Manufacturers' Monthly June 2015

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

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ANCA named Manufacturer of the Year

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Inside

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JUNE 2015

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For daily news visit manmonthly.com.au

Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au Managing Editor: Branko Miletic Ph: (02) 8484 0976 Fax: (02) 8484 0722 branko.miletic@cirrusmedia.com.au Editor: Matt McDonald Ph: (02) 8484 0645 Fax: (02) 8484 0722 matthew.mcdonald@cirrusmedia.com.au

6 Editorial

40 Women in Industry

■ The brave new world of Australian manufacturing

■ Who’s in the running ■ Profiles of finalists

8 News & Analysis

Journalist: 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: Dave Ashley david.ashley@cirrusmedia.com.au

■ The cream of the leadership crop

NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8011 3184 anthony.head@cirrusmedia.com.au

14 IT @ MM ■ Always use your mobile while driving ■ Cyber hygiene and peace of mind

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

16 Endeavour Awards

NSW, SA/NT & WA Sales: Cirrus Media Ph: (02) 8484 0868 anthony.head@cirrusmedia.com.au

■ Appreciating CMMS ■ Hydraulic nuts cut maintenance times MA 0 6 1 5 _ 0 0 3

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54 Waste Management ■ DAF treatment and biogas ■ Mobile water disinfection

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

Lightweight hole punchers Safer torque wrenches Giant injection moulder Metatarsal protecting boots

58 The Last Word ■ 3D printing boom continues

Behind the cover

ANCA was named Manufacturer of The Year at Manufacturers’ Monthly’s 12th annual Endeavour Awards, held at Crown Casino Melbourne.

The company repeated its 2013 achievement, as well as picking up the Industrial Product prize. ANCA exports 99 per cent of its tool grinding technology to markets all over the world. Touch anything of complexity, explains co-founder Pat Boland elsewhere in this magazine, and “it’s probably been touched by a cutting tool which has been manufacANCA named tured on our machines.”

Manufacturer Among many examples of the diversity, cleverness and innovation within Australian of the Year manufacturing, other winners include a world-leading plastic landfill recycler, a biody2 0 1 5 - 0 5 - 1 5 T1 5 : 5 4 : 1 0 + 1 0 : 0 0 namic dairy manufacturer, and a mining supplier diversifying with 3D printing.

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50 Materials Handling ■ Stackers for any warehouse ■ Wire rope inspection ■ New lightweight pallet

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36 Plant & Machinery Maintenance

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■ Access an issue with industry grants

55 What’s New

■ A wrap-up of the big night ■ Profiles of 2015’s winners

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48 Insider Series

Snapshot Stokes to quit manufacturing Tax and IP development Australian industry grows again

12 Comment

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Comment

BRANKO MILETIC – Managing Editor

The brave new world of Australian manufacturing

A

NEXTISSUENEXTISSUE • Automation & Robotics • Sheetmetal Working • Compressors & Pneumatics • Workplace Safety • IT@MM – Production Software • Warehousing & Storage Design M A 0Spotlight 6 1 5 _ 0 0 0 Control _ T RU • Product – Process

CCORDING to Aldous Huxley writing in Brave New World, “One believes things because one has been conditioned to believe them.”

This can be easily applied to Australian manufacturing.

As the editor of Manufacturers’ Monthly 13 years ago, I was constantly struck by the negativity and doom and gloom of many of those working in the manufacturing sector. I got to accept, or rather became conditioned to this negativity being the norm.

Fast forward to 2015 and after 13 years of plying my journalistic trade far and wide and to all and sundry, I’ve come back to the magazine where I started my career. And what a change it’s been.

Gone are the doom and gloom merchants, replaced by those that can only see positive things in Australian manufacturing. Those who were predicting the demise of Australia’s industrial sector by 2010 are these days singing its praises from the roof tops of their shiny, brand new purpose-built premises.

As for the industry-pundits that casually wrote off the manufacturing sector 10 or 15 years ago – well, many of them to this day still work in that sector.

This may have something to do with what many in - this 1 country 2 0 1 have 5 - 0been 5 - led 2 7 to T believe 0 9 : 5 about 0 : 0 Australian 7 + 1 0 : 0 0 manufacturing. Making cars we were told was of national

importance. Tariffs apparently were required and a host of other olde worlde industries that should have gone the way of the horse and buggy were also supposedly ‘integral’ to our survival.

Perhaps Charles Darwin was right after all. The species that survives is the one that can adapt the best.

Conditioning oneself to believe in fallacies is certainly not conducive to adapting. In fact, it has the opposite effect.

At this past National Manufacturing Week, I found that after talking to dozens of manufacturers and industry personalities, there are legions of Australian manufacturers out there that are doing very well.

And let’s be clear – they are not just doing well – they are actually prospering.

Companies like ANCA and Heat Technologies Australia are opening up plants in Europe and the US. Others like HI Fraser and Sage Automation are winning accolades from their peers. And for each of these, there are hundreds of other Australian manufacturers’ that are quietly scoring daily runs on the board.

Being forced to adapt has done our manufacturers a huge favour. And that’s not conditioning – it’s the facts on the ground. branko.miletic@cirrusmedia.com.au

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News&ANALYSIS Tax should account for importance of IP

Australian manufacturing growing again AUSTRALIA’S manufacturing sector ended five straight months of contraction in May, according to the Australian Industry Group (AI Group) Australian Performance of Manufacturing Index.

The monthly PMI recorded an overall result of 52.3, up 4.3 points from April.

Any result above 50 indicates expansion.

Though local demand remained weak, five of seven sub-indices were in positive territory.

Exports climbed 10.9 points to 58.3, and the new orders and production sub-indices both climbed back above 50.

In the previous month’s result, every sub-index was under 50.

The CEO of the Ai Group, Innes Willox, said that the benefits of a lower Australian dollar were starting to show up as exports lifted.

“This was a clear positive for performance in May, together with strong residential construction activity and very low interest rates, and helped propel the sector into expansionary territory for the first time in six months,” he said in a statement.

“There remains a fine balance however and the rapid decline in mining construction, the progressive closure of automotive assembly and subdued local business investment in machinery and equipment continues to weigh on local demand.”

THE Australian Advanced Manufacturing Council has called for a Productivity Commission review of Australia’s innovation ecosystem, and for policies that recognise the current realities of manufacturing.

The AAMC has made its submission to the federal government’s tax review, and requested that changes that encourage innovation, particularly collaborative efforts, be considered.

“Advanced manufacturing relies on intellectual property (IP) as its key asset and yet the tax system is still designed around the assets of old manufacturing – plant and machinery,” said John Pollaers, chair of the AAMC, in a statement.

“In our estimation, a significant amount of tax revenue is being lost through IP that is developed

by Australian individuals and companies moving offshore. These are IP investments that could very easily have been located here.”

Among suggested policies to lift productivity and encourage the development of IP in Australia were the doubling of the R&D tax incentive done “in collaboration with an approved Australian Research Institute or university”, a removal of the $100 million cap on R&D expenses claimed as a tax deduction, and to recognise IP as a depreciable asset.

The AAMC also cites Australia’s poor record in terms of industry/research institution cooperation as well as tax-based incentives introduced elsewhere in the region to Mencourage A 0 6 1 5R&D. _ 0 0 0 _ COM 1 2 0 1 5 - 0 5 - 2 2 T0 9 : 5 9 : 1 6 + 1 0 : 0 0

Old Aussie company quits manufacturing AUSTRALIAN company Stokes Limited, founded in 1856, has sold its manufacturing operations to focus on supplying lighting and audio-visual equipment.

One of the country’s oldest businesses has divested its appliance parts manufacturing and services division to an undisclosed buyer for a reported $5 million, according to Fairfax.

“The appliance parts division has undergone a major transformation since new management implemented a restructuring program in October 2012,” reads the company’s statement to the ASX. “The business being sold has annual revenues of over $8 million and EBITDA over $1.2 million.”

This continues the transformation that has taken place under the leadership of managing director Con Scrinis, who owns a 15 per cent stake in Stokes.

“When we came to Stokes we wanted to fix up Stokes,” he told Fairfax.

“That was our main concern.”

“I couldn’t have written a script back then that this is what we would be doing now.”

Stokes’s history includes making the original “Rising Sun” badges worn by the 1st and 2nd Australian Imperial Force soldiers in WWI and WWII. manmonthly.com.au

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News&ANALYSIS In brief...

Solar tech exported to Japan Precision Components’ new Heliostat SA division is producing technology licenced from CSIRO for export to Japan.

Precision received a $1 million Automotive Diversification Programme grant.

150 panels will be used at Mitsubishi Hitachi Power Systems. This follows Heliostat exports to Cyprus researchers.

Hub to boost prefab housing A new University of Melbourne’s Industrial Transformation Research Programmes hub aims to increase to share of prefabricated housing from 3 to 10 per cent of the construction sector.

The centre will support 14 PhD and six post-doctoral roles and is led by Dr Tuan Ngo and Professor Priyan Mendis.

CFA truck work for Ballarat A $3 million contract for SEM Fire and Rescue in Ballarat will be a boost for the region’s manufacturing sector, said the Australian Industry Group.

SEM will build 20 Country Fire Authority trucks for the Victorian government, securing four years of work and benefiting their suppliers.

3D printed macadamia nuts?

A three-year, multi-disciplinary research will go ahead on creating a sustainable, 3D printed “Microtimber” out of forestry and agricultural waste, including macadamia nut shells. Part of the funding was from the Forestry and Wood Products Association.

No decision made to close Pt Kembla steelworks: BlueScope BLUESCOPE has denied that it has made a decision to close its Port Kembla steelworks, following comments from the Australian Workers Union that this was under consideration.

The Illawarra Mercury broke the news that the AWU were to meet with the company early this month, with the union claiming employees had been told the plant might be shut if savings of $50 per tonne of steel weren’t made.

“The worst case scenario is you’re looking at anywhere upwards of 700-1000 jobs in the Steelworks directly, with a flow-on effect to Manufacturing costs remain too high for steelworks. thousands, including all the contractors and “Most of the [workers] have quite big mortgages, suppliers,” the AWU’s Wayne Philips said. they have families to look after and its just simply not BlueScope released a statement to the ASX good enough that we have Bluescope Steel manageshortly after this, denying that any decision had been ment operating in a cone of silence speaking to made to close the steelworks though conceding that each other but not speaking to its employees or the manufacturing costs “are too high” and it was seeking broader region,” said Watson. “game changing” ways of reducing these.

The ABC reported that the BHP’s Lysaght produc“The global steel sector is continuing to change tion remained profitable, but raw steel was marginal and we must adapt with it,” the statement read. and the AWU believes importation is being considShellharbour NSW MP Anna Watson criticised the ered. time taken to make a statement after the reports.

What members of our community thought about steel costs

Where’s our venture capital?

Silicon Valley investor and founder, Founder Institute, Adeo Ressi, has said meagre venture capital and a small market were seeing start-ups exit Australia.

Ressi said to ease the “brain drain”, governments should invest in education and foster venture capitalism.

North Melbourne hub hopes Merrivale, a fully masterplanned suburb in Melbourne’s north, could become a manufacturing hub, said MAB Corporation founder Andrew Buxton. “We expect new forms of manufacturing that use clean technologies to establish themselves at Merrifield,” he said. Early industrial residents will include Dulux, which has committed to a $165m factory.

10 JUNE 2015 Manufacturers’ Monthly

Alfred Arthur Arnold Be Of cause they will close it; when is the only thing outstanding. All manufacturing is now in China and India. Roll steel is now selling in China for less than $700 a ton compared to what they can get here, like ColorBond is $2500 here but $900 in China per ton. Funny but made by OneSteel/Bluescope.

And they rip us off here for what they can get. High wages have destroyed our future here in near all things, We can no longer compete on world markets.

rates is a viable thing? Are you putting your hand up for a pay cut?

Alfred Arthur Arnold Be No, just no more demands until other countries catch up or we go under like Greece big time.

What do you think?

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

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

telescope What and paying Chinese labour

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Comment

INNES WILLOX – CEO Australian Industry Group

The cream of the leadership crop The latest figures suggest Australian leadership, which used to rank well internationally, has fallen behind the pack. This trend, writes Innes Willox, needs to be reversed as soon as possible.

T

HE evidence, from both academic research and business surveys, shows that workplaces with more effective leadership and management capability are more productive, profitable and innovative.

It follows, therefore, that lifting Australia’s leadership capability in order to enhance productivity, innovation and sustainability is critical to our future – and particularly for many Australian manufacturers confronting challenges including the imminent end of auto assembly and an economy rebalancing amid declining demand from the mining sector.

While of course there are exceptions, there remains a growing concern about the comparatively low standing of leadership and management of Australia’s enterprises.

Using the measures of the International Institute of Management Development (IMD) World Competitiveness Yearbook, the perception of management practices by Australian employees relative to other countries has been dropping, with our ranking falling from 8th in 2009 to 18th in 2014.

This month, Ai Group launched a key policy paper, Addressing Enterprise Leadership in Australia*, which identifies some key barriers to the improvement of leadership practices.

M reading A 0 3 1 the 5 _ report, 0 0 0 _our MO S On posi-

12 JUNE 2015 Manufacturers’ Monthly

tion may seem hard-hitting. But the changes needed must be shared by all – businesses, government, the education sector, and organisations such as ours.

What is clear is that a step change is needed regarding the commitment to developing our leadership capability and evolving our organisational structures and systems if Australia is to improve its productivity and capacity to innovate.

Ai Group urges the following to kick start this change:

“

must commit to a more complete approach to the development of their workplace culture and the leaders within them.

• Collaboration between our schools, academic institutions and business will be fundamental to innovation and sustainability – we’ve been ranked dead last for collaboration by the OECD (2013) out of 33 countries.

• Culture impacts on strategy and in the case of Australia it is impacting on our ability to innovate. We need

Change must come from all – businesses, government, the education sector, and organisations like Ai Group...

to better understand how our cul• Businesses must recognise that exture at both the organisational and isting levels of leadership capability national level is impacting on Ausin Australia need to be improved. tralia’s ability to remain competitive.

• Organisations should be encourAi Group is practising what we aged to cultivate a longer-term oripreach. We are committed to helping entation and to consider how they Australian industry and its leaders to create value for all stakeholders in thrive, and we are doing this by: the short, medium and long term.

• working on furthering our under• Australia must continue to reform standing of Australia’s unique its leadership and management cultural barriers as they relate to education through context-specific 1 programs.

2 0 1 5 Equally, - 0 2 - 2organisations 6 T 1 5 : 3 0 : 4 1our + 1leaders 1 : 0 0and their ability to lead

their organisations. This will help enormously in informing our development approach and methodology; • forming alliances with relevant education partners to cultivate a longerterm outlook across businesses at the Executive and Board level; • developing a leadership community where we can collaborate, offer insight, and discuss leadership challenges with industry; • working with Government to advocate and support further reform in the education sector as it relates to management education; • seeking out opportunities to collaborate in areas of practical leadership research relevant to Australia; • continuing to develop leadership tools and information to support the practice of leadership; and finally by • sharing and promoting leadership success stories from across our membership to celebrate exceptional leadership and recognising its importance.

Australia’s future, its level of innovation uptake and its ongoing competitiveness and sustainability will largely depend on the capability of our leadership and the changes we make now. * The full report can be found at www. leadershiprevolution.com.au/#report www.aigroup.com.au

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TechnologyIT@MM Always use your mobile while driving Mobile device management software connects technologies commonly used on forklifts for increased visibility. Hidde Hannenburg writes.

A

TOTAL of 59 Australians died while using forklifts from 2003-2013, including six workers in 2013, which was the highest number in three years.

As a result, forklift use is now considered high risk work according to Safe Work Australia and as such the organisation is focusing on worker safety, training, and business compliance across industries operating forklifts.

Safe Work Australia requires that a person who operates a forklift must hold a high risk work forklift licence.

Training to get a high risk work licence must be completed as part of a course from a Registered Training Organisation (RTO).

They also state that most forklift incidents involve pedestrians, therefore businesses should make sure there are clear, separate pathways for pedestrians and forklifts.

Alternatively high visibility work wear should be worn if walking outside of designated walkways. There are penalties to companies if these safety guidelines are not followed.

There is also an enormous cost to business associated with forklift accidents, with the Australian manufacturing industry dealing with 110 serious claims regarding falls from a height due to forklift use between 2009 and 2011. Minimising liability costs is therefore paramount for companies using forklifts.

Add to this the high costs associated with repairing damaged forklifts, which are very expensive business assets. Businesses tend to expect long life-cycles of around five to seven years for forklifts and are therefore highly motivated to reduce damage and the associated costs.

Forklift user management It is vital that managers of warehouses, factories, as well as field workers take charge in managing forklift use to ensure workers are safe and compliant.

14 JUNE 2015 Manufacturers’ Monthly

committed to improving the safety of its workers.”

Safety and cost benefits

Mobile device management allows a business to connect their technology hardware with the business’ back-end systems to greatly enhance the visibility and information managers have to hand when making decisions.

Mobile device management allows a business to connect their technology hardware with the business’ backend systems to greatly enhance the visibility and information managers have to hand when making decisions.

Honeywell Scanning & Mobility device management software connects a wide range of mobile technologies commonly used on forklifts to a business’ platform, such as a WMS, for increased visibility.

This offers businesses flexibility in the mobile technologies they choose to deploy on their forklift fleet.

Technologies best suited for forklift use include rugged vehicle mount computers that withstand vibrations, hands and eyes free voice technology for safety and long-distance scanners.

Honeywell is also developing new vehicle sensing technology to better track the performance of workers and forklifts, including ignition interlock to only allow trained workers to start up a forklift, as well as acci-

dent sensing cameras and alerts to management so they can assess if it is a false alarm or an actual accident that requires appropriate steps to be taken.

Finally the ability to detect poor forklift driving or behaviour will be included.

Optimised visibility of forklifts and workers also allows a business to show a commitment to measuring occupation health & safety (OHS) performance.

This is important, because as noted

by Safe to Work, “Poor OHS leads to higher accident and injury rates.

“Poor OHS can also increase business operating costs and lower productivity, workplace culture and morale.

“Commitment to OHS is best sustained through a focus on performance outcomes which can be reported on and monitored over time.

“Measurement of OHS performance demonstrates that a business is

When devices are made accessible on the network via mobile device management, managers are in control of complex forklift costs and life cycles.

For instance, managers can see each forklift’s usage and properly schedule maintenance and associated costs, have a record of leased forklift usage for overage charges and ensure forklifts are cycled for equal usage across the fleet.

Some MDMs can predict when device batteries will fail, so replacements can be installed proactively.

Device management also helps maintain uptime of a varying fleet of mobile assets, such as forklifts, vehicle mount computers, voice technology and scanners, that are often at different stages of their lifecycle.

In 2009 VDC Research Group released a paper supporting device management, saying: “A powerful resource to control the costs associated with device failure and solution upgrades, MDM software lowers incidence of repair, ‘no trouble found’ tickets and the need for spare devices.

Investments in MDM have successfully improved the networking ability for line of business applications and customer relationship management.

Ultimately, MDM decreases workforce downtime and variable costs across an enterprise’s entire mobile fleet.”

Mobile device management provides worker safety, forklift and device reliability, higher productivity and enhanced profitability, which is important in an increasingly competitive business climate.

[Hidde Hannenburg is Global Product Marketing Manager, In-Premise Mobility with Honeywell Scanning & Mobility] Honeywell Scanning & Mobility 03 9420 5555 www.honeywellaidc.com manmonthly.com.au

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Cyber hygiene & peace of mind Cyber security needs to be taken seriously. And, as Matt McDonald writes, it is not just the high profile targeted attacks that industry needs to watch out for.

B

ACK in 2010 ‘somebody’ carried out a cyberattack on Iran’s nuclear program.

They did so with Stuxnet, a drone-like computer virus that was more sophisticated than anything that had come before it. And they successfully destroyed one fifth of the nation’s nuclear centrifuges.

The attack attracted plenty of attention and raised plenty of legitimate fears about the future of warfare and the possibility of cyber terrorist attacks.

This cyber-attack led to concerns about not just the security of nuclear installations but also of other large industrial plants in the mining, energy, and oil and gas sectors.

Should those sectors be preparing themselves for another Stuxnet?

“That was a targeted attack,” Chee Ban Ngai who leads Honeywell’s Industrial Cyber Security business in the Asia-Pacific told Manufacturers’ Monthly.

While these are an obvious concern, he said, non-targeted cyber threats are also a big problem.

“What we are very worried about is cyber threat intrusion that [arise] from the use of poor practices from the engineers and operators in plants,” he said.

“We are talking about contaminated USBs or ensuring the hygiene of a laptop that a vendor brings into a plant.”

High stakes Ngai pointed out that the stakes are high in the mining, oil and gas, and energy sectors.

“We’re talking about chemical reactions. We’re talking about the environmental impact. We’re talking about the risk to human safety.” And on top of this, he said, these industries are crucial to the nation’s economic wellbeing.

Ngai explained that, in terms of cyber security, these industries all face the same types of threats.

“The common denominator that they face is that they are quickly migrating out from the proprietary process control systems,” he said.

“Most of them are in the midst of introducing open system architecture. Many of them are upgrading windows servers and windows operating systems as part of the platform to manage the control environment.” manmonthly.com.au

Risk Manager uses advanced technologies that translate complex cyber security indicators into clear measurements and key performance indicators.

And the moment they decided to make those changes they opened themselves up to increased cyber risks.

Risk Manager To deal with this increased risk, in recent years Honeywell Process Solutions has invested heavily in cyber security. For example, the company recently launched the Honeywell Industrial Cyber Security Risk Manager, a digital dashboard designed to proactively monitor, measure and manage cyber security risk for control systems for refineries, power plants and other automated production sites.

Ngai explained that the approach the company uses is to first provide customers a cyber-security assessment in order to uncover any threat they are facing. If found, these are reported to management and remediation is provided.

“Risk Manager comes in very nicely after that because what we can see then is that the plant… will have achieved a baseline security level, sort of like a clean slate…when the risk manager moves in and starts monitoring the system,” he said.

Risk Manager uses advanced technologies that translate complex cyber security indicators into clear measurements and key performance indicators, and provides essential information through an easy-to-use interface.

The intuitive workflow allows users to create customised risk notification alerts and perform detailed threat and vulnerability analysis so they can focus on managing risks that are most important for reliable plant operations.

“It empowers customers. It allows them to have a more participative role instead of relying on

security experts to watch over them,” Ngai said.

With Risk Manager, he added, they can watch over themselves “and of course escalate for higher support if they find something which is beyond their means to address.”

Cyber Security Lab In an effort to advance its development and testing of new cyber security technologies the company also recently opened the Honeywell Industrial Cyber Security Lab in the US city of Duluth.

The lab includes a model of a complete process control network that Honeywell cyber security experts will leverage for proprietary research, hands-on training, and to develop, and test industrial cyber security solutions. This lab will help accelerate development time of new cyber protection technologies and speed availability to customers.

“Most importantly, the lab will allow us to certify our methods, our solutions, our approach, such that we can quickly roll them out to customers when we carry out the cyber security investment,” said Ngai.

Concluding, he explained that no nation is immune to cyber security threats.

“When we carry out assessments…from Australia, to New Zealand, to Malaysia, the ASEAN countries, even to India one of the common things we see is that there is a huge catch up to do in terms of basic hygiene.”

Given the importance of the resources sector to Australia, the problem is worth taking seriously.

Honeywell Process Solutions 1800 456 066 www.honeywellprocess.com Manufacturers’ Monthly JUNE 2015 15

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EndeavourAWARDS

PROUDLY SPONSORED BY

EndeavourAWARDS ??? OF THE YEAR

The Endeavour Awards have come and gone for another year. We take a look at the evening’s highlights and profile all this year’s winners.

PLATINUM SPONSOR

MANUFACTURER OF THE YEAR

ANCA wins again!

R

OUTINELY cited as an example of Australian manufacturing at its very most advanced, ANCA’s accolades could fill pages.

Victorian Manufacturing Hall of Fame (2003). Oodles of export awards. First Australian company to design and make a CNC machine.

At the Endeavours alone, its prizes include Most Innovative (2011), Exporter of The Year (2013) and Young Manufacturer of The Year (2014).

This time around, at Melbourne’s Crown Casino, it repeated its achievement in 2013: Manufacturer of the Year.

The tool grinder specialist exports an incredible 99 per cent of what it makes, and counts firms including Boeing, GE and Sandvik among its customers.

As co-founder Pat Boland told

Manufacturers’ Monthly after his company won its two awards (it also took out Industrial Product), ANCA’s reach is vast.

“If you touch virtually anything in the world of any complexity, it’s probably been touched by a cutting tool which has been manufactured on our machines,” he said.

ANCA and other advanced manufacturers have achieved success for a number of reasons, including the adoption of the latest technology and processes.

A high-level of value was cited by Boland when asked how the words “advanced manufacturing” – that tricky-to-pin-down term – applied to his own company.

“To me, advanced manufacturing is where you’ve got very high valueadding,” Boland said, adding the difficulty in providing a comprehensive definition.

Grant Anderson, CEO, ANCA Group, and Tony Gent, State Manger VIC/TAS, BlueScope Steel.

Judges’ Comments “Founded in 1974, ANCA is a stand-out company with a long history of achievements, including the manufacture of the first Australian CNC. The judges agreed that the FX Linear tool grinder range continues the company’s tradition of quality and innovation.

It sets ANCA apart as Australian Manufacturer of the Year.”

“You’re delivering a whole lot of value beside just the basic material cost of whatever you’re manufacturing.”

And people will pay for that value, wherever they are in the world.

Manufacturers’ Monthly would like

16 JUNE 2015 Manufacturers’ Monthly

to thank our sponsors: Bluescope Steel (Platinum Sponsor), ifm efector, ECi Solutions, Atlas Copco, ICN, BOC, SICK, and SEW Eurodrive. The evening would not have been possible without their generous support.

We’d like to thank the judges for lending their expertise to the awards.

These were Dr Ivan Cole, Chief Research Scientist, CSIRO; Stephen Johnson, Acting Manager Industry Team for Manufacturing and Electrocom, NSW Department of Education and Communities (now retired); Mark Goodsell, NSW Director of the Ai Group; Derek Lark, Executive Director, ICN; Dr John Blakemore, founder of Blakemore Consulting International; and Scott Blakemore, Principal, Blakemoresource.

Finally, we’d like to congratulate all the winners and thank everybody who took part.

See you next year for our lucky 13th Endeavours! manmonthly.com.au

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EndeavourAWARDS

PROUDLY SPONSORED BY

TECHNOLOGY APPLICATION OF THE YEAR

KEECH AUSTRALIA KEECH 3D ADVANCED MANUFACTURING It has a long history in high integrity steel castings, particularly for mining, but Keech’s reputation for additive manufacturing expertise continues to grow with its 2015 Endeavour Award for Technology Application of The Year.

The multi-generational, family-owned Keech group of companies dates back eight decades, though the ideas of innovation and adaptation have always been part of its DNA. It is best known as an OEM and direct supplier to the world’s largest miners and equipment makers. In recent times it has been diversifying in 3D printing services.

Keech has constantly worked to upgrade its systems and its processes, aiming to lift the productivity of its foundries and the people that work in them.

“It means adapting advanced manufacturing techniques, from the most basic manufacturing right through to the most complex,” Herbert Hermens, the company’s CEO, told Manufacturers’ Monthly after winning the Endeavour Award.

“Companies such as my own – which is a foundry, and is thought to be the secondoldest profession in the world – we can adapt and we can put processes in and

control information so that we can improve our systems and reduce our production costs.”

To Hermens, advanced manufacturing – what goes on at Keech’s Bendigo headquarters – involves operating in a thoughtful way, making sure that everybody’s involved in the process.

Being advanced was absolutely vital, added the CEO. “It is not necessarily talking about a unique and dynamic change in manufacturing, it just means a process development,” he said.

“And that’s the key.”

Among many efforts to improve the way it runs, the company had experimented with 3D printing for several years in its patternmaking division before deciding a couple of years ago to be a serious provider of 3D printing services, both for its region and the country.

The patternmaking department had been a major bottleneck, with a shortage of skilled patternmakers available.

The company recognised 3D printing as suitable for making its patterns, and was excellent for reverse engineering old designs (with digital scanning).

Hermens and the giant Stratasys Fortus 900 mC machine.

18 JUNE 2015 Manufacturers’ Monthly

Herbert Hermens, Keech Australia CEO, and Dave Delany, managing director, ifm efector.

A major recent development was re-branding its patternmaking division Keech 3D. The subsidiary was then launched as Keech Advanced Manufacturing 3D, showcasing its brand new, ultralarge Stratasys Fortus 900 mC production machine last July.

Keech has invested around $1 million in machines and implementation. Its suite of additive manufacturing systems includes an Objet PolyJet machine, Mcor paper machines and the little uPrint Plus that started the company’s experiments in 3D printing.

It has acted on its earlier vision of being the major provider of the technology for the Central Victoria region – where it has been based since 1995, relocating from Mascot in Sydney’s south – with early clients including defence giant Thales.

“Keech 3D is a major new manufacturing initiative for Victoria and makes large scale 3D printing, design and advanced manufacturing accessible to businesses across the state,” its nomination reads.

“As well as supporting its own business customers, Keech 3D enables its parent company Keech Australia to implement advanced manufacturing technologies within its core business of providing high integrity steel castings to global customers.”

Within Keech, accelerated design processes and rapid prototyping help its Quality and Innovation Centre (which

Judges’ Comments “The establishment of Keech3D Advanced Manufacturing continues Keech Australia’s principles of continuous innovation, finding new solutions, and being among the first to anticipate future needs.

The subsidiary will help the organisation bring new products to the market more quickly.” opened in 2012) bring products to market more quickly.

This year it announced a partnership with the CSIRO and became the first Australian company to have guaranteed access to the research organisation’s metal additive manufacturing capabilities.

Other recent developments include Keech’s agreement to offer back-end support for Officeworks’ new 3D printing services.

The Bendigoan engineering solutions provider continues its winning ways at the Endeavour Awards, following its victory in the Most Innovative category last year.

Keech 3D Advanced Maufacturing 03 5400 1210 keech3d.com.au/ manmonthly.com.au

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EndeavourAWARDS

PROUDLY SPONSORED BY

ENVIRONMENTAL SOLUTION OF THE YEAR

B.-D. FARM PARIS CREEK ENERGY EFFICIENCY PROJECT B.-d. Farm Paris Creek is one of Australia’s finest producers of award winning, certified organic dairy products, including milks, yogurts, Quarks, butter, soft cheeses and hard cheeses.

For years, the company has constantly been increasing production, processes, productivity, and environmental sustainability and at the same time has been decreasing its environmental carbon footprint, the impact on waterways and air-pollution.

On the farms it maintains a sustainable environment, with biodynamic farming methods as the basis for this: no artificial fertilisers are used and no chemical treatment is used on soil, animals or crops.

Not just an advanced manufacturer, B.-d. Farm Paris Creek also employs advanced agricultural techniques in its business.

“I would say in our farming system, biodynamic farming is one of the most advanced farming methods,” Ulli Spranz, the company’s managing director, told Manufacturers’ Monthly after receiving the award. “[And] I would call us an advanced manufacturer because we are using the most modern technology in what we are doing, in producing our dairy products: cheese and milk and yoghurt and butter.

“And we are always looking for the most modern technology to keep the

Advanced farming, advanced manufacturing.

20 JUNE 2015 Manufacturers’ Monthly

healthiness in the products, to keep them as natural as possible.”

B.-d. Farm Paris Creek is located in Meadows, South Australia, between Adelaide Hills and Fleurieu Peninsula.

The original farm was purchased by Ulli and Helmut Spranz who immigrated from Germany, in 1988. It took in 165 acres and 40 milkers.

Ulli and Helmut have worked for more than 27 years educating consumers, farmers and processors to understand the impact of chemical farming on the land, extensive water usage on farms and the impact of chemically induced waste water from processing to the environment.

They have made improvement after improvement to the site since 1988. The farm was immediately conversed to biodynamic-organic farming principles and set up of liquid composting plant utilising dairy waste/water.

To them, it was clear that biodynamic farming was the only sustainable way of farming to support preservation of the environment for future generations, they said in their entry. “[Eliminating] fresh/ground water pollution, nurturing the soil with ‘biodynamic preparations’, free of chemical input such as artificial fertilisers, fungicides, pesticides, no drenching, no GMs, no antibiotics, no hormones,” was the only way to

Ulli Spranz and Alain Lefranc, General Manager, Atlas Copco Australia. go, the company’s Endeavours nomination told us.

The business was incorporated in 1995, and a state-of-the-art processing facility built to further increase production for steadily, Coles, Woolworths, interstate and exporting.

A cheese factory was added in 2007 to produce European soft and hard cheeses to balance milk over-production.

The energy efficiency project started in 2012, with an energy monitoring system installed and energy audit conducted.

In the next year a new dairy farm was purchased to further increase milk production The following year a Clean Technology Investment Program Grant was received and a photovoltaic solar system was installed (100kw electricity production).

A 250kw hot water solar system was installed in March 2014, and an energy saving flexi line pasteuriser installed (with optional ESL/homogenizing/pasteurising) in April.

What was involved in successfully making so many significant upgrades?

“Doing research, research, research,” explained Spranz, who said Australian businesses needed to look far and wide when considering the most effective way to invest.

“We travelled overseas. We looked at what other companies are doing. And we then picked the methods that fit us most.

Judges’ Comments “The dairy product maker has managed to decrease chemical usage, decrease energy usage, and cut costs, while also significantly increasing production. In fact, B.-d. Farm Paris Creek expects to double its milk intake by 2016/17. A worthy winner.”

“We have achieved over 30 per cent of energy savings. It was only possible because we looked worldwide for the best systems available for what we are doing.

Because in manufacturing you can’t have downtime, so it needs to work every day – that’s very important. And we have done a very, very long research [program] over two years to then decide what we set up.”

At B.-d. Farm, work on a multi-million dollar, fully integrated ESL (extended shelflife) project has begun. A filling line for fresh milk production and bottling and new aseptic yogurt filling line will be integrated and connected to the solar system, with plans to double milk production by 2016 with minimal increased impact on fossil fuelled energy usage.

B.-d. Farm Paris Creek 8 8388 3339 www.bdfarmpariscreek.com.au manmonthly.com.au

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CONGRATULATIONS As a long running sponsor of the Environmental Solutions of the Year Award, we would like to congratulate the winner, B.-d. Farm Paris Creek.

In 2015, we were once again recognised at the World Economic Forum in Switzerland for our commitment to sustainability. We rank as the 23rd most sustainable company in the world on the Global 100 list.

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EndeavourAWARDS

PROUDLY SPONSORED BY

.

SAFETY SOLUTION OF THE YEAR

AUSTUBE MILLS COP CAMPAIGN Austube Mills celebrated its 80th anniversary last year. Its Endeavour Awardwinning Code of Practice safety campaign has also been a long time in the making.

The former OneSteel Australia Mills business saw parent company Arrium update its Codes of Practice (COP), and this became a catalyst for rethinking Austube’s entire approach to safety.

This approach has been adopted at sites at the company’s network of manufacturing and warehousing facilities in NSW, Queensland and Victoria.

“We pride ourselves as Austube Mills to be a strong manufacturer of high-quality product,” Garry Meagher, Austube’s Manager, Safety, Quality, Environment

Austube’s COP campaign’s ambassador: ‘Zero’.

22 JUNE 2015 Manufacturers’ Monthly

and Training (SQET), told Manufacturers’ Monthly.

“But the underlying thing that embeds that is that we care for our people, and it’s about providing safe environments so that our people can flourish and have the opportunity to make quality products in Australia.”

Austube’s COP campaign was launched in January 2015 with its animated ambassador ‘Zero’, to help encourage teams to alays choose the best safety behavior - whether at work or at home.

The launch took place across the company’s three sites and was also Skyped to their inter-state sales managers to ensure everyone had the same simultaneous experience.

Garry Meagher, Austube’s Manager, SQET, and David Duncan, Managing Director, SICK. The presentation involved a letter read to the audience that was written by Austube’s Safety, Quality, Environment and Training (SQET) Council to explain why the campaign was being rolled out, how it was evolving and what each individual could do to keep it relevant.

The letter read, “The video and the five posters are the first stage of this campaign, with the rest of the 10 codes to be rolled out at a later date, so all will stay tuned for more later this year.

“Our business has certainly had an interesting journey up to now; from being safe because we have to adhere to the rules, to being safe because we want to protect from harm, and while ever our people are still harmed, we still have work to do.

Staff were brought in on the making of the video and Austube’s site lead teams in on the campaign’s messaging to gain relevance to Goal Zero: Zero Harm, Zero Waste.

The campaign included an updated and rebranded personal COP booklet, educational video and poster suite, a 12 month employee engagement strategy, an infographic detailing the campaign’s journey, internal communications activities in the lead up to the launch – all aiming to develop employees into stronger safety leaders.

“Our key message was this – ‘You do it mostly right at work because you have to, now it’s time to take those best practice

Judges’ Comments “Austube Mills showed that it was prepared to go the extra mile to ensure employee safety, not just in the workplace but in all areas of their lives. Features such as the 12 month employee engagement strategy convinced the judges the company takes safety seriously.” behaviours off site so you can help protect your loved ones at all times,” reads their nomination.

“You’d hate to have allowed harm to occur to your baby, wife or father, knowing you knew how to prevent it from happening.’”

Austube the largest Australian manufacturer of the widest range of high quality structural steel pipe, tube and open profile sections that are third-party certified (ACRS) to the highest AUS/NZ Standards.

“We benchmark Australia-wide and worldwide. But again, it comes down to the human factor for us, and we rely on and invest in our people,” said Meagher.

Austube Mills 1800 281 424 www.austubemills.com.au manmonthly.com.au

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COMPLETE SOLUTIONS FOR EFFECTIVE HEALTH & SAFETY.

SICK has an enviable record of working with partners to develop well proven innovative safe solutions that continue to push that competitive advantage. This is why we are proud to once again sponsor this years “Safety Scheme of the Year� Endeavour Awards program, which recognizes companies and individuals for their contributions to the Australian manufacturing industry.

For more information please visit www.sick.com.au or call 1300 405 807.

Manufacturers Monthly Endeavour Awards Advertisement.indd 1

30/04/2014 11:32:51 AM

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EndeavourAWARDS

PROUDLY SPONSORED BY

GLOBAL INTEGRATION AWARD

TECHNOFAST INDUSTRIES HYDRO POWER STATION – SOUTH KOREA Following considerable investment in time building relationships with key personnel in South Korea’s ower generation industry, Technofast’s products are now being used on one of the country’s major hydro power projects.

“This is fantastic achievement for us,” said John Bucknell, the company’s CEO and founder.

“We are a small company, based in Brisbane, but our innovative products, which are all developed and manufactured in house by our dedicated team, are now being recognised around the world for their quality, reliability and time-saving ability.”

The Technofast method resulted in an installation time of around thirty minutes using two personnel, compared with eight hours and four personnel using the previous method.

Bucknell explained that time savings of this order, and better, were possible using the EziTite fasteners instead of conventional methods involving sledgehammers, stud heaters and multi-jackbolt tensioners.

Technofast Industries is a worldwide leader and specialist in bolt tensioning, providing innovative and effective technical solutions along with uncompromising customer service.

“We found our niches through innovation and development of intellectual

property, Bucknell told Manufacturers’ Monthly after winning the award.

“I think, we’ve seen with the death of the automobile industry and the loss of things like tyre manufacturing in Australia that we have to be smarter, we have to find our niches, and we do rely on science, advanced manufacturing techniques and the like, to find those niches.”

By using Technofast’s innovative EziTite hydraulic bolts, the Korean hydo power facility was able to reduce its maintenance downtime by 80%. The hydraulic bolting system has proved to be so successful, saving both time and money, that funds have now been allocated to change all other water turbines onsite to Technofast’s EziTite hydraulic bolts.

Technofast has recently moved into a new, purpose-built premises, allowing the company to expand its manufacturing capability for export markets with major distributors in international markets.

At present, the company has 16 employees, however that figure will double in the near term once the new factory becomes fully operational.

Technofast also has an office in Rockingham WA to service the company’s West Australian customers.

Training and ongoing education for employees was an important part of

Technofast is gaining worldwide recognition for their quality and time-saving ability.

24 JUNE 2015 Manufacturers’ Monthly

John Bucknell, CEO, Technofast Industries, and Derek Lark, Executive Director, Industry Capability Network. the business, said Bucknell.

“We like to put our guys through apprenticeships, even some of the more mature guys that’ve come on board have done adult apprenticeships,” he said.

As a specialised manufacturer of unique bolt tensioning products, Technofast is not able to establish and maintain regional offices and support staff internationally, instead the company has been very successful in building productive relationships with international marketing and joint venture partners to best exploit its technologies globally.

Affiliations such as those with Westinghouse Electric, Curtis Wright Corporation, Mitsubishi Electric, Jaques Terex, Siemens Electric’ Korea Electric Power Company, East West Power (Korea) and DSME (Korea) have allowed Technofast to introduce products which are now in use on equipment such as that used in power generation, mining and shipbuilding in many countries.

The building of international relationships is a necessarily costly exercise, with a great deal of travel and consultation with partners in foreign destinations.

These relationships are critical to the acquisition of critical design data, as well as access to customer lists, machine populations and location data.

Many of the OEM relationships have included sales and distribution of

Judges’ Comments “The judges felt that relationship building has clearly been key to the international success of Technofast Industries. They concluded that the company is a role model for other companies considering an international presence.”

Technofast products to their customers by the OEM directly.

Technofast does make considerable budget allocation for such costs annually. These expenses are necessary as, in its experience, foreign businesses are generally very receptive to efforts to establish close relationships with Australian suppliers.

Technofast has continued to integrate itself with supply chains internationally, and is currently engaged in negotiations for specialised and general product supply and distribution with companies located in the United Kingdom, Korea, Russia and the USA. This Endeavour Award follows Technofast’s success in 2014 in the Australian Steel Innovation category.

Technofast Industries 07 3375 1431 www.technofast.com manmonthly.com.au

MA0415_000_ICN

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EndeavourAWARDS

PROUDLY SPONSORED BY

AUSTRALIAN INDUSTRIAL PRODUCT OF THE YEAR

ANCA FX LINEAR TOOL GRINDER RANGE The overall Manufacturer of The Year, ANCA, also won in the Australian Industrial Product of The Year category, for its FX Linear tool grinder range.

The FX range consists of three new machines - the FX3 Linear, FX5 Linear and FX7 Linear.

The entry level range is ideal for tasks from light manufacturing, to regrinding and full production. Its many new features include a new touchscreen customisable with Windows, handheld pendant for easier set-up, and an easy to access front loader door for slide out pallets.

“The real measure of success I have with ANCA is whether or not we’re selling our products in the field,” co-founder Pat Boland told Manufacturers’ Monthly after winning the award.

“We’re exporting precision grinding machines from Melbourne to Switzerland, to Germany, to Japan, to US, China,

Holland, Sweden, Russia – that’s the measure of success, really.”

The company has seen great acceptance in the field of FX at this early stage after releasing the new range late last year. It adds to ANCA’s export success, with 99 per cent of what it makes exported.

ANCA developed its own LinX cylindrical linear motor technology for X and Y-axis movement on the new machines.

These provide superior surface tool finish, reduced cycle times and increased productivity.

The company’s strength is producing machines that are versatile, precise and user-friendly.

The easy-to-use software is also a key feature of their machines. Key industries such as aerospace, medical, automotive, tool manufacturers and electronics are supported through a global network of offices and agents.

The FX Linear tool grinder is compact but also has a large working envelope.

Every part on the machine, from the two choices of automation – both contained

The machines take up less factory space than competitor units.

26 JUNE 2015 Manufacturers’ Monthly

Pat Boland, co-founder, ANCA, and Chris Barnes, General Manager, Gases Product Management, BOC. within the canopy, to the new AM5000 control system, has been designed to enhance accuracy and increase productivity.

The range consists of three machines (FX3 Linear, FX5 Linear, FX7 Linear) that grind a variety of tools from blanks (or regrind used tools) such as endmills, ballnose, etc for tool manufacturing companies, or specific industries (such as automotive, or electronic).

The machines take up less factory space than competitor units, but still have a large working envelope allowing a wide range of tools to be made. Also saving space is the fact the two choices of automation (including a robot) can be inside the machine Every element of the machine is new - hardware, software and the electrical system. The machine includes new, faster electronic drives and CNC, a new customisable user panel and Graphic User Interface.

Pat McCluskey, the co-founder (with Boland) and team leader, threw out the corporate rule book and developed a more lean and agile way to develop this project to maintain innovation and design speed for the radically new ideas in this project.

McCluskey pulled together a core group to work on the FX Linear machine, while another group developed the LinX

Judges’ Comments “The judges were impressed by the fact that the FX Linear tool grinder range offers the latest technology available and therefore provides the market with something new. Other pluses are the fact that it saves on space and does not require its own dedicated cooler unit.” cylindrical linear motors required for the machine.

This technology was new to the company. For the first time the company used an agile methodology called ‘Fast Track’, a sub-branch of concurrent engineering which aims to get things happening in parallel. Management reviews were replaced with peer reviews, rapid hypothesis testing was included and enough time was built into the schedule to experiment with new ideas.

They had working FX Linear prototypes on the floor in 10 months which would normally take over 18 months.

ANCA 03 9751 8200 www.anca.com manmonthly.com.au

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Supporting innovation and success BOC is the proud sponsor of the Australian Industrial Product of the Year category in the 2015 Manufacturers’ Monthly Endeavour Awards.

It is fitting that we supported the category which recognises innovation in new industrial products, as it is something that is very close to our hearts at BOC and an important hallmark of our own business.

At BOC, we aim to be admired for our people, who provide innovative and sustainable solutions that make a difference to the world. These awards reflect and promote the same kind of spirit, and we acknowledge the terrific efforts of all entrants who share our passion to excel.

BOC wishes to congratulate the winners of the 2015 Manufacturers’ Monthly Endeavour Awards, particularly ANCA Pty Ltd for winning the Australian Industrial Product of the Year category for their KX Linear tool grinder range. We encourage all businesses, big and small, to strive for continuous improvement with commitment, courage and creativity.

BOC Limited

Riverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 Australia boc.com.au |131 262 BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2015. MP15-0093|ML|MM|0615

facebook.com/bocsouthpacific

A Member of The Linde Group

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EndeavourAWARDS

PROUDLY SPONSORED BY

YOUNG MANUFACTURER OF THE YEAR

BRYAN EMMERSON MACHINERY AUTOMATION & ROBOTICS Bryan Emmerson has helped create significant value, both for his employer and for the red meat industry.

The young engineer has displayed exceptional proficiency in a number of areas, and was put forward for three projects he helped complete in his first 18 months.

These were a “3D modeling project for the Red Meat Industry”, “iPad Apps for the Red Meat industry”, and “Product development of Bandsaw operator aid for the Red Meat Industry to reduce the risk of serious injury”.

“The judges were impressed by the broad range of Bryan Emmerson’s achievements, particularly his 3D modelling project for the Red Meat Industry,” the Endeavours’ panel commented in their judgement.

In the modelling project, Emmerson researched and utilised commercially available 3D modeling software to create 3D models of meat cuts, primal and carcasses.

The ability to produce these 3D models has supported and assisted MAR with the development, adoption and commercialisation of automation within the Red Meat processing through enabling 3D models to be created and used for the design of automation components, and through enabling 3D models to be created for use in presentations, documentation, 3D layouts and simulations.

The iPad Apps for the Red Meat industry effort increased adoption of MAR robot systems developed for the red meat industry and has driven a need for improved technical support and management mechanisms.

As a result, Bryan developed three iPad applications aimed at providing support to management and maintenance staff by enabling them to successfully keep their systems functioning with minimum assistance from MAR service. The three apps developed are • Red Meat Remote – suitable for enabling management to monitor the robot system remotely; • Red Meat Service Tool – enables maintenance staff to report issues and send to MAR via email complete with video, photos and faults logs from the robots; and • Red Meat HMI APP – allows maintenance staff to constantly monitor the cell and quickly identify any issues.

The other project was in product development of Bandsaw operator aid for the Red Meat Industry to reduce the risk of serious injury. Emmerson further developed early generation software for Bladestop to the point where the Bladestop product has now been commercialised.

BladeStop reduces the risk of serious injury by mechanically stopping a bandsaw blade when the unit senses

Bryan Emmerson, a young engineer displaying a “high degree of initiative, innovation”.

28 JUNE 2015 Manufacturers’ Monthly

Thomas Hughes, Emmerson’s co-worker, and Daniel Noonan, Managing Director, ECi Solutions. a person has come in contact it.

Upon sensing contact with the operator, the blade stops operating within 15 milliseconds – which can make a huge difference between just having a small skin cut and an amputated finger.

All of these projects, said MAR, showed “a high degree of initiative, innovation, and technical competence under the guidance of senior MAR Automation Engineers”.

Under the mentorship of Project Engineers and the Electrical Engineering Manager, Emmerson carried out tasks including design a functional specification; designing panel layouts for enclosures, control stations and terminal boxes; designing and producing electrical circuits using AutoCad – ElecDes; carrying out PLC, HMI, Robotic, Vision & SCADA programming; researching the use of new products including how they work and technical information re-implementation; and installing and commission projects, locally, interstate and international when required.

Asked what might be done to grow innovative companies such as MA&R, the company’s Thomas Hughes (accepting the award on Emmerson’s behalf) said that “… it comes back to the grass roots of manufacturing and what the industry needs in regards to support from the government.

“We’re a very passionate industry, and we work very hard on our trade. And I think we need support from all the areas of

Judges’ Comments “The judges were impressed by the broad range of Bryan Emmerson’s achievements, particularly his 3D modelling project for the Red Meat Industry. They said he has already shown himself to be proficient in his chosen field and he appears to have a solid future ahead of him.” government to ensure that manufacturing stays vibrant within this country.”

Another important ingredient for success was staying up to date with what was going on outside of the country.

“Small manufacturers like ourselves - we need to have access to the different aspects of cutting-edge technology and innovation from overseas,” Hughes said.

This awards caps an impressive showing by MAR at the Endeavours.

Two of Emmerson’s co-workers - Daniel Egan-Wyer and Hughes – qualified as finalists in the Young Achiever category, and BladeStop made the finalists’ list in the Safety category.

Machinery Automation & Robotics 02 9748 7001 www.machineryautomation.com.au manmonthly.com.au

MA0615_000_ECI

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1

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Leading ERP software for growing manufacturers

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ECi, M1 and the ECi Red Box logo are trademarks or registered trademarks of ECi Software Solutions, Inc. All rights reserved.

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EndeavourAWARDS

PROUDLY SPONSORED BY

MOST INNOVATIVE COMPANY

PLASTIC FORESTS GREENMONGREL RANGE OF RECYCLED PLASTIC SHEET PRODUCTS Quietly chipping away since 2010 at a task many experts believed was impossible, Plastic Forests launched last year and has achieved many successes since.

The problem of contaminated plastic film is one that many thought too difficult to tackle. Only 4 per cent of it is re-used, the rest of it ending up in landfill.

Getting it back to a usable quality is achievable, but requires great effort and a lot of water. Each kilogram of film treated needs about 6 litres of water to be wet washed.

The low rate of recycling is explained by the uneconomic nature of doing so.

Among other things, Plastic Forests has been awarded the Most Innovative Manufacturing Company for being the first company – in the world – able to recycle dirty film (landfill rescued) at a commercial scale.

“I think if you’re going to be advanced you have to be in front of the pack, and if you’re going to be in front of the pack

that means you’ve got to ask ‘a better question,’” David Hodge, the company’s director, told Manufacturers’ Monthly after claiming the award. “[And] if you can solve an existing problem better, better than anyone else globally: then you’re going to be at the front, added Hodge.

In only a short amount of time, they have gained several clients – some of them multinationals – for which they treat plastic back up to a reusable standard.

The company not only provides a service to manufacturers, but is a manufacturer itself, with its GreenMongrel range of underground cable covers and garden edging products distributed through Tapex. These are made from film using PF’s in-house process.

It also manufactures other high value products such as garden edging, builders’ film, garbage bags, and plastic resin pellets for the plastics industry. All made from previously unrecyclable plastic film.

A high-tech recycler and manufacturer of plastic products.

30 JUNE 2015 Manufacturers’ Monthly

David Hodge, director, Plastic Forests, and Nick Lobianco, General Manager, SEW Eurodrive.

The Endeavour Awards winner for Most Innovative Manufacturing Company began five years ago as a small team of inventors, chemists and manufacturers with a promising prototype process for dry cleaning plastic film.

The process was refined the next three years to remove the many contaminants that were in the plastic waste, anything from metal, food or glass, down to the micro-contaminant level.

Problems were separated through chemical engineering to their macro, micro, and molecular levels, said Hodge.

“By being able to do that, in a functional way, was part of the steps to the solution,” said Hodge. “Not one thing – but the steps to the solution.”

Trials for producing underground cable cover and garden edging from cleaned plastic film began in 2013. Trials was undertaken to develop a product that could meet Australian Standards.

Production commenced at the beginning of 2014, with a national distributor in place. However, in June 2014, the advanced waste treatment facility decided on another use for their contaminated plastic film, and this supply of mixed municipal film ended.

Prior to the Endeavour Awards, they had received other honours during their brief existence, including being contacted by the United Nations Division of Technology, Industry and Economics

Judges’ Comments “Plastic Forests scored a world first. The company managed to come up with a dry cleaning process for recycling contaminated plastic film before anybody else did. As such, the judges said, this company ranks as a world leader in the important field of waste management.”

Environment Programme, and being named in the top five waste management stories (world-wide) in 2014, by Eco-Business magazine.

On the country’s potential in advanced manufacturing, Hodge said there’s no reason why it can’t flourish. We just have to ask the right questions and then go from there.

“I think we’ve got a bit of an attitude problem,” he said, referring to ideas about Australia being unable to produce competitive manufacturing businesses.

“I think that we ask really great questions and we come up with really great answers and great outcomes.”

Plastic Forests 0405384030 plasticforests.com.au manmonthly.com.au

MA0615_000_SEW

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SEW-EURODRIVE – Driving the World

Congratulations to Plastic Forests for winning Most Innovative Manufacturing Company

Why do manufacturers turn to SEW? One of our core values is service. It’s this proud tradition of providing unparalleled service that forms the cornerstone of the company globally, and why we have a network of state-of-the-art facilities spanning across Australia. It’s also the reason why SEW-EURODRIVE is usually the first address when searching for drive technology to drive this great nation. Many household brands are secure in the fact that SEW is working quietly in the background ensuring a seamless path into the market place.

www.sew-eurodrive.com.au 1300 SEW AUS (1300 739 287) to be directed to your nearest office Melbourne (Head Office) I Sydney I Brisbane I Townsville I Perth I Adelaide

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2/06/15 8:18 AM

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EndeavourAWARDS IT APPLICATION OF THE YEAR

MANSFIELDS INFOMOTION ERP: A RECIPE FOR SUCCESS FOR MANSFIELDS Mansfields are a privately owned Australian company located in Victoria, with over 40 years’ experience providing dry food manufacturing services to an extensive range of clients, including some of the largest local and international food companies.

Mansfields is nationally recognised as the leader in the dry food contract manufacturing industry and has in place one of the industry’s most well-developed and highly effective food safety and quality assurance programs with HACCP accreditation.

Mansfields also offers research and product development services to its clients and, with its own strong engineering department, can tailor plant and equipment to suit a customer’s specific requirements.

Products include blending, sachets, display cartons, tubs, cns, DOY packs, P.E.T. bottles and jars.

The company has capacity for blending 16,000 tonnes of food products each year and is capable of automatically filling and sealing over seven million plastic tubs per year. In addition, its produces more than 124 food sachets annually.

Although some of Mansfields’ contracts are planned well in advance, the nature of contract manufacturing is such that the company’s services are frequently required

at short notice. Fast turnaround times are expected as a matter of course.

To support the agility essential in this environment, Mansfields recently undertook a major information technology upgrade, replacing its legacy manufacturing and accounting software with a new integrated enterprise resource planning system from InfoMotion.

InfoMotion’s Australian-developed solution met many of Mansfields requirements and although the system didn’t contain a quality assurance module, InfoMotion was willing to custom-build a module to meet the company’s exact requirements.

InfoMotion ERP takes a holistic view of an organisation’s requirements and delivers an end-to-end single platform software solution which is fully integrated for company-wide deployment and complete with highly automated workflow processes.

Integration, innovation and automation are at the core of its design and they provide organisations with the greatest efficiencies and best response times for key processes. This includes real-time tracking of data which in the manufacturing environment supports order completion, raw material replenishment and prototyping of food products.

At the same time, InfoMotion ERP is a “Formulations” based system rather than a

A “Formulations”-based rather than BOM-based ERP system was the way to go.

32 JUNE 2015 Manufacturers’ Monthly

Geoff Humbert, Managing Director, Mansfields, and Branko Miletic of Manufacturers’ Monthly. bill of materials-based system and is ideal for blends and food processing companies such as Mansfields.

InfoMotion ERP utilises ics Logistics, a modern enterprise-class management platform architecture that is highly scalable, flexible and with guaranteed longevity but possessing a low cost of entry. This means both development costs and hardware requirements are significantly lower than most of other solutions which use legacy databases or relatively obscure infrastructure and technology.

InfoMotion’s aim is to develop, as much as is possible, a fully paperless solution with advanced mobility functionality on readily available and relatively low cost technology and hardware such as wireless Windows Mobile devices, touch screen terminals or tablets.

Manfields required a system that would replace manual processes and automate the recording of production data all the way from the factory floor to the office. If data could be captured and reported in real-time, Mansfields would gain benefits in data accuracy, flexibility and resource efficiency. The company would also benefit from improved decision making.

“Certainly, commissioning an integrated external software build was a gamble for us,” says Geoff Humbert, Managing Director, Mansfields. “But the people at InfoMotion understood my business very quickly. They understood consumption of

Judges’ Comments “Mansfields’ introduction of InfoMotion and the resulting automation of previously manual processes has reduced demand on resources in administration by 30 per cent. The judges were impressed by the fact that the company is getting very close to being a paperless manufacturing site.” raw and packaging materials, formulations and bills of materials, and they got what I was trying to do. I was confident they could do it.”

Mansfields estimates that the introduction of InfoMotion and the resulting automation of previously manual processes has reduced demand on resources in administration by 30 per cent. Automation has also helped to improve the speed of data availability and accuracy of data being captured. The company is getting very close to being a paperless manufacturing site, with everything keyed into the system from the factory floor up.

Mansfields 03 9701 8711 www.mansfields.com.au manmonthly.com.au

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EndeavourAWARDS EXPORTER OF THE YEAR

PWR PERFORMANCE PRODUCTS PWR is based in Queensland and specialises in the design and manufacture of light weight, high performance aluminium cooling solutions.

The fast-growing Gold Coast company is a globally-recognised name in the world of motorsport. Its radiators, oil coolers and intercoolers are used worldwide by leading automotive race teams, as original equipment in some world leading cars, in military applications, and in the automotive aftermarket.

PWR designs and manufactures all its heat exchangers at its own purpose built factory and ships them globally. It exports in excess of 80 per cent of its sales with export sales having grown at an average 20 per cent per annum for five years.

UK and Europe account for 70 per cent of sales and USA 30 per cent. PWR has its cooling products in all major race series around the world from F1 to NASCAR to WRC to DTM with the majority of all teams in these series using cooling solutions.

PWR supply OEM products into low volume car production lines like the Porsche 918 Spyder. The company uses its own million-dollar wind tunnel to continually push the boundaries in cooling.

Many leading race teams visit Australia to validate performance on PWR’s wind tunnel test facility, plus measure

improvement from using PWR cooling solutions.

It started supplying into NASCAR in 2008, F1 in 2010, IRL in 2011, WRC in 2012 and found a ready acceptance from race teams for a cooling product that was built to their requirements with the all-important core designed and manufactured by the same supplier.

PWR set up wholly-owned subsidiaries in UK and USA and employed qualified sales staff to search for opportunities.

All design and technical specifications are controlled from the factory in Australia with significant exchange of technical data with the customer to validate performance requirements.

The company has evolved processes that also enable it to be hugely responsive to customers. When required to, it is able to custom-make a part and ship it halfway around the world in a week.

To keep ahead of the competition, PWR also spends over 7 per cent of turnover on R&D and tests new product developments on its in-house wind tunnel facility.

In the last 5 years PWR has doubled its staff to 90 people in Australia, sales have grown at 20 per cent per annum and exports now exceed 80 per cent of sales.

As success in race markets spread,

Its Ormeau factory includes a $1 m wind tunnel, used by race teams from around the world. manmonthly.com.au

PWR began supplying F1 teams in 2010. other customers like Porsche have been attracted to PWR’s unique blend of design, manufacture, product validation, quality and service. The ability of PWR to build to tight time frames and deliver anywhere in the world within days has enabled PWR to grow around the globe.

Its Endeavour Award is far from the first gong PWR has received for exporting. Their other achievements include the Australian Exporter of The Year (Small to

Judges’ Comments “PWR Performance Products, a manufacturer of high performance radiators, oil coolers and intercoolers, counts international automotive racing teams and the military amongst its customers. The fact that racing teams choose to come to Australia to use PWR’s testing facilities speaks volumes for its expertise.”

Medium Manufacturer category) at the Australian Export Awards in 2012.

“At PWR we always like to measure our businesses against similar businesses,” Marshall Vann, PWR’s General Manager, told Manufacturers’ Monthly, after winning the category.

“The Endeavour Awards is a great way to do this because you are judged against the best manufacturers in Australia.

To compete against the best and win the Exporter of the Year award is quite humbling.”

PWR Performance Products 07 5547 1600 www.pwr.com.au Manufacturers’ Monthly JUNE 2015 33

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EndeavourAWARDS LIFETIME ACHIEVEMENT

JOHN GUEST JUBILEE SPRINGS The winner of the Endeavour Awards Lifetime Achievement category has spent 41 years and counting at the family-owned Jubilee Springs.

The company was established before the Second World War, and moved from Camperdown to Ourimbah – its current location – in 1989.

Dating back to 1938, Jubilee Springs is Austalia’s longest running spring manufacturing company. With a solid track record over 75 years, Jubilee Springs is proudly owned and managed by the Guest family, descendants of the founder, John Guest Senior.

Jubilee is a rarity as an Australian spring maker, and one of the very few remaining.

John Guest Jr started in 1973 after father died, leaving school in year 9 to work at the business his dad started.

“I had to learn the right way and I worked right from the start of the place, sweeping the floors, right through the company,” he told an ABC interviewer on AM in 2013.

He has worked no shortage of different roles at Jubilee, becoming a fitter and machinist after starting, and has worked up from the factory floor up to running the company.

On the management side, he has overseen the decentralisation to the Central Coast, and managed the building of three new factories there.

He has been involved in the taking over of several companies, including 4 Slide Forming, Peerless Pegs, and C&K springs.

Guest even reintroduced an innovative, Australian-made mouse and rat trap to the industry after Standfield closed.

“Yes, the Government came to us and said that Woolworths and Coles were having problems getting a supply of mouse-traps so we redesigned the mouse-trap ourselves and we turned it into a recycled, recyclable mouse-trap,” he explained.

“And we probably sell between one and two million of those mouse-traps a year totally Australian made.”

Under Guest’s leadership, the company has grown from just five employers to over 40. It now sees its third generation heavily involved in the running of its operations.

Part of its longevity is due to investing in ways to stay modern, said Guest.

“The only way of keeping ahead with a world market is having the latest equipment, and we’ve always gone out around

John Guest manning the booth at National Manufacturing Week.

34 JUNE 2015 Manufacturers’ Monthly

John Guest, managing director, Jubilee Springs, and Manufacturers’ Monthly’s managing editor, Branko Miletic. the world to seek the latest equipment,” he told Manufacturers’ Monthly shortly after winning the Lifetime Achievement award.

“And at Jubilee Springs we have three of the latest spring coiling machines in the world, literally. So we’ve got to keep ahead of overseas with the technology, otherwise they’ll just leave us behind.”

On the topic of competing globally, Guest pointed out that there was a sad lack of recognition about the realities involved in doing so.

“I think the key to a lot of it is the philosophy as far as the level playing field is not happening and I think if we’re getting products out of countries that are so subsidised by their governments and we’re not, we should, I feel, be applying some sort of tariff to those particularly,” Guest said.

“Because the people aren’t getting paid what our people are getting paid, and we have a lifestyle in this country that we don’t want to lose, and we don’t want to have a lower [standard] economy as far as people not earning incomes.”

Deeply involved in his part of the manufacturing community, Guest is also the current president of the Australian Wire Industry Association and has been so since October 2013. Prior to this, he was Vice President of the same organisation for five years.

A non-profit organisation, AWIA was

Judges’ Comments “The judges were impressed by John Guest’s years of dedication to a successful family business.

Today Jubilee Springs is the longest standing spring manufacturing company in Australia. Much of that longevity can be attributed to John’s efforts.” formed in 1993 by companies as a merger of several groups (such as the Reinforcing Steel Manufacturers Association and Spring Manufacturers Association) involved in the sector to support the long term development and prosperity of the wire industry throughout the Australian, New Zealand, Pacific and South East Asian region.

Guest helped to establish the AWIA spring training course.

As an educator and mentor passionate about maintaining the skills to keep local manufacturing strong, Guest also has an ongoing commitment to investing in Australian apprenticeships and retraining.

Jubilee Springs 02 4389 1411 www.jubileesprings.com.au manmonthly.com.au

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Plant & MACHINERY MAINTENANCE Getting the most out of CMMS There is more to CMMS (Computerised Maintenance Management System) than just choosing a maintenance package. Alan Johnson writes.

W

HILE CMMS has been around for a number of years now, there are still manufacturers who do not fully appreciate the considerable benefits CMMS offers in streamlining a company’s maintenance operations.

Basically, CMMS helps organisations track the upkeep of their assets and associated costs of the work, with the ultimate goal of prolonging an asset’s lifespan at minimal expense.

This can include maintaining assets in a single facility or a range of facilities, or maintaining a group of equipment like a fleet of vehicles or other types of machinery.

David Powell, Director with Ampro Software, says that when setup correctly, a CMMS is a powerful tool that will assist in scheduling and monitoring jobs, budgeting, and preparing life cycle analysis for plant and equipment.

“And it is no desk anchor. A CMMS correctly structured will only require a little attention by the manager,” he said.

“Plus having maintenance jobs created in CMMS allows for ease of scheduling, making it effortless to move jobs around or to assign to workers, with simple reports showing what’s due when.”

Powell explained that a CMMS records the work that is being done.

“And if a job is extended over a period of days/weeks this is recorded, including who did it, when it was done, how long it took, and what inventory was used.

“A CMMS can also record how much the labour component cost and the total cost for the asset by a number of different methods including by job, cost centre, date range and budget versus actual. It can also record a company’s current stock on hand and value, reorder points, plus suppliers’ details.”

Powell says that by investing in a CMMS, companies ensure that their assets, plant and equipment are kept

manmonthly.com.au

CMMS a great tool in reducing unplanned downtime. in the best possible condition for the role that they play.

“It means companies are able to retrieve data without having to flick through folders and files. CMMS users have access to all jobs that have been completed, and still outstanding, as well as all the details that go with these jobs.”

More than maintenance Powell points to OH&S legislation, where records must be kept and easily accessible when required.

“Keeping them electronically is a quick way of presenting data quickly and efficiently. Because if jobs that need to be done are not documented and logged they only have lip service in the eyes of the law.

“You must have documented proof that work was carried out on

time and by a qualified person,” he said.

Powell says it is important companies understand the responsibilities of Engineering/Maintenance Managers.

“For example, if something was to happen, an equipment failure, or an accident, who is the first person questioned; why and how could have it been prevented, and what steps are in place to prevent this?

“Having the ability to keep the asset in safe working condition, while ensuring the correct qualified person is doing the job is the answer.”

According to Powell, maintenance managers need to have more input in CMMS purchasing.

“The finance department often governs the purchase, which in most cases is based on price, unless the

argument is put forward in a well presented submission.”

Powell warns that whenever an accident happens in Australia, where there is an injury or death, Work Place Health and Safety will investigate.

“And if the victim sues, it all comes back to how good the company’s records are,” Powell said.

He points out that a CMMS can also be used to assist in the preparation of the next budget.

“Tracking the jobs, the costs etc. by asset and the workers who carried out the work, CMMS users have the ability to quickly put together a structure for the budget.

“This helps in asset purchase requirements and resource requirements (both in-house and contract labour), and the amount of inventory to stock.

Manufacturers’ Monthly JUNE 2015 35

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Plant & MACHINERY TOOLS “Keeping stock levels to a minimum and ordering just in time will see a savings in the cost of materials on hand,” Powell explained

Choosing a CMMS According to Powell, selecting a CMMS is just as important as using any other tool that is required to do a job.

“If all users are going to do is record history on assets then they do not need to spend hundreds of thousands of dollars buying a CMMS that links into the mainframe finance system, or any other of the features that these systems can have.

“It is important to select a CMMS that will do what is required, but also will allow for growth as company requirements grow.”

Powell says reporting is an important part of a CMMS, and is critical the information is available as quickly and accurately as possible, with the capability of filtering the reports so not to have too much information.

“Plus a CMMS must have the ability to suppress the lower frequency jobs for the same asset if two or more Preventative Maintenance (PM) procedures are due around the same time.”

Powell says it’s also important not to have too many people involved in the selection process, which can over complicate things.

“Just stick to the key players, the maintenance manager working with IT to ensure an adequate system is selected, and sits well on the company’s system.

“Companies sometimes get tied up trying to find a system that will do everything. Remember, if your company eventually goes to an enterprise system, then it is a simple process to transfer CMMS information into an enterprise system.

“But in the meantime sending reports and exporting figures from within the CMMS is just as efficient because the system is normally easier to use and that means it will be used,” Powell said.

Getting a CMMS approved As with most asset approvals, getting the package together for submission to management is a potential stumbling block.

36 JUNE 2015 Manufacturers’ Monthly

Users can access info on jobs completed and outstanding.

Powell says one of the biggest problems he encounters is not enough investigation and preparation being done when going into bat for a CMMS. “Management wants facts and figures, including how many jobs need to be done to ensure a site complies with state and federal legislation.

“This can be done by preparing all the PMs and inspections and assigning approximate durations and skill levels required to each, then prioritising them.

“Then you go through them all again and confirm that these are absolutely required for OHS and safe working of the equipment.”

Powell says it is vital to use accurate figures. “If you fudge them and get caught out, then the whole exercise will be for nothing.

“We all know that when it comes time to carry out maintenance work, things go wrong or people get called away. This is an ongoing problem and we should not budget for this but have an understanding that it does happen from time to time.

“It is important, management understands what is expected and what is achievable with the tools you have.

As Powell explains, a CMMS will ensure that the scheduling and resourcing of maintenance jobs is done quickly and efficiently.

“However, if management tells

you not to do certain items, have that in writing.

“You have stressed the importance of the maintenance, now it is management’s call to do it or not. Doing this yourself is a much bigger decision than just saying ‘not this week I’ll try and get it done next week’.”

Powell’s way of looking at this is asking finance for $100 and seeing the amount of hoops employees need to jump through to get it.

“Assigning work to trades should be no different. It is your authorisation to work on plant or equipment.

It needs to have the procedures for them to follow marked clearly on the order prior to them picking up any tools as well as any safety concerns risk assessment on each job.”

When it comes to the architecture of the system, Powell says database choices range from Microsoft Access through to Oracle, Microsoft SQL Server, all of which add additional dollars onto the cost of the system.

“Microsoft Access database is OK if the number of concurrent users is low (less than 5), while Microsoft SQL Express is a good option for larger system requirements without the need for Microsoft SQL Server licensing.”

Powell says it is important the maintenance department works closely with IT for they know the company’s network better than anyone.

“Even if you plan to only run the CMMS on a stand-alone PC, ensure back up procedures are in place,” he said.

Powell says when CMMS systems are implemented correctly, with procedures for staff to follow, they have an excellent ROI. However, he points out that it is not about just buying the software where the costs are.

“The budget needs to include the data collecting, data entry, maintenance procedure development and then triggering so the system will automatically activate jobs when due.

“This can be accomplished by inhouse staff or the use of consultants that specialise in this area.

“Then you have a management system that will not only assist in everyday scheduling but save money in the control of the work force and the management of inventory,” Powell concluded.

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

Ampro Software 1300 174 172 www.amprosoftware.com.au manmonthly.com.au

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Hydraulic nuts slash loader maintenance times

By ALAN JOHNSON A NEW generation hydraulic bolt fastening technology has enabled operators of a 5000TPA loader to tension bolts during slew bearing replacement more than five times faster than by using conventional torquing or hazardous manual methods.

A total of 72 specially designed Technofast EziTite hydraulic nuts were used to tension grade 12.9 studs that secure the slew bearing of the loader.

Simultaneously tightened in groups of four to enhance precision, speed and safety, and cut load scatter, the hydraulic nuts are rapidly applied by being placed onto bolt studs and hydraulically actuated to stretch the bolt to the precise tension required then locking it in place mechanically with a lock ring. The reverse procedure permits equally rapid disassembly when it is eventually required.

Technofast CEO, John Bucknell, said M the A EziTite 0 6 1 5 hydraulic _ 0 0 0 _nuts K Eare E ideal for maintenance applications by

The EziTite hydraulic nuts were simultaneously tightened in groups of four to cut load scatter.

Bucknell explained that on the tensioning all the studs on a flange, joint or cover simultaneously; loading loader, the EziTite nuts were simply placed in position by hand then entire groups of fasteners at once. groups of four were linked together “This simultaneous tensioning and pressurised simultaneously, regives an extremely accurate and even ducing bolt load scatter and offering load onto the flange/joint, enhancits0long 1ing 2 1 5 term - 0 5security, - 2 7 Tsafety 0 9 : and 4 9 : 2 dramatic 8 + 1 0 :time 0 0 savings.

He said using torque wrenches, for reliability.”

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example, would have taken about 30 minutes to tension four bolts, whereas the EziTite fasteners completed the task in under five minutes.

“Also, there are no pinch points associated with Technofast tooling and it does not need to be handled whilst being pressurised, eliminating inherent health and safety hazards,” Bucknell said.

He then explained that the EziTite nuts also overcame bolt load scatter problems commonly encountered with standard slew bearing replacement procedures using torque wrenches.

“Bolt load scatter, due to a single bolt being fastened at a time, could have caused undue wear on the slew bearing, leading potentially to downtime on this particular application and on scores of others where slew bearings are mission-critical,” Bucknell said.

Technofast Industries 07 38375 1431 www.technofast.com

experts focus on customer challenges and

trust Keech products for the toughest work in earth.

www.wearpact.com.au

Manufacturers’ Monthly JUNE 2015 37

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SPONSORED CONTENT

Analysing Thread Treatment Options

By Andy Bardon, Senior Application Engineer, Henkel Corporation

Proactively treating threaded pipes and fastener with thread treatment products is critical to efficient and cost effective manufacturing. A major cause of industrial equipment failure, threaded fastener loosening results in millions of dollars of unscheduled downtime costs each year. Similarly, more than a billion litres of industrial fluids are wasted through leakage each year. Beyond the value of lost fluids and gases, leaks affect toxicity, emissions, safety, contamination and personnel.

Threaded fasteners set and hold tolerances on assemblies ranging from light-duty equipment to heavy machinery. To ensure reliable performance, it’s imperative that the specified tolerances hold during the equipment’s entire service life.

To lubricate, protect, seal and hold threaded fasteners to their original tolerances, various forms of thread treatments are used to increase an assembly’s reliability. Thread treatments are placed into three categories: thread sealants, thread lockers and anti-seize materials.

Threadlockers Threaded fasteners continually receive various types of differential stress.

Stresses such as vibration and shock, thermal expansion and contraction, and micro-movement of the fastened parts all can reduce clamping force and, ultimately, cause machine failure.

Many mechanical devices such as spring washers, wire retainers and locking bolts were created in an effort to prevent uncontrolled fastener loosening. These mechanical locking methods add significant cost to the fastener assembly, yet can’t reliably prevent loosening due to the side-sliding motion that causes self-loosening. They also don’t seal or prevent corrosion within the assembly

Threadlockers, available in different strengths for different applications, allow threaded fasteners to maintain critical clamp load pressures even in extreme environments.

and must be sized appropriately for the specific fastener.

Applied drop-wise to fastener threads, liquid anaerobic products fill the grooves of the threads and cure to a hard thermoset plastic when exposed to active metal ions in the absence of air. Locking the threads together prevents unwanted movement or loosening of the fastener and seals the threads, preventing leakage or corrosion.

Although a properly prepared surface ensures the most consistent threadlocker performance on bonded assemblies, advancements in anaerobic technology have delivered unique products that limit the need for thorough cleaning and surface preparation. New formulations for threadlocker such as LOCTITE 243 and LOCTITE 263 now cure on inactive metal surfaces, tolerate oily surfaces and allow cure speed to be specified. Surface primers are only required when using conventional liquid products on challenging applications

and substrates. Threadlockers can help prevent common failures such as misalignment (where there is a loss of clamp load). When shafts for gearboxes and motors are aligned, you must properly torque the mounting bolts to maintain proper alignment.

However, over time these mounting bolts can loosen due to vibration, thermal expansion and contraction, or shock. This results in a loss of clamp load and, ultimately, misalignment.

Proactive use of liquid threadlockers helps to maintain clamp load in this example and prevent misalignment.

Threadlockers, available in different strengths for different applications, allow threaded fasteners to maintain critical clamp load pressures even in extreme environments. These adhesives offer high shear strength, very good temperature resistance, rapid cure, easy dispensing and excellent vibration resistance. New anaerobic formulations are available including surface-insensitive varieties, high-temperature formulations for

exposures up to 230°C, chemically resistant materials and formulations engineered to withstand severe vibration. Certain threadlockers such as LOCTITE 2620 and LOCTITE 2422 are capable of temperature resistance up to 350°C. Contrary to common belief, any bolt previously locked with threadlocking adhesive may be reused simply by removing old adhesive before applying new threadlocking material and reassembling. Threadlockers are available in low-strength formulations for easy removal, medium-strength grades that can be removed using common hand tools, and highstrength formulations that offer the highest holding abilities. However, no threadlockers are completely permanent; even the highest-strength threadlockers can be removed using standard hand tools following direct exposure to 230 to 260°C for about five minutes.

You can remove significant amounts of old threadlocker residue by using a

ons

emically mulations vere kers such TITE 2422 resistance

lief, any bolt adlocking mply before material ockers are mulations strength d using ghoffer the wever, letely st-strength ved using ng direct for about

ant amounts by using a

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stiff brush. Light levels of threadlocker residue are compatible with the next application of threadlocker, as long as they do not restrict the re-installation of the fastener.

Thread Sealants Most leaks are traced to pipe joints.

Threaded joints in piping are necessary evils. Pipe system designers seek to reduce the number of joints wherever possible, but without joints that can be dismantled, each repair would require the removal of massive pipe links. Despite the standards created to maintain uniform fittings, tapered pipe threads are imprecise; and during the course of use and repair, the threads can become damaged and even more vulnerable to leakage. The area where the crest and the root of the thread meet forms a spiral leak path. No amount of tightening will eliminate this.

Thread sealing is an attempt to block this leak path in pipe connections.

Mechanical thread sealants include a variety of products such as sealing tapes, dopes, pastes, O-rings and cone fittings. While effective, these pipe sealing methods create problems over time.

Tapes act as a lubricant only and can shred, may clog pipes or even cause over-tightening, which can damage threads. Tapes are manually applied, limiting automation of the application, and offer poor vibration resistance due to their slick surface.

Most pastes contain solvents and exhibit creeping and shrinking problems as they dry. Such problems limit their chemical and vibration resistance. O-rings require large inventories and a special joint design, and may be easily damaged during handling or assembly. Machined cone fittings require costly machining and are easily damaged.

Thread sealant adhesives are liquid to past-like products that are easily applied, and cure through an anaerobic reaction. Like anaerobic threadlockers, thread sealant formulations don’t contain any volatile solvents that evaporate out of the threads over time and affect the long-term performance of a sealed joint.

These materials seal and lock threads at the same time, and act as a lubricant during assembly to promote tightening while ensuring

“

Threaded fasteners set and hold tolerances on assemblies ranging from light-duty equipment to heavy machinery.

unions and compression fittings, and provide exceptional fluid compatibility and sealing ability.

Threaded hydraulic fittings are a

Threaded hydraulic fittings are a common place for leakage... consistent assembly torque. Uncured thread sealant dissolves, eliminating the potential for contamination. Once applied, these materials provide instant low-pressure (500 psi) seals.

After cure, many formulations are rated to seal to pressures of 10,000 psi. Thread sealants also can seal pipe

New formulations such as LOCTITE 243 now cure on inactive metal surfaces.

common place for leakage. This is because alternative sealing products fail over time because of shrinkage (which results in a leak path) or loosening because the alternative sealant is really just a lubricant and does not seal the voids. Anaerobic thread sealants provide the best of both worlds by providing lubrication to help assemble the fittings and by sealing without shrinking to provide long-term seals.

Anti-Seize Anti-seize materials protect threaded and slip-fitted metal parts from rust, corrosion, galling and seizing at high temperatures. They also reduce friction, wear, and breakage on critical parts in the most severe operating environments.

These high performance anti-seizes (formulated with or without specific types of metal flake) help ensure that fasteners are easy to assemble and

disassemble. At the same torque, a consistent bolt tension is always achieved using anti-seize materials, even in performance extremes.

Specific formulations cater to the type of metal used for the threads, as well as temperature extremes.

Many products perform well in excess of 538°C and some perform in temperature extremes up to 1350°C. Anti-seize can be used on a furnace door hinge, for example, preventing the hinge from seizing in the harsh environment.

New Technology Recent advances in the stability and reactivity of threadlocking and thread-sealing materials have allowed the development of semi-solid “stick” formulations that complement liquid counterparts.

The sticks are very useful when an assembly operation is timesensitive or must be staged. Here, the threadlocking material is applied in advance without having to worry about it running off the part. Treated parts are then assembled all at once without time- consuming matching of mechanical locking devices or drop-wise application of liquid thread treatment.

LOCTITE Technical Hotline 1300 885 556 loctite.enquiries@henkel.com

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WomenIN INDUSTRY AWARDS Australia’s Women in Industry finalists A round-up of the women going above and beyond in Australia’s industrial sectors.

Last year’s inaugural awards saw more than 150 attendees.

M

anufacturers’ Monthly is proud to present the finalists for the 2015 Women in Industry Awards.

Last year’s inaugural Women in Industry Awards were a huge success, and with over 100 entries,

this year’s program is also proving to be very popular within the industry.

The Women in Industry Awards recognises and rewards the achievements of women working in the industrial sectors, and aims to raise the profile of women within Austral-

The awards run across 10 categories.

40 JUNE 2015 Manufacturers’ Monthly

ia’s industry, as well as promote and encourage excellence.

Manufacturers’ Monthly has teamed up with Australian Mining and PACE to acknowledge women who have achieved success through their invaluable leadership, innovation and commitment to their sector.

The program aims to recognise women who are leading change in their chosen field and breaking down the barriers in what can often be male-dominated industries.

The only national awards program of its kind to encompass mining, manufacturing and engineering, it also encourages the industrial world to raise the profile of women working in the differing sectors by embracing diversity and flagging clear paths for the next generation to follow.

And with so many thought leaders together in one room on the night of the awards, it provides a forum for women to meet and exchange

information, ideas and solutions to problems and offers individuals an opportunity to expand personal and business networks, maintain awareness of industry developments and make a contribution to other women in the industrial sector.

Any women working in the industrial sector can enter the awards next year, with this year’s event culminating with a cocktail event at the Ivy Ballroom in Sydney on Thursday, 25th of June.

CATEGORIES • BDM of the Year • Employer of the Year • Excellence in Engineering • Excellence in Manufacturing • Excellence in Mining • Industry Advocate • Marketing/Communications • Mentor Award • Rising Star Award • Social Leader manmonthly.com.au

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Platinum Sponsor

Excellence in Mining

After the success of the 2014 inaugural Women Mining Machinery Developments in Industry Awards, Pacific Merchandising has Australia ( MMD Australia) is a upped its commitment to the event. The company designer and manufacturer of material is the Platinum Sponsor for 2015. processing equipment used in Recognising excellence amongst women various types of surface and in male dominated industries is a great way to underground mining operations. provide inspiration and leadership for change.

In particular, MMD extended the Pacific Merchandising looks forward to wonderful technology of mineral degradation with entres from some of the innovative women out the original development of low profile there in the field. high capacity compact sizing machines Pacific Merchandising is an experienced in 1978. industry specialist supplier of promotional MMD Australia is an equal merchandising to Mining, Oil & Gas, Construction opportunity employer which and Transport and Australian Trade Unions. encourages women to join, not only in A one-stop shop with expert help from the mining industry, but also in the sourcing to art design, decoration to manufacture, varied industry sectors in Australia and and gift packaging to freighting, the company abroad. specialises in leading global brands and wholly Today the company celebrates Australian craftsman designed and manufactured the excellence women bring to our goods, such as custom belt buckles (and keyrings). environment and encourage all similar organisations to join it.

Pacific Merchandising 1300 88 77 95 MMD Australia www.PacificMerchandising.

07 3193 2800 M A 0 6 1 5 _ 0 0 0 _ K A E - com.au 1 2 0 1 5 - 0 5 - 1 3 T 1 2www.mmdsizers.com : 0 3 : 0 3 + 1 0 : 0

Excellence in Engineering ABB is one of the world’s leading power and automation engineering companies. It provides solutions for secure, energy-efficient generation, transmission and distribution of electricity, and for increasing productivity in industrial, commercial and utility operations. Ultimately, the company helps customers meet their challenges with minimum environmental impact and with safety and quality as the highest priority.

ABB’s portfolio ranges from light switches to robots for painting cars or packing food, and from huge electrical transformers to control systems that manage entire power networks, mining operations and factories. Its products and solutions serve a number of industries including mining, oil and gas, manufacturing, paper, transport, marine, consumer, automotive and building industries. Employing 145,000 people across 100 countries, including nearly 2000 people in Australia, ABB understands what it means to provide a workplace that is careerenriching and culturally safe. The company encourages individualism, values diversity and understands that culture forms part of everything it does.

ABB in Australia is proud to support the Women in Industry awards and recognises and acknowledges the value of a diverse workforce.

The company looks forward to playing its part at the event and wishes the best of luck to all participants.

ABB Australia 1800 222 435 new.abb.com/au 0

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Manufacturers’ Monthly JUNE 2015 41

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Women IN INDUSTRY AWARDS INDUSTRY ADVOCACY CHRISTINE KATIC – OPERATIONS MANAGER, BOC LIMITED As the Production Manager of BOC’s South Australia and Northern Territory Operations, Christine Katic is responsible for leading all activities related to these sites. She has excellent technical skills with a specialty in chemical engineering and a unique ability to work with all levels of business to achieve outcomes in often challenging circumstances.

In addition to this role, Katic was also the Head of Healthcare Operations for BOC’s entire South, Pacific business. She has played a significant role in advocating innovative solutions for use in the healthcare industry like the adoption of 3D Modelling for BOC’s installation of the medical gas pipeline at the new Royal Adelaide Hospital.

CARLI HOBBS – GENERAL MANAGER, GLADSTONE ENGINEERING ALLIANCE Carli Hobbs is an advocate across many different industries, but her passion is for companies based within the Gladstone region.

Hobbs works tirelessly between local industry groups, government departments and individual local businesses advocating the region and GEA member companies.

JILL FOLLINGTON – EXECUTIVE (FOUNDING) DIRECTOR, INDUSTRY MID NORTH COAST Jill Follington is passionate about manufacturing in Australia and is determined to see businesses and individuals succeed.

Her passion combined with her entrepreneurial spirit resulted in the formation of IMNC and continues to see the member organisations work together and learn from one another.

ELIZABETH LEWIS-GRAY – CHAIRMAN, AUSTMINE Elizabeth Lewis-Gray has been a stalwart of industry since 1996 when she co-founded Gekko Systems.

Since then, Lewis-Gray has grown Gekko to a multinational business and used her know-how to inspire others in the sector.

In 2013, Lewis-Gray was appointed as chair of Austmine, the peak industry body in Australia for the mining equipment, technology and services (METS) sector.

IRINA LINDQUIST – HEALTHCARE SOLUTION ARCHITECT, SCHNEIDER ELECTRIC Irina Lindquist has been an outstanding contributor to the work of the Digital Hospital Design group (HISA) of which she is a key member.

The group’s objective is to broadly influence the way in which technology is applied in healthcare, enabling high quality, people centric and cost effective care.

KYM CLARKE – FOUNDER AND DIRECTOR, SHE’S EMPOWERED Having worked as an accountant in the mining industry for seven years, Kym Clarke understood the challenges women faced on-site with their workwear from a fit-for purpose, comfort and style perspective.

This inspired her to create the SE Workwear range.

With zero knowledge about designing and manufacturing clothes, Clarke spent weeks researching and ended up boarding a plane to Asia to find a manufacturer.

Since the brand launch in November 2013, the SE Workwear collection has rapidly gained traction with Clarke now having regular involvement and engagement across the gender equality debate through keynote speaking and media.

SUZANNE DAUBNEY – MANAGING DIRECTOR, BANNISTER DOWNS DAIRY Suzanne Daubney has consistently proven herself to be a tireless and passionate advocate for the agriculture and food sector, and her contributions to the industry are plenty through her representation on numerous boards and committees.

Daubney is an excellent example of a business woman with a bold, passionate and powerful vision not just for her business, but also for the local community she lives, the people she employs and the industry she propels forward for the betterment of all Australian dairy farmers.

BDM OF THE YEAR CARLY BRADSHAW – BUSINESS DEVELOPMENT AND OPERATIONS MANAGER, AUSTRALIAN DUST CONTROL Carly Bradshaw is responsible for the design and functioning of the entire business and has created the systems that sustain and operate the company, providing Australian Dust Control with the framework to source and service new business. Specifically, Bradshaw has created mul-

tiple one-off and ongoing sales campaigns, which the company execute to generate fresh leads and maintain existing client relationships.

CARRIE HARTFORD – SENIOR ENGINEER, JENIKE & JOHANSON In January 2012, Carrie Hartford moved her husband and three children from California USA to Perth to establish a new engineering office and lab facility for Jenike & Johanson (J&J). J&J is a specialised bulk material engineering firm with expertise in powder and bulk materials storage, handling, conveying, and processing. Hartford arrived in Perth to an empty office and warehouse. Soon the office and lab were filled with state of the art solids flow characterisation equipment.

EMMA COOK – BUSINESS DEVELOPMENT MANAGER, AGILITY PROJECT LOGISTICS Emma Cook has implemented a strategy of aggressive targeting of focused markets through in depth research of perspective clients business drivers, and facilitated the introduction of a solution-based sales approach, enabling clients to focus on increasing their market share.

SANDRA TAYLOR – TENDER MANAGER I&R EAST, LEND LEASE Since joining Lend Lease in October 2013, Sandra Taylor has developed and implemented a robust strategy for bids and tenders that is used across the business to support new business growth.

Taylor has driven a thriving team culture that is based

on open dialogue and team work. Tender submission quality and evaluation processes have increased as a result of Taylor’s leadership; and she has developed and initiated processes and systems for work winning, tender evaluation, quality and submission.

NICOLETTE HINSON – GENERAL MANAGER BUSINESS DEVELOPMENT AND STRATEGY, ELGAS Nicolette Hinson’s leadership, Elgas has significantly grown its liquefied natural gas (LNG) stationary energy business with revenues increasing some 2500 per cent since 2011. Hinson drove the signing of two major customers and expanded the sales personnel team to grow the LNG business in Queensland and New South Wales.

RISING STAR RACHEL HOGAN – ABB GRADUATE PROGRAM, ABB AUSTRALIA Rachel Hogan joined ABB’s Power Conversion business unit during her first 6-month rotation within ABB Australia’s Graduate Engineering Program.

Hogan has contributed to ABB’s power Conversion business unit in many ways. She utilised her engineering expertise to set up the technical parameters of a

42 JUNE 2015 Manufacturers’ Monthly

substantial solar inverter installation at the site of a large global manufacturing organisation.

SALLY MAYBERRY – ENVIRONMENTAL ADVISOR, ORIGIN ENERGY Sally Mayberry’s role determines environmental risks, deciphers legislative requirements and works towards implementing on-ground solutions. A business critical supply chain issue occurred early 2014 and Mayberry was called upon by Origin’s field operators to coordinate the urgent sampling of 14,000 soil and drilling mud samples. All drilling rigs were stood down in response to the HSE risk at significant monetary and scheduling cost. At this point Mayberry’s role was critical to the success of the taking this action.

Using her environmental knowledge and relationships

with internal and external stakeholders and service providers, she was able to coordinate a response team of specialists to over 190 different sampling locations.

The eventual compliance outcome of the event was that waste transport was identified as a significant risk to the business.

KATE FRANCIS – CIVIL ENGINEER, HYDER CONSULTING Kate Francis is a Civil Engineer who graduated with First Class Honours from the Queensland University of Technology in 2012. She has a double major in Civil Engineering and Environmental Engineering. Since graduating, Francis has been employed at Hyder Consulting. Francis has worked in both the Urban Development and Transport teams. She has experience

in all facets of civil design, contract administration, preparation of cost estimates and independent verification.

KATE MACFARLANE – PRODUCT MANAGER, BOC LIMITED Since joining BOC more than four years ago, Kate Macfarlane has consistently achieved excellent results and helped develop strategies to grow BOC’s bulk business and delight its customers. She has been a key player behind expanding the supply chain of Ethylene in Australia for BOC South Pacific. Her contributions and work have not gone unnoticed, recently she was selected to take‐part in a round‐table forum with Linde BOC’s global CEO, which only a select few Australian employees participated in.

manmonthly.com.au

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Running the world without consuming the earth?

ABB is proud of its technology alliance with Solar Impulse, which is in the midst of its first round-the-world flight powered by the sun.

ABB has a long heritage of technological innovation in renewable energy, efficiency and sustainable transport. We are working to broaden the impact of clean technologies so that, together, we run the world without consuming the earth. www.abb.com/betterworld

Naturally.

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Women IN INDUSTRY AWARDS EXCELLENCE IN MANUFACTURING CHRISTINE MORRIS – HR DIRECTOR, JOY GLOBAL AUSTRALIA During her tenure at Joy Global, Christine Morris has seen the highs and lows of the mining industry with periods of record revenue to a period of business realisation where the market dropped significantly.

Morris has been able to effect the required changes to the business in this time whilst keeping the respect and support of her colleagues.

Morris was the mastermind behind the merger between two business units (Joy Mining Machinery and P&H MinePro) with distinctly different cultures and

the integration of a business acquired by Joy Global (LeTourneau).

SVETLANA ZATSEPIN – MANAGING DIRECTOR, COOLON LED LIGHTING Svetlana Zatsepin came to Australia in 1991 with her husband, children, and a budding love for a country that would become her new home. While learning English, she used her electronics engineering background to assemble and solder PCBs. Her meticulous attention to quality resulted in growing demand for production of PCBs, and soon her husband, Alex, left his occupation at Bosch to join her in a family venture, creating electronic circuitry designs while Zatsepin focused on production.

MICHELLE VINCE – GROUP RANGE DEVELOPMENT MANAGER, BLUNDSTONE GROUP Michelle Vince accepted an invitation from Centennial Coal to discuss improvements to existing range

of boots and consider developing a new underground mining leather boot.

After initial meeting with Centennial representatives and discussions around understanding the environments for which the boots would be required to work in, Vince along with colleagues spent days underground in operations in varying conditions, engaging coalface personnel to discuss issues with current boots on the market and what their requirements were to make the working day as comfortable as possible. Working closely with mining personnel and representatives, she lead development, trials and production of a completely new product.

COLLY GALBIATI – MANAGING DIRECTOR, SOMA ORGANICS In late 2012, Colly Galbiati launched premium snackfood company Soma Organics Pty Ltd. Galbiati is passionate about healthy eating and raising public awareness for quality organic food and nutrition and

through this passion, Soma Organics was born. In November 2012, Soma Organics started in the kitchen of her home where she begun hand making the (future) award-winning Soma Bite range.

Galbiati has developed 3 health snack bar ranges for the Soma Organics brand – the award-winning Soma Bite range, Your Soma Bar – protein bar; and the latest project Eco Bars – a raw energy snack made from cricket flour.

KAMINI WIJEKULASURIYA – MANUFACTURING MANAGER, WESTERN SYDNEY SERVICE CENTRE, BLUESCOPE Kaminin Wijekulasuriya is the Manufacturing Manager at BlueScope’s (BSL) Western Sydney Service Centre (WSSC), the company’s flagship COLORBOND Paintline. She is a successful and highly regarded operations manager in the business and has contributed significantly to BlueScope’s success in some of the most challenging parts of its operations.

EXCELLENCE IN ENGINEERING HAYLEY MCIVER – SENIOR PROCESS ENGINEER, AUSENCO Hayley McIver is a core member of the Ausenco process engineering team and provides professional and competent support to the work Ausenco does in coal.

McIver manages studies, does detailed process engineering and then goes to site to provide commissioning services and operator training to ensure the facility designed can achieve its design goal, or better.

McIver led the team to lift yields from 34.6 per cent to a peak of 42.4 per cent (May ’14 to Feb ’15). This has realised nominal revenue gains for the client in

delivering both a better product split (+USD$6.9M) and a higher coking yield (+USD$43.0M).

CHRISTINE CHARLES – HEAD OF SPACE PLASMA, POWER AND PROPULSION DIVISION, THE AUSTRALIAN NATIONAL UNIVERSITY Professor Christine Charles is a highly respected member of the Australian and international space industry. She is known for her technical excellence, her ability to translate research into innovative solutions for industry, and her dedication to mentoring students, in particular young women.

Prof. Charles is the Head of the Space Plasma, Power and Propulsion (SP3) Laboratory at the Australian National University. For the past twenty years, she has been working on experimental expanding plasmas (hot ionized gases) and their applications to electric propulsion, microelectronics and optoelectronics, astrophysical plasmas, and more.

Astrium, now part of Airbus Defence and Space,

started its collaboration with Prof. Charles’ team back in 2006 following her successful early tests of the Helicon Double Layer Thruster (HDLT).

Cecil Park manufacturing plant previously, there were very few established relationships, so she would need to quickly develop these to succeed.

CLAIRE BIANCO – ENGINEERING SUPERVISOR, CECIL PARK PLANT, CSR LIMITED In late 2014, the CSR Cecil Park site undertook a multi-million dollar upgrade of its facility to restore a previously mothballed section of its manufacturing plant.

The implementation timeframe and budget was an aggressive target and Claire Bianco, who was a recently new employee for CSR, was given the opportunity to take on the project manager role which she enthusiastically accepted.

The project would require the co-ordination of multitudes of external contractors, in-house operators and site engineering teams to work together whilst not impacting the existing ongoing manufacturing processes of the plant. As Bianco was not based at the

CARA RYAN – OFFICE MANAGER, BUILDING PERFORMANCE CENTRE, SCHNEIDER ELECTRIC For her part in in establishing the Australian remote service performance centre for Schneider Electric, Cara Ryan has been nominated for the Excellence in Engineering Award.

Schneider Electric says Ryan was responsible for providing customers with remote facility management support and the deployment of one of the most advanced building analytics solutions on the market.

Not only did she successfully start up this important new team and launch the analytics solution to the Australian market, she has taken it upon herself to understand the needs of Schneider’s customers and creatively solve problems.

networks and providing continuing professional development.

CEOs or managing directors of the largest manufacturing companies across the region.

She was also the founder of the first Regional Economic Board that has since inspired strong working relationships between the 6 LGAs in the region, a Regional Manufacturing industry Action Plan and also a plan for tourism, construction and transport and logistics.

SOCIAL LEADER TEAGAN DOWLER – FOUNDER, THE BLUE COLLARED WOMAN Teagan Dowler started a social media movement called The Blue Collared Woman (The BCW). The BCW is dedicated to supporting and empowering women to be confident leaders in the engineering, construction and resource industries.

The ethos of The BCW is to encourage women who work in these (and other masculine industries) to view 44 JUNE 2015 Manufacturers’ Monthly

their feminine side as a strength and remain true to their values, whilst being savvy and aware of the cultures they work within.

This platform exists as a website, blog, Facebook page, Instagram and Twitter account.

SAMANTHA KERR – SCADA, COMMS & PROTECTION IMPLEMENTATION ENGINEER, ENERGEX Samantha Kerr is a leading female engineer who has provided significant positive social benefit through her creation of the “Save Our Sanity” (SOS) interactive sessions in Queensland through Women In Engineering Qld (WIEQ), a special interest group of Engineers Australia.

The SOS program aims to retain women in engineering through fostering positive support

SUE WEBSTER – EXECUTIVE OFFICER, AGRIBUSINESS GIPPSLAND Since Sue Webster assumed the position of executive officer of Agribusiness Business, the group has transacted $750,000 in local, state and federal government assistance, as well as corporate support, all used for industry-good activities. In that time the group has been directly involved in the formation of five local agri-companies that employ 10-15 people.

JILL FOLLINGTON – EXECUTIVE DIRECTOR, INDUSTRY MID NORTH COAST Jill Follington is the inspiration and energy behind the first regional industry association that is led by 10

NICOLE BORKOWSKY – ASSOCIATE DIRECTOR, CDIF GROUP Nicole Borkowsky has been a member of the Women in Engineering Queensland (WIEQ) Committee since June 2013.

WIEQ is a group within Engineers Australia, whose objective is to attract, support, celebrate and retain women in the engineering profession. manmonthly.com.au

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Supporting leadership and success BOC is the proud sponsor of the Excellence In Manufacturing category in the 2015 Women In Industry Awards.

It is fitting that we supported the category which recognises excellence in manufacturing for women, as encouraging diversity in leadership is very close to our hearts at BOC and is a core value for our own business.

At BOC, we aim to be admired for our people, who provide innovative and sustainable solutions that make a difference to the world. These awards reflect and promote the same kind of spirit, and we

acknowledge the terrific efforts of all entrants who share our passion to excel.

BOC wishes all finalists the very best of luck in the 2015 Women In Industry Awards and encourages all businesses, big and small, to strive for continuous improvement with commitment, courage and creativity.

BOC Limited

Riverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 Australia boc.com.au |131 262 BOC is a trading name of BOC Limited, a Member of The Linde Group. Š BOC Limited 2015. MP15-0093|ML|MM|0615

facebook.com/bocsouthpacific

A Member of The Linde Group

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Women IN INDUSTRY AWARDS EXCELLENCE IN MINING MARIA JOYCE – GENERAL MANAGER, MEC MINING Just over 12 months ago Maria Joyce took on the challenge of the General Managers role for MEC Mining.

Through this position she is responsible for the leadership, mentoring and technical output of all of the Australian-based consultants both in the office and on site (35 permanent

staff and additional subcontractors). Joyce champions the culture within MEC Mining and this is something that she holds close to her heart.

The second major focus in her role that sets her apart from others in the industry is her strength in maintaining quality client relationships. Joyce has an exceptional ability to continuously keep the lines of communication open with clients and ensure that her team delivers trusted expertise and proven outcomes on each and every project.

GAIL CLAMP – SPECIALIST MINE MANAGEMENT, RIO TINTO COAL AUSTRALIA Gail Clamp currently holds the role of Specialist – Mine Management within the productivity division of Rio

Tinto Coal Australia. This role requires her to be involved with projects that drive optimisation within most areas of mining and work with multiple open cut sites within RTCA, to provide a common valuable output. In some cases she not only needs to competently learn about the technology involved but as well, bring together minds, work cultures, methodology, integration, site expectations and business objectives for a common goal.

KATHY ZUNICA – SENIOR GEOLOGIST, AMC CONSULTANTS Kathy Zunica was recently engaged by Ignite Energy Resources to work on the Gelliondale Project. Zunica was tasked to provide ongoing advice and bespoke

modelling and analysis on the deposit based on the resource estimate completed by AMC at an earlier date.

Zunica also received a rave review from the Geological Survey of Victoria (GSV) where she has provided specialist resource modelling and documentation services over the last two years.

STEPHANIE HARDY – ENVIRONMENTAL ADVISOR, MONADELPHOUS KT PIPELINES Not only is Stephanie Hardy working with the industry to ensure there is minimal environmental impact on the environment, she is also paving the way for fauna relocation techniques in the industry and providing the WA government with new records of species only found in the Pilbara.

MARKETING COMMUNICATIONS ROSALINDA WILLCOX – MARKETING COMMUNICATIONS SPECIALIST, BOC LIMITED Since joining BOC more than fifteen years ago, Rosalinda Willcox has consistently implemented effective marketing communication strategies to help grow BOC’s business.

The knowledge that she has gathered from working across different business divisions at BOC has meant that she is a regular “go-to person” for staff members who have a query related to marketing communications within BOC or a product in general.

NATALIE CHAPMAN – CORPORATE COMMUNICATIONS MANAGER, ALKANE RESOURCES Natalie Chapman and her communications team have enthusiastically brought a new way of communicating the complexities of Alkane’s Dubbo Zirconia Project and the job opportunities available to the local communities in the Central West.

This has assisted Alkane with its open and transparent way of doing business in forging new relationships, and cementing old ones, with members of the community of all ages.

SALLY DURRANT – COUNTRY COMMUNICATIONS MANAGER, ABB AUSTRALIA Sally Durrant has been described as a “breath of fresh air” to ABB’s Australian business around the marketing and communications area. An ambassador of ABB, her input to the Country Management Team is highly valued and has been described as refreshing.

Durrant and her team are the external voice of ABB to its customers, to the media, and to the Government, and ensure a consistent brand and a consistent message are maintained.

MENTOR OF THE YEAR CHRISTINE COTTON – REGIONAL GENERAL MANAGER, TCYO FIRE & SECURITY Christine Cotton is a strong advocate for the development of Tyco’s people regardless of gender, however her real passion lies with ensuring the company’s female M A 0 2 1 4 _ 0 0talent 0 _ not D Aonly T re-ceive career deve-

lopment opportunities but also in assisting them balance the many demands of life in general. Cotton has been instrumental in the establishment and ongoing development of Tyco’s Pacific Women’s Growth Network ensuring the program remains at the forefront of Tyco’s daily activities.

ASHLEA WALLEY – VTEC MENTOR/DSG SIMON BRADWELL – MANAGING DIRECTOR, PROGRAM COORDINATOR, WIRRPANDA EBM-PAPST A&NZ PTY LTD FOUNDATION Simon Bradwell was appointed Managing Director of Ashlea Walley works as a mentor with the Wirrpanda Foundation 1 2 0 in1 the 4 - Deadly 0 1 -Sista 0 7Girlz T 1program 5 : 4and 1 : 3ebm-papst 1 + 1 1A&NZ : 0Pty0 Ltd in 2005, and with him the company’s management approach changed. Now the Vocational Training and Employment Centre (VTEC)

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which has seen her work with young Aboriginal and Torres Strait Islander women and their families. She has demonstrated her dedication to the young Aboriginal and Torres Strait Islander women by supporting them through their training to secure sustainable longterm employment and create a positive relationship with employers for future jobseekers.

company has 66 per cent of the engineering team female and 50 per cent of the leadership team female whereas in 2005 all these roles were performed by men.

VANESSA SEWELL-ROSENBERG – TALENT & ORGANISATION DEVELOPMENT MANAGER, BOC Vanessa Sewell-Rosenberg is the Talent and Organisation Development Manager at BOC South Pacific and has been a vital member of the Human Resources division for more than six years. Sewell-Rosenberg has a passion for developing best-practice programs that have measurable outcomes.

EMPLOYER OF THE YEAR CABLEX At Cablex currently over 60 per cent of all staff members are female, well above the Australian engineering/equipment manufacturing average of 22 per cent. Women are also very well represented at management level and above, with 50 per cent being female.

Cablex’s COO and part owner Heidi Krebs is also a female. Cablex has developed many formal workplace initiatives which women find favourable in the work place including job redesign, flexible working options for those with family responsibilities, up-skilling and the appointment of talented women.

The company also provides many social opportunities

for the team which enable strong bonds and a high level of trust to be formed between all employees.

INDEPENDENT RACKING INSPECTIONS & AUDITS Independent Racking Inspections & Audits, under the leadership of Jayne Helding, has fostered a unique flexible working environment for the many women who have been attracted to and retained by the company.

IRIA is unique in providing a dynamic working environment by offering flexible hours and the option of working remotely to enable women to work that would otherwise not be able to due to restricted requirements.

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InsiderSERIES

GRANTS

Access an issue with industry grants Most industry programs have survived the Abbott government’s proverbial axe; however gaining access to them has never been harder. Alan Johnson reports.

A

QUICK search on the Internet for government grants for the manufacturing sector will reveal a far more streamlined approach than with the Labor Government, with all grants and assistance programs now lumped together under business.gov.au. While some have received questionable name changes, their contents are much the same.

Despite the Abbott government looking to cut some programs, and reduce expenditure, it has been forced to keep some programs open for longer than they would like. Instead of being able to cut programs, feedback suggests the government is now attempting to limit its outgoings by making it much harder for manufacturers to access them.

Mark Philips, Australia’s Head of Manufacturing with Grant Thornton one of the world’s leading organisations of independent assurance, tax and advisory firms, says the biggest frustration he has with the government’s grant programs is accessibility.

“The government opens up these programs for an available period so you can make submissions, but then closes them very quickly. They then go through a lengthy process of consideration.

“Programmes, which only open for three to four weeks, are not open for long enough to put together a well thought out, plausible case,” Philips told Manufacturers’ Monthly.

Hit and miss hurts industry Like a lot of large organisations, he says there’s a bit of hit and miss.

“The government likes to manage the programs through their bureaucracy (AusIndustry), who receive the applications, consider them, but don’t give any set time limits to deliver the outcomes of the application.

“Most times the process is outside the commercial speed of business.

“A company only has an opportunity when a government program happens to be open, and only if 48 JUNE 2015 Manufacturers’ Monthly

Other programs include the Certain Inputs to Manufacture (CIM) Program which provides import duty concessions on certain imported raw materials, intermediate goods as well as prescribed metal materials and goods.

While for the TCF industry there is the Clothing and Household Textile Building Innovative Capability scheme (BIC scheme), which provides grants for innovation activities for registered Australian clothing and household textile firms carrying out eligible activities in Australia.

Assistance schemes Government schemes are still handing out money to industry, it’s just more difficult to obtain. they can respond quickly enough, normally a short three to four week period in which they can apply.

Philips pointed to the Automotive Diversification Program (ADP) which opened and closed within three to four weeks.

“The applications had to be in by the end of April, a fairly complex process, but we won’t see an outcome until July or August.”

He says the present government is far slower than when Labor was holding the purse strings.

“And you never know how many rounds there will be. They will tell you the budget of the program, and then depending on the number of successful applicants determines whether there is another round of that program or not.”

According to Philips, there needs to be a consistent program in place that allows businesses to be able to look at opportunities in a commercial timeframe.

He also pointed to problems with the Automotive Transformation Scheme (ATS) with the government recently conceding that it would not take $500m out of the fund the program, which would proceed until 2020.

“Officially they have said that fund is in place but is only open until 2017, when the last vehicle is produced in Australia.

“But this is factually incorrect; the scheme does not rely on the vehicle producers and is open for other companies to participate.

“Unofficially, the administrators of the program, AusIndustry, are putting applicants through the wringer in an attempt to minimise the amount they can claim,” Philips said.

Manufacturing schemes As well as the ADP, there is also an Automotive Industry Structural Adjustment Programme providing redundant workers from eligible auto companies (including component suppliers) with immediate access to intensive employment support.

These programs are part of the $155m Growth Fund.

Closely linked is the Next Generation Manufacturing Investment Programme, a $60m competitive grants programme, which supports businesses that are investing in capital projects to establish or expand high value manufacturing operations in SA and Victoria. At the time of writing the program was closed.

One of the industry’s most successful assistance programs, Enterprise Connect, is still available, but now known rather clumsily as the Entrepreneurs Infrastructure Program.

The key components of the program remain, with up to $20,000 available to engage a skilled business adviser who will work one-on-one for up to 40 hours to identify areas of opportunity, at no cost.

Business advisers work with people throughout various operational levels of the business to develop a thorough view of, for example, the strengths and weaknesses of a business, strategic business issues and potential areas for business improvement and growth.

The Business Review is a collaborative process, with the business adviser and key people in the business working together to identify changes that could be made to increase the business’s competitiveness.

Each business receives a report outlining findings and recommended actions.

Once the company has the report, it can apply for a Tailored Advisory Service (TAS) government grant, which gives the company the chance to engage a consultant/s to make the improvements the Business Adviser recommended in the Business Review. They will reimburse your manmonthly.com.au

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business half the cost, up to a maximum of $20,000 (excluding GST), of engaging the consultant/s.

The types of improvements eligible for funding may include, but are not limited to: supply chain management, business and quality management systems, Lean manufacturing, strategic and business planning, resource management, people and change management, new product/ service development, diversification/economies of scope, and export strategy.

“This is a great scheme, where the grants help manufacturers to take on professional support is quite beneficial,” Philips said.

“Often companies can’t find that seed money to do any research or have the resources needed.

“Another type of grant that is important to manufacturers is capital contribution to plant and equipment costs, where companies can’t compete in achieving the desired rate of return on investment when they are going up against an alternative global location.”

He says the biggest issue is global players who have money that can be placed anywhere around the world, with Australia one of the most expensive locations to set up.

“That’s where the ADP comes in, and some of the regional infrastructure programs largely aimed at the funding of capital for plant and equipment.

“If the government is able to assist in funding plant and equipment,

ICN Victoria provided a win-win situation for SRX and Hofmann Engineering through its Gateway program. then following the acquisition comes jobs,” he said.

Stop and start approach While not critical of the government funding R&D, Philips points out the funding only produces the R&D. “You don’t get the multiplier of the R&D being converted into a product in the Australian marketplace.”

He advises government to take a close look at the Patent Box, a UK program where manufacturers receive tax deductions on income that is generated from R&D. “They only forgo the revenue by actually producing the product in the UK. “If you look at the amount of IP we generate here, then you look at

Companies exiting the car industry should note the number of schemes available from Canberra. manmonthly.com.au

the level of product from that IP which is manufactured here, then I think we are missing out on a huge opportunity.”

Philips believes the government’s stop and start approach to grants makes it difficult to get involved.

Perfect Partnership One government program that all manufacturers should register with is ICN’s (Industry Capability Network) Gateway, a comprehensive online system with around $400bn worth of projects and more than 70,000 suppliers listed.

Free to manufacturers and suppliers, the system offers companies an opportunity to build the perfect partnership. It allows suppliers to browse and send their expressions of interest in new business and it helps project managers manage the supply chain process.

A connection recently facilitated

by ICN Victoria has created nearly a million dollars’ worth of work for a local company and could lead to further work for items that would have been imported.

The project required by electronic contract manufacturing company SRX will be delivered by Hofmann Engineering, and is an example of how ICN can work as a business connector.

Late in 2014, SRX was looking for a company that could provide an aluminium extruded part that had to be

machined to very high tolerance. One of ICN’s business consultants, Peter Moore, met with SRX representatives and established what was needed.

Moore and ICN was able to develop a list of Australian companies with the capability and capacity required for the work, through which SRX found the best company.

In addition to this, SRX is now talking with Hofmann Engineering about two other products that are currently imported but, for quality reasons, SRX would prefer to have made locally.

Moore said to win the first part of the work Hofmann Engineering had tooling built specifically to handle the job and was looking at dedicating a machine to do the task.

“Now with a local company providing the product, SRX has much better control and better service.”

SRX General Manager Jeff Malone said the knowledge base and work of ICN Victoria had provided a win-win situation for SRX and Hofmann Engineering.

“We now have a quality local provider for this project, and we are talking to them about other possibilities. It gives us greater confidence in the products we will require and it also means we are spending our money in Australia and thus supporting local jobs,” Malone said.

Industry Growth Centres A new policy direction of interest is the $188.5 million Industry Growth Centres Initiative, designed to lift competitiveness by focusing on five identified areas of competitive strength: Advanced Manufacturing; Food and Agribusiness; Medical Technologies and Pharmaceuticals; Mining Equipment, Technology and Services; and Oil, Gas and Energy Resources.

The Centres will also facilitate engagements between enabling services and technologies, such as Information and Communications Technology, where they provide essential and direct support to the growth sectors.

For more information on government grants and industry assistance schemes go to www.business.gov.au, while for more information on ICN go to www.icn.org.au Manufacturers’ Monthly JUNE 2015 49

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MaterialsHANDLING Tool for wire rope inspection

Refurbished 2.5-tonne 8-Series 62-8FD25 delivered recently.

Refurbished forklifts for training

KONECRANES South East Asia Pacific’s advanced diagnostic tool for wire rope hoists, RopeQ Magnetic Rope Inspection, is designed to enhance the safety, reliability and service life of overhead cranes in materials handling, land transport and port lifting facilities.

The tool is used to evaluate the working condition of wire ropes integral to a huge variety of lifting equipment using advanced, proprietary Non-Destructive Testing methods.

“To evaluate the safety of a wire rope, you need to know what’s happening both on the outside and on the inside,” said the company’s John Bailey, General Manager, Service Development, Konecranes SE Asia Pacific, an integral part of the Konecranes group. Konecranes group is an organisation that globally has over 430,000 cranes under maintenance contract.

The diagnostic tool uses electromagnetic technology to assess the inner and outer wires and strands of a wire rope. This testing method achieves reliable, accurate, and – importantly – repeatable inspection results that help ensure safe use and may also improve the total lifecycle cost.

“Routine maintenance often relies on pre-determined replacement intervals regardless of the actual condition of the wire ropes, meaning that safe and operable ropes might be replaced too often or too

Toyota Material Handling Australia Orange branch manager Richard Bopping said the presentation of the Toyota forklifts was an important consideration for Integral Skills.

“The quality equipment and the professional image it conveys to their customers suits their business, and budget,” Bopping said.

Integral Training’s forklift course is run once every fortnight on average, and is the company’s most popular.

Toyota Material Handling 1800 425 438 JUNGHEINRICH is unveiling further 1 2 0 1 4 - 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 www.toyotamaterialhandling.com.au models of order pickers over the coming months, starting with the ECE 225 HP (hydraulic lifting platform) and the ECE 225 HP-LJ (hydraulic lifting platform with control unit) variations.

All variations are based on the ECE 225 model, which was recently developed as a platform concept with completely overhauled drive and control technology.

We ooffer We ffee cost effective solutions for your automation ff The models feature enhanced acceleratech te chno noll technology needs Australia wide. tion and driving performance, with up to 10 At IIS&E S&EE we specialise in systems integration and S& percent higher turnover compared with the auto au toma ma automation projects, big and small. previous series.

For mor more information phone us on 07 3856 2232.

According to the company, initial measurements in the field revealed that energy INDUSTRIAL SOFTWARE & ELECTRONICS consumption has simultaneously gone Tel: (07) 3856 2232 Fax: (07) 3355 1012 down by as much as 14 per cent.

E-mail: info@industrialsoftware.com.au Web: www.industrialsoftware.com.au The standard version of the truck also

INTEGRAL SKILLS, an industry training provider, is using forklifts from Toyota’s range of refurbished equipment.

Based in Orange, NSW, Integral Skills purchased its first refurbished forklift 12 months ago. Director Matt Molloy was so happy with it he recently took delivery of a refurbished 2.5-tonne 8-Series 62-8FD25.

“Since we need them for training purposes we weren’t in the market for a brand new forklift, but when they arrived our refurbished models pretty much looked and operated as if they were brand new,” MM0 4 1 4 _ 0 0 0 _ I N D Molloy said.

Diagnostic tool uses electromagnetic technology. soon, resulting in unnecessary downtime and increased costs,” said Bailey.

Most importantly, the tool is able to detect flaws that are not visible to the naked eye, thus improving the overall safety of the lifting equipment.

“RopeQ can improve the total lifecycle costs of equipment by optimizing wire rope change intervals in high duty applications and critical equipment,” Bailey said.

Konecranes 02 9933 3900 www.konecranes.com.au

Innovative order pickers

SCADA SYSTEMS PC & PLC PROGRAMMING

50 JUNE 2015 Manufacturers’ Monthly

The order pickers feature an integrated day LED driving light. has a patented new, cushioned stand-on platform which can be individually set to the driver´s weight, thus contributing to a significant reduction in human vibrations.

NTP Forklifts Australia 08 8243 1222 www.ntpforklifts.com.au manmonthly.com.au

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Affordable forklift trucks NACCO MATERIALS HANDLING GROUP’S Utilev range of forklift trucks provides an affordable option for those industries that require materials handling equipment but don’t need advanced functionality or attachments.

These counterbalance forklift trucks provide affordable, reliable and cost-effective solutions in applications where the materials handling equipment is required to work intermittently.

The range is available in four different capacity ranges with either diesel or dual-fuel power and the latest addition to the range being the 8-10T product.

Features of the UTILEV 8-10T range include two – speed auto shift transmission, a tough steel frame for extreme durability, great visibility, drive axle mounted masts for maximum stability, Euro Stage 3A compliant engines, flexi-coupled suspended powertrain and large filters for optimum performance.

Furthermore, the axles are designed for durability and longevity and like all UTILEV forklift models use conventional automatically adjusted drum brakes.

With familiar automotive-style controls that ensure ease of operation, these models also feature easy-to-read dash displays.

According to NACCO Materials Handling Group, General Manager Pacific and Big Trucks, Ian Neilson, “All our UTILEV dealers offer peace of mind, fast support, and nationwide spare parts availability helping to ensure your materials handling operations stay on track and within budget.”

NACCO Materials Handling Group M A 0 3 1 5 _ 0 0 0 _ C R O - 02197952 3800 0 1 5 - 0 3 - 0 3 T1 0 : 1 7 : 2 4 + 1 1 : 0 0 www.hyster-yale.com Available in four different capacity ranges.

CONNECT. MANAGE. ACHIEVE. With InfoLink ™, you have a real-time, wireless connection to your entire fleet, virtually regardless of truck brand, giving you the operator and forklift data you need to ensure your operation is running as efficiently and safely as possible. We build it to your specs and customise it to your facility.

Designed, Developed and Supported by Crown.

All your do is use it to ensure your get the most out of your operators and your fleet every day.

To see how Infolink helped Steelcase reduce their fleet size by 30%, call 1300 909 827 to book your demonstration today.

crown.com

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Materials HANDLING Stackers for any warehouse

800 x 600 x 134 mm and weighing 2.5 kilograms.

YALE’S range of stackers covers everything from the pedestrian warehouse stacker to the counterbalanced stacker, each specifically engineered to optimise materials handling operations in whatever space is required.

For example, its MRW020-30E trucks extends time on the warehouse floor with features that enhance productivity, including a separate drive motor and transistorised hoist and traction controller. uncompromising strength to weight ratio”.

Designed for minimum maintenance, The product’s dimensions are 800 x the MRW020-30E truck is easy to service 600 x 134 mm and a weight of 2.5 kiloand includes fill and drain plugs to ensure grams. Maximum loads are 500 kilograms adequate lubrication. The MRW020-030E (dynamic) and 1000 kilograms (static). excels in manufacturing and warehousThe pallet has 3 security sets: full, ing applications where space utilisation is partial or none. It is PE in composition and crucial and load widths vary. pallets per stack can be as high as 80. It Yale pallet stackers also combine accommodates extra-wide forklift entry. innovative design, industrial-strength It is suited to industries including pharcomponents and state-of-the-art manumaceutical, agricultural and food. facturing. According to NACCO Materials Plastic2go Handling Group, General Manager – Ian Neilson, it’s their 1 2 0 1 5 - 0 5 - 1 3 T 07 1 13136 : 53088 9 : 4 Pacific 0 + 1 &0Big : 0Trucks, 0 www.plastic2go.com.au rugged and reliable design that makes

New lightweight pallet PLASGAD describes its new “semipallet” as well suited for a wide range of workplaces.

Adding to the Israeli-based company’s range of products and solutions, the semipallet was launched following repeated customer requests that raised the need for a small and functional plastic pallet.

The eventual response, a mini pallet, has a wide range of functionality, according to the company.

Following extensive market research, the business’s M A 0R&D 6 1team 5 _ came 0 0 0up_with S Uwhat M itsaw as an optimal solution, and one “with

Extends time on the warehouse floor. them ideal for any warehouse application.

“Yale Pallet Stackers provide productivity and superior quality in warehousing applications, which is why many operators prefer Yale Pallet Stackers for their warehouses,” he said.

NACCO Materials Handling Group 02 9795 3800 www.hyster-yale.com

WHEN PRECISION IS CRITICAL, USE SUMMIT MATSU CHILLERS

MATSU . COM . AU | 1300 CHILLERS

52 JUNE 2015 Manufacturers’ Monthly

SUMMIT MATSU CHILLERS PROVIDE AN ACCURATE AND RELIABLE SOLUTION FOR THE PROCESS COOLING ESSENTIAL IN THE MANUFACTURE OF PHARMACEUTICALS

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Waste& POLLUTION MANAGEMENT Power for mobile water disinfection OFF-GRID and mobile water disinfection is now possible thanks to a unique product recently released by Australian water disinfection specialists, UV-Guard. A PLC operated controller packed with integrated features, including the ability to operate on 12V and 24V DC power supplies, now gives UV-Guard’s off-grid and mobile customers the ability to disinfect water via UV treatment.

UV-Guard Principal Water Treatment Engineer, Luke Chamberlain, said the company worked closely with customers to ensure the new controllers met their needs.

The 12V and 24V DC function was the final option to be added to the new controllers boasting a number of features.

“This option has been added after receiving a number of enquiries from operators of solar powered buildings and other customers who require UV disinfection but are off the grid. We have also heard from customers who require mobile UV

UV-Guard customer James Galbraith with his UV unit compatible with his off the grid solar system. disinfection for commercial and domestic applications,” Chamberlain said.

“We have been working in partnership with select customers to ensure these

enhancements meet their requirements across the industry. Having worked with an Australian developer it has allowed us to release this new range at a competitive market price whilst incorporating functionality which would ordinarily bring with it a greater price tag.”

The 12V and 24V DC PLC controller can control UV-Guard’s UV systems up to a power of 40W. This means that recommended UV dose rates can be provided at flows of up to 60lpmby using the SLF, SLT and S-Series of systems. It can also control the storage tank headspace disinfection systems, the T-series.

“We see this as the ideal disinfection solution for drinking water provision and commercial applications for our off the grid and mobile customers,” Chamberlain said.

UV-Guard 02 9631 4900 www.uvguard.com.au

DAF treatment and biogas DISSOLVED Air Flotation (DAF) is a tried and trusted treatment of industrial wastewater effluents produced by food, beverage and primary processing plants that are integral to the economies of many countries in Australasia, Asia, Africa, America and Europe.

DAF’s great strengths as a primary treatment include relative simplicity in installation and proven costefficiency in separating oil and suspended solids from wastewater in diverse applications such as dairy, cereals and sugar cane.

Compact and robust DAF systems reduce Chemical Oxygen Demand (COD) loading by the removal of high COD contaminants including fats, oils and greases, colour, organic matter and colloidal material.

A reduction of up to 70-80 per cent COD and suspended solids can be achieved in some instances with chemical addition.

As environmental and cost-efficiency demands increase on food, beverage and primary processing plants – and as such plants increasingly overlap with expanding urban areas – they face the twin pressures of achieving ever-higher wastewater discharge and waste disposal standards while also achieving greater cost efficiencies.

Neighbouring communities these days won’t tolerate ground water pollution and air pollution in the form of smells form piles of rotting sludges and by-products.

54 JUNE 2015 Manufacturers’ Monthly

Biogas (methane) can be used to fuel boilers and heat processes.

Shareholders, meanwhile, demand that any solution be ecologically sustainable and highly cost-efficient.

These twin demands used to present a virtually indissoluble dilemma, a real paradox, because better environmental technologies cost more, not less. But not anymore. Because proven DAF technologies can be very profitably combined with the latest anaerobic waste digestion technologies which not only extract very high levels (up to 90 per cent) of harmful COD contaminants from waste water streams and sludge by- products, but also convert them into profitable green energy.

The sludge floated in the DAF process can be anaerobically digested thus eliminating a sludge dewatering and sludge disposal issue. Anaerobically digested sludge produces methane which can be used to fuel boilers.

This biogas (methane) can be used to fuel boilers and heat processes, replacing costly and polluting fossil fuels. Or, if there is enough biogas, then it can be fed to generators for conversion to electricity that can be fed back to local grids and used to achieve carbon credits or pollution reduction credits. The UN has backed this method of achieving localised and highly efficient sources of electricity, which don’t suffer from the same energy losses as centralised electricity systems and do benefit their local communities.

“DAF and anaerobic digestion are very complementary technologies, which offer double benefits in the form of far cleaner effluent and green energy (methane biogas) to cut fossil fuel bills and pollution,” said Michael Bambridge, Managing Director of CST Wastewater technologies, which has installed DAF systems for numerous primary producers and food processors in Australasia over the last 20 years as well as advanced anaerobic digestion systems.

CST Wastewater Solutions 02 9427 1279 www.cstwastewater.com

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What’sNew Giant injection moulding machine

DC servomotors are robotically manufactured to customisations.

KRAUSS MAFFEI recently installed their largest injection moulding machine to date in Switzerland, for Georg Fischer Piping Systems.

The MX 3200-101.000/101.000 machine will produce large volume pipe fittings with diameter up to 500mm. Fittings are used to connect pipe for the public water supply.

Challenges included large shot weight and the need for flexibility regarding material, size and geometry when producing

pipe fittings. For this reason the machine included two injection units that can be interconnected as needed.

Another challenge was the high viscosity polythylene 100 material to be proceesed. The solution involved optimising the screw geometries and drives for the plasticising unit.

HBM Plastics Technologies 02 8814 3100 www.hbm.com.au

New breed of DC servomotors MAXON MOTOR’S latest style DC servomotor has been automatically manufactured from a customer’s direct inputs into an internet based motor configuration tool.

The first feature to observe on the motor, gearhead and encoder combination, is the complete lack of any screws, pins or clamps between any of the components. This is achieved even for the encoder with continuous flow laser welding. By removing the traditional mounting plate design between DC motor and planetary gearhead, it saves on overall length.

A complete weld revolution between the motor and gearhead also eliminates the possibility of oil or water ingress into the motor at this point. The encoder cable exit is also sealed providing both strain relief and sealing.

Using the web configuration tool, features including shaft length, shaft flats, cable lengths, gear ratios and winding characteristics can be customised.

Maxon Motor Australia 02 9457 7477 www.maxonmotor.com.au

Moisture transmitter MICHELL INSTRUMENTS’ new dew-point transmitter has gained rail approval for permanent installation on rolling stock.

The transmitters will give continuous, online measurements of dew point of the compressed air which is used to supply the braking systems and doors on train carriages to provide a full assurance of safety and efficiency.

The new dew-point transmitter is the first of its kind to have gained industry approval. According to the company, it is cost-effective for rail companies to fit the units permanently to each carriage.

The approvals include: • EMC/RFI approval to rail standard EN50121-3-2 • Shock/vibration approved to rail standard IEC16373:1999-01 The transmitter itself has a heavy duty M12 electrical connector and is calibrated to measure within the range of -60°C to +60°C dew point: wide enough to cope 56 JUNE 2015 Manufacturers’ Monthly

Provides fast, reliable readings of dew-point. with extreme conditions found in railways around the world.

AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

Can produce pipe fittings with a diameter as large as 500mm.

Gear unit for agitators SEW-EURODRIVE will present its new application gear unit for agitators at September’s AIMEX. The X Series Agitator range is purpose built for agitating and mixing applications within the mining and minerals processing industries. This solution is perfect for when high bending moments combined with high levels of torque are required.

The range is suitable for the most extreme conditions, such as high ambient temperatures or ATEX. In addition to the torque that has to be transmitted, high radial or axial forces are often brought to bear on the output shaft.

Depending on the load criteria there are different options for light, medium and heavy loads. The model with universal housing for helical gear units and bevel helical gear units performing in the 6.8-475 kNm torque range suits light loads.

Designed for agitating and mixing applications within mining.

SEW-EURODRIVE 03 9933 1000 www.sew-eurodrive.com.au

manmonthly.com.au

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Brought to you by

Hydraulic bolt tensioner TECHNOFAST INDUSTRIES, one of Australia’s leading hydraulic fastening companies, has updated its very popular EziJac B3S series of hydraulic bolt tensioners to make them even more efficient, longer lasting, userfriendly and safe.

The B3S Series EziJac is a modular style hydraulic bolt tensioner featuring a spring return mechanism which automatically resets the tool Ideal for confined and difficult nut locations. to its full working stroke.

The modular design allows tensioner due to lower friction. multiple adaptor kits to be interchanged with Founder and CEO John Bucknell said just the one load cell. the new seal also improves the longevity of Suitable for whenever accurate and the bolt tensioners, which are now capable repeatable loading is required across a wide of well over 1000 cycles before seal replacerange of industries, the new updated model ment is required. includes a number of important features all “Customers will be very impressed with designed to reduce maintenance costs and the longevity of this new model, which was improve productivity. already outstanding,” Bucknell said.

One of the key features of the upgraded B3S Series EziJac hydraulic bolt tensioner Technofast Industries is an innovative new two-piece seal design 07 3375 1431 which offers even faster operation of the www.technofast.com

Machinery health monitor EMERSON PROCESS MANAGEMENT has introduced the CSI 3000 Machinery Health Monitor, a compact protection system for a wide range of machinery such as pumps, compressors, centrifuges, blowers, and generators.

The monitor delivers protection data in situations where a standard rack-based system simply will not fit or is not a costeffective approach. Easy assembly and user-friendly, customisble setup means the monitor has a short path out of the box to improving availability and ensuring safety of rotating assets.

The monitor measures shaft vibration, bearing vibration, position, speed and generates key signals. The system provides the user with alarm outputs for each channel and does not require additional signal converters for shaft vibration and displacement measurements.

“Emerson offers a complete line of protection monitors – from the rack-mounted manmonthly.com.au

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YOU KNOW THE BEAST

NOW MEET THE BEAUTY

The new Strenx portfolio of high strength steel for structural applications is the world’s widest selection of steel available in the 600-1300 MPa and 0.7-160 mm range. Strenx allows for stronger, lighter, smarter and more attractively designed products. That’s the beauty of Strenx: You can do more with less steel, and everybody wins.

SSAB Swedish Steel Pty Ltd Office & Stocks Perth Brisbane Melbourne & Adelaide

:+61 8 9353 2146 :+61 7 3891 3533 :+61 3 9529 5759

E-mail: australia@ssab.com www.ssab.com www.strenx.com System provides the user with alarm outputs.

CSI 6500 online monitoring system and the basic CSI 9360 Vibration/Position Transmitter, to the CSI 6300 SIS that guards against overspeed conditions,” said Björn Müller, Emerson’s product manager of online sensors.

Emerson Process Management 03 9721 0200 www.emersonprocess.com

SSAB is a Nordic and US-based steel company. SSAB offers value added products and services developed in close cooperation with its customers to create a stronger, lighter and more sustainable world. SSAB has employees in over 50 countries. SSAB has production facilities in Sweden, Finland and the US. SSAB is listed on the NASDAQ OMX Nordic Exchange in Stockholm and has a secondary listing on the NASDAQ OMX in Helsinki.

Manufacturers’ Monthly JUNE 2015 57

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The last WORD The 3D printing boom continues The appetite for additive manufacturing continues to grow in all segments of the market. Brent Balinski spoke to long-time industry watcher Terry Wohlers, principal consultant and president of Wohlers Associates, following the release of the annual Wohlers Report’s 20th anniversary edition.

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HERE’S been a fairly recent change of mood at many big companies, according to Terry Wohlers.

According to Wohlers, founder of leading consultancy Wohlers Associates – which advises a long list of multi-billion dollar companies – those at the top are now pushing to invest in additive manufacturing (AM).

“So that’s quite different from most of the 27 years in the past where it’s been a bottom-up push, where you’ve got engineers, technicians and lowlevel managers going to upper management and saying ‘Hey, we need to invest in this,’” Wohlers told Manufacturers’ Monthly.

A lot has changed since Wohlers started consulting, when 3D printing was in its infancy and long before it was a must-have for manufacturers, schools, engineers and geeks.

The annual Wohlers Report, sometimes informally referred to as the “bible” of the industry, recently released its 20th anniversary version. Edition one calculated the global market to be worth $US295 million.

Wohlers Report 2015 – which features input from around the world from 40 makers of AM systems, 87 service providers and 78 co-authors – put the industry’s size at $US4.103 billion. This was a healthy increase of 35.2 per cent (CAGR) for the year. CAGR for the last three years has averaged 33.8 per cent.

Wohlers tracks the “tipping point” for the technology back to 2012, a year in which there was widespread media attention and notable events including the opening of America Makes (the National Additive Manufacturing Innovation Institute, a collaborative hub) in Ohio.

Additive manufacturing has boomed since, both at consumer and industrial levels.

At the desktop level, 139,584 consumer (sub$US5,000) printers sold, almost doubling in a year.

At the other end of the scale, 12,850 production level machines sold in 2014.

The last year’s developments Since this magazine last spoke to Wohlers in June 2014, there have been countless announcements in the industry, feeding news sources eager to share news on the Next Big Thing in additive manufacturing.

Some of these are interesting to the veteran industry watcher. He puts Voxel8, which creates PLA parts containing conductive silver ink, in this category.

58 JUNE 2015 Manufacturers’ Monthly

“And that’s who they’re going after – not the consumer”.

On metal and market research

At enterprise and consumer levels: business is huge.

Others perhaps don’t deserve so much attention, such as Carbon3D (“Interesting, but it’s still very early in its development stage... It’s too soon to get overly excited about it.”)

However, he lists last October’s HP Multi Jet Fusion technology (slated for a 2016 release) announcement as a potential game-changer.

The technology – a dual-carriage system which repeatedly lays out layers of thermoplastic and chemical agents – lives up to claims of being 10 times faster than sintering methods, said Wohlers, based on two demonstrations he’d seen.

“The speed, colour, part quality, and strength, coupled with being able to control the material properties at the voxel level—are very impressive.” he added.

Citing HP’s size, marketing and distribution muscle, and successful history with enterprise-level (2D) printers, Wohlers believes they are likely to make a difference.

“They have a lot of experience with building these very large machines for industrial users,” he said.

2014 saw metal AM machines continue to grow in popularity. Sales by unit increased 54.7 per cent on 2013.

There have been some acquisitions here in recent years, but Australia’s share is small. According to a count by Stefan Ritt of SLM Solutions, there are 21 metal-based systems operating in Australia.

Metal 3D printing is a young industry but there have already been some local successes in biomedical applications. These include reported world firsts, such as last October’s titanium heelbone replacement and pioneering work at RMIT on bone implants.

There has also been some work from Monash and Amaero in aerospace that has gained international attention.

However, there doesn’t appear to be any companies in Australia making production parts yet.

We sought Wohlers’ in-demand opinion on how much the industry was likely to grow, and if recent predictions from various market research firms were realistic.

Wohlers Associates research tips the industry to be worth $US7.3 billion globally in 2016, $US12.7 billion by 2018, and $21.2 billion by 2020.

Citing 20 years of data, he said Wohlers Report research was good enough to be relied on by some of the instant “experts” charging thousands and thousands per their own, sometimes derivative, reports.

“Nearly all of the market research companies that we know of have bought our report. It’s kind of a coincidence that some of their numbers are very close to ours,” he said.

As 3D printing has grown, so have the number of sources charging a pretty penny for analysis on the industry’s predicted rate of expansion.

“I can’t even name any people at those companies because they’re all new to the industry,” said Wohlers.

“We’ve focused on 3D printing for 25+ years and then companies get into it and they’re suddenly experts. This is what happens when an industry gains so much attention and grows and matures, so from that standpoint, it’s good.”

Wohlers Associates www.wohlersassociates.com manmonthly.com.au

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Clean water. Clean image.

See how we work with our clients and the community on the challenges of CSG at veolia.com.au/kenyaplant

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