cent of turnover going to R&D. It 900 mm x 900 mm x 600 mm FDM currently employs 117 in Australia. machine in April and a Mcor TechAt the Bendigo site it moved nologies machine able to 3D print to from Sydney in 1995, the thirdin paper, as well as metal additive generation, family-owned company has added an Innovation and Quality manufacturing capabilities after that.

It currently has the capabilities centre (in 2012), and invested heavto print in a range of a dozen therily in the last few years upgrading moplastics, including Nylon 12. its smaller No. 2 and then its No. 1 The focus, explained Baird, is on foundries and opening a chilean end-use parts, citing trends shown by subsidiary along the way.

Its efforts to improve what it does the annual Wohler’s Report. A decade ago, the amount of end-use products saw it ranked 7th in the BRW Top created through the technology 50 Innovative companies List at the was tiny, but Terry Wohler’s closelyend of last year. watched compendium of industry Last August the company antrends last year saw end-use purposes nounced that it wanted to become a make up 30 per cent of the total. major provider of additive manufac1 2 0 1 4 - 0 in 4 the - 0 state, 3 T 0and 9 : has 0 2 : 1 0“We + 1still 1 : have 0 0 service offerings turing solutions around prototyping, but we really made significant progress since.

Keech 3D is focussed on producing end-use parts.

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want to concentrate on a material that would be able to be used as end-use parts as opposed to prototyping,” said Baird.

Within the company, it has opened up huge possibilities, in patternmaking - though Keech can still chisels out patterns the old-fashioned way - and elsewhere.

“It’s had a significant effect on the way designers can look at things,” said Baird.

“We have design engineers with us for our parent company and they’ll come downstairs and say to me ‘Doug, I’ve got an idea, here’s a cAD model’ and the very next day they’ll have that part in their hand and they’ll play with that and look at how it fits into the part they’re building,” explained Baird.

“They might come back to me and say they’ve made a couple of tweaks and ask for another one. And the next day or later that day they’ll have that part in their hand. And that really speeds up the design process.”

Besides this, the company has been able to reverse-engineer old patterns through digital scanning.

“It might be 20 years old and there has never been a cAD model for it or even a drawing, it might’ve been [from] a customer’s drawing,” said Baird.

“So we can scan that, turn it into a cAD model and then 3D print that and have complete repeatability.”

Outside of the site where the Keech companies operate, there is an aim to provide engineering, design and additive manufacturing solutions to not just the region but the world. And they have already had some success in this goal.

Keech has manufactured for the defence industry since WWII, where it made munitions from its old Mascot factory. A current large defence customer is Thales, which wanted a model of its hawkei light armoured vehicle (and some of its sub-components) additively manufactured in a hurry for an exhibition in Paris.

“We had them shipped over to Paris and the guys at Thales used them in their show and all the reports back were that they wowed everyone and we’ve now got orders from France for more models directly from Bendigo,” recalled Baird.

“So I guess we’re not talking central Victoria - we’re talking globally

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[Laughs]... already in the short time we’ve been in additive manufacturing, we’ve already sent parts to Indonesia, the Netherlands, Japan, china, and France.”

Keech hopes to build on its early success and be seen as a “one-stopshop” for engineers, designers and manufacturing companies in Australia.

With its main source of local revenue (80 per cent of what it makes is

“

... We’re not talking central Victoria - we’re talking globally... we’ve already sent parts to Indonesia, the Netherlands, Japan, china, and France. – Doug Baird. sold here, with the rest exported) at the mercy of mining activity, Keech’s strategy now includes making itself useful to local industries who could benefit from the considerable collection of technology and material science smarts the company invested in during the good times.

“They can come to us with an idea or a model, we can prototype it for them, give them different iterations as they require, and we can hopefully take those parts to production as well; a full service offering,” said Baird.

“We would be expecting into next year that Keech 3D would be a major player in the additive manufacturing sector throughout the country. With an export market as well.”

Keech 3D 02 9648 3100 www.keech.com.au Brent Balinski has been a journalist at Manufacturers’ Monthly since 2012, and is particularly interested in 3D printing and innovation. Find him on Google Plus at https://plus.google. com/+BrentBalinskiCirrusMedia

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CoverSTORY What will SA’s manufacturing future look like?

South Australia’s manufacturing future will be defined by intelligent, high-end companies competing on innovation and value rather than cost.

The need to get there has only been heightened by the collapse of auto. Brent Balinski reports.

“

MANUFACTURING has always been a very important part of this state’s heritage and will continue to be so,” Len Piro, group executive director for manufacturing innovation for DMITRE, told a group of visitors on a tour of some of South Australia’s factories in February.

“There’s no question about that. But it’ll change, it’ll be different in the future.”

With Labor retaining government (with a minority in the lower house this time around), it is able to continue with its ten-year strategy to protect the state’s manufacturing jobs. The thing that has changed is the urgency, due, of course, to the end of Australia’s auto sector by 2018.

DMITRE estimates that there are 719 local companies involved in the automotive industry, with 35 per cent of these suppliers. Of the Tier 1 suppliers, most have not diversified.

Manufacturing Works, the plan to reposition the state’s industry, is informed by Professor Goran Roos’s stint as Adelaide’s 23rd Thinker In Residence and his Manufacturing Into The Future report, and aims to steer SA’s businesses towards sophisticated, high-value manufacturing, able to compete on value rather than cost.

According to the Weatherill government, the strategy will “Enhance the capacity of manufacturers to innovate; Upgrade the leadership, knowledge and skills of the South Australian workforce; Capture future markets and opportunities and Address infrastructure and policy gaps.”

There are companies that won’t adapt to an Australia that no longer assembles passenger cars.

There will also be those that thrive.

Part of the plan includes clustering, and one of the government’s most notable efforts at bringing education and manufacturers together in a precinct is Tonsley Park, “a critical element” in the state’s planned advanced manufacturing future.

Tonsley is a high-profile part of the SA government’s effort to encourage advanced manufacturing, focussing on areas such as medical technology and sustainable building products.

Below is an interview with Basetec, whose business development and strategy manager Con

16 MAY 2014 Manufacturers’ Monthly

Koutsounis will explain what led the high-tech pipemaker to set up its first site outside of China at Tonsley Park.

The clustering effort will include companies such as Basetec, Siemens and ZEN Energy Systems. Bookending the ends of the site are TAFE’s Sustainable Industries Education Centre and a Flinders University facility (scheduled to open next year) including a school for computer science, engineering and mathematics, as well as centres for medical device research and nanoscale technology.

It is also on the former Mitsubishi site, which ended its manufacturing operations there in 2008.

“We are keeping it a part of community’s fabric as well as a demo for what future manufacturing could look like,” explained Megan Antcliff, director of the Tonsley Redevelopment.

“It’s very much about having a place where companies and researchers are linked… The future will be defined by partnerships, with Tonsley an example.”

Elsewhere in this edition, you can read about Precise Advanced Manufacturing Group, who realised that it couldn’t depend on supplying to car makers and who began transitioning away from

Tonsley Park is where “industrial pioneers will find their niche” says the SA government.

the sector in 2004. We spoke to CEO Grant Tinney in the middle of the company’s move to set up its JV (with Ellex Medical) site at Thebarton, another high-tech cluster site.

We will also hear from high-tech SMEs K-TIG, a little Salisbury company who is planning to take on the world in welding technology, and Redarc Electronics, who have grown incredibly through a commitment to investment in innovation.

For some contrast, we spoke to French power solutions giant Schneider Electric, who have kept the iconic SA brand Clipsal it bought in 2003.

Clipsal and Schneider Electric Partner Business’s boss David Gardner tells us a few things about how Clipsal can produce both in huge quantities and yet respond quickly to custom orders. It employs 1,100 Adelaidians at its Gepps Cross factory.

Manufacturing will continue to be important in SA and, yes, will continue to change. Read on for some of the companies who’ve managed to adapt.

Manufacturers’ Monthly attended the Around Our State tour as a guest of Brand South Australia.

South Australian manufacturing employment by industry sub-sector

manmonthly.com.au

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Why Basetec chose the move to Tonsley The South Australian government is evangelising projects like Tonsley park as manufacturing’s saving grace after the fall of the auto industry – but when it comes to clustering, it’s a question of what kind of business makes the right fit. Jack Baldwin spoke to Basetec Services’ Business Development and Strategy Manager, Con Koutsounis.

B

ASeTeC Services first announced their intention to invest $9 million in to the Tonsley clustering site in February 2014.

Basetec and their affiliate company NovaFast manufacture and service glass reinforced epoxy (GRe) pipes and fittings for use in high-intensity applications, their product being corrosion free and able to withstand exceptionally high temperatures and pressures.

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their direct marketing capability. significant. We think it’s going “The facility is going to be to get to $1.5 billion a year. slightly different. It’s going That tells us that it’s justified,” to be a technology centre of Koutsounis says. excellence as opposed to a Their facility in Tonsley will factory – but we’ll still have be the first Australian centre the ability to manufacture,” of GRe technology, one of 17 Koutsounis tells me. in the world, and Basetec’s The manufacturing side will first manufacturing capability be focused on the quick turn outside of China. around and shorter supply lines For them, the redeveloped that businesses within Australia Mitsubishi factory isn’t just a require and depend on. space for production; it’s an “We certainly see a lot of opportunity to collaborate with synergies in regards to some educational institutions, pursue -partnerships 1 2 0 1 with 4 - 0likeminded 1 - 1 0 T 0 8 : of 0 4the : future 4 1 + 1sectors 1 : 0 of 0 South Australia, specifically mining, businesses, as well as building

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Manufacturers’ Monthly MAY 2014 17

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Cover STORY oil and gas. All of our products are used in those industries.

“One of the difficulties that those sectors have had is supply chains being able to accommodate those big projects. We think Tonsley is part of that.”

Looking at prototypes and samples of their piping, it’s not hard to see that prospective customers might be wary when comparing it to heavier, thicker carbon steel piping that they’re often used to – the centre plays a role there too, as a hands-on showroom.

What Basetec’s new facility really hones in on, and where they’ll likely experience the biggest benefit in clustering, is research and development.

“The focus will be on the RnD and value add.”

With TAFE and Flinders University onsite, Basetec has the ability to leverage the institutions for research and training purposes, pushing towards these goals.

“We’re really starting to push composites technology in to the universities. We think that’s important. We’re already working with the University of South Australia on an RnD project. We’ve spoken to the TAFE up there about partnering for blue collar training.

“We intend to speak to Flinders and other institutions about some white collar training as well. SANTOS and BHP are moving their training to Tonsley. We’ve had some discussions on how to support that, especially with SANTOS given they’re an existing client.”

“There’s a lot of synergies. That’s what we like about Tonsley – the ability to cluster. The ability to leverage off others in the precinct.”

The story of how Basetec made it to Tonsley covers a long distance, originating at a business and investment forum in South Australia’s sister state, Shandong, China.

“We attended the forum and signed a memorandum of understanding to establish a joint venture company in Adelaide,” Koutsounis recalls.

Basetec are no strangers to China, having Chinese partners and a large factory already producing their NovaFast IP’s glass reinforced epoxy (GRE) pipes.

The forum led to an introduction to DMITRE, the South Australian Government’s Department for Manufacturing, Innovation, Trade, Resources and Energy.

“I had heard about what the government were trying to do at Tonsley and given that we’d signed the MOU already - well, we were already well advanced with our own internal plans to base the facility just down the road here.”

After returning to Adelaide, DMITRE invited Basetec on a tour of the Tonsley site. Their plans to build on a site not far from their Prospect HQ on the outskirts of Adelaide were put on hold.

“It was just the perfect fit for what we were 18 MAY 2014 Manufacturers’ Monthly

Image: DMITRE trying to do. And it was the perfect fit for the government, for Tonsley.”

“Tonsley gave us the opportunity to build something that was a lot bigger than what we had previously envisioned. It means a bit more risk for the business, but we think it’s a calculated risk.

Part of the intention behind the joint venture undertaken with Sinoma (the China National Materials Group Corporation) is to export the technology and IP that will originate at Tonsley.

“Tonsley underpins our global plans. We want

to establish seven hubs around the world with Tonsley as a feeder. We develop the technology, the IP, the nous right here.

“We think we’ve got the right technical know-how, the right educational and training institutions to be able to do that and compete globally.”

Basetec Services 08 8269 5211 basetecservices.com.au manmonthly.com.au

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Exciting things in the pipeline for welding tech company Formed to commercialise a technology developed at the CSIRO, K-TIG (short for keyhole TIG) is beginning to see export success.

Brent Balinski talked to the company about what lies ahead.

T

patented by the CSIRO. hE Salisbury welding technology company After CSIRO moved its Adelaide lab to K-TIG announced its first exports in August Melbourne, Jarvis took the IP back and 2012, and has been developing its sales commercialised it. network since.

Recent boosts include deals with by two large K-TIG believes they can revolutionise the way US companies, one of these a household name. many jobs are carried out, automating the welding Details will be released in the year’s second half. of thick gauge materials (up to 16 mm). The Though broadly applicable, K-TIG sees a major process is claimed to be 10 to 100 times faster than part of its future in pipeline installations. conventional TIG. “It’ll be an enormous market for K-TIG and will “Conventional welding [requires] long really shape our development and growth.” weld times, high power consumption, high gas Whatever the growth of the company over the consumption and the need for edge preparation,” next few years and its role in the global welding the company’s Belinda Latz told Manufacturers’ industry - tipped by BCC Research to be worth $US Monthly.

25.1 billion in 2019 - it will likely remain small.

K-TIG’s story began in 1997, with founder Most of the employment pain in SA from the Laurie Jarvis’s research at the Adelaide branch automotive manufacturing industry’s collapse will of the CSIRO’s Division of Manufacturing MA 0 3 1 4 _ 0 0 0 _ K E L 1 2 0 1 4 - be 0 2felt - 0around 4 T 1 Salisbury 5 : 3 8 : and 0 4Playford, + 1 1 : 0according 0 to Technologies.

DMITRE. Its method was developed over eight years and

manmonthly.com.au

Can do a six-hour weld in four minutes.

Could K-TIG, which Latz says employs three at its headquarters, take on some of those who have lost auto jobs?

“We are fairly light manufacturing, so we’ll never be a huge organisation to be able to take up that sort of slack from holden,” said Latz.

K-TIG 08 7324 6800 www.k-tig.com

Manufacturers’ Monthly MAY 2014 19

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Cover STORY Redarc realises the power of investing Lonsdale’s Redarc Electronics, a maker of power solutions for vehicles, has found success through ambitious goals and a constant reinvestment of revenues in its people and facilities. Owner and CEO Anthony Kittel spoke with Brent Balinski.

I

n 1997 Redarc was, as they say, on the bones of its bum. In 1995 its founder had died and, by its current owner’s admission, it had lost its way.

It then employed eight people and had revenues of about $800,000, selling a family of basic voltage converters for trucks.

Today, operating out of a new, sophisticated, completely integrated manufacturing facility – with sales and marketing, innovation centre, assembly and logistics centre all under one roof – its turnover is about $25 million a year, and its rapid growth over the years has been recognised with a swag of awards. These have included repeated placings in the Deloitte Technology Fast 50 Australia and the BRW Fast 100.

According to an article published last year, the company’s revenue is currently growing at 25 per cent, yearon-year, and it employs over 100 staff.

Owner and CEO Anthony Kittel, who purchased Redarc in 1997 with his wife, has ambitions to grow revenues to $50 million in 2017.

The company provides power solutions widely used by groups including miners, grey nomads, and recreational four-wheel-drivers.

A big part of its success in this market is due to its willingness to invest in R&D. The company puts such investment at about 15 per cent of revenues.

“We punch above our weight in terms of R&D capacity,” said Kittel, who said with some pride that the company didn’t even cut down on this during the GFC. “It’s a pipeline, and like anything you need something to put into that pipe,” explained Kittel.

“Customers are willing to pay for that innovation, features 20 MAY 2014 Manufacturers’ Monthly

and reliability: a product that’s engineered to survive the Simpson Desert, Canning Stock Route - these sorts of environments - will survive Russia, will survive Africa and so forth.”

Redarc has grown from selling a low-technology product to being a solutions provider.

“We have 20 people in R&D fulltime; that’s pretty unusual. And that innovation contribution we can measure each and every year to our business.”

In terms of being a solutions provider, he puts the breakdown of what he calls “Redarc push and customer pull” at about 60/40. This means that about 40 per cent of what is made is driven by the needs of a client.

“And I guess you want to balance the risk, because if you’re pushing products onto the market, that’s where the high risk is, and so, by spreading the risk between us pushing and customer pulling, we’re able to balance and know that our R&D investment is sustainable,” Kittel told Manufacturers’ Monthly.

R&D is also carried out in collaboration with educational institutions, for example through the Auto CRC’s Vehicle Electrification Program.

Developing skilled workers inhouse – and keeping them there – is also important. Kittel mentioned partnership with South Australian universities who gain project work at Redarc in their third year. Many key members of the company’s staff began as undergraduates and stayed.

Kittel was made to see the value of staff development early on in his own career.

“I was lucky enough a long time ago, back in the 80s, when BHP gave

Redarc has grown from selling a low-t echnology product to being a solutions provider.

me a cadetship, paid for my studies, and I stayed on as an engineer for quite a number of years,” he explained.

“We follow those same sorts of values here and we have young people who come into the business, whether they’re unskilled, semi-skilled, or undergraduate professional people, and we provide that career path for them.”

The company has elsewhere named participation in the Workplace English Language and Literacy (WELL) Program as part of Redarc’s expansion since 1997.

Production workers, many of whom have not finished school and/or are from non-English speaking backgrounds, have been put through the WELL program.

When asked what an electronics company needs to do to survive in Australia, Kittel didn’t hesitate to go back to re-investing in people and their skills. To this, he added

marketing – often considered as something Australian manufacturers tend to neglect.

Redarc’s brand is something the company is proud of, and it refuses to perform any requests to do private label manufacturing. The Redarc brand is clearly visible on everything that comes out of the Lonsdale factory. If you break down, call Club Assist, and take note of the name on the lemon yellow-coloured charger used to get your car running again.

“And so you can’t just be an engineering business, you need to be a market-driven company,” explained Kittel.

“If you have the front end of your business looking good, then backed up by great products, built and designed by great people, you’re going to have a good business.”

Redarc Electronics 08 8322 4848 www.redarc.com.au manmonthly.com.au

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Cover STORY Switched on: Clipsal stays competitive The company that produces the ubiquitous Clipsal switch, Schneider Electric, remains competitive in Australia by combining productive practices, being responsive to customers, and having a strong brand. Brent Balinski spoke to the company’s David Gardner.

“

WE have approximately 50 trucks leaving the facilities every day; around about 75,000 movements out the door,” explained Gardner, head of the Clipsal and Schneider Electric Partner Business.

“Per month, products go out to over 1,000 distributors that we service here in Australia.”

The Clipsal brand’s reach in Australia is huge, covering customers’ electrical needs from the power station to the power point, as the company likes to put it.

Though it was sold for $750 million to French energy management giant Schneider in 2003, ending four generations of ownership by the Gerard family, Clipsal has remained both a hugely important brand in South Australia - continuing to sponsor Adelaide’s premier motor sports contest, the Clipsal 500 - and a reminder that, done right, high-volume manufacturing in Australia can be successful.

Gardner joined Schneider over two decades ago, and has been in his current role for 18 months, overseeing the “leveraging of two very strong brands” in the market.

“We make sure people understand that, quite uniquely for us in the Schneider world in this part of the world, we’re actually keeping and maintaining and are keen to in the future keep and maintain this Clipsal brand,” he told Manufacturers’ Monthly.

The headquarters and main manufacturing site for the Clipsal brand, established by Alfred Gerard in 1920 and named for the “clips all” metal conduit attachment he invented, is at Gepps Cross, northern Adelaide.

The three-shifts-a-day, 30,000 square metre facility was opened in 2009, after a $35 million refurbishment by Schneider. It replaced the company’s Bowden site, which had been Clipsal’s home since 1936.

The Gepps Cross site features 25,000 square metres of combined logistics and manufacturing space, with 22 MAY 2014 Manufacturers’ Monthly

small, highly flexible, multi-skilled work cells able to produce in large quantities, but also able to respond quickly to custom orders and help these turn over in less than a day.

Gardner credits strict adherence to Schneider Production System with enabling the rapid turnaround, with strict attention on everything from a cut-off time on entering the order to getting it out the door.

“Provided that order’s entered that day we are really talking about next-day dispatch,” said Gardner.

“That would come, I’m talking the volume part of the business, from our

Clipsal sponsors Adelaide’s premier motor sports contest, the Clipsal 500.

Schneider currently employs nearly 1,100 at the Gepps Cross site. finished goods stock, which would need to be rapidly replenished.”

“We have fantastic standards around kanban supply techniques to the workshop floor. We are manufacturing in batches where we can keep the raw materials and finished goods at minimum levels, but at the same time meeting the on-time delivery commitments that we do have to our customers.” He mentioned that in the last month, the Gepps Cross facility achieved its - strictly measured personal best for on-time dispatch of 95.3 per cent. On the topic of speed, a decisive advantage to keeping the Australian customer base happy is

keeping Clipsal’s manufacturing in Australia.

“It’s really one of the strengths we have with local manufacturing, we can very quickly manufacture and adapt from base components, specific [items] that the customer may need, for example an industrial plug or socket,” said Gardner.

The labour component of what Clipsal produces has been reported as up to 40 per cent of total costs.

Cutting this by manufacturing overseas would also mean much longer lead times for Australian customers.

“But even outside of Adelaide we

want people to understand that we are part of a global organisation, and in fact we manufacture at 250 sites in more than 100 countries,” said Gardner.

Schneider currently employs nearly 1,100 at the Gepps Cross site.

Just under half of these employees work in the manufacturing and logistics areas. As far as the future is concerned, Clipsal believes that the companies in SA and the rest of Australia best placed to prosper will be the ones who are looking to the future and where opportunities are likely to emerge and grow.“ Certainly a very big [trend] is around digitisation, for example,” Gardner said.

“This new generation coming through are certainly demanding immediate availability of information, remote control, for example of products; connectivity of product within their home or their workplace or other environment. Certainly that’s been the case in the industry for a long time.

“But I think now with new technology being more readily available for people and them being more adaptive to using it, it’s up to us to find those opportunities in the market.”

Schneider Electric (Australia) 1300 369 233 www.schneider-electric.com.au manmonthly.com.au

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Metalworking& MACHINE TOOLS Adaptability is the key While many manufacturers in the car industry are thinking gloom and doom at the moment, history shows that as one door closes another often opens. Val Pavlovic reports.

D

ESPITE the present tough conditions for many in the metalworking industry, adaptability still abounds, with examples right throughout industry where adaptive change not only ensures a manufacturer survives in a changing landscape, it sharpens its ability to thrive and become more dynamic.

From being heavily immersed in the BlueScope economic whirlpool in the NSW industrial region of Illawarra, Jason Leussink director of Leussink Engineering woke one day to hear BlueScope was scaling back dramatically.

Bad news admittedly, so why didn’t Leussink panic?

“BlueScope downsizing was never the death knell in our minds; it just allowed us to take a step back and see just how much experience and technical skill we had developed over a long length of time and allowed us to develop new market, much further afield,” said Leussink.

“We created successful new export markets, work closely with other

dynamic companies in the region to develop outstanding new technologies and products, involved ourselves in growing networks across the country, regularly bring on board new business streams for stronger diversification and, something on which we pride ourselves, we continue to take on apprentices every year.

“If we can impart simple but valuable advice to other manufacturers, it is basically that strength lies within the experience of management and definitely in your people.

“If ever your industry suffers some sort of setback or downturn, don’t forget that your capabilities are often transplantable into other industry sectors.

“From fabrication, we have branched into developing new mining technologies, solutions for bulk materials handling, refurbishment work and repairs for heavy transport and rail, plus we distribute arguably the best worktables in Australia

(Demmeler), and we even have branched out into the recycling game,” Leussink said Compost worms may seem a million miles from the fabrication sector, but this rather unusual direction illustrates the message Leussink is putting forward; that is, pretty much everything you do arms your company with the ability to adapt.

In this instance, it was during a major construction project managed

by Leussink to increase the energy rating of a high-rise building.

Rather than boost air conditioning or thicken windows et al, Leussink all but eliminated recycling skips in favour of composting worms which eat just about anything organic – not just food, but paper, packaging materials, wood etc.

Engineering skills

In the export sector, Leussink Engineering has seen rapid success refurbishing steel mills in Kazakhstan.

24 MAY 2014 Manufacturers’ Monthly

While Leussink’s innovation skills have been impressive, it’s the company’s engineering skills that have proved the big drawcard. Quite recently, in partnership with nearby engineering firm Soto Consulting, Leussink helped develop the SWIFTA.

Designed for underground mine operators, the device allows the driver of a wheel changing unit to actually leave the load handling device (LHD) vehicle and come out and operate the hydraulics panel on the SWIFTA itself.

This means that everyone associated with the wheel change can see the wheel perfectly without obstructions – which to date has been the industry norm because control has traditionally been done from the LHD. “But as soon as an operator begins to move from the LHD, the LHD is disengaged with an automatic cut-off and the SWIFTA becomes the control point for the tyre change procedure,” Leussink explained.

“Operators are removed from the potential ‘crush zone’; so operator risk is minimised. They are not exposed to the mass of the wheel because all manual handling is eliminated,” he said.

Safety Leussink said challenges come at the company from all angles. manmonthly.com.au

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Designed for underground mines, the SWIFTA allows the driver of a wheel changing unit to actually leave the load handling device (LHD) vehicle and come out and operate the hydraulics panel.

“A recent example again came from the underground mining sector where the incumbent method was not acceptable.

“It all centred around the susceptibilities of a small lever that activates hydraulic power in the process needed to fix roof bolts. The position of the control lever made it a potential trigger for accidents.

“

Because underground mining operates on a relatively low ceiling height, this lever, for practical reasons, is mounted on the manifold at leg level.

This always left the lever susceptible to accidental knocks and bumps by someone’s leg which would cause a roof bolt to release which can fall down from the roof height and land on the finger, foot, or head of a worker and cause a severe crush injury, or even amputation.

...Strength lies within Exporting success In the export sector, Leussink the experience of Engineering has seen rapid success management and in refurbishing steel mills with Corts Engineering in Kazakhstan. definitely in your Leussink Engineering sent people – Jason six of its specialists from NSW to Kazakhstan to machine six rolling Leussink.

“We looked at the nature of the problem and devised a simple solution to keep the lever where it normally is but to better ensure the safety of workers was heightened,” Leussink explained.

The lever, which activates the hydraulics for power and operation in the process of roof bolting, is mounted on the hydraulic manifold.

mill stands for ArcelorMittal.

The Corts-Leussink partnership can make a complete refurbishment to even the oldest rolling mills (ferrous and non-ferrous) in the world to original specification and extend their lifespan to remain productive and work almost as if new.

Leussink Engineering 02 4260 7777 www.leussink.com.au

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Metalworking & MACHINE TOOLS How to deal with insert failure Don Graham looks at eight common insert failure modes and explains that, using simple tools, manufacturers can analyse used tooling to predict usage and achieve maximum tool life.

I

NSERT failure and its negative impact on manufacturing equipment is similar to an athlete exhausting a good pair of running shoes.

Much like a shoe under the weight of the runner wearing it, an insert endures tremendous stress over and over again, creating wear and tear.

If not addressed, wear can cause pain for an athlete and inaccurate processes or poor productivity for a manufacturer.

Manufacturers, however, can analyse used tooling to achieve maximum tool life and predict tool usage, thereby maintaining part accuracies and reducing equipment deterioration. Early insert examination is important in determining the root cause of its failure as is careful observation and reporting. By not taking these important steps, it’s possible to become confused between the different types of failure modes.

To assist in the insert examination process, a stereoscope with good optics, good lighting and a magnification of at least 20X, can pay great dividends in identifying these eight common failure modes that contribute to premature insert wear.

Flank wear An insert will fail due to normal wear in any type of material. Normal flank wear is the most desired wear mechanism because it is the most predictable form of tool failure.

Flank wear occurs uniformly and happens over time as the work material wears the cutting edge, similar to the dulling of a knife blade.

Normal flank wear begins when hard microscopic inclusions or workhardened material in the workpiece cut into the insert.

Causes of such wear include abrasion at low cutting speeds and chemical reactions at high cutting speeds. In identifying normal flank wear, a relatively uniform wear scar will form along the insert´s cutting 26 MAY 2014 Manufacturers’ Monthly

large enough to cause the insert flank to chip, deform or possibly result in rapid flank wear.

Built-up edge Flank wear edge. Occasionally, metal from the workpiece smears over the cutting edge and exaggerates the apparent size of the wear scar on the insert.

To help slow down normal flank wear, it’s important to employ the hardest insert grade that does not chip, as well as use the freest cutting edge to reduce cutting forces and friction.

Rapid flank wear, on the other hand, is not desirable, as it reduces tool life and the normally desired 15 minutes of time in cut will not be achieved.

“

...A stereoscope with good optics, good lighting and a magnification of at least 20X, can pay great dividends in identifying these eight common failure modes...

Rapid wear often occurs when cutting abrasive materials such as ductile irons, silicon-aluminium alloys, high temp alloys, heat-treated PH stainless steels, beryllium copper alloy and tungsten carbide alloys, as well as non-metallic materials such as fibreglass, epoxy, reinforced plastics and ceramic.

The signs of rapid flank wear look the same as normal wear. In correcting for rapid flank wear, it becomes key to select a more wear

Cratering resistant, harder or coated carbide insert grade, as well as make sure coolant is being applied properly.

Reducing cutting is also very effective, but counterproductive as it negatively affects cycle time.

Cratering Often occurring during the high speed machining of iron or titaniumbased alloys, cratering is a heat/ chemical problem where the insert essentially dissolves into the workpiece chips.

A combination of diffusion and abrasive wear causes cratering. In the presence of iron or titanium, the heat in the workpiece chip allows components of the cemented carbide to dissolve and diffuse into the chip, creating a ‘crater’ on the top of the insert.

The crater will eventually grow

Built-up edge occurs when fragments of the workpiece are pressurewelded to the cutting edge, resulting from chemical affinity, high pressure and sufficient temperature in the cutting zone.

Eventually, the built-up edge breaks off and sometimes takes pieces of the insert with it, leading to chipping and rapid flank wear.

This failure mechanism commonly occurs with gummy materials, low speeds, high-temperature alloys, stainless steels and nonferrous materials, and threading and drilling operations.

Built-up edge is identifiable through erratic changes in a part´s size or finish, as well as shiny material showing up on the top or the flank of the insert edge.

Built-up edge is controllable by increasing cutting speeds and feeds, using nitride (TiN) coated inserts, applying coolant properly (e.g. increasing the concentration), and selecting inserts with force-reducing geometries and/or smoother surfaces.

Built-up edge

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Chipping

Chipping Chipping originates from mechanical instability often created by nonrigid setups, bad bearings or worn spindles, hard spots in work materials or an interrupted cut.

Sometimes this occurs in unexpected places such as during the machine of powder metallurgical (PM) materials where porosity is deliberately left in the components.

Hard inclusions in the surface of the material being cut and interrupted cuts result in local stress concentrations and can cause chipping.

With this type of failure mode, chips along the edge of the insert are highly noticeable. Ensuring proper M A 0tool 5 1set 4 up, _ 0 minimising 0 0 _ FLI machine deflection, using honed inserts,

Thermal mechanical failure controlling built-up edge, and employing tougher insert grades and/ or stronger cutting-edge geometries will deter chipping.

Edge deformation

Thermal mechanical failure

failure include multiple cracks perpendicular to the cutting edge. It A combination of rapid temperature is important to identify this failure fluctuations and mechanical shock mode before chipping begins. can cause thermal mechanical It´s possible to prevent thermal failure. Stress cracks form along mechanical failure by applying coolthe insert edge, eventually causing ant correctly or, better yet, removsections of the insert’s carbide to ing it from the process completely, pull out and appear to be chipping. employing a more shock-resistant Thermal mechanical failure is grade, using a heat-reducing geommost often experienced in milling etry and reducing feed rate. and sometimes during interruptedcut turning, facing operations on a large number of parts, and Edge deformation 1operations 2 0 1 4 with - 0 4intermittent - 1 0 T 0 8coolant : 1 7 : 2 Excessive 7 + 1 0 : heat 0 0 combined with flow. Signs of thermal mechanical mechanical loading are sources of

edge deformation. High heat is often encountered at high speeds and feeds or when machining hard steels, work-hardened surfaces and hightemperature alloys.

Excessive heat causes the carbide binder, or cobalt, in the insert to soften. Mechanical loading happens when the pressure of the insert against the workpiece makes the insert deform or sag at the tip, eventually breaking it off or leading to rapid flank wear.

Signs of edge deformation include deformation at the cutting edge and

For more information and videos go to www.flir.com.au/manufacturers-monthly FLIR Systems Pty Ltd. Free Call AU: 1300 729 987 NZ: 0800 785 492 Email: info@flir.com.au

All images are used for illustration purposes only.

Technical specifications subject to change without notice.

Improve production efficiency, increase quality control Thermal imaging cameras are used across a wide variety of industries to monitor continuous processes, easily collecting information on product quality and/or production efficiency that is difficult or impossible to capture using conventional means such as thermocouples or visible light cameras.

A FLIR A65, A35, A15 or A5 is the perfect solution for such applications, and with features and functions designed to make it the natural choice for anyone who uses PC software to solve problems.

Extremely affordable Ideal tool for putting thermal imaging at work in an automation or machine vision environment.

Extremely Compact Only 40 x 43 x 106 mm. Easily integrated in every production line.

PoE Power over Ethernet (PoE )

Communication and power supplied with only one cable.

General Purpose Input/Output (GPIO) One output that can be used to control other equipment and one input to read the status from the same equipment. ...°C ...°C ...°C ...°C

HIGH SENSITIVITY < 50 mK

Synchronization Possible to configure one camera to be master and others to be slave(s).

Wide temperature range Visualizes temperatures between –40°C and +550°C. High sensitivity < 50 mK < 50 mK thermal sensitivity captures the finest image details and temperature difference information.

GigE Vision™ standard compatibility

Camera interface standard developed using the Gigabit Ethernet communication protocol.

GenICam™ protocol support

Provides a generic programming interface for all types of cameras.

edge

manmonthly.com.au

Manufacturers’ Monthly MAY 2014 27

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Metalworking & MACHINE TOOLS finished workpiece dimensions not meeting the required specifications.

Edge deformation is controllable by properly applying coolant, using a more wear-resistant grade with a lower binder content, reducing speeds and feeds, and employing a force-reducing geometry.

Notching Notching occurs when an abrasive workpiece surface abrades or chips the depth of cut area on a cutting tool. Cast surfaces, oxidised surfaces, work hardened surfaces or irregular surfaces all can cause notching.

While abrasion is the most common culprit, chipping in this area can also occur. The depth of cut line on an insert is often in tensile stress, making it sensitive to impact.

This failure mode becomes noticeable when notching and chipping starts showing up in the depth-of-cut area on the insert.

To prevent notching, it’s important to vary the depth of cut when using multiple passes, use

Notching a tool with a larger lead angle, increase cutting speeds when machining high-temperature alloys, reduce feed rates, carefully increase the hone in the depth-of-cut area, and prevent build-up, especially in stainless steel and high-temperature alloys.

Mechanical fracturing Mechanical fracturing of an insert occurs when the imposed force overcomes the inherent strength of the cutting edge. Any of the failure modes discussed in this article can contribute to fracturing.

It´s possible to avoid mechanical fracturing by correcting for all other failure modes besides normal flank

Mechanical fracturing wear. Utilising a more shock-resistant grade, selecting a stronger insert geometry, using a thicker insert, reducing feed rates and/or depth of cut, verifying set-up rigidity and checking the workpiece for hard inclusions or difficult entry are all effective corrective actions.

By understanding these eight common failure modes and developing failure analysis skills, manufacturers stand to gain a lot.

Increased productivity, improved tool life and tool life consistency,

improved part tolerance and appearance, less wear and tear on equipment, as well as a decreased chance of catastrophic insert failure that shuts down production and damages an important job are all important benefits.

[Don Graham is Manager of Education and Technical Services at Seco Tools.]

Seco Tools 1300 55 7326 www.secotools.com

Waterjet cutting machines WHILE cutting operations using a waterjet machine are usually characterised by high levels of noise, along with a lot of mess, Techni Waterjet’s machines are said to be the cleanest and quietest on the market, while delivering true ‘Light’s Out’ operation.

A typical high-pressure waterjet piercing process results in an abrasive jet stream that “rooster-tails” back into the environment for the duration of the pierce. While some manufacturers rely on a rubber deflector to diffuse the stream, the diffused stream creates a garnet laden mist that goes into the environment, including on the beams, rails, bearings, controller and electronics.

However Techni Waterjet machines utilise a tank equipped with an air bladder designed for the rapid raising and lowering of the water level. This feature enables submerged cutting, meaning there is no mist, and any abrasive is contained within the waterjet tank.

In addition, submerged cutting delivers a reduction in noise levels. Because the highpressure water stream is underwater and the stream is not exposed to air, minimal noise is emitted because it is ‘trapped’ underwater,

28 MAY 2014 Manufacturers’ Monthly

The waterjet cutting machines are said to be the cleanest and quietest on the market. reducing the noise level from over 100dB to below 78dB. While many manufacturers use hydraulic intensifier pumps which can be loud, large and require substantial amounts of downtime, the Quantum ESP (electric servo pump) used on Techni’s machines takes up less than half the space occupied by an average hydraulic intensifier, with a lower profile and a more ergonomic design. It also offers up to 60% more efficiency and has a decibel A-weighting of less than 68dBA, allowing for near-silent operation.

The machines also feature Techni’s Tech-

Sense abrasive monitoring device which warns the operator with an audible alarm and flashing light if a machine is not running efficiently, and will pause the machine if the problem could potentially damage the part or material being cut.

When integrated with SMS Offsite Notification, the operator is free to leave the site altogether, making ‘Lights Out’ operating a reality.

Techni Waterjet 03 9357 8360 www.techniwaterjet.com

manmonthly.com.au

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DeltaPac WITH DELTA-S-T -S- ECHNOLOGY®: -S-T PLEASE DON’T MIND THE GAP ANY MORE.

DeltaPac closes every gap. No more gaps on conveyors when separating items. No more gaps in time when stopping after a collision. Instead, always know what’s going on in the system. For the energy balance: faster and quieter production. For system design: explore new ground with streamlined hardware! DeltaPac: the new, uniquely efficient photoelectric sensor from SICK. For uninterrupted detecting and counting. For production that is faster, smarter, more efficient and less prone to errors.

For the most innovative manufacturers. DeltaPac is bridging the gap. We think that’s intelligent. www.sick.com/DeltaPac

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NMW Preview 13-16 MAY 2014

Sydney leads the way to manufacturing’s high tech future News that sydney has overtaken Melbourne as Australia’s largest manufacturing centre speaks to the success of its many niche manufacturers, says Anthony Reed, exhibition Director of National Manufacturing week 2014 (NMw), in sydney from 13-16 May. It is also good news for visitors to NMw, which is constantly evolving to reflect the latest trends. Designed to showcase technologies that help businesses build innovative, marketdriven manufacturing capabilities, NMw is a significant opportunity for local manufacturers to arm themselves with the tools to maximise productivity, evolve their product offering and grow their business.

NMw will also put visitors in direct contact with research providers at its R&D Hub.

Highlights include: • K eynote Address: Professor Ian Chubb, Chief scientist of Australia.

When: Tuesday 13th May, 10:30am - 11:00am • The NSW Manufacturing Sector - Innovation and the Future: The Hon. Andrew Constance, MP. When: Wednesday 14th May, 11:00am - 11:15am • The Imperative for Innovation: Marlene Kanga. When: Wednesday 14th May, 10:20am - 11:00am

Here is a selection of this year’s exhibitors: 1

TXM – Stand 2422

Learn how lean thinking can help your business survive and grow from Australian lean manufacturing consultants, TXM. TXM has enabled over 100 Australian manufacturers across a diverse range of industries to improve their competitiveness and productivity and to grow in today’s competitive environment.

The TXM team bring practical manufacturing experience to your business as well as a deep understanding of lean manufacturing principles. The team see themselves as manufacturing people first, consultants second. This means they can get to grips with the issues in your business quickly and work with your team to deliver practical solution.

Their experience extends over a broad range of 30 MAY 2014 Manufacturers’ Monthly

manufacturing industries including engineering, metal manufacturing, food and beverage, construction materials, machinery manufacturing, boat building, transport components, electronics, high technology, plastics, packaging, pharmaceuticals etc.

2

>>

1

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Better Springs - Stand 1211

with modern electronic testing equipment at its disposal, Better springs aims to deliver quality and consistency on prototyping springs and production runs.

An Australian owned family business established for over 45 years, Better Springs manufacture all types manmonthly.com.au

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NMW Preview 13-16 MAY 2014

of springs, wire shapes, pressings and leaf springs. wire sizes range from 0.3mm to 16.0mm and for leaf/flat springs from 0.2mm to 32.0mm thick.

Industries serviced include defence, agricultural, after-market automotive, mining, general and heavy engineering. They can supply any quantity from one off to many thousands. In addition, they undertake design and development work.

Materials utilised include high and low carbon steels, stainless, monel, inconel, phospor bronze, etc.

created a product for the spindle bearing market with their patented grooved roller bearing. The new bearings have radial, thrust and combination load option, with space saving opportunities for new and existing designs.

4

3

Colt Group - Stand 2923

Internal heat generating processes and the typical Australian climate turn many industrial production and warehouse facilities into uncomfortable, unproductive and unsafe hot boxes. In some

CGB Precision Products – Stand 2518 3

CGB will be presenting its range of specialty bearings and engineered products, including major developments for plain bearings and the spindle bearing markets: • Bowman-Bowmet Bearings - Bowman International Ltd, of the UK have developed the new BowMet range of rolled plain bearings/ bushings manufactured in the material ToughMet Spinodal bronze from Materion.

BowMet rolled plain bearings/bushings are said by the company to deliver increased load carrying capacities, heat resistance, speeds, M A 0 5 capabilities 1 4 _ 0 0 0 and _ T aElong C -service 1 life.

2 0 1 4 - 0 4 - 0 3 T0 9 : 0 8 : 3 0 + 1 1 : 0 0 corrosion • CMC Grooved Roller Bearings - CMC have

4

TECHNI Waterjet Systems are so clean & quiet, yyou ou could operate them just abou ut..... anywhere about.....

QUIET Less than 68dBA with almost silent operation.

CLEAN No water splashing on machine components and floor.

Scan this QR code to hear how quiet the pump is!

The Quantum NXT Waterjet Pump and Submerged Cutting Function has created the Quietest and Cleanest Waterjet in the World!

www.techniwaterjet.com

1800 15 9616 • sales@techniwaterjet.com 32 MAY 2014 Manufacturers’ Monthly

Innovation Through Passion

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13-16 MAY 2014

5

6

7

Samhwha Stand 3108 7

applications, the hot temperatures affect the process and therefore quality of the end product.

Most businesses accept this as a fact of life, but Colt has an innovative, energy efficient and climate friendly system which aims to solve this problem.

Colt International’s Coolstream evaporative cooling and ventilation system is an innovative, energy efficient, green space cooling systems for industrial applications. It is intended to provide comfort for people and controlled environments for workflow processes.

Colt combines the Coolstream system with its range of natural roof ventilators to extract hot air at eaves or roof level whilst utilising the Coolstream unit to circulate cool air at lower levels.

5

Donaldson - Stand 2624

Donaldson offers industrial dust collection, compressed air and process filtration and replacement parts. For decades, Donaldson has offered manufacturers advanced and reliable filtration solutions.

Their extensive range of equipment, filters and parts include the smaller, smarter PowerCore Dust Collector series, the innovative Ultra-Web filter technology and the DF Filter range for the protection of compressed air systems.

Donaldson’s dust collection, compressed air and process filtration products are designed for a range of applications and industries including chemicals and plastics, food processing, grain, agriculture and feed, mining and rock products, laser and plasma cutting, mining, quarrying, cement, abrasive blasting, weld fume, woodworking, pharmaceutical, and powdercoating.

6

Precision One - Stand 1209

Precision One is a subsidiary company of Thermoway Industry of Taiwan. The company specialises in manufacturing thermocouple equipment and heaters.

They also distribute leading industry brands including Omega, Inor, TYCO, Johnson Metthey and more.

Their current customers are spread across various industries including steel, power plants and small and medium enterprises. They can develop and customise products to suit your needs. manmonthly.com.au

A leading Korean masterbatch manufactur, samhwa has been providing the world plastic industry with colour concentrates, additive masterbatches and XLPE compound since 1986.

The masterbatches are tailored for each customer to meet the specific requirement and challenges of the A 1 1 1Continuous 3 _ 0 0 0 investment _ B O K - in new 1 equipment 2 0 1 3 - 1and 0 -technology 0 9 T1 4 : 1 3 : 4 6 + 1 1 : 0 0 given M project.

F R E E C ATA L O G U E & B R O C H U R E

WASHERS & STAMPINGS

Call +1-612-7299365 FAX 612-7298910 • sales@bokers.com

WWW.BOKERS.COM/MANM Manufacturers’ Monthly MAY 2014 33

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NMW Preview 13-16 MAY 2014

13-16 MAY 2014

9

10

has played an important role in achieving monthly production capacity of 2,000 tons of samtech masterbatches.

The company is also involved in research and development. The specific needs of each application are identified and extensive development projects are carried out. Quality is assured through quality checks in all stages of production. strict specifications are set and production samples are tested accordingly.

8

8

Supagas - Stand 1239

11 with multiple distribution centres, branches and agencies growing nationwide, supagas is able to provide fast and reliable service.

9

Xtralis – Stand 2822

Xtralis will introduce VESDA-E, a smoke detection solution for automated manufacturing plants, at this year’s NMw. supagas is an Australian owned and operated company which has provided Described by the company as belonging to the next generation of airgas services within Nsw and Queensland since 1997. sampling smoke detection, it can discriminate between different smoke From its beginnings selling and refilling forklift gas, the company now MA 0 1 4 _ 0 0range 0 _ N A - including 1 2 0domestic 1 4 - 0 gas, 4 - heatagas, 0 4 T 1 0 helium, : 3 0 : 0 4 and particle types. This is a major benefit for manufacturing operations + 1 1 : 0 0 offers an5extensive ofPgases, characterised by background levels of manufacturing smoke, welding hospitality gas, industrial gas, LPG, specialty gas, and welding gas. fumes, dust and soot that can trigger nuisance alarms, resulting in business disruption, and costly visits by the emergency services.

The system’s intelligent Flair detection technology and VESDA Analytics mean targeted detection of threats is possible without nuisance alarms.

VESDA WireTrace allows specific targeting of burning wire events at a level close to the ambient environmental smoke level.

10

Laser & Sign Technology - Stand 1431

Recently appointed distributor for envisionTEC 3D printers, Laser & Sign Technology (LST) will introduce its new range at NMW. Direct cast and mouldable materials, electroplatable ceramics and even bio-compatible components can be printed on one of these machines.

The company also distributes ULS (USA) and SEI Lasers (Italy), with laser powers from 10 to 1000 watts using CO2, YAG, Vanadate and Fibre technologies with bed sizes from 100mm x 100mm to 2m x 3m. Plus, they stock a large range of laserable consumables, including large LeD edge lit light guide panels capable of producing 3m x 2m acrylic panels at speeds up to 50m2/hr.

LST is the Australian distributor of the Type3 range of software solutions.

These include industry specific CAD/CAM solutions such as LaserType (Laser Operators), TypeEdit (CNC Operators), 3DesignCAD (Jewellery Design and Manufacture) and 3Shaper (3D Artists and Product designers).

11

Kockums Bulk - Stand: 2231

Kockums Bulk systems specialise in the design and supply of powder handling systems, from raw materials through to packed goods.

The company’s diverse product range includes bulk bag filling/emptying, IBC systems, aero mechanical conveyors, pneumatic conveying, silo discharge aids, weighing, metering, bagging, palletising systems and wrapping/hooding.

Kockums Bulk is also an innovator in the field of vacuum assisted lifting solutions.

34 MAY 2014 Manufacturers’ Monthly

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Materials HANDLING On the conveyor line Speed, reliability and flexibility are top priorities for local manufacturers when considering conveyor systems and associated equipment. Sarah Falson investigates.

T

ensure customers can upgrade their production radiTiOnally, manufacturers have lines without affecting the flow of product going adopted conveyors to speed-up their out the door. processes and save on manual labour. But with changing consumer habits, increasing global competition and shorter lead times, manufacturers Key conveyor features are under pressure to deliver smaller runs of For Tsubaki australia national manager – mining varying product lines more quickly than ever and industrial, Gary Griffiths, all manufacturers – before. regardless of which sector they operate in – require Considering the relatively small scale of three key components from their conveyors: speed, australia’s manufacturing market when compared reliability and flexibility. to its global counterparts, local players need to “This includes the largest conveyors used for be extremely flexible, constantly changing their conveying mining products such as coal and iron processes to deliver products faster, cheaper and ore to smaller conveyors used in the food and of a consistently high standard – not only for local beverage industry,” Griffiths told Manufacturers’ customers, but also for growing export markets.

Monthly.

Key to this flexibility is production equipment, Sydney-based Tsubaki supplies chain and in particular conveyor systems, which need to allow power transmission products for conveyor systems smooth processing and prevent bottlenecks from throughout australia, new Zealand, Papua new M A 0 Equipment 5 1 4 _ 0 0suppliers 0 _ TSU 1 safety 2 0 1 4 - Guinea 0 4 - 0and 3 Tthe 1 0South : 1 4Pacific. : 2 1 +The 1 1company’s : 0 0 occurring. must- build main in to their systems, and offer short lead-times to business is either replacing equipment on existing

manmonthly.com.au

Tsubaki’s Power Cylinder is an electromechanical linear actuator designed for conveying applications requiring pushpull movement.

Manufacturers’ Monthly MAY 2014 35

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Materials HANDLING conveyors, or supplying OEM product for conveyor engineers.

“Manufacturers need conveyors to be reliable so they can transport their product onto ships, trains, planes and trucks for delivery to the consumer. if a conveyor is down, and deliveries cannot be met, these days consumers have multiple choices to buy a competitor’s products,” said Griffiths. “[also], as consumers’ needs and demands are changing faster than ever before, manufacturers must be able to alter or offer different products to meet those needs. as such, conveyors need to be flexible to allow for different products to be conveyed on the same conveyor.

Modular conveyor systems are very popular in food and beverage industries to accommodate varying sizes of cans, boxes and packages.”

The team at Tsubaki has been experiencing a notable rise in the popularity of its lube-free lambda chain in the food manufacturing sector; Griffiths says this type of chain eliminates the need for lubricant, therefore reducing the risk of lubricant contaminating edible products on the manufacturing line. “lambda chain has also provided our customers with increased chain life and less unplanned failures, due to its wear resistance properties,” Griffiths said.

Choosing a conveyor supplier australis Engineering – also based in Sydney – designs, manufactures and installs integrated materials handling solutions comprising mechanical, electrical and automation components.

The company’s engineering manager, anthony Gustafson, says he has noticed a shift in the market away from customised or ‘turn-key’ solutions towards proven or ‘preengineered’ systems; this means the customer ultimately spends less on its conveyor system, and can receive the solution faster.

“Traditionally the type of systems and conveyors we built were completely custom-designed and built to meet a specific application.

[However], we are now seeing that many clients want a proven system rather than a one-off customdesigned system – so utilising predesigned and tested modules which 36 MAY 2014 Manufacturers’ Monthly

Automation systems integrated with the conveyors allow cartons to be conveyed to specific pallet off-take positions.

(Image: Australis Engineering)

go together in various configurations to meet the client’s need are becoming more popular,” he told Manufacturers’ Monthly.

“This approach also means less engineering time so a cheaper overall project, while good background engineering means that even a pre-designed system can be tailored enough to suit a specific application.

“Of course, there are some applications where a custom-designed system is needed, so in those applications we still use a library of standard designs and components which can then be customised – we refer to this as ‘customised standard equipment’.

This provides the best of both worlds for the client.” according to Gustafson, the leadtime between specifying a conveyor system and receiving the equipment is one of the top factors affecting the decision-making process for manufacturers when searching for an equipment supplier.

“The decision-making process has become more extended over the last few years, however the delivery deadlines always remain the same – so being able to quickly supply equipment is a constant demand,” Gustafson said.

“On an actual equipment level, clean design within the food industry has always been present, but there is [now] more and more focus on this

along with looking at ways to improve designs to make cleaning easier. also, as company maintenance teams are reduced, quick and easy maintenance is more of a priority now.” in Gustafson’s experience, the food and beverage, and warehousing

“

...all manufacturers – regardless of which sector they operate in – require three key components from their conveyors: speed, reliability and flexibility. sectors, are the fastest adopters of new conveyor equipment in the manufacturing space.

“The food and beverage industry have always been big users of conveyors and there are always new developments in products and packaging, so they have constant need for new systems. The other area is in warehousing and pallet handling: as more imported products come into the market, there is naturally a greater demand for systems to handle pallets,” he explained.

Safety is also a key priority in conveyor system design and implementation, and oftentimes manufacturers will specify new equipment to fix existing safety issues. “in many cases, a new conveyor system is used to remedy or lessen an OH&S issue. One client recently implemented a conveyor system to transport their product from production to warehousing, via an elevator feeding onto a 130m-long overhead conveyor, which travelled between two buildings and over a roadway,” Gustafson recalled.

“This removed the vast majority of forklift movements around their production area, while also providing a more ergonomic and safe method of palletising the product in the warehouse. “in implementing this solution, the production area was also freed of pallets on the floor, meaning better room and access around production machines, easier access for operators to perform their tasks, and therefore better production efficiency.”

Tsubaki Australia 02 9704 2500 www.tsubaki.com.au Australis Engineering 02 9707 5888 www.australiseng.com.au manmonthly.com.au

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Materials HANDLING Tubular cable conveyor factory-integrated FlExiCOn is now offering its Flexidisc line of Tubular Cable Conveyors for fragile materials, integrated with upstream and/or downstream equipment that sources material from single or multiple locations and delivers it selectively to storage vessels, filling machines or other processing equipment.

Upstream equipment ranges from inlet Hoppers and Metering devices to Bulk Bag dischargers, drum/ Box/Container Tippers, Bag dump Stations, Weigh Batching/Blending Systems and Storage Vessels. Typical downstream equipment includes Bulk Bag Fillers, drum/Box/Container Fillers, Packaging Machines and Storage Vessels. all equipment is available to sanitary or industrial standards with manual or automated controls, and is factory-tested for seamless integration with the conveyor and the userâ&#x20AC;&#x2122;s process, according to the MA 0 5 1 4 _ 0 0 0 _ F A N company.

The conveyor moves material using

The conveyor moves material using high-strength polymer discs in 10 cm and 15 cm diameters. angle, through small holes in walls high-strength polymer discs in 10 cm or ceilings. The system can have and 15 cm diameters that are affixed single or multiple inlets and outlets, to a stainless steel or galvanised and convey over short distances or cable. The discs glide within smooth hundreds of metres. stainless steel tubing, moving fragile 1products 2 0 1 gently, 4 - 0 quietly 4 - 0 4and T 1dust4 : 3 5 : 0 2 + 1 1 : handling 0 0 Gentle offered by the conveyor makes it suitable for food free, horizontally, vertically or at any

products that are prone to breakage or degradation including: cereals, coffees, teas, dried fruits, frozen vegetables, grains, nuts, beans, peas, pet foods, seeds, snack foods and spices. Typical non-food applications include bulk chemicals, minerals, chopped fibreglass, microspheres, regrind, pellets, tobacco and other friable materials.

Modular system components of 304 or 316 stainless steel include tubing, drive wheel housings, tension wheel housings, metered and nonmetered inlets, and discharges with and without valves, as well as accessories for wet or dry cleaning, including CiP sanitising.

Free testing is offered at Flexicon test laboratories on full-scale Tubular Cable Conveyors and upstream equipment that simulate customer processes.

Flexicon 1300 353942 www.flexicon.com.au

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manmonthly.com.au

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Automation& ROBOTICS Time to get on board Much has been written about Industry 4.0 being the next industrial revolution, but how many Australian manufacturers really understand the concept? Alan Johnson reports.

W

demonstrating how such a system HILE some Australian can work in practice in a smart manufacturers have factory in Kaiserslautern, Germany, dismissed Industry which was built in cooperation with 4.0 as just a gimmick, many large 20 industrial and research partners, international companies, including including Siemens.

Siemens, see it as the next stage of This pilot facility uses soap industrial manufacturing, describing bottles to show how products it as a paradigm shift towards smart and manufacturing machines can factories, and even proclaiming it communicate with one another. as the advent of a fourth industrial Empty soap bottles have RFID revolution. tags attached to them, and these tags Chris Vains, Head of Siemens inform machines whether the bottles Automation Systems Australia & NZ, should be given a black or a white cap. describes the first three industrial In other words, a product that is revolutions as coming about as a in the process of being manufactured result of mechanisation, electricity The next industrial revolution, Industy 4.0, is described as a marketplace in which machines carries a digital product memory with offer their services and exchange information with products in real time. and IT. it from the very beginning and can “But it’s the fourth industrial communicate with its environment revolution where we are heading facility, in today’s world: How does a journey towards 4.0. However, there via radio signals. today. We are talking about cybermachine know how many bottles need are certain things that still need to The product thus becomes a cyber- happen. physical systems and the joining a white cap and how many require a physical system that enables the real of the virtual online world and black one? How does it know whether “Still things have to be defined world and the virtual world to merge. the physical, which might be enough caps are available in the plant, and these things need to have manufacturing for example,” Vains or when they will be delivered? Are standards to communicate to one told Manufacturers’ Monthly. there enough people in the warehouse another for example, with a set of Nearly there to take deliveries? Today, all of this rules.

Those involved describe producAccording to Vains, the production information is contained in different “We are moving towards tion in an Industry 4.0 system as a environment described above will systems. there, but realistically the whole marketplace in which machines offer gradually become a reality.

For example, an ERP system is implementation of this advanced their services and exchange informa“From a Siemens standpoint, with responsible for managing materials technology could be 15 to 20 years tion with products in real time. all our advanced technology and M AGerman 0 5 1 4 Research _ 0 0 0 _Centre BOG 1software, 2 0 1 4 0 4 - 0we 4 are T 1 at 5 3.8 : 0 5 : 4 away.

0 + 1 It’s 1 :in0a02030 space,” Vains said. logistics, personnel planning, and cost The we- believe calculations, while a manufacturing Regarding the soap bottle pilot for Artificial Intelligence (DFKI) is and we want to take customers on the

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execution system (MES) controls production operations.

The problem is that the various formats, operating systems, and programming languages used in these different systems prevent the smooth and complete transfer of data from one system to another – precisely what’s necessary to enable the merger of the virtual and the physical worlds.

Vains points out that Industry 4.0 does not belong to Siemens, or Germany. “It’s just about the 4th Industrial Revolution and where the future of technology is going around the world.

“We have a lot of components that are working towards it, but from a US standpoint they are going down the advanced manufacturing and advanced automation path.

The movement has several different names across the world, India and China have their own names for it.

“We are all doing different things,

but it’s the technology companies that are driving this and we are moving towards the common global goal; the future of industry,” Vains said.

“

How does a machine know how many bottles need a white cap and how many require a black one?

As part of the initiative, Siemens has announced $US100m funding to help technology based start up companies around the world, not just Germany.

“This is for young companies that are showing promising technology advances in the industrial space - manufacturing for example, and Australian companies could be recipients.

“In fact, the Australian Government should already be investing in our own local technology and innovation companies, but if companies fit the right requirements to drive this industrial revolution, then yes Australian companies will be open to that as well.

“Manufacturing is still a pillar of Australia’s economy, whether we become the food bowl of Asia or whether we focus on other niche manufacturing areas.

“As a vendor we are not here to decide what is the right thing for Australia to manufacture, but we really believe Australia needs to embrace these manufacturing concepts and move with the US and Germany and the rest of the manufacturing world, otherwise we will be left behind and in a worse condition than where we are today.

“One of the steps towards Industry 4.0 is using energy more appropriately. There are so many opportuni-

ties for industrial energy efficiency programs that can help make us more competitive in Australia.

“One simple example was when Sunshine Sugar recently replaced its DC power drives with AC drives, which has led to huge energy savings for the company.

“While we believe we need government support to be successful in manufacturing, it must be the right government support, it needs to be a consultative approach, including education, manufacturers, associations etc,” Vains said.

[Alan Johnson is Manufacturers’ Monthly’s former editor. He has researched and written about all aspects of the Australian manufacturing sector for more than 25 years.]

Siemens www.siemens.com.au/ futureofmanufacturing/

Multi-stream loading controller HONEYWELL Enraf has introduced the Fusion4 MSC-L, the company’s most sophisticated multi-stream controller for loading products from refineries and chemical plants into transports such as railcars, tankers and barges.

Accurate, scalable and versatile, the controller is an intuitive device interface that enables every installation, operation and maintenance M A 0 to 5 1be4 controlled _ 0 0 0 _ in B the O Gfield 1 function

device, so users need fewer using a large display and integrated units, with the intuitive interkeyboard that works as a complete face and display giving those hazardous area operating station. in the field full system visThe controller can operate up ibility and control to get more to six loading arms simultaneously, done in less time. providing safe, reliable control for Based on mobile phone and tablet road loading, as well as tank farm computing “apps”, on-screen icons transfers and marine and rail termiare designed to make it intuitive, nal operations. cutting training times and reducing According to the company, the the risk of human error. Combined controller can control more streams, 3 2 0 1accuracy, 4 - 0 4 than - 0 4any T 1other 5 : 0 6 : with 5 8 the + 1 installed 1 : 0 0 keyboard, it offers with high

The controller can operate up to six loading arms simultaneously.

simple, secure and fully functional control of the loading system from the unit itself.

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Automation & ROBOTICS Controller networking and sensor cascading The latest automation controllers focus on safety and offer revolutionary new ways to bring modular machine concepts to life. Alan Johnson reports.

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ersaTile configuration options of the latest automation controllers, not only enable safe control systems to be structured in a way that is individually scalable, but also provide the user with an intelligent, modularity concept.

For example, siCK’s powerful Flexi soft safety controller now offers two new intelligent solution concepts for unlimited networking of machines, and for cascading safety switches and sensors within a machine: Flexi line and Flexi loop. according to Gary Milburn, Product Manager - industrial safety systems with sick australia/ NZ, most complex automation concepts have a modular structure, meaning distributed machines or machine elements need to be combined and networked in some way. “in some instances, the safety functions of a machine also need to be available to other machines. This enables, for example, an emergency stop in a particular module to initiate shutdown of other machine modules,” Milburn said. “it is also necessary to transmit, process, and

42 MAY 2014 Manufacturers’ Monthly

The Flexi Line interface makes it possible to connect up to 32 Flexi Soft stations and link safety functions across multiple machines. evaluate safety-related signals within the machine network bidirectionally.

“Thanks to its Flexi line interface, the Flexi soft safety controller now provides a simple yet

efficient method of connecting modular machines.”

Milburn explained that this function is now included in the Flexi soft main module as a standard feature.

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“All the user has to do is connect the main modules of the individual Flexi Soft stations via the Flexi Line interface. The interface makes it possible to connect up to 32 Flexi Soft stations safely and link safety functions across multiple machines, which can be done step by step rather than all at once,” Milburn said.

“This means that a system designer can define a single required process image as a safety application solution for the entire system.

“From this image, the system modules obtain the data they require to respond in the way they should and pass on only relevant data to the image.

“Depending on how the production or commissioning process needs to proceed, it is then possible to put individual system elements into operation or even integrate individual machines into the entire network at a later stage.”

In networking scenarios, Milburn said, cable lengths of up to 1,000m can be connected between the MA 0 5 1 4 _ systems.

0 0 0 _ PI E individual control “The customer defines the entire

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communication of the process image (for the next station, the previous station, or both simultaneously), as well as data exchange for the control systems, in just one task in the Flexi Soft Designer software,” he said.

Flexi Loop portal

Milburn said more reliable series connections are one of the major innovations that have been brought about through Flexi Loop.

“In cases where conventional wiring is used, series connection “masks” consequential errors and therefore stops various problems from being identified,” he said.

Milburn added that Flexi Loop prevents this by monitoring each individual sensor.

“And while conventional cascaded wiring results in the safety PL dropping to Cat 3, PLd or PLc when multiple sensors are being used, Flexi Loop switch and sensor cascading meets the requirements of Cat 4 and PLe in accordance with DIN EN ISO “What this means, for example, is 13849-1 in every single case, assuming that there is no need to process and that suitable devices are being used. evaluate each signal in every single “The response time of the entire station. “Additionally, individual system is reduced too. In contrast to machines can be disconnected from discrete wiring, Flexi Loop achieves the safety and control elements a response time that is considerably of the machine network for shorter than the cumulative response maintenance purposes and then retimes of the individual sensors.

1connected, 2 0 1 4 all - 0using 4 - 0 3 T 1 0‘teach’ : 0 8 : 5 4 + 1 1 to : 0Flexi 0 Loop’s decentralised a simple “Due function.” integration concept, up to eight

“

More reliable series connections are one of the major innovations that have been brought about through Flexi Loop.

sensor cascades – each with up to 32 dual-channel safety switches and safety sensors – can be connected within a Flexi Soft control solution,” he said.

“Plus Flexi Loop’s connection nodes for both electro-mechanical safety switches and safety sensors with OSSD (Output Signal Switching Device) switching outputs are available for series connection and linking to various expansion modules of the Flexi Soft safety controller.

“The power supply and communication paths between the individual nodes can be as long as 30m, meaning that a full “loop” may amount to as much as 960m in total.

“Furthermore, the Flexi Loop nodes provide vital diagnostic information during operation. In the event of a fault, the operator can use the controller or a connected HMI operating panel to pinpoint which switch or sensor is reporting the issue and what the nature of the issue is,” Milburn said.

SICK 1300 405 807 www.sick.com

Manufacturers’ Monthly MAY 2014 43

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Automation & ROBOTICS Digitising your factory Digitisation a factory through IT and software is driving innovation in manufacturing processes, providing better visibility and greater efficiency. Stephen Keys reports.

T

This transformation can be rehrough the Internet, smart ferred to as Industry 4.0, or the fourth devices and smart machinery industrial revolution. The overall can now communicate with goal of this movement is to create an each other, allowing an organisation intelligent or “smart” factory, where to gain much greater insight into its mass production of individual goods own processes. and customised products can cost the Consider smart machines and same as a standardised product. smart products: imagine if a product This revolution is already happenknows the supply chain that it’s being ing. Product lifecycle management assembled within. already expands beyond the producProduct packaging intelligence tion lifecycle. driving the production process to For example, car manufacturagile robots; 3D printing; predictive ers can monitor the status of a part maintenance; augmented reality throughout the product lifecycle, and training or products that can instruct beyond the production process itself. machines how to form them - these Imagine what insights a manufacare all elements of the digital transturer can acquire if they know almost formation that we can expect to see A Dthe _ P A C E P L A Mindustry A R _ 1 in 2 . peverything df P a about g e their 1 1products 5 / 0 2 / 1 2 , within manufacturing throughout that product’s lifecycle. the not too distant future.

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Parts could be modified or replaced more rapidly, systems monitored more precisely and safety measures taken so risks don’t become issues.

Creating a digital factory A key step in the path to creating an intelligent factory with dynamic processes and greater automation is about obtaining visibility.

Data visualisation is key here, meaning real-time monitoring of machine data and making it visible to operational staff. This gives more insight into what kind of manual processes can be automated that interfere with the production process and supply chain. ultimately, through obtaining visibility, a manufacturer can better understand and comprehensively manage the production process.

For example, automatic alerts can let a manufacturer know when an impending supply disruption is detected.

And they can do so fast enough to prevent any incidents from occurring.

44 MAY 2014 Manufacturers’ Monthly

Maintaining visibility gaining visibility can be achieved through the implementation of software which monitors a company’s big data output in real-time.

For example, the costly effects of downtime can be reduced in the factory through using real-time and predictive analytics for predictive maintenance.

This involves monitoring automated machinery for failure points and scheduling maintenance in advance.

From a sustainability perspective, this also means you are using machines more efficiently and therefore reducing the carbon impact of those machines which would not be operating at peak performance. having transparency across operations means a manufacturer can essentially identify success or failure early enough to change the outcome and before the customer is impacted.

Through IT, manufacturers can deliver the perfect order by automating order processes and monitoring them in real-time. manmonthly.com.au

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Already, car manufacturers are monitoring the status of a part throughout the product lifecycle, and beyond the production process itself.

For example A global technology manufacturer specialising in lighting, healthcare and consumer lifestyle products and services is one example of a company using visibility to improve its processes.

In 2011, the manufacturer embarked on a journey to become an agile, process-oriented global company.

To this end, they launched the â&#x20AC;&#x153;Accelerate!â&#x20AC;? program to build an agile and focused transformation process to help business owners bring propositions to market faster and improve existing business-market combinations.

This manufacturer uses ARIS, a system from Software AG designed to improve collaboration between business process owners, IT and internal and external partners.

Able to capture the various business models and visualise the endto-end processes across domains, the system can document the Components Business Models (CBM) to identify critical/non-critical, differentiating/ non-differentiating and common/uncommon capabilities to understand manmonthly.com.au

how best to win in the market.

Even though programs of this scale normally take years to produce results, the approach is already helping this global manufacturer to transform into a truly process-oriented company.

The business architecture approach has helped save millions by reducing and preventing unrewarded complexity in non-differentiating processes.

The new industrial revolution is here. Those manufacturers wanting to avoid becoming competitively disadvantaged in an industry driven by digital technology must consider how they can create greater transparency across processes to drive efficiency and automation. Moreover, in order to become a true factory of the future, manufacturers must not underestimate the benefits of analysing data in real-time to make more intelligent decisions and predict problems before they even occur.

[Stephen Keys is Senior VP for AsiaPacific and Japan at Software AG.] Software AG 1800 064 970 www.softwareag.com.au Manufacturersâ&#x20AC;&#x2122; Monthly MAY 2014 45

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Automation & ROBOTICS

Automation: challenges and benefits The challenging manufacturing landscape in Australia is seeing companies adapt to their changing needs through automation. Christine Filippis reports.

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HILE a high cost base is hurting Australia’s competitiveness, boosting productivity continues to drive strategy for the manufacturing sector in 2014.

According to David Hegarty, Rockwell Automation’s MD for Australia and NZ, this generates a series of challenges and opportunities aided by rapidly advancing technologies that surround the productivity issue.

“A high manufacturing cost base calls out for productivity and improving productivity has always been a priority for manufacturers.

It’s likely that this will become more important in 2014,” he said.

It is clear, many companies are moving towards integrating automation with mobility, big data and analytics to create connected enterprises and help enhance productivity.

This overlap in technologies extends to common infrastructure systems through increasing demand for Ethernet and Internet Protocol With Ethernet paramount for achieving the flexibility, visibility and efficiency required for (IP) technologies. integrated automated systems, companies need to be aware of the security risks involved.

However Hegarty warns that Hegarty says is crucial for success in recent years and we are already as these strategies to improve today’s competitive marketplace. seeing the flow-on effect with technology prove successful they also “Companies that are not expose manufacturers to new security technologies such as wireless, and currently using a common network concerns that must also be addressed. cloud computing,” he said. infrastructure stand to lose several Industrial Ethernet provides “The proliferation of Ethernet advantages of this modern-day companies with a way to help technologies into manufacturing has enabled M A 0 significant 2 1 4 _ 0 technological 0 0 _ DAT 1 improve 2 0 1 processes 4 - 0 1 - and 0 7productivity T 1 5 : 4 1 : 3 commercial 1 + 1 1 : 0tool.

0 “The increased uptick of Ethernet while reducing expenses, which advances for these industries in technologies is part of a change from within these industries related to network infrastructure, data WHEN YOUR SYSTEM LETS YOU DOWN availability and network investment.

I would expect that this trend will Control Systems — When you need an upgrade and / or retrofit ... continue in the coming years, if not accelerate,” said Hegarty.

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Security concerns While Ethernet is paramount for achieving the flexibility, visibility and efficiency required for a competitive industrial environment, Hegarty warns security has becomes a key issue that requires consideration.

“Usage of Ethernet is growing rapidly and many users aren’t on top

of the evolving security requirements that come with it,” he said.

However, through a partnership with network manufacturer Cisco Systems, Rockwell Automation intends to expand its capability for providing solutions for network security.

Further investigation into the use of mobile devices, such as iPhone and tablets, and their ability to enhance productivity will be targeted in line with this focus.

“New mobile applications are being released at a rapid pace and we are becoming more aware of how they are adaptable to process automation.

“At the same time this opens up more security issues where a new breed of innovation will be required,” said Hegarty.

Innovation The pursuit of productivity has largely been in response to Australia’s challenging economic environment, which remains an issue for industry.

Although the Australian dollar has fallen during late 2013 a further drop would aid improvement in the local manufacturing industry.

Mauro DelleMonache, Marketing Director with Rockwell Automation says Australia needs to support innovation and is currently seeing pockets of tremendous innovation in the country, as well as in New Zealand.

“The growing trend of Australian companies implementing remote operations is an ideal way of overcoming some of the common issues documented in the country, such as a skills shortage.”

“Throughout 2014 we plan to continue to expand our capability around process automation, as well as developing architecture for machine builders where Rockwell Automation is planning to release new products in the coming year,” concluded DelleMonache.

Rockwell Automation 1300 319 741 www.rockwellautomation.com.au manmonthly.com.au

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Australian Mining, Manufactures Monthly and PACE Magazine invites you to attend the 2014 Women in Industry Awards in Melbourne. This exclusive event aims to raise the profile of women within industry, as well as promote and encourage excellence. The winners will represent high achievers from mining, engineering, manufacturing and process control industries, from the most senior to the stars of tomorrow.

VISIT WOMENININDUSTRY.COM.AU TO BOOK YOUR TICKETS

TICKETS Date: Time: Venue: Tickets: Dress:

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To view finalists or for more information please visit womeninindustry.com.au or contact Nicole Pusic 02 8484 0944

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Automation & ROBOTICS Transitioning to Industry 4.0 The latest automation technology offers manufacturers the tools needed to join the present automation direction. Alan Johnson reports.

A

S the manufacturing world transitions to the so called fourth industrial revolution (Industry 4.0) it is clear manufacturers need the right technology to prepare them for the journey.

While Australian manufacturers are travelling at varying speeds in the direction of Industry 4.0, more and more companies are producing the technology to help manufacturers on the journey.

Siemens, for example, recently launched its Simatic S7-1500 automation controller and TIA (Totally Integrated Automation) portal engineering framework in Australia. Bernd Lieberth, Siemens’ automation and industrial Motion functionality features of the new controller enable analog and Profidrive-compatible drives to be connected communication specialist and Chairman of the without additional modules.

Profibus/Profinet Association for Southeast Asia, said the automation controller family is the latest Lieberth said technology is the new “gold class” in technology for medium to high-end machine and automation technology. plant automation.

“This new technology is taking us into “The controller is a key component of our TIA the future of manufacturing and will allow portal, which allows manufacturers to be more manufacturers to be more nimble, adaptable and efficient in the engineering process,” he said.

MA 0 5 1 4 _ 0 0 0 _ E L E 1 2 0 1 4 - 0 4 - 0 3 T1 3 : 5 4 : 3 7 + 1 1 : 0 0 intelligent in the production process.”

Launching the controller and portal in With some observers questioning whether the Australia with a 3D Gold Class cinema experience,

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intellectual property used with Industry 4.0 is sufficiently protected, Lieberth admits there’s a lot of valuable information in this data, but says that this latest equipment contains sophisticated security systems already integrated into them to protect the valuable data.

“This latest controller, for example, has password protection which acts as a firewall and other features to make it as secure as possible. Most companies already have robust security systems in place, this is not new,” he told Manufacturers’ Monthly.

Lieberth said the software has come a long way in the last year.

“It has a broad range of applications including automation right across manufacturing; for OEMs, factory automation and water treatment. It’s a general workhorse.”

Lieberth explained that this is a new technology for Siemens with a redesigned architecture to take advantage of ethernet capabilities and other technologies. “This is our platform for the future.”

Siemens www.siemens.com

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What’sNew Safety switch

The throttle actuators provide a 50% duty cycle at max load.

Throttle actuators

The Schmersal AZ300 is not a typical mechatronic safety switch. It was designed with an RFID based electronic safety sensor, an IP69K rating and other unique features.

Its unique design is intended to allow the safety switch to accept the actuator from any of three sides, providing mounting flexibility for either left or right-hinged doors, or sliding guards.

Because of its protection class IP 69K, it is suitable for use in hygieneThe safety switch also has integrated a radio sensitive areas. frequency identification (RFID) sensor to detect the actuator and indicate a closed guard. This noncontact operating principle limits wear on components, tolerates misalignment, and offers the option of individual coding: The basic version of the sensor responds to any AZ300 target actuator; The “I1” version only accepts the coded ID number of the specific target actuator which is taught in during the first start-up; The “I2” version allows the teach-in process to be repeated, allowing replacement of a lost or damaged actuator.

The safety switch features all of the diagnostic advantages of Schmersal Pulse echo sensors. With continuous internal function tests and monitoring of the safety outputs, the safety switch can be wired in series without detriment to the safety levels.

Diagnostic LeD’s on the sensor indicate various errors, misalignment and door open/ closed signalling. For more advanced indication the safety switch is also available with serial diagnostics.

Control Logic 1300 374 073 www.control-logic.com.au

The Thomson electrak Throttle Actuator boasts a rugged and space saving design with integrated features that combine to deliver highly robust, reliable and versatile throttle control operation.

Designed to meet the high standards required for automotive component applications, the throttle actuator is equally suited for rugged, harsh industrial settings.

Applications range from agricultural and construction equipment, military and rescue vehicles, and trucks, forklifts and mass transport vehicles to industrial automation installations, marine applications, and garden, forestry and mining equipment.

Actuator models are available in numerous, user-selectable configurations, including choice of: 12 or 24 VDC supply voltage, flying leads or connector installation, straight or right angle cable exit, and a variety of on-board electronic options such as potentiometer feedback, end-of-stroke electronic limit switches and CANBUS MOTORS and gear units from communication.

SeW-eurodrive meet the requirements Other standard features include integrated mounting holes, worm screw drive for equipment intended for use system with stainless steel extension tube (providing 50 mm/2 in travel length), and a in potentially hazardous areas in rugged IP69K rated, e-coated aluminum housing for corrosion resistance. accordance with IeCex standards The electrak platform offers further versatility with custom-tailored modifications to (international). Additionally, SeW’s meet specific individual application requirements. motors and gear units meet ATeX (europe) and hazLoc-NA (Northern Action-ESG America) standards. Being certified 03 8586 6900 The hazardous area gear units and motors are MM0 4 1 4 _ 0 0 0 _ I N D 1 2 0 1 4 - 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 produced with special components and particular according to these standards makes www.action-esg.com.au attention is paid to quality assurance. them ideal for worldwide use.

The motors and gearmotors are offered in IeCex according to equipment protection levels (ePL) Gb and Gc (gas protection) and Db and Dc (dust protection). The combined gas/dust approvals for SeW gearmotors simplify the selection process for the relevant drive components, reduce the number of variants and allow you to use the gearmotors in combined gas/dust zones.

The 4-pole motors of categories 2 and 3 (or ePL .b and .c) are suitable for operation We ooffer We ffee cost effective solutions for your automation ff on a frequency inverter and in field weakening operation. The motors and inverters tech te chno noll technology needs Australia wide. are available as electrical equipment in protection types “e” (increased safety), “nA” (non-sparking) and tb and tc (dust explosion protection). The gear units as non-electrical At IIS&E S&EE we specialise in systems integration and S& auto au toma ma automation projects, big and small. equipment are certified in protection types “c” (design safety) and “k” (liquid immersion).

The compact, performance-oriented properties of the standard drives from the For mor more information phone us on 07 3856 2232. company are also included in the hazardous area motors, which are available in various designs in the power range of 0.12-75 kW. INDUSTRIAL SOFTWARE & ELECTRONICS SEW-Eurodrive Tel: (07) 3856 2232 Fax: (07) 3355 1012 E-mail: info@industrialsoftware.com.au 1300 331 968 Web: www.industrialsoftware.com.au www.sew-eurodrive.com.au

Hazardous area gear units and motors approved for Australian market

SCADA SYSTEMS PC & PLC PROGRAMMING

50 MAY 2014 Manufacturers’ Monthly

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hyUNDAI heavy Industries has unveiled twelve small and medium models of 9-series diesel forklift ranging from 2.2 tons to 5.0 tons.

The forklifts are designed to enable operators to safely load and unload goods with a monitor that displays the weight of goods, the slope of all directions, and the angle between the ground surface and the mast in real time.

Other features in the new models include high visibility LeD lamps and rear cameras which are installed to prevent rear-end collisions, OPSS (Operator Presence Sensing System) to prevent unforeseen accidents by automatically activating brakes when operators leave the operating cabin, and a diagnostic system that helps operators monitor conditions and the replacement period of expendables of the forklift.

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What’sNEW MR reach trucks yALe’S MR reach truck has several new features, including its new chassis, mast design, operator compartment and control systems.

Its maximum travel speed is 14km/h and its lift speed is 0.8m/sec. Coupled with its manoeuvrability and ease of use, the company claims it can help boost productivity.

A new design of mast channel on which a patent is pending offers improved deration performance as loads are raised while reducing mast deflection to a minimum. This allows smaller capacity trucks to be used for lift heights that would previously have required substantially larger and more expensive models.

A wide access step and dedicated grab handles are intended to help operators enter and exit the truck smoothly.

Once inside the operator’s compartment, the leg room, fully adjustable full suspension seat (which reduces transmission of vibration from uneven floor conditions), adjustable armrest with integral mini-lever module and adjustable steering column all contribute to operator comfort.

It has an optional touch screen display, which provides the operator with information on the truck’s status from battery charge and direction of truck movement to mast position and load weight, and allows easy tailoring of the truck’s operational performance characteristics.

The standard display module with LCD screen also provides truck status information and performance mode selection.

Nacco Materials Handling 02 9795 3812

Visibility from the operator’s seat has also been enhanced.

New technology for thermal cameras

TURCK has released the high speed Q25 inductive linear sensor to the automation market. The internal measuring frequency is user selectable and can be as high as 5 khz. This is said to result in accurate measuring speeds of 5 metres per second.

This high measuring frequency is intended to allow the senor to provide real time monitoring and measuring and result in more precise control than previously available in other linear measurement systems.

The linear position sensors do not require a magnetic position device and are unaffected by metal debris commonly found in many industrial applications. The sensors provide high resolution and can be used to accurately measure lengths up to 1 metre.

The linear inductive sensor operation is based on the RLC resistance inductance capacitance principle. Unlike potentiometric or magnetostrictive technologies, the sensors incorporate precisely manufactured printed emitter and receiver coil systems.

The emitter coils are activated with a high frequency AC field and produce an inductive RLC circuit with the positioning element. The element is inductively coupled with the receiver coils, which are arranged so different voltages are induced in the coils, depending on the position of the actuator.

FLIR MSX technology is designed to facilitate faster and more detailed electrical, mechanical and building inspections.

Being able to share camera images with customers or coworkers is a great benefit of thermal imaging technology. however, a thermal image alone is not always enough to help them understand what Thermal image with MSX. Note how the motor numbers are legible. they are seeing.

For that reason, the company developed the MSX Multi-Spectral Dynamic image mode which brings together both the visual and thermal spectrums in an innovative way.

The technology is now onboard most of the company’s cameras for the industrial and building market. According to the company, it instantaneously generates a definitive, all-in-one thermal picture that easily orients you to the location of the problem as soon as you see it on the screen or in a report.

The system employs an internal digital camera to enhance the thermal image. The high-contrast skeletonised visual image allows for key aspects of the visible spectrum to be overlaid on top of the thermal output, while still keeping the important thermal information prominent.

Turck Australia 1300 273 687 www.turck.com

FLIR Systems Australia 1300 564 230 www.flir.com

The sensors have a temperature range of -25 to 70°C.

Linear measuring solution for use in high speed motion systems

52 MAY 2014 Manufacturers’ Monthly

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Brought to you by

Energy-efficient pump drive solutions The SK 200e series comprises reliable and economical frequency inverters especially tailored to pump applications that precisely adjust power output as required. They are compatible with mains voltages worldwide.

NORD configures complete drive systems for various application areas (IP55/IP66, ATeX zone 22/3D). Integrated process and PI controller functions enable the fully automated control of process variables and compensation of disturbances – in stand-alone and mobile applications as well as in complex setups with several drives.

Thanks to two analog inputs, the inverters can directly process sensor data such as pressure or flow rate. Optional signal and power plug connectors facilitate handling and ensure compatibility.

A programmable energy-saving function automatically reacts to partial load operation – increasing efficiency and significantly reducing running costs.

Operation is straightforward and flexible via control terminals, bus, or via an optional potentiometer that enables adjustments directly at the inverter. Up to four operation modes can be stored, saving setup time; for instance during cleaning cycles or media changes.

The customized parameters can be quickly exported to other units via a pluggable storage module, the system bus, or ethernet interfaces.

The integrated pump drives can store up to four operation modes that can be displayed and changed directly at the control unit.

NORD Drivesystems 1300 050 347 www.nord.com

Quick Termination Tool CLIPSAL’S Actassi Quick Termination Tool has been designed to save time and money. easy to use, it is said by the company to provide fast and reliable termination of cabling, saving you approximately 15 per cent on overall network cable termination time.

The tool is ergonomically designed for comfortable repeat use and requires minimal force. Constructed from cast alloy, the Quick Termination Tool is suitable for Actassi Cat.6 and Cat.6A UTP connectors and accommodates 30 Mech and keystone connectors. It features a locking handle for neat storage and its small size makes it easy to store in a tool box. every Quick Termination Tool comes with a spare cutting module, which provides up to 5,000 terminations. Additional cutting modules can be purchased separately and they are easy to replace.

Schneider Electric 1300 369 233 www.schneider-electric.com

Industrial cleaning cloths

The termination tool is designed to facilitate faster work.

Worm gearboxes TONSON Australia (SAMT) has introduced Tramec K series worm gearboxes. They are available in a wide range of versions, with or without feet, making them suitable for a range of applications.

The worm gearboxes The worm gearboxes are extremely light thanks to the compact provide versatility. shape of their housing which is in cast iron and also die-cast aluminium.

This housing is in quench hardened alloy steel and ground.

Available in many different ratios, power and torque outputs, they are carefully engineered to maximise performance and efficiency, as well as ease of installation and usage.

The company offer a complete range of industrial gearboxes, industrial geared motors, modular worm gearboxes, planetary gear units, large gearboxes and screw jacks for use in all major industries.

Tonson Australia (SAMT) 1300 348 512 www.tonson-motor.com.au manmonthly.com.au

TORK Industrial Cleaning Cloths are premium industrial cleaning items. Soft and flexible, they are designed to prevent scratches when wiping and polishing.

According to the company, the cloths have efficient absorb and release properties so fewer cloths are required to do the job and they minimise consumption of solvents by approximately 27%.

They are capable The cloths are designed to prevent scratches. of absorbing commonly found industrial mess such as oil, grease, solvents and water; and are available in a flexible wall mounted system which is intended to provide portion control.

Alternatively, they may be purchased in the industrial cleaning cloth folded handy box. According to the company, one handy box with 280 cloths can do the job of a 25kg bag of coloured rags, so they save on space.

Other Tork products available include dispensers, paper towels, toilet tissue, soap, napkins, and industrial and kitchen wipers.

SCA Hygiene 1800 643 634 www.sca.com Manufacturers’ Monthly MAY 2014 53

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The lastWORD Getting out of cars and moving on Diversification is a must for hundreds of South Australian businesses in the automotive supply network. Brent Balinski spoke to one company that’s negotiated the leap early and successfully.

P

reciSe Advanced Manufacturing Group is in the middle of moving some of what it does into the new Tech Hub in the Thebarton Technology Precinct. The development of intellectual property - for itself and for others - will be the biggest contributor to its revenues by 2016 if its transformation strategy is successful.

Yet a decade ago, almost all of Precise’s turnover was related to supplying the auto industry.

Grant Tinney is the ceO and owner of the 43-year-old business, at which he started as a 15-year-old apprentice in 1977.

“We are a traditional automotive supplier,” Tinney told Manufacturers’ Monthly.

“Predominantly moulds and dies for the industry. We were 90 per cent automotive-focussed from 1971 to 2004.”

The company has moved further and further away from its roots in mould and die manufacturing for automotive since 2004, and is well on the way to its goal of being predominantly a manufacturing solutions provider for a broad range of industries.

The aim when the process started was to be less than 50 per cent automotive-focussed by year 2008.

By the company’s figures, it has now shrunk that the car industry’s contribution to the business to 36 per cent.

To its mould and die operations it added precision machining - buying a machining business - and automation solutions. it targeted industries that, unlike the car industry, were experiencing growth, such as mining, clean technology, defence and medical.

The company’s transformation was accelerated further still after the global financial crisis hit, and a new business strategy emerged, adding the development of Precise’s own iP and assisting in the commercialisation of other companies’ iP. it aims to, by 2016, have the former contribute 54 MAY 2014 Manufacturers’ Monthly

Grant Tinney, CEO of Precise Advanced Manufacturing Group. to 25 per cent and the latter contribute 50 per cent to total revenues.

“We had all the skills and all of the building blocks in place...we had a few things, like we partnered with ellex Medical in Adelaide so that we could bolster our regulatory approval side of the business, for gaining TGA and FDA approval for medical devices,” said Tinney.

“Partnering with them meant that we could achieve that. But we’ll be partnering with other companies in mining and defence realms over the coming year in order to better position our group of companies to commercialise products in those sectors.”

Precise currently employs 60, and plans to have grown this to 75 by early next year.

The group covers five divisions from cavity moulding, machining, medical device commercialisation (Precise Global: the division in its joint venture with ellex Medical), products commercialisation and rapid prototyping/industrial design.

At the Tech Hub facility, Precise will host its product commercialisation centre, including its additive manufacturing machines, prototyping laser machines and industrial assets.

There will also be a clean room facility operating for the production of electronic medical devices.

The goal is to be able to take any client’s idea from a drawing on the back of an envelope right through to a finished product out in the market. it believes with the expertise among its staff, its equipment and its facilities, it offers a solution to many businesses who have great ideas and who can benefit from a suite of offerings. it has been operating in this area for the last 18 months.

“We’re gaining a lot of momentum in that area and really being a onestop shop for the commercialisation of product is definitely where we need to position our company and certainly it’s an area that Australia as a whole and South Australia need to do a lot better at: the commercialisation of products, and taking innovative products and taking them to market,” explained Tinney.

At the time of writing, Precise has, by its count, 17 commercialisation projects on the go. These include efforts in medical devices, defence, mining and a large renewable energy project.

The company has a big head start on many companies who have traditionally operated supplying the automotive industry, which employs roughly 45,000 according to recent ABS figures.

The decline of the Australian automotive industry has been noticeable

for some time. in 2004 there were over 420,000 cars made in Australia. in 2013 - the year in which Holden and Ford announced they would end the assembly of their cars in Australia - around 118,000 Australian-made cars were sold here.

Tinney saw “the writing on the wall” a decade ago. Some suppliers, such as Futuris Automotive, have looked abroad to ensure their survival as the local market dwindled.

Others have been able to identify and sell to different industries. But many have been slower to act.

According to tracking of the industry by the Department of Manufacturing, innovation, Trade, resources and energy, in Tinney’s state there are 719 local companies involved in the supply chain, with 35 per cent of these suppliers. Most of the Tier 1 suppliers have not diversified.

“A lot of the companies out there will not change, will not adapt,” said Tinney. “There’s various reasons for that.”

He believes that with the limited time available to those with a hope of diversifying, it is only worth trying to assist those truly willing to have a go at the difficult task.

Tinney, whose company was awarded an Automotive New Markets Program grant worth $600,000 in 2012 to assist in its diversifaction, believes that both tiers of government “are doing quite a lot”.

“The key thing [for diversification] is that you’ve got the management team that is very entrepreneurial and strategic in its forward thinking, in terms of it knows that it has a problem, it does the research and looks around to see what other global companies have done to transition and not reinvent the wheel, and have aimed for a niche area that is within their core competencies.”

Precise Advanced Manufacturing Group 08 8241 0888 www.precise-amg.com.au manmonthly.com.au

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