Manufacturers' Monthly September 2014

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

Est. 1961 SEPTEMBER 2014

Anatomics gets its head into biomed

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IT@MM Is CAD training worth the time?

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Metalworking Waterjet cutting – a versatile option

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Materials Handling A fork in the road – the latest on forklifts

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Inside

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For daily news visit manmonthly.com.au

SEPTEMBER 2014

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Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au

6 Editorial

Managing Editor: Kevin Gomez Ph: (02) 8484 0976 Fax: (02) 8484 0722 kevin.gomez@cirrusmedia.com.au

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■ The burgers are better at...

Editor: Matt McDonald Ph: (02) 8484 0645 Fax: (02) 8484 0722 matthew.mcdonald@cirrusmedia.com.au

8 News & Analysis ■ Snaphot ■ Still time to adapt for auto suppliers

Journalists: Brent Balinski Ph: (02) 8484 0680 Fax: (02) 8484 0722 brent.balinski@cirrusmedia.com.au Editor-at-Large: Alan Johnson Ph: (02) 8484 0725 alan.johnson@cirrusmedia.com.au Graphic Designer: Louis Santos louis.santos@cirrusmedia.com.au Production Co-ordinator: Mary Copland Ph: (02) 8484 0737 mary.copland@cirrusmedia.com.au VIC/Overseas Sales: Michael Northcott PO Box 3069, Eltham, VIC 3095 Ph: 0448 077 247 michael.northcott@cirrusmedia.com.au NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8484 0868 Fax: (02) 8011 3184 anthony.head@cirrusmedia.com.au

12 Comment

46 Materials Handling

■ Saving manufacturing by first killing it ■ Learning from the experts ■ Know your product

■ A fork in the road ■ Reach trucks ■ Modular goods-to-person storage and retrieval system

16 IT@MM

50 Energy & Power Management

28 Automation & Robotics ■ Automation: a challenge and an opportunity ■ Process sensors ■ Materials handling robots ■ Automate to manage energy

20 Metalworking & Machine Tools

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

■ Extra knowledge can go a long way ■ High speed face mill ■ Cool cuttings ■ Automating structural steel fabrication

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Est. 1961 SEPTEMBER 2014

34 Made in Australia ■ Australia’s Hidden Champion Manufacturers ■ Local knowledge forges success

■ Metal matters: innovate or perish

Anatomics, one of Australia’s Hidden Champion Manufacturers, operates in gets its head the field of craniofacial reconstruction into biomed technology.

The company, which was founded by its current Technology & Production Manager Robert Thompson, embodies all the attributes that are mentioned when ‘Australia’s manufacturing future’ is 2 0 1 4 - 0 3 - 0 5 T1 6 : 1 8 : 0 2 + 1 1 : 0 0 brought up.

INSIDE >>

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Metalworking Waterjet cutting – a versatile option

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It is a nimble SME, offering niche, high-value products, created through mass customisation by highly-skilled workers.

What’s more, Anatomics is taking its products to the world.

“Australia is a relatively small market,” said Thompson. “So the export market is of greater importance. It’s one of our key strategies to grow our export business to ensure the growth of the company.”

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Manufacturers’ Monthly SEPTEMBER 2014 5

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Comment

KEVIN GOMEZ – Managing Editor

The burgers are better at ...

F

NEXTISSUE • • • • • • • •

Cooling and Fans Compressors and Pneumatics Fasteners and Adhesives Manufacturing Sustainability Forklifts and Attachments Supply Chain Management Sensors and Analysers MA 0 9 1 4 _ 0 0 0 _ F A N Labelling and Packaging

and more supportive governments or the past 28 years, The in some other countries. In addition, Economist’s Big Mac Index has we’re burdened by an unhelpful tax been offering a light-hearted regime. There is a push for us to adopt but valid insight into purchasinga policy similar to the UK’s patent power parity. box system which reduces tax payable The index released in June this from profits derived from the commeryear priced the Big Mac at US$4.81 in cialisation of qualifying intellectual Australia. The same bun, meat patty property within Australia. and cheese creation costs 42 percent GlaxoSmithKline claims the UK’s more in Switzerland. tax changes encouraged it to build a So when Australia’s largest biotechnew pharmaceutical plant in Britnology manufacturer decided to build ain and to bring many patents held its $500 million plant in Switzerland, overseas back into the UK. Patent it was cause for alarm – and action. applications filed by German busiSwitzerland shares Australia’s high lanesses in Britain increased 27 percent bour costs and unfavourable exchange in 2012, ahead of the introduction of rates, but that did not deter CSL. the patent box.

Australian manufacturing has lost There are companies like Cochover 100,000 jobs in the last six years and there’s no sign of this trend revers- lear and roDE Microphones who intend to retain their manufacturing ing or even slowing. CSL’s new Swiss operations in Australia. Cochlear plant will create 500 jobs – jobs that needs highly specialised skills for low Australia desperately needs.

1Local 2 0manufacturers 1 4 - 0 7 - 3have 1 T long 0 9 : 0 4 : volume 0 0 + 1manufacture 0 : 0 0 of their hearing implants and automation is not an called attention to higher productivity

option. roDE is using cutting-edge equipment and lights-out manufacturing to keep its production local.

Unfortunately, companies like roDE and Cochlear are becoming the exception rather than the norm.

Worryingly, more and more Australiandeveloped patents are being sold overseas with the products manufactured offshore. on finding about about CSL’s new Swiss plant on www.manmonthly.com. au reader ron posted this comment: “5 Australian employees get the ideas and 1000 Swiss get the jobs.”

Australia needs to get its house in order, or else the high price of Big Macs alone is not going to stop other companies venturing overseas.

We’d love to hear from you. Email us, follow us on Twitter or join the discussions on Facebook and LinkedIn. kevin.gomez@cirrusmedia.com.au

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© 2014 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. All other logos, trademarks or service marks used herein are the property of their respective owners.

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Answers for industry.

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8 SEPTEMBER 2014 Manufacturers’ Monthly

Dow Chemical’s Liveris blasts cuts to R&D AustrAliAn-born Dow Chemical chairman and CEo Andrew liveris has criticised recent cuts to research and Development in the budget and the overall state of federal politics. liveris, speaking recently at an Australian institute of Company Directors lunch, warned that Australia could lose another 15,000 manufacturing jobs in the next five years due to ineffective policies.

The Courier Mail reports that liveris, who is also co-chair of the us Advanced Manufacturing Partnership steering Committee, was scathing of the recent budget cuts to the Csiro, worth $111 million over four years. “i’m hoping this country will wake up one day,” the Courier Mail reports him saying. “if you go down the scale of r&D investments from a public-sector leverage point of view to the universities and Csiro, you will keep tumbling down that scale. “i believe Australia punches above its weight but in this area it is falling behind in the intersection of innovation and production.’’

Dow Chemical chairman and CEO Andrew Liveris. liveris was also critical of the state of federal politics, calling for more bipartisanship to avoid derailing the government’s mandate for reform.

He said the quality of debate in the last six years had approached that seen in America. “instead of working together you just throw things at each other and yell at each other,” he said. “that is really scary. i have never seen an Australia like that.” manmonthly.com.au

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News&ANALYSIS In brief...

CSL bypasses Australia Biotherapies company CSL has decided to build a new $500 million plant in Switzerland due to factors including a low corporate tax rate and government assistance. The $33 billion manufacturer short-listed four countries, including Australia, before deciding on the Swiss option.

Target names suppliers Target Australia has listed its Bangladeshi supplier factories as part of a movement towards greater supply chain transparency following last year’s Rana Plaza disaster. The company is among the signatories of the Accord on Fire and Building Safety in Bangladesh.

Death of car making inevitable The death of Australian car manufacturing was part of the nation’s adaptation to the economy of the 21st century, according to ANZ chief Mike Smith. He said Australia will become more technologically-driven and, in the future, will concentrate on agriculture, education, medical research and high value manufacturing.

Redarc named business of the year Electronics manufacturer Redarc has been named the Telstra South Australian Business of The Year. The Lonsdale-based company which makes automotive aftermarket power solutions impressed this year’s judges with its financial success, resilience and potential to grow.

New Aerospace Hub Collaborative manufacturing network META launched a new National Commercial Aerospace Hub at the CAPA Australia Pacific Aviation Summit. The hub’s goal is to “take advantage of huge untapped opportunities” in the global market. The opportunities, according to those involved in the hub, are vast.

Call for Fair Work Act review Key business groups, the Australian Industry Group and the Australian Chamber of Commerce are pushing the government to begin the planned Productivity Commission review into the Fair Work Act. The calls for IR reform come despite the fact that wages growth is at a record low.

10 SEPTEMBER 2014 Manufacturers’ Monthly

Still time for auto suppliers to adapt THERE is still an opportunity for suppliers tied to Australia’s vehicle manufacturers to find new markets, according to independent assurance, tax and advisory firm Grant Thornton Australia.

Mark Phillips, head of Grant Thornton’s National Automotive Manufacturing team, has called for calm among those looking to transition as Holden, Ford and Toyota all end their car assembly operations by 2018.

“There is a golden opportunity here.

It is really unique. We have companies in Australia that are manufacturing parts for three car companies, and that doesn’t happen very much around the world,” Phillips told The Australian.

“Usually it is a facility manufacturing parts for one or two customers, not multiple customers. If our guys get it right on the low volume, there is no reason why they can’t be manufacturing parts for other brands.

“We have this opportunity to become

short-run specialists on parts and accessories. We have more car brands here than anywhere in the world. There will be at least half a dozen companies that will embrace those opportunities.’’

Phillips noted that three years is a lot of time for action to be taken and said, “…unfortunately people are putting messages out there that they have to react suddenly now. They don’t need to panic.’’

Mark Albert, managing director of of MtM – established in 1965 as Melbourne Tooling Co and a component maker for all three car companies – believes some businesses are unequipped to deal with the issue.

“It is a mindset,” he said. “To now ask the supplier industry to go out and seek new markets is very unusual for them, which is why a lot of them won’t survive” MtM exports to destinations in Asia, South Africa and South America, and has partnered with Tomcar Australia to make its all-terrain vehicle.

What members of our manufacturing community think of the future that Australian auto component suppliers face...

Bibek Banerjee Mindset change is required no doubt, but it’s not enough to look for newer markets. It’s important for these companies to introspect and realize that it is their fault at least partially for the current situation.

Let me explain: Would we buy a European expensive car almost twice the price of a Holden / Ford here? I think yes and there is a reason behind this.

European manufacturers working on cutting edge technology for cars realised decades ago that a modern day car is not a mechanical product. Far from it, a car is a network of computers with up to 80 Electronics Control Units (ECU) and millions of lines of software code.

There is a reason Mercedes Benz is planning to integrate Google Glass - the future is software intensive products and systems. Mechatronics is here to stay but it is going to be primarily software driven.

What is stopping GM or Ford or Holden from innovating and coming up with technologically superior cars that people are willing to pay for?

You don’t need to invest in a new manufacturing plant, just focus on the software that goes into your ECU. You could for example have a voice recognition system built at less than $150.

If you have a great product, people will want it and pay for it even if they didn’t have the “real” need for it (think iPhone).

Understand what customers want, design and develop a great quality product, accelerate your time to market and watch your bank balance grow.

shouldn’t panic but definitely should be planning as it takes time to change direction.

Who knows what the auto manufacturers might do tomorrow.

Editor’s note: Comments are as received. Corrections are made for spelling and grammar only.

What do you think?

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

Anthony Mark Albert is absolutely correct, it requires a mindset change. If many businesses are unequipped to deal with transition, they should seek assistance to make changes.

In my opinion they

manmonthly.com.au

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Comment Saving manufacturing by first killing it Forget about incongruous comments from bankers about the death of car making. Australia needs to work out how it is going to finance manufacturing into the future. Kim Carr writes.

E

ArliEr this month the chief executive of the ANZ Bank, Mike Smith, gave Australian manufacturers the benefit of his wisdom on the country’s economic future.

Mr Smith said that the death of the car industry was an inevitable part of the transformation of the economy to meet the needs of the 21st century.

Then came a punchline that revealed the bank boss’s shaky grasp of his own argument: Australia had to become more “technologically driven”, he said, so that it could concentrate on things in which it had an advantage – like “high-value manufacturing”.

Just how we are to become more technologically driven by abandoning an industry that is the exemplar of advanced manufacturing and which has long been the great driver of innovation in manufacturing, Mr Smith did not say. i don’t point out the contradiction in his remarks to score a debating point. it is because the industry of which Mr Smith is a part is itself one of the obstacles to Australian manufacturing becoming more “technologically driven”.

Manufacturers already know this, but apparently bankers either don’t know it or prefer to ignore it.

Consider, for example, this comment by Ai Group in their submission to the Financial Systems inquiry: “Ai Group has been concerned for some time that banks impose especially stringent lending criteria on the manufacturing sector. in a 2011 survey of members, we concluded that financial institutions, responding to the perception of higher risks facing the industrial sector, were downgrading manufacturing industries and making access to finance more difficult and expensive for businesses across the entire sector, regardless of the individual circumstances and risks.” lest anyone mistake Ai Group for a radical organisation with avantgarde left-wing views, here is a simi12 SEPTEMBER 2014 Manufacturers’ Monthly

lar remark made last year by Philip lowe, deputy governor of that establishment pillar, the reserve Bank: “The low level of investment in the manufacturing sector is particularly noteworthy, as manufacturing has traditionally accounted for about one-fifth of total non-mining investment.” if Mr Smith really wants an Australia with more high-value manufacturing and a diverse economic base, he and his counterparts in the other major banks are well-placed to do something about it.

But they haven’t been rushing to provide innovative Australian manu-

“

The AMWU has called for the establishment of a Manufacturing Finance Corporation... facturers with the investment capital they need. instead bank executives seem more comfortable offering gratuitous advice on the “inevitable” death of an industry that was not inevitable at all.

A couple of days after Mr Smith blithely consigned to history the automotive industry and the 200,000 jobs it sustains, i attended a manufacturers’ forum in Adelaide, organised by the South Australian Government.

No one pretended that there is no crisis in manufacturing, or that it is not bound up with the shutdown announced by the motor vehicle producers.

But until that actually happens, the automotive industry – not only the carmakers but the supply chain as well – remains Australia’s great

repository of advanced skills and industrial capability. innovative investment could adapt that capability to create the technologically-driven future Mr Smith recommends. A future that will sustain high-paid, high-skilled jobs for Australians.

But we need to keep the capability alive, and we need to find a reliable source of investment capital. The question is what that source might be. it isn’t going to be the Abbott Government, which has ripped $2.5 billion out of the industry Department and axed programs such as Enterprise Connect and Commercialisation Australia that were established to assist innovative firms.

The Government has also announced cuts of $900 million from the Automotive Transformation Scheme. it intends to close the scheme, putting in jeopardy supplychain firms that have made investment decisions based on the expectation of ATS grants. labor will do all it can to block these cuts in the Senate, because we know that industrial capability must be kept alive. For the same reason we will oppose any Government decision to buy the navy’s new submarines overseas, instead of building them here.

But there remains the problem of future finance. We shall have to find new means of fostering innovative investment.

Unlike the Government, some people are already turning their minds to possible solutions. in its submission to the Senate Economics Committee’s innovation inquiry, the AMWU has called for the establishment of a Manufacturing Finance Corporation (MFC) on the model of the Clean Energy Finance Corporation (CEFC). like the CEFC, the MFC would be independent of government. it would not dispense handouts to struggling businesses. The aim would be to form partnerships with industry, spurring the transition to more advanced manufacturing and creating new jobs.

The MFC would be seeded with Commonwealth capital but over time its operations would have little impact on the budget because, unlike grant-based schemes, there would be no regular government outlays.

Overseas experience has already demonstrated that investment funds of this model type can fill gaps in the financial market and make strong enough returns to become selfsustaining.

That has happened in the US, where the Small Business investment Company, an initiative of the Small Business Administration, has been highly successful since it was established in 1958 and has bipartisan support.

Such funds are able to support investments that are viable but may not generate the return of more than 14 per cent that banks often expect. in doing so, they make a return for the taxpayer and the broader economy. in addition, as has happened with the CEFC, investment decisions by government-backed funds attract subsequent private finance as banks and other investors leverage off the finance corporation’s due diligence. i commend the AMWU for offering an innovative suggestion that could become one element in a suite of measures as we seek to rebuild the industry policy framework the Abbott Government is busy tearing down.

That is why labor established the Senate inquiry into Australia’s innovation system: to seek new ideas for overcoming the barriers to future technical innovation. in the meantime the task is to defend the manufacturing base we already have, because if we do not there won’t be any “technologically driven”, “high-value manufacturing” future.

[Senator Kim Carr is the Shadow Minister for Higher Education, Research, Innovation and Industry]. manmonthly.com.au

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Comment

INNES WILLOX – CEO Australian Industry Group

editor@manmonthly.com.au

Learning from the experts there are still plenty of well-run and dynamic businesses in this country. Manufacturers facing an uncertain future have a lot learn from the experienced outfits. Innes Willox writes.

I

in collaboration with academic t is difficult to overstate the extent of the challenges that Aus- and private-sector R&D providers; often despite the interventions tralian manufacturing has faced of governments and government over the past decade. In many ways agencies; and also, hopefully, with they are bigger even than the shock some cooperative facilitation from of two to three decades ago when the public sector as well. manufacturing was jolted by the And, while this future will build on wind-down of tariffs and the recesthe existing base of our manufactursion of the early 1990s. ing and engineering capabilities, it While the pressures have not endis a future that will be different in a ed, in a very real sense the impacts to number of key respects from Australdate can be seen as having demonia’s manufacturing traditions. strated the strengths and resilience Fortunately there are of domestic manufacturing more than opportunities as well as challenges. its weaknesses.

And there can be little doubt that It is a future that will be Australia has strong manufacturing made in large part by businesses and engineering capabilities and very themselves acting on their own well-run and dynamic businesses. initiatives; in partnership with other A D _ M-Aboth N Mhere NPA MA Y _ 1 3 . p d fthere P aare g eplenty 1 of3 examples / 0 4 / 1 3 , businesses and abroad;

of them. this includes Banlaw who have transformed from being a manufacturer of fuel pumping equipment to an information technology and service company providing global fuel monitoring for large mining companies and national transport operators; Nupress with its niche stainless steel products

“

the DBK is a collection of information and advice on how digital 1technologies 1 : 1 3 : 2 1 A M can AEDT create real benefits for SMEs… and services in glass architecture for buildings both in Australia and in North America; and Hedweld who have gone from constructing steel industrial buildings in the Upper Hunter regional to a manufacturer and exporter of mining and earthmoving equipment. It also operates a facility on North America. there is a lot to learn from these businesses with their emphasis on quality; the strong partnerships they build; the attention they give to the development of their businesses; the investments they make in their workforces and in their capital equipment; and the ongoing quest for new opportunities.

While we have some solid reasons for measured optimism about the potential for Australian manufacturing – both from the supply and demand sides – success is far from assured.

For one thing we have already seen quite a loss of capability – you can’t lose 9 per cent of your workforce and not lose capability.

And we know that there is

14 SEPTEMBER 2014 Manufacturers’ Monthly

considerable pressure building on other parts of the sector.

What we have to do in the face of this is to build and rebuild capability.

One area of management capability development that Ai Group has been working on over the past year or so under a contract with the Department of Communications is in developing material for what is called a Digital Business Kit (DBK). the DBK is a collection of information, tips, case studies and advice on how digital technologies can create real benefits for the small to medium enterprises within the manufacturing industry.

Designed as an introduction to the possibilities that digital technologies offer businesses, the kit contains useful information and tips from companies who have found real success in integrating new digital technology within the operations and management of their businesses.

An example is FPM – Bendix Brakes, an automotive supplier based in Ballarat. they developed an app that uses face recognition technology that enables a customer to take an image of the brake pad, the app recognises the part, automatically searches an online catalogue and identifies the right replacement. the company attributes this and their social media marketing strategy as key in their survival in the automotive aftermarket.

Digital technology and the internet are creating disruptive changes that bring major opportunities and challenges in product and production innovation.

With the correct approach and responding positively to the inherent challenges and opportunities, Australian manufacturing firms who are not only technologically sophisticated, but are also agile, adaptive and efficient will be most likely to excel. www.digitalbusinesskits.com.au manmonthly.com.au

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Comment Know your product the forklift market has expanded significantly in recent years. While increased choice is a good thing, not all machines are of high quality and consumers need to do their homework before buying. Ross Grassick writes.

M

AtERIALS handling has changed dramatically over the past thirty years in Australia. For example, forklifts are no longer a luxury. Every warehouse has them.

When it comes to forklifts, these days we are actually spoilt for choice; there are nearly as many brands of forklifts available as cars.

So what should prospective forklift buyers look for now? How can they work out if they are getting value for money? And do all the forklifts supplied comply to Australian Standards?

It is important to remember that not all forklifts that come into Australia were built for Australia and A 0 products 5 1 4 _ 0made 0 0 _overseas F L I do that M some not meet our safety standards.

is based on a 500mm load centre, Australian regulations specify that units be rated to a 600mm load centre. this is because the standard Australian hardwood pallet is 1200mm square. the point of this is that a 2500kg unit will not lift that capacity at a 600mm load centre. We are required to rate to include other factors such as attachments and lift height. these affect the capacity. Consumers should confirm with the supplier that the unit being supplied will provide the capacity required for their applications.

[Ross Grassick is Managing Director of Lencrow Materials Handling. Contact him at rossg@lencrow.com.au].

doesn’t mean it’s no good. Consumers there are used products coming need to find out how long the units into Australia that are referred to as have been around. Some of the lesser ‘grey imports’. these may not comply known brands actually do offer excelwith local standards and their parts lent quality and value for money. may not be supported in this country.

Right now, forklifts do not require And in the case of new units, annual inspections but must be you may not get what you paid for. maintained in line with manufacturMany lower priced units do not offer compliance and come with little or no ers’ instructions and with Australian Standard AS 2359. after sales support.

All new machines should be supWhen purchasing a forklift, conplied with an operator’s manual that sumers should check how many units outlines controls and operation; and have come into the country; what outlines a maintenance schedule. they offer in warranty and after sales service; how long has the supplier has In addition, the units must be fitted with a compliance plates that show been in business; and how long that capacity at a load centre that relates supplier has sold the product. to the tines or attachment fitted.

But, as Shakespeare said, “What’s 1in a2name?”

0 1 4 -In0the 4 -case 1 0ofTforklifts, 0 8 : 1 7 : 2 7 + 1 0 : 0point 0 that should be noted Another just because you don’t know the name, is that, while the rating of many units

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

All images are used for illustration purposes only.

Technical specifications subject to change without notice.

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

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

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

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

PoE Power over Ethernet (PoE )

Communication and power supplied with only one cable.

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

HIGH SENSITIVITY < 50 mK

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

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

GigE Vision™ standard compatibility

Camera interface standard developed using the Gigabit Ethernet communication protocol.

GenICam™ protocol support

Provides a generic programming interface for all types of cameras.

manmonthly.com.au

Manufacturers’ Monthly SEPTEMBER 2014 15

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TechnologyIT@MM CAD, 3D printing and dreams of the future Improved understanding of 3D printing and additive manufacture have generated new business ideas and opportunities. According to Samson Khaou, these range from home hobby machines to printing buildings on other planets.

D

AssAult systèmes has been involved with 3D printing since its inception 30 years ago. Indeed 3D digital modelling is needed to programme 3D printers and additive manufacturing equipment. 3D digital models created with software such as solidWorks or CAtIA allow designers to simulate and develop products on the screen before they are physically produced.

3D printers are already used extensively in automotive, aerospace and consumer goods industry applications to validate form. Over the last three decades considerable business and technical experience has been built up in enterprises that use this technology and in many cases Dassault systèmes’ 3DEXPERIENCE Platform is instrumental to its creative and efficient usage. On this foundation, and now that prices are falling, many more machines are being put into service.

Not only have 3D printers become less expensive, their capabilities have evolved. Machines that can print titanium, aluminium, and silver are revolutionising many businesses including, for example, jewellery making, by enabling production of shapes and designs that could not be made by conventional techniques. the opportunity to show people what a design will look like - even make a plastic example first, allows people to acquire often-unique pieces with no risk of disappointment or surprise at the outcome. the same idea is current in the life sciences industry where dentists will soon be able to produce perfect crowns on demand from in-houses machine while other types of medical implant could be literally made to measure. there are opportunities throughout these developments for new types of services that will evolve to help companies make the most of the technology. Manufacturing is entering a renaissance where start-ups can produce brilliantly designed high quality products without the need for a factory.

Light bulb moment In the past, to have an idea for a product was one thing but to have it made was quite another. 3D printers have changed that - now a single product can be made, small batches are easy to produce and individual customization has become practical.

If demand increases, more machines can be simply added to meet it.

Additional materials are coming onto the market and the ability to mix them during printing offers more scope for designers. For example some 16 SEPTEMBER 2014 Manufacturers’ Monthly

3D printers are already used extensively in the automotive, aerospace and consumer goods industries. manufacturers that Dassault systèmes works with make stock standard products that are finished to individual customer specification at the last minute. this facilitates stock holding reductions with massively increased product range flexibility.

Companies that show manufacturers how to do this are in demand because when technology is used this way, it leads directly to higher margins through a more efficient use of resources.

Existing manufacturing can easily adapt to accommodate 3D printing and many successfully deploy it extensively. New types of companies are also emerging that exploit the reduced cost base of 3D printing set-ups. these offer innovation through flexibility that is hard to match in a more traditional manufacturing environment. there are opportunities too in the spares industry. Companies that are obliged to provide spare parts for many years, such as in the automotive or aerospace industry, face storage and logistics costs with ‘dead’ stock. With 3D printing, it is simple to maintain ‘digital spares’ that are printed to order. that means that any amount of digital spare parts can be held in stock indefinitely. this effectively extends products lives with all the reputational and environmental benefit that brings.

Fast and faster Dassault systèmes Aerospace, F1, satellite, consumer product and life science customers are increasing their 3D printer deployment to help

them innovate faster. And in areas of economic under development where industry has not taken a foothold, 3D design and printing is also offering great business innovation potential.

Creating products locally means that new agile businesses can start with low investment, minimal infrastructure and potentially high returns. the ability to manufacture to demand is very appealing in poor areas of the world that view 3D printing as a way to leapfrog the industrial world’s production and development cycles.

Innovative manufacturers are benefiting from this development by siting machines across the world to take advantage of operating conditions and energy costs.

Military and security services also see 3D printing as a way to avoid lengthy spare parts procurement supply chains by making parts and equipment on-site.

Robot builders in space Many people belief that Man’s future includes colonising other planets. Development of technologies for mining asteroids is already underway and in 20 years mining in space may be a reality.

Robotised 3D printing and other manufacturing in space could be an alternative to sending product supplies from Earth.

It is predicted that the first permanent off Earth dwellings will be built by robots using 3D printing techniques developed for the materials and conditions that are found on other planets. this long-term business opportunity has already spawned several development companies with Richard Branson and Google’s larry page as investors.

Dassault systèmes 3DEXPERIENCE technology currently helps in the design and construction of the systems and vehicles, to get people into space.

All the subsequent systems for exploring, mining, refining and manufacturing of goods for use either in space or for return to Earth could be developed using the same technology.

Back on Earth 3D printing offers a lot to the education market. Recent studies at Queens university in Belfast proved that Dassault systèmes digital 3D animated models are very effective teaching and training tools in comparison to written or verbal instruction.

When this is coupled with the ability to output students’ work as 3D physical models, learning is further accelerated. the imagination is also fired manmonthly.com.au

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when students use additive manufacturing techniques to make ‘impossible’ shapes and effectively produce ‘something from nothing’. Adding social networking and communication to the mix enables student collaboration, ideas exchange and further innovation from young minds. This can spawn low cost start up manufacturing businesses that students can develop on graduation.

Fab gear Started as an outreach project from Massachusetts Institute of Technology’s Center for Bits and Atoms (CBA), Fab Labs aim to develop programmable molecular assemblers able to make almost anything. Projects in Fab Labs include solar and wind-powered turbines, computers and equipment for agriculture and healthcare, housing, and printing complete working machines, including 3D printers. Not surprisingly there are many business opportunities and new enterprise scenarios being developed around Fab Labs and their intensive use 3D digital modelling is needed to programme 3D printers and additive manufacturing equipment. of 3D design technology.

Another idea is for people to use designers’ an item with your phone and making a part is also basic forms to customise their own products. not far away. This means, for example, people could This means that people without design skills can scan, make, repair and replace parts rather than partner with designers to create new products. As M A 0 9 prices 1 4 _ fall 0 0 this 0 _ market S A G driven 1 by 2‘col0 1 4 - discard 0 8 - 0products 8 T 1 0 because : 3 4 : 5 1 + 1 0 : 0 0is faulty. one component 3D printing The financial argument is strong because there is lective intelligence’ will inevitably grow. Scanning

immediate return through money saved. Roadside breakdown repairers could even manufacture parts on the way to a vehicle that has communicated directly with a 3D printer on-board the recovery vehicle.

With its 3D EXPERIENCE Platform used by more than 190,000 companies to develop 3D digital models and product simulations, Dassault Systèmes is positioned at the heart of additive manufacturing. Working with many 3D printerusing innovators, Dassault Systèmes is helping them achieve maximum business advantage from the technology as it develops. This lets anyone from the maker of a jet airliner to a start up with a good idea, execute their business while creating downstream opportunities as the technology is rolled out.

In the coming years, 3D printing is set to grow exponentially and as it does, new business opportunities will abound. Correctly positioning a business to capitalise on that prospect presents many exciting ways for enterprises to flourish.

[Samson Khaou is Managing Director of Dassault Systèmes Asia Pacific].

Dassault Systèmes 02 897 37581 www.3ds.com

There are dozens of reasons for choosing

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Technology IT@MM Is 3D CAD training worth the time?

3D CAD software increases not only the quality of the design but also the productivity of the designer. It pays to learn how to use it.

C

omputer Aided Design (CAD) software is a critical tool in the creation of intellectual property in the manufacturing sector.

But, when it comes to CAD usage, there is a problem that doesn’t lie in a lack of awareness of 3D CAD software but in the fear of losing valuable time to learn the software; and in deciding whether to take a formal training course or learn it on the job.

With 3D CAD software becoming more intuitive to use and with massive amounts of online tutorials and Youtube clips available many new users decide to self-teach and elect not to take a formalised training course offered by most reputable CAD VArs. this allows the user to continue producing design M A 0 drawings 9 1 4 _ 0while 0 0 _learning HAR and detail the software.

18 SEPTEMBER 2014 Manufacturers’ Monthly

Formalised training courses such as the Solid edge Fundamentals course held by eDGe plm Software, is four days in length. In this training course the user is taught all the skills and techniques required to be productive back in the office. Solid edge training courses are taught by a professional 3D CAD trainer. tony mazonowicz, training manager at eDGe plm said he was very conscious of the pressures actively developing new courses and engineers and designers are under and is aware that four days away from methods of delivery. the company is committed to providing Solid edge the office is not always possible. He users with the right information added that the company is therefore at the right time as painlessly as continually looking for new ways possible, because they know the end to deliver cost and time effective results will be worthwhile. training. tomcar Australia is an example of one of eDGe plm’s staff recently 1 2 0 1 4the - 0Certificate 8 - 1 4 TIV 1 in 5 : 3 7 : 0a 1company + 1 0 : that 0 0 made the decision to completed move towards Solid edge Software. training and Assessment and is

tomcar used Solid edge software, provided to them by eDGe plm, to help produce tough-all terrain vehicles. As a small to mid-sized player, tomcar needed to compete against products of larger players in the market. to do so, they needed that edge on the local and global competition.

Since its establishment in

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2005, Tomcar saw using advanced technology as the way for a company to breakthrough and most effectively compete in an already highly established automotive market. EDGE plm helped in mentoring Tomcar to better help their understanding and usage of the 3D CAD software.

The time spent training had its long term rewards. With the aid of CAD technology, high quality materials and some of the best engineers in the country, Tomcar met its goal of breaking through the clutter and competing effectively.

Using Solid Edge enables Tomcar Australia to accelerate its design process, makes faster revision and substantially improves data re-use.

Moreover, Solid Edge has enabled Tomcar to operate like a large manufacturer, while maintaining its mid-sized business model.

One of the most successful results of using Solid Edge was that Tomcar was able to go from finalising the design of the vehicle to full production in only 12 months, a time M which, A 0 9 1according 4 _ 0 0 0to_Brim, K E Lwasframe virtually unheard of in the industry.

Essentra Ads.indd 2

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Solid Edge training courses are taught by a professional 3D CAD trainer.

“For our small team of developers “The average time it takes a and manufacturers, the solution was traditional automotive company a natural fit. Solid Edge has been to set up vehicle production from the best software we’ve used, and design inception can take up to seven the results we yield from using it years. Completing the development continue to impress us.” of a reliable and performance-heavy If awareness of the time benefits product within a 12 month period of adopting this critical software is requires intense activity and an 1extremely 2 0 1 4robust - 0 8 and - 1 efficient 2 T 1 0 :PLM 3 7 : 1 made 7 + 1more 0 : 0apparent 0 to companies and designers, this program will be infrastructure,” he said.

adopted by most companies involved in manufacturing. Manufacturers need to start focusing on long term time benefits, rather than worrying about the short time issue of time lost on training.

Edge PLM Software 1300 883 653 www.edgeplm.com.au

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Manufacturers’ Monthly SEPTEMBER 2014 19

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Metalworking& MACHINE TOOLS Hermle High Speed 5-axis CNC Machining Centre from Applied Machinery.

A little extra knowledge can go a long way High speed milling has been with us for a while now. However, it hasn’t quite had the impact it could have had. Matt McDonald looks at why a lot of manufacturers are still wary of high speed techniques and what can be done to ease their fears.

H

igH speed milling isn’t the easiest concept in the world to define.

“There are a lot of factors going into it,” Prashant gokhale, CNC Machine Tools Manager at Applied Machinery told Manufacturers’ Monthly.

He explained that having the right machine and spindle are parts of the equation, but not the whole story.

He added that high speed milling also involves using software with a ‘look ahead function’. This enables the machine “to read multiple lines ahead to be able to perform those operations smoothly.”

“And you need to have the right tools for it as well and the right cutting conditions including your coolant.”

So high speed milling involves several components and, in its early days, was seen as complicated.

20 SEPTEMBER 2014 Manufacturers’ Monthly

in fact, according to David Morr, Technical Manager at Seco Tools it was over-complicated.

“The high speed milling strategy promised a lot of things to a lot of people,” he told Manufacturers’ Monthly.

But, according to Morr, people have now realised the concept is really about things like small actual cutting depths which produce small chip thickness.

“And when you produce a small chip thickness it comes back down to using your milling tools in an appropriate fashion,” he said.

“When you’re actually side-milling, using only say five per cent of the cutters width or even two per cent of the cutters width, you really can begin to start using the milling cutters into the high cutting speed strategies.”

By using such a technique, he explained, you can actually start to increase cutting speed and feed to compensate for that average chip thickness being reduced to such a small level.

“

The technology is out there but too many businesses are not up to speed… in addition, there’s more contact time and therefore it is possible to increase the cutting speed to ensure that there is enough heat in the cutting zone. “i think the strategy behind high

cutting speed milling is really about reducing your chip thickness,” Morr said. By reducing chip thickness you can improve efficiency and productivity.

High speed milling does involve a lot of components and you need to know what you’re doing to successfully use the techniques, but it doesn’t have to be over-complicated.

Since the early days, it has become a lot simpler and it shouldn’t be approached with excess caution.

Nevertheless, a lot of businesses that could be using high speed milling techniques aren’t. And they are missing out. And, in addition, a lot of manufacturers just aren’t getting the best out of the machines they have.

According to gokhale, the major reason for this is the initial cost. He manmonthly.com.au

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explained that, given the difficult times manufacturers are now facing “...the initial costs of these machines and tooling them up properly is high. People are using yesterday’s technology to do today and tomorrow’s job. And a lot of people are using second hand machines.”

“People can’t justify buying a good machine,” he said. And they can’t justify buying the correct tooling and software to go with it.

However he believes that, while the initial costs may be slightly higher, in the long term the benefits will outweigh the costs.

And on top of costs, said Gokhale, it is also a matter of education.

“A lot of customers aren’t aware of Trochoidal milling or high speed milling team strategies or push-pull strategies. There are a few different ways of high speed milling and unfortunately a lot of people aren’t aware of these things,” he said.

Morr expressed similar views.

Though in his opinion, price is less significant.

“I think price is always a factor in a lot of new technology but I think it really comes back down to what the customer is actually machining.

If they’re just doing some basically ordinary skills, to be honest the price shouldn’t be a factor. I think it’s the concept of actually how to do it is the real factor,” he said.

For Morr, education is the big issue.

“I think there’s a technology gap,” he said.

The technology is out there and there are users out there who have expertise and knowledge to share.

But too many businesses are not up to speed. They are not aware of the technology and are not aware of the techniques.

Morr sympathised with those who find themselves in this position.

“They don’t get the opportunities to meet and explore different opportunities and different possibilities in tooling and machining. And that technology gap does tend to grow...these days more than ever,” he said.

Citing metal cutting as an example, he said, “People are doing it all day.

They’re always cutting steel, turning, milling, drilling, whatever, but nobody’s really given the time to sit down and explore what’s actually happening and

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Seco Tools offers an education programme - STEP. the fundamentals of metal cutting behind the process.”

Training Morr explained that education and training are available. And you don’t have to go back to uni or TAFE to get it.

For their part, Seco Tools runs the Seco Technical Education Programme (STEP), a practical programme designed to familiarise users with the latest tooling systems and metal cutting techniques.

It aims to address the ‘technology gap’ and help participants improve their machining productivity; and to keep them up-to-date with changes in the industry. It is recommended for machine operators, manufacturing engineers, programmers, and company owners: anyone who stands to benefit from an improved understanding of tooling and machining strategy.

Topics covered include machining language, concepts, and terminology; cutting tool design, selection and application; as well industry-specific components.

The good news is that there are many such courses appearing on the scene. All will surely go a long way to ensuring that some light is shone on hard-to-define concepts like high speed milling; and that more businesses start taking advantage of them.

[Matt McDonald, a Manufacturers’ Monthly journalist, writes on a broad range of topics. His special interests include Safety and Industrial Relations. Contact him at google. com/+MattMcDonald28] Applied Machinery 03 9706 8066 www.appliedmachinery.com.au Seco Tools Australia 1300-55-7326 www.secotools.com/au

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Metalworking & MACHINE TOOLS Laser sensor for challenging measurement applications MicroMax offers the Banner Engineering LE550 laser sensor. Designed with linear array technology, the non-contact laser sensor provides high repeatability and accurate measurement for challenging targets ranging from shiny metal to black rubber.

With easy, ready-to-use operation, the sensor measures 100 mm to 1000 mm right out of the box—making it an ideal detection solution for diverse measurement applications, including roll diameter, loop control, thickness measurement and positioning.

Featuring an intuitive two-line, eightcharacter display, the sensor makes adjustments and menu navigation simple and easy to read. The visible red, class 2 laser beam and small spot size ensure quick setup and alignment.

The sensor is also available with an optional metal, rotatable connector

and multiple mounting bracket options, allowing operators to save time and money while accommodating flexible application requirements. according to the company, the sensor’s linear array imager enables use on a wider variety of materials, reflective surfaces and colours. it is intended to help users reduce and detect errors, while streamlining automated inspections.

For optimal use in demanding environments, the sensor is enclosed in a rugged, die-cast zinc housing and includes a polycarbonate lens cover rated to iP67. all models meet Military Standard 202 G requirements method 201a, in addition to iEc 60947-5-2, to withstand applications subject to vibration or shock.

The sensor is also available with an optional metal, rotatable connector.

Micromax 1300 94 15 32 www.micromaxsa.com.au

Spindle growth system for high speed milling BESTEch australia introduces the SGS 4701 Spindle Growth System, a new displacement measurement system developed specifically for high speed milling machine applications. high machining speeds and the consequent heat generation require the linear thermal extension of precision machine tool spindles to be compensated for, in order to keep the tool in a defined position at all times.

The SGS sensor measures The displacement measurement system has a cost-effective design. the thermal and centrifugal force extension of the spindle with the measurement values fed into the cNc machine tool as correction values, compensating for any positioning errors. The SGS 4701 operates on the eddy current measuring principle, with the non-contact measurement method not only eliminating wear but also resisting disturbances such as heat, dust and oil. consisting of a sensor, a sensor cable and a controller, factory calibrated for ferromagnetic and non-ferromagnetic measurement objects, the SGS 4701 is installed using two miniature sensors directly in the spindle, where the measurements take place. in addition to measuring linear thermal extension, the temperature of the sensor is also detected. The compact controller can be installed on the spindle housing via a flange or directly in the spindle.

Key features of the displacement measurement system include cost-effective design; miniature sensor design; miniature, compact controller; sensor technology integrated completely into the sensor; suitable for ferro- and non-ferromagnetic materials; and temperature measurement integrated in the sensor.

Bestech Australia 1300 209 261 www.bestech.com.au 22 SEPTEMBER 2014 Manufacturers’ Monthly

Universal lathe/cutter PrEciSioN Metal Group’s F-Max portable universal lathe/cutter is designed to handle a diameter range from 350mm to 6000mm.

The lathe/ milling machine allows for multiple operations including facing, internal and external bevelling, creation of concentric and/or spiral cylindrical grooves, preparation of edges and chamfers for welding as well as radial drilling for circular series of holes.

The machine is entirely controlled by an electronic controller capable of performing diverse machining jobs on the faces of large cylindrical tubing with excellent finish and accurate results.

Key features of F-Max portable universal lathe/ cutters include the capacity for quick on-site installation, easy handling and versatile functioning; as well as inertia balancing which permits operation in any position: horizontal, vertical or inclined. according to the company, their innovative design compensates for radial and axial stress and tilting moment. This helps to minimise harmful vibration.

They may also be used as precision drilling/tapping machines.

Precision Metal Group 1300 554 978 www.precisionmetalgroup.com

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BySprint Fiber 6000 6.0 kW Fiber Laser cutting

Full lights out automation Automatic nozzle changing CutControl-cut quality monitoring ByPos Fiber-automatic focal control

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31-33 Sullivan Street Moorabbin Victoria 3189 Tel: (03) 9555 5525 Fax: (03) 9555 2970 Web: www.lmclaser.com.au Email: sales@lmclaser.com.au

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Metalworking & MACHINE TOOLS Cool cuttings There are several different ways to cut metals. For small to medium operations that value versatility and economy over speed and precision, waterjet cutters are one of the best options.

Matt McDonald writes.

W

hen most people with a passing interest in metal work hear the words ‘metal cutting’ their minds head quickly to lasers.

And this is fair enough. Laser cutters have come a long way in recent years and they do what they do very well. When it comes to speed, nothing can touch them and they have transferred the words ‘lights out manufacturing’ from a concept into a reality.

But lasers aren’t the whole story.

Other technologies, such as waterjet cutters have a role to play. In fact, they can do some things that laser cutters can’t.

And waterjet cutters offer a number of their own advantages.

First off, they are relatively cheap.

They cost about a quarter the price of laser cutters and also cost less to run.

Versatility Waterjet cutters were developed in the 1930s and were originally used to cut soft materials like paper.

According to Matt Weaver, waterjet applications specialist at headland Machinery, these days they can can cut anything except toughened glass. (he explained that this tricky product will shatter when hit by a jet stream).

So they can handle all metals, from aluminium to brass to steel.

Weaver told Manufacturers’ Monthly waterjet cutters are “good for exotic materials”. This is important because there is not much else out there for machining such materials.

In comparison, said Weaver, “lasers and plasmas are more restricted in what they can cut. They can only cut certain materials and up to certain thicknesses...”

Lasers generate a lot of heat and therefore they can’t cut anything much thicker than about 25mm.

Waterjet cutters, in contrast, can cut metal with a thickness of 50mm, 100mm, or even 200mm.

24 SEPTEMBER 2014 Manufacturers’ Monthly

Waterjet cutters can cut anything except toughened glass.

Weaver added that “you can go from cutting 2mm thick aluminium to cutting 200mm thick tool steel… completely different parts, in under a minute.”

In other words, they are versatile.

They are great for smaller businesses which haven’t identified speed and volume as their top priorities. (Those who are chasing speed should choose laser cutters).

Although, as Weaver added, “A lot of people have both. A lot of laser shops are investing in laser jets because it gives them the versatility.”

In addition, waterjet cutters can handle complex shapes. As Prashant Gokhale, Machine Tools Sales Manager at Applied Machinery told Manufacturers’ Monthly, they can even cut three dimensional shapes.

FASTFACTS

Features of waterjet cutters • Can cut almost anything • You can easily swap from one part to another • Slower than laser cutters • Relatively cheap • They are great for SMEs • Operator must load and unload all sheets • Cold-cutting technique does no harm to metals cut • Can handle 3D shapes Gokhale pointed to 5-axis technology which has facilitated new waterjet cutting options.

The normal axes on a waterjet are named X (back/forth), Y (left/right) and Z (up/down). The 5-axis system adds two new axes – an A axis (angle

from perpendicular) and C axes (rotation around the Z-axis) – and in so doing opens up a range of cutting options.

“You can do spirals,” Gokhale explained. Or you can do “impellers for turbo charges or it could be blisks or…turbine blades.”

Cold cutting Another advantage of waterjet cutting is that it doesn’t compromise the material being cut.

“That’s why it’s great for things like the aerospace industry because they can’t have any alterations to the mechanical properties of the material...because it adds stress,” Weaver said. he explained that this is because it uses a cold-cutting process. “It’s manmonthly.com.au

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Metalworking & MACHINE TOOLS basically high speed erosion... It’s the abrasive that’s doing the erosion and the water is the carrier for the abrasive which does the cutting.”

“You’re not putting heat into the material and you’re not hardening the edge the way you are with a laser or a plasma... It’s virgin material on the edge,” Weaver continued.

Water usage Water is a scarce resource so it’s pertinent to ask how much water waterjet cutters use.

“We basically use four litres a minute. Six litres a minute if you include the cooling circuit,” Weaver said. “But that’s only being used while the nozzle’s actually on.”

So when you’re just setting up, loading sheets, or having lunch you’re not using any water at all.

According to Riverina Water County Council, a ten minute shower accounts for 200 litres of water and the average Australian uses 340 litres a day. In that context six litres a minute is a very modest amount.

And Weaver added that it is MA 0 1 4 _your 0 0 water.

0 _ T “We E C dopossible to8re-use closed loop systems which recirculate

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the water. So you fill it up once and that’s it.

It will just recirculate,” he said.

The OMAX 60120 JetMachining Center features a precision OMAX MAXJET 5i Nozzle.

Software The latest machines come with powerful software systems.

For example, one of Headland’s offerings the Omax60120 includes the Intelli-MAX software suite which was terms of automation. According to Gokhale, while software now comes developed to ensure the waterjet is with monitoring capabilities, “you controlled at all times and the finish cannot use lights out machining with is optimised. waterjets at the moment.”

According to Weaver, its Automation may come in the automated programming software is future but at the moment, the intended to allow the user to go from operators of waterjet cutters have to loading a drawing to cutting parts load and unload all the sheets. in just five steps. And pre-drawn In any case, as Matt Weaver designs are input with a USB stick. explained, the demand for such According to Gokhale, right now automation is currently not there waterjets are unable to cut very anyway. large objects; they can’t handle “At the moment the majority massive big plates, large water tanks of our systems are sold to fairly and so forth.

1 And 2 0 waterjet 1 4 - 0 7cutting - 0 8 T 5 :a 2 5 : 4 small 0 + 1businesses, 0 : 0 0 because it’s cheap, is 1still because it’s versatile, because it’s fair way behind laser cutting in

easy to run,” he said.

“The attraction is what the Americans call the ‘Mom and Pop shop’.”

And they’re not interested in lights out operation. They are more interested in the versatility and reliability that waterjet cutters provide.

Applied Machinery 03 9706 8066 www.appliedmachinery.com.au Headland Machinery 1300 592 061 www.headland.com.au

Manufacturers’ Monthly SEPTEMBER 2014 25

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Metalworking & MACHINE TOOLS Automating structural steel fabrication AdvAnced Robotic Technology (ART) has released the Metaltek XB series 10-axis structural steel fabrication system.

“We developed the Metaltek XB series to answer the need for fully automated structural steel processing in one machine,” company director david White explained.

“To eliminate as much manual labour as possible we included full material handling and all functions are automated and simple to operate. The whole machine is designed to reduce labour and double handling while increasing productivity and profits.”

With a footprint of 3750 x 3600 mm, the system offers full 4-sided plasma processing for the steel fabrication industry, advanced cnc robotics, high-definition plasma cutting and in-house developed user-friendly software and control interface.

Moreover, 3-axis material handling conveyor systems and cross-transfer conveyors for load and unloading are intended to eliminate a large percentage of lifting, flipping and moving of steel members between machines.

The machine is suitable for hot

The machine is suitable for hot and cold rolled structural steel profiles and cold rolled structural steel profiles, including RHS, SHS, UB, Uc, PFc, TFc, eA and UA, with maximum beam cross sections of 1260 x 600 mm. All copes, mitres, square cuts, slots and holes can be cut automatically.

Full bevel weld preps can be applied to all surfaces including underneath. Plasma etch marking is also a standard feature for part numbers, welding instructions, alignment marks etc.

The company’s ProfileShop v4

touchscreen automates all cutting settings, resulting in optimum cut quality. The advanced cnc reads industry standard dSTv and dXF drawing files, supporting software packages such as Tekla, Strucad, Autocad and more.

Advancements in high-definition plasma cutting have long enabled structural steel fabricators to use the technology in their shops. ART uses HyPerformance technology by Hypertherm, which, combined with

its machine motion control systems and software, further improves plasma cutting.

Specifically, Hypertherm’s True Hole technology uses a specific combination of cutting parameters optimised for steel applications.

According to the company, the end result shows an improvement of up to 50 % in the shape of the hole. At the same time, taper and dings are virtually eliminated on holes with an equal diameter to thickness ratio.

The system features a cnc-controlled 3-axis in-feed and out-feed roller conveyor system, an integrated automatic hitch-feed mechanism, as well as cnc cross-transfer drag conveyors for loading and unloading.

Inside the cell work area, the machine automatically senses material dimensions, and an extraarticulated robotic arm performs the desired cuts, even underneath the beam. In conjunction with the gantry system, the arm’s reach is maximised.

Advanced Robotic Technology 1300 565 528 www.advancedrobotic.com

Double Octomill High Feed face mill DesigneD to increase metal removal rates in steel and cast iron applications, the new seco Double Octomill High Feed face mill features 16 cutting edges per insert and brings versatility, productivity and economy to roughing operations.

While traditional face mills typically use inserts with four edges, the Double Octomill High Feed, available in diameters from 80 mm to 160 mm, incorporates insert pockets with a negative axial angle that allows for doublesided inserts with a total of 16 cutting edges. The inserts themselves use a positive rake angle to minimise power consumption while achieving higher cutting speeds for a significant increase in productivity. seco has further enhanced the cutter’s performance by grinding location grooves on the inserts to ensure precise and stable positioning in relation to the edge and seat of each insert pocket, which allows very tight tolerances to be held. each pocket incorporates a strong centre lock screw and axial and radial high speed steel (Hss) location pins that mesh with the insert grooves. These pins increase tool life because the pockets do not wear 26 SEPTEMBER 2014 Manufacturers’ Monthly

features a hard HV 700 coating that protects the tool from wear and prevents chips from welding onto the cutter. seco offers a comprehensive On09 insert range for the Double Octomill High Feed, with three first-choice insert geometries (M12, M14 and MD16) and four firstchoice grades (MP1500, MP2500, MK1500 and MK2050).

This range of inserts allows the cutter to be successfully applied across a wide range of steel and cast iron applications. The Double Octomill High Feed is available in normal pitch versions. in terms of machining parameters, manufacturers can combine a shallow depth of cut with high feed per tooth and use the Double Octomill High Feed to achieve higher metal removal rates and increased part production. such parameters also increase process stability and tool life by directing the cutting forces axially, which reduces the risk of vibration.

The High Feed face mill features 16 cutting edges. out as fast when compared with a traditional face mill.

Additionally, the Double Octomill High Feed cutter body

Seco Tools 1300 55 7326 www.secotools.com/au manmonthly.com.au

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AM

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MA0914_028

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Automation& ROBOTICS Automation: a challenge and an opportunity The automating of processes in manufacturing and other industries continues apace, and robot sales have never been higher. Brent Balinski talked to spokespeople from three Australian Packaging and Processing Machinery Association member companies about some recent trends.

I

n manufacturing and elsewhere, the drive for higher levels of automation is undeniable.

“Demand for all types of robots is on the way up,” explained Bill Saylav, Engineering Manager at JMP Engineering, when Manufacturers’ Monthly asked about demand for increasingly popular lightweight robots.

Automation has been a hot topic this year especially, featuring in debates about growing economic inequality and efforts to completely automate container terminals.

According to the International Federation of Robotics (IFR), worldwide purchasing of industrial robots has never been more robust.

The IFR’s figures show about 179,000 robots were sold globally last year.

The standout country was China, buying nearly one in five of all robots sold. Combined, the next four most robot-happy countries, Germany, Japan, USA and Korea accounted for half of the total market.

Asia/Australia stood out as the leading region overall. A regional increase in installations of 18 per cent – to roughly 100,000 – was seen.

In Australia, the rush to robotise was even used recently to explain an increase in joblessness after the ABS showed unemployment creeping up to a 12-year high.

Automation is, according to shadow treasurer Chris Bowen, among the “greatest unspoken challenges” in the national economy.

“There is a disconnect here,” he said at the Financial Services Council annual conference last month.

“Productivity is going up but employment is not following to the degree that it should.”

28 SEPTEMBER 2014 Manufacturers’ Monthly

The jobs that automation has replaced aren’t limited to those in logistics and factories, with plenty of examples including in agriculture, trading, and even journalism.

In manufacturing the unavoidable need to automate to stay competitive has been used to explain the decline in demand for lower-skilled jobs, and the overall decrease in manufacturing employment.

As reported earlier this year, recent demand in Australia for robot assistance has been strong, with one company telling this magazine earlier this year that units sold increased from 690 to 1214, “a 76 per cent jump from 2011 to 2012.”

Are some workers worried?

“In short, YES,” Stuart Shaw, Innovations Manager, Machinery Automation & Robotics, told Manufacturers’ Monthly.

“Production line workers tend to have this view.”

Those positive about the increase in automation say it’ll liberate employees from tedious tasks.

“Robots will free workers from repetitive tasks enabling them to move to more interesting roles,” Mark Emmett, Managing Director of HMPS told Manufacturers’ Monthly.

Saylav said there was some time to go until every production line role has been replaced by a robot.

“We can see that Australia still has a long way to go before it’s saturated by total automation,” he said.

While all types of robots are in increasing demand, there are some particular trends that some are noticing among types of machines and segments of the manufacturing industry.

According to Emmett, the use of robots in food and beverage has dou-

According to JMP Engineering, demand for all types of robots is increasing. bled every year in the last five.

Also, “Robots are replacing conventional mechanical systems,” he said.

Saylav agreed that demand was particularly strong in the types of robots required in food and beverage, in “mid- to high-speed” varieties.

“Australians are definitely consuming more than ever before and expect the supermarket shelves to be full at all times,” he explained.

Another trend apparently in effect, pointed out by the IFR and others, is the need for lightweight, particularly collaborative, robots.

The CSIRO has pointed out that these types of machines can offer productivity and flexibility advantages while being safe to integrate into a production line.

“Smaller, lightweight robots are the fastest growing robotic segment,” said Emmett.

Shaw agreed.

“Interest is increasing as the awareness and capabilities of lightweight robots is disseminated,” he said.

“Interest is escalating for collaborative robots that can work safely alongside humans.”

Collaborative ability (including teachability), flexibility, safety and speed all come up in conversations about automation trends.

“High demands require high speeds,” said Saylav, adding that JMP had increased the speed of its offerings in June.

“High speeds [also] require high efficiency.”

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

JMP Engineering 03 9460 1219 jmp.co.nz Machinery Automation & Robotics 02 9748 7001 www.machineryautomation.com.au HMPS 08 8150 1000 hmps.com.au manmonthly.com.au

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Compact infrared temperature sensors IFM EFECTOR has released new temperature measurement sensors for hot objects. These new industrially-compatible infrared temperature sensors have been developed for non-contact measurement up to 2,500 °C. The TW type sensors show the temperature value on a display and send it as analogue or switching signal to the controller.

To achieve a maximum accuracy you can select from sensors with different spectral ranges for different temperature ranges. Therefore users will get a sensor optimised to their application.

For a precise measurement the emissivity of the target object can be set using pushbuttons and the display.

Scratch-resistant precision lenses minimise the impact of divergent light. In combination with different lengths of optical fibre separate measuring heads allow use at extremely high ambient temperatures up to 250 °C. Besides variants with switching and analogue outputs (4...20 mA), sensors with two freely programmable switching outputs are also available.

For a precise measurement the emissivity of the target object can be set using pushbuttons and the display.

Process sensor with a new look

MA 0 9 1 4 _ 0 0 0 _ P I E Display size has been increased.

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1

to an alternating indication of “red IFM EFECTOR’S newly improved PN green”. Therefore, switching states can series combines reliable quality with be highlighted or an independent colour extra user friendly features. window can be created. The sensor is Although the housing size has quickly and easily set using the three remained unchanged, the display size pushbuttons. has been increased once again for The new PN sensor is extremely easier display and the two switching flexible. The fitted sensor can rotate status LEDs on the sensor head are 2 0 1 4 - clearly 0 8 - visable.

1 2 T 1The 1 display : 1 8 :can 3 be 3 + 1 in 0 every : 0 0direction and there is an also additional 1/4” male thread in addition switched from the indication of “red”

to the normal female version.

High overload protection, IP67 for all types within the series, and the captive laser labelling make the new PN sensors a good choice, even in the most harsh environments. ifm efector 1300 554 584 www.ifm.com

Manufacturers’ Monthly SEPTEMBER 2014 29

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Automation & ROBOTICS Materials handling robots THE new Industry 4.0 robot was launched by German robotics manufacturer KUKA at the Automatica in Munich this year.

Designed to revolutionise the automation of materials handling, KUKA’s Industry 4.0 robot, called the LBR iiwa, is a 7kg or 14kg payload robot that supports the Human and Machine Cooperation (HMC) concept with features that allow the new range to work without traditional safety fencing.

Greg Sale, CEO of KUKA Robotics Australia , who was in Germany for the launch, explained that the user’s ability to start and stop the robot with a gentle touch of the hand takes the whole operator/machine relationship to a new level.

Features of the new generation Industry 4.0 robots include using the sensitivity of the robot to check the correct weight of the product being picked up; waiting for a product to bump it before picking it up, making redundant theM use of 7external A0 1 4 _ sensors; 0 0 0 _orSclosing EN a machine door just as a human would,

Supports a wide range of DC input 9V~36V.

A 7kg or 14kg payload robot supporting HMC. with variable force, all without the need for external or add on devices.

Speaking about the safety factor, Sale recalled he was a little nervous the first time he put his hand into the path of the LBR assembling two halves of a gearbox; however the force was a gentle touch and the robot pulled back without even leaving a mark.

LBR iiwa is the first industrial robot to have force torque sensors on all of its seven axes.

Fanless rugged system with 4th Generation Intel i7/i5/i3 Processor

BACKPLANE SYSTEMS TECHNOLOGY is pleased to release Perfectron’s new EBX Extreme Rugged Fanless System, the SR100. The SR100 is based on the Intel Haswell QM87 chipset and is powered by Intel 4th generation Core™ i7/i5/i3 processor onboard.

The SR100 can operate effectively in harsh environments under temperature KUKA Robotics Australia ranges 1 2 0 1 4 - 0 6 - 1 6 T0309244 9 : 3500 1 5 : 1 1 + 1 0from : 0-20°C 0 to 60°C (-40 to 70°C optional) and is a perfect solution for www.kuka-robotics.com/australia military, transportation, factory automation and digital signage applications.

The SR100 is based on an EBX form factor which features with stackable PCIe/104 and FPE expansions, onboard Nano SATA(3.0)16/32 GigaByte SSD and - Turnkey Upgrade Solutions Swissbit XR-DIMM up to 8GB. It supports Improve Productivity - Quality - Safety triple-display with 2x DisplayPort and 1x DVI-I, plus 2x GIGA LAN ports, 4x USB Conveying • Palletising (2x 2.0, 2 x 3.0), 1x COM port and 2x

Machine & Process Automation • • Printing • Registration • Winding • Batching • Weighing • Sorting • Web control • Tension

Backplane Systems Technology 02 9457 6400 www.backplane.com.au

TCC-H Over / Under Current Control

• PLC • HMI • Drives • Programming • Electrical • Mechanical • Installation • Upgrade • Repair

Packaging • Winding • Printing • Food Sentient Automation Pty Ltd

Unit 7/36 Latitude Blvd, Thomastown, Victoria 3096 Ph +61 (0) 450 129028 www.sentientautomation.com

30 SEPTEMBER 2014 Manufacturers’ Monthly

mPCIe expansion slots (one co-layout with mSATA). The SR100 supplies wide power voltage from 9 to 36V DC-in designed for use in a range of industrial applications.

It also features standard I/O functionality by stacking with SK401, and with PC/104 Universal Bus of Type 2. There are four-set SATA signals on the SK401 functioning through 2x main SATA signals, the user can decide to use 1x external SATA connector and 1x mSATA, or 1x on board 2.5” SSD/HDD and 1x mSATA .

The SK401 supports operating systems including of Windows 7, Windows XP, Linux and DOS. The dimension of this add-on module is a mere 109 mm x 96 mm.

AUTOMATED CONTROL and Hiquel introduce the TCC-H Over / Under Current Control Monitor from the TIP Series.

Providing high-performance monitoring for equipment (eg. cooling pump or fan motor) with trip outputs should the current flow go above or below the set-point.

The TCC-H monitors either AC (1 Phase) or DC currents and has three measurement ranges, 5mA- 10A RMS. The current control monitor has LED indicators for power supply, contact and reaction timer, and programmable latch/no latch alarm.

The TCC-H Over / Under Current Control Monitor is DIN rail mount (45mm) and has adjustable start delay timer (inrush), reaction timer and hysteresis.

Features include: supply voltage variation nominal voltage +10% / -15%; frequency range 48 - 63 Hz; duty cycle 100%; start surge delay 0 - 10s; reaction time 0 - 5s; reset time < 100ms; operating conditions -20 to +60 °C non condensing.

Automated Control specialises in process and automation control equipment, serving industries including water, industrial, food, mining and petrochemical markets.

Automated Control 02 4964 4022 www.automatedcontrol.com.au

manmonthly.com.au

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Automation & ROBOTICS

Automate to manage energy Good management can ensure that large energy reductions are completely realistic. The big challenge for manufacturers is to identify the low hanging fruit, writes Florian Güldner.

R

the current crisis in the Ukraine, EDUCING costs remains the the long-term supply of Russian primary target for energy gas in Europe could be threatened management initiatives in (and almost certainly will get more industrial facilities. Projects and expensive). measures can shift from difficult to In North America, a boom in easy as new technologies are used. unconventional energy, including ARC Advisory Group research both oil sands and shale gas and oil, indicates that by employing has lowered feedstock and energy appropriate energy management costs for chemical manufacturers, measures, energy-intensive leading to a resurgence in domestic companies can reduce their energy consumption around 30 to 40 percent production.

In Japan, industries are reover a timespan of around 15 years. thinking their energy strategies in The challenge, of course, is to the wake of the 2011 earthquake identify the right “low hanging “energy rich,” several countries have and nuclear disaster, which may lead fruit” to target initially, and to started taking measures to increase to the total phase out of nuclearimplement the right measures. energy efficiency and reduce their generated electricity there, further Much has changed since ARC dependence on fossil fuels. increasing the need to import LNG Europe held its first workshop on and other fossil fuels. energy ma nagement in 2012. In Europe M A 0and 7 1Asia, 4 _ 0energy 0 0 _ prices ROB 1 2Even 0 1 in 4 -the 0 Middle 6 - 1 6 East, T 1 0which : 3 9 : 0 Lessons 3 + 1 0 : from 0 0 the survey is generally perceived as being have continued to rise and, with As we learned from our recent energy management survey, reducing costs remains the primary target for energy management initiatives in industrial facilities, followed by the Robot Spares is now an established local need to optimise existing processes supplier of robot spare parts and services. and a desire to plan for the future, when both the volatility of energy Many parts can be shipped Robot Spares is now an established local supplier of robot from Robot Spares local prices and the intensity of global warehouse on the same day. spare parts and services. competition are likely to increase.

Demand charges and increasing Australian robot users, Items not available locally volatility of energy prices, in especially users of ABB robots, can be dispatched from GRP to combination with rising price and Australia and be available to your finally have an alternative margin pressure, also makes the need site within 4-5 days. local supply of quality new and to plan future energy consumption a exchange robot parts, all with top priority for end users.

With over 30 years experience 1-year warranty.

The process industries are by working with ABB robots, Robot far the most energy-intensive of all Robot Spares holds a Spares staff have the technical industrial sectors and ARC estimates knowledge to deliver expert comprehensive range of stock training and support. and has access to spare parts and that the percentage of energy as consumables for the latest releases a variable cost, which on average Now in its second year of as well as older generations robots. accounts for approximately 8 Supported by Europe’s largest operation, and with a solid base percent of variable costs today, could independent supplier of ABB robot of repeat customers. rise to 25 percent globally by 2025.

spare parts, Global Robot Parts (GRP), Robot Spares is able to deliver the right part on time and at a competitive price.

For further information, please do not hesitate to contact Per Stigsson.

Mob: 0414 843 191 Email: sales@robotspares.com.au Web: www.robotspares.com.au

32 SEPTEMBER 2014 Manufacturers’ Monthly

Director Per Stigsson is confident Robot Spares can compete on quality, price and delivery.

Real-world experience In our European Forum in Amsterdam in March, ARC hosted a workshop on energy management in which Bayer Technology Services presented its approaches to energy management.

Global chemical manufacturer Bayer developed its STRUCTese

energy management approach in 2005 with the initial goal to reduce emissions for every metric ton of product produced by 25 percent by 2020. Based on the program’s success, Bayer raised its goal, and now aims to achieve a 40 percent reduction in emissions within 15 years.

The program goes beyond capital investment to encompass all aspects of energy management. This includes new technologies, process improvements, and operations and maintenance. The company found that improvements in operations and maintenance often brought large savings without requiring any capital investment.

One of the key elements is the energy loss cascade. The concept of dynamic and static loses are similar to what ARC calls active and passive energy management. By reducing partial loads, Bayer was able to reduce energy consumption to a significant degree without requiring any capital investment.

In addition, the company was able to improve the efficiency of many processes by using smaller equipment and correctly sized motors. During this process, it’s important to re-evaluate the point of optimal operations, or the “perfect unit.” In the end, investment needs to be profitable. The accompanying chart shows Bayer’s approach to clustering investments in energy management. Projects and measures can shift from “difficult” to “easy” manmonthly.com.au

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as new technologies are used, or from “non-profitable” to “profitable” as energy prices rise.

The company has rolled out the program in more than 50 plants, which has introduced new challenges related to knowledge management and knowhow.

Even in Europe, which is somewhat ahead of the curve when it comes to industrial energy management, many companies have still not harvested the “low hanging fruit” of energy management by addressing basic operational

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2 0 1 4 - 0 8 - 1 2 T1 0 : 2 4 : 4 8 + 1 0 : 0 0

issues, right-sizing pumps and motors, or installing more efficient motors and/ or AC drives.

First movers, such as Bayer, have already successful harvested the easy energy savings and must now move into the next phase and explore new opportunities for further improving their energy efficiency, business competitiveness, and reputation.

[Florian Güldner (fgueldner@arcweb. com) is an Analyst at ARC Advisory Group].

Provides up to 15.4 W of power per port.

5-Port and 8-Port Unmanaged IP67 Ethernet Switch ICP ELECTRONICS AUSTRALIA has announced ICP DAS’s NS-205/8PSE-IP67 and the NS-205/8-IP67 Series of IP67 Unmanaged Ethernet Switches designed for industrial applications in harsh environments.

The rugged RJ-45 connector ensures tight, robust connections, and guarantees reliable operation, even for applications that are subject to high vibration and shock. The NS-205/8PSE-IP67 switch provides 5 or 8 fast Ethernet with 4 or 8 IEEE 802.3af compliant PoE ports. The switch is classified as power source equipment (PSE) and provides up to 15.4 W of power per port.

Key features include 4/8 PoE Ports with Power Sourcing Equipment (PSE) Operation (NS-205/8PSE-IP67 Series), and Auto-Detection of PD (Powered Devices) and Automatic Power Management (NS-205/8PSE-IP67 Series).

The Ethernet Switch supports IEEE 802.3/802.3u/802/3x with 10/100M, full/half-duplex, MDI/MDI-X auto-sensing, and provides an economical solution for industrial Ethernet networks. Delivery includes all RJ-45 plugs and caps.

ICP Electronics Australia 02 9457 6011 www.icp-australia.com.au manmonthly.com.au

Manufacturers’ Monthly SEPTEMBER 2014 33

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Made in AUSTRALIA Australia’s Hidden Champion manufacturers The Hidden Champion concept was created almost three decades ago by a wise old german to help explain his country’s success as an exporter. There are plenty of companies that fit the mould, right here in Australia. Brent Balinski reports.

T

HougH the Term Hidden Champion often refers to an elite type of german Mittelstand firm dominating a certain global niche, such businesses exist the world over.

According to the Manufacturing Excellence Taskforce of Australia (META), there are many manufacturers who share qualities identified by the influential management thinker Professor Hermann Simon in his influential Hidden Champion model, which he has been researching since 1986.

“Here in Australia, there are already strong examples of companies operating who share a common set of values and leadership mindset, demonstrating M Afoundation 0 9 1 4 _ to 0 build 0 0 _aM UM a strong bright future for Australian manufacturing,”

Albert goller, META’s founding chairprice driven,” according to Simon. man, told Manufacturers’ Monthly.

(For more on the Professor’s concept, Simon - who visited Australia late please see an in-depth feature article last october to discuss his popular published by this magazine in October last concept - says Hidden Champions year. - ed.) are in the top three in the world or goller’s organisation has dominate their continent in their identified many Hidden Champion particular niche, earn revenues under manufacturing firms right here in 5 billion Euro annually, and are generAustralia as part of its META 500 ally unknown. project.

Their typical features include a “The defining characteristics deep value chain, an above-average exhibited by these companies are R&D spend (which is also more ambitious goals and high growth productive, dollar for dollar, than that targets; a global outlook; and of other businesses), a high degree customer intimacy and strong of specialisation, and a high level of consumer insights,” he explained. closeness to their customers.

“These are key ingredients to their Importantly, their competitiveness success and competitive advantage.”

1is not 2 0based 1 4 -on0price.

8 - 0 8 T1 0 : 3 2 : 1 5 + 1 0 :Hidden 0 0 Champions also These “Strategies are value-driven, not fit a modern concept of advanced

manufacturing, detailed in CEDA’s Advanced Manufacturing: Beyond The Production Line policy paper, released this April and to which goller contributed.

In the following pages, Manufacturers’ Monthly profiles four of Australia’s Hidden Champion companies - PWR Performance Products, Anatomics, Textor Technologies, and Nobody Denim.

Selected randomly for us by META, they are four of many and they represent a range of industries, including medical, automotive, textiles and electronics.

The difficulties facing manufacturing are well-known and get regular attention. We believe it is also worth highlighting the successes.

We have over 600 products made here in Australia.

Long lasting quality tools that get the job done. www.mummeproducts.com

34 SEPTEMBER 2014 Manufacturers’ Monthly

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PWR moved into its current home, a 7,000 square-metre, $10 million, purpose-built site at Ormeau, Queensland in 2008.

Keeping the world’s racing cars cool PWR Performance Products is a partner to some of the biggest names in motorsport.

Brent Balinski talked to the company, our first Hidden Champion, about how it plans to continue its brisk growth.

“

IT probably comes down to the fact that - and this is not boasting - there’s really not another PWR in the world,” explained the company’s general manager M arshall Vann.

Based at ormeau, between Brisbane and the gold Coast, PWR Performance Products operates in a niche as an engineering specialist in high-performance, lightweight cooling products including radiators, oil coolers and intercoolers.

Its clients include members of a long list of auto racing codes, including Formula one, NASCAR and the World Rally Championship; as well as Porsche (in their 918 Spyder), Aston Martin (in the one-77 supercar) and even the uS military, who have used PWR for retrofitted cooling equipment in army vehicles.

It also sells its goods through retail channels.

PWR was established in 1997 by Paul Weel, a former V8 Supercar driver, and his father Kees (who also

manmonthly.com.au

co-founded K & J Thermal Products with wife Judy).

According to Vann, the company has grown on average, year-on-year, at 20 per cent for the last four years.

Demand has been stoked by greatly increased exports, with the uK and Europe big drivers in the last two years.

“When I started, exports were 45 per cent of sales and they are now 82 per cent, so that’s in four-and-a-half years,” explained Vann, who came from outside the business to assist in systematising and corporatising the family-owned operation as it moved into a higher gear. In that time PWR’s headcount has also increased from 45 to 85.

The company’s overseas sales achievements saw them named Australian Exporter of The Year (Small to Medium Manufacturer category) and Prime Minister’s Exporter of The Year in 2012.

PWR moved into its current home, a 7,000 square-metre, $10

million, purpose-built site at ormeau, Queensland in 2008.

The facility also has a “full commercial kitchen,” explained Vann, and workers are served three meals a day The integrated operation (almost everything is made on-site) includes design, an atmosphere-controlled

“

There’s really not another PWR in the world… brazing furnace for custom-creating radiator cores, a CNC machine shop, fabrication cells, and unique testing facilities, including a $1 million, 30-metre wind tunnel.

“That is capable of testing water, oil, charge air - we’re capable of testing multiple loops in a single

test,” sales engineering Matthew Bryson told Manufacturers’ Monthly of the wind tunnel.

“So we can simulate very closely the conditions of our products as intended to be installed, coupled with the test data we’re obviously recording.”

Manufacturing everything on site is another advantage in the demanding world of top-level auto racing. Vann mentioned this in relation to a competitor in the uS, C & R Racing.

“They’re a fabrication shop,” he told Manufacturers’ Monthly.

“They’re very good at fabricating, but they’re buying the cores for the radiator from somewhere else.”

Vital to the company’s success has been its manufacturing approach, which is highly flexible as well as highly integrated.

“The way that the business started was about being able to deal with short volume runs, whether it be one or whether it be ten [items Manufacturers’ Monthly SEPTEMBER 2014 35

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Made in AUSTRALIA in an order], or, now, we can [do] thousands,” said Bryson.

“It’s [also] the attitude of the people, but it’s about the process and the equipment that we put in place that means we’re more efficient at making small runs to a high quality and with short lead times.”

The business also offers itself as an engineering partner to its customers, rather than just a company that cranks out product.

Solutions are tailored to each racing customer’s desired outcome, of which a racing team will have a fairly detailed idea.

It’s not just about heat exchange, but also “total vehicle development” explained Bryson.

“Because a large amount of the product that we produce is air-cooled, our product and how the product is installed in the car, how it consumes air is of vital importance to the vehicle’s aerodynamic efficiency,” he said.

“And we can develop our cores and change characteristics such that we can either be producing M A 0 9or1reducing 4 _ 0 0 drag.”

0 _ ASS downforce PWR has developed systems

PWR currently provides cooling solutions for nine-tenths of the NASCAR and more than half of the Formula One teams.

Custom-made. Shipped halfway to cope with urgent requests, and around the world. In a week. according to Vann, if pushed, the “That’s pushing the envelope to operation can respond to an urgent make sure that happens, but that’s order made by a NASCAR team on certainly something we do,” he said.

Monday (uS time) and have the 1order, 2 0via 1 4uPS, - 0 with 8 - 1the 3 team T 0 8“at : 1 5 : 0 0 +PWR 1 0 currently : 0 0 provides cooling solutions for nine-tenths of the 10:30 am the following Monday.”

NASCAR and more than half of the Formula one teams. These results have been achieved rapidly: NASCAR deals only began in 2008, and the first prototype for Red Bull’s Formula one team was delivered in late-2009.

The company believes it has the potential to keep growing at the current rate, and the reserve ability to handle this.

Barring peaks, PWR is only a single-shift operation.

“And most of what you’d consider to be the key elements of our process are probably only operating at somewhere near 30 to 40 per cent of their total capacity,” said Bryson.

Citing “different audiences” opening up in oEM and elsewhere, Vann believes that PWR will continue to expand at its current pace.

“Who knows what the future holds, but we certainly can’t see any reason why it won’t continue growing around similar rates,” he said.

PWR Performance Products 07 5547 1600 www.pwr.com.au

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The business of building skulls Anatomics occupies a demanding niche, providing custom products that help surgeons do their job. In the second instalment of our Hidden Champions series, the company’s Robert Thompson spoke to Brent Balinski.

T

HERE’S no shortage of articles and talkfests about what the future of Australian manufacturing might look like.

Nimble SMEs offering niche, high-value products, created through mass customisation by highly-skilled workers (often aided by 3D printing) who are commercialising innovation are parts of the imaginary model that often gets constructed.

Anatomics is one company that neatly matches the characteristics above. It dates back to 1996 and the commercialisation of Brisbane-based PhD research.

“The foundation research developed was stereolithographic biomodelling, now referred to more broadly as patient specific surgical solutions,” Robert Thompson, the company’s Technology & Production Manager, told Manufacturers’ Monthly.

Anatomics has long been using 3D printing for purposes like its patented BioModel process (which converts CT scans into plastic surgical models of things such as organs).

Its main business is in craniofacial reconstruction technology, tailored to each patient’s needs, and provided to surgeons around the world.

The company also has a range of in-house software.

Anatomics began with one employee, Thompson, and is now a growing company based out of St Kilda. It consolidated operations at this second site in Melbourne (which received ISo 13485 certification last year), migrating from the Brisbane site in 2006.

Important to the company’s growth, which it plans to continue through the release of a new microporous implant product, has been its ability to keep surgeons happy.

“That’s one of our key strengths: being able to be very responsive to individual surgeon’s requests,” explained Thompson.

Meeting the demands of a profession synonymous with precision is vital to the company’s continued success.

“We have an electronic system that enables customers to give us their exact requirements, and basically we can use that to satisfy most of our order details,” explained Thompson.

“But if we need to get input from surgeons

manmonthly.com.au

Anatomics’ main business is in craniofacial reconstruction technology. regarding difficult cases and detailed designs and things like that, we can engage in online surgery planning as well with them and design the implant online...surgeons really like that - it gives them a chance to see the implants being designed.”

Earlier this year a peculiar bit of surgery at university Medical Center utrecht in the Netherlands (and Anatomics’ usefulness to the surgeons involved) gained worldwide attention.

An unnamed young lady of 22 had a rare condition which caused her skull to thicken, both inwards and outwards, putting great strain on her brain. “ultimately, she slowly lost her vision and started to suffer from motor coordination impairment,” said the uMC’s brain surgeon Dr. Bon Verweij in a statement.

“It was only a matter of time before other essential brain functions would have been impaired and she would have died.”

After a 23-hour operation, the woman’s skull was completely replaced with a plastic substitute manufactured by Anatomics - which the university and many others reported as being 3D printed.

It was a tremendous achievement and the patient’s reported return to work three months after having nearly her entire cranial vault replaced was inarguably a win.

However, the skull was not 3D printed, contrary to reports by publications including The Huffington Post and Wired.

“A lot of the media around that incorrectly reported that the implant was actually 3D printed, where it actually was not 3D printed,” said Thompson.

“3D printing was used, as it is, in all of our processes as part of the manufacturing processes, but not the actual implant.”

How the two-piece implant was created was a

trade secret, but it was not made on one of Anatomics’ 3D Systems machines.

Thompson’s company is hoping another boost to the attention it receives around the world will come from the new material it developed in collaboration with the CSIRo: PoreStar.

“It’s a porous star-shaped particle implant,” explained Thompson, who cites the product, currently being launched, as an example of a successful collaboration between private business, researchers, and government.

“And that was supported by the Victorian government’s technology voucher program,” he noted.

The innovation was registered last year as Australian trademark 1560161, and Anatomics is currently in the process of promoting it to customers.

“It will create new jobs... as well,” said Thompson.

“We’re just gearing up now to start selling that to our re-sellers overseas and promoting it throughout Australia as an Australian-made alternative to the currently available products, which are all made overseas.”

Looking abroad, increasing its exports is of great importance to Anatomics, which currently exports to about 20 countries, and it hopes to earn increased overseas revenues from PoreStar.

“Australia is a relatively small market,” said Thompson.

“So the export market is of greater importance.

It’s one of our key strategies to grow our export business to ensure the growth of the company.”

Anatomics 03 9529 8088 www.anatomics.com Manufacturers’ Monthly SEPTEMBER 2014 37

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Made in AUSTRALIA going against the received wisdom our third Hidden Champion, Textor has one customer, nappy-maker Kimberly-Clark.

Brent Balinski spoke to director Philip Butler, whose commitment to investing heavily in innovation, people and equipment, has helped ensure the compay’s success.

T

HE received wisdom is that Australian manufacturers should aim to produce specialised products in small quantities, and that the country’s businesses are unable to produce anything in large volumes.

While Textor’s non-woven healthcare fabrics are IP-heavy and the company’s focus on innovation is strong, producing on a large scale is also a feature of its success.

Years ago it decided to focus on low-margin output at high-volumes. It might seem unusual in an Australian context, but it works. And volumes have been building.

“In a week we can ship 24 40-footer [containers] overseas,” Philip Butler, the company’s director, told Manufacturers’ Monthly.

“So that’s not just local product, that’s overseas.”

Also, this statistic is for one product, found in Huggies premium line of newborn nappies.

The fabric for the nappies, known as ultraAbsorb, was introduced only last year, and has proven so popular that Textor is looking to increase capacity for the material - 35-fold - to keep up.

It is all made-to-order, with a lack of warehouse space making a just-intime approach the only option.

“It’s not rocket science,” explained Butler.

“The automotive industry’s been doing it for decades. So it’s really a very simple case of understanding the need...and it’s important to do just in time, it saves capital, it improves your balance sheet, but most importantly it means that you don’t have to double-handle the product.”

The method is one of many steps taken by the company to deal with the high Australian dollar and high local costs.

The company runs a 24/7 operation.

While the family-owned Textor has invested in sophisticated machinery and in its staff, it has not added to its headcount of about 50 in the expansion.

38 SEPTEMBER 2014 Manufacturers’ Monthly

According to Philip Butler, there are “a lot of industrial secrets” about how UltraAbsorb is made.

The recent growth of Textor’s revenues and massive (a recent figure of $17 million given by the company is less than what will be the actual case) investment in increased productivity are “all to do” with the popularity of ultraAbsorb.

The super-absorbent, 3D material was developed in “open collaboration” with CSIRo and the Australian subsidiary of Kimberly-Clark, Textor’s sole

“

The most important incentive is survival Phillip Butler customer. The arrangement was possible due to the trust that had been built up between the three organisations.

Textor’s relationship with the personal care giant goes back over a decade, and the Tullamarine-based SME was named Kimberly-Clark’s Supplier of The Year in 2011.

How ultraAbsorb is made involves “a lot of industrial secrets”, and it has six global patents attached to it.

Much of it makes its way to Kim-

berly-Clark’s Ingleburn nappy plant, but it is being rolled out in KimberlyClark’s nappies around the world.

Initially exported to just Asian countries, Textor’s product has moved into markets, including “Russia, Mexico, America, South America, Costa Rica, Colombia,” noted Butler.

Butler often describes Textor’s move towards collaborative innovation as its “journey”, and the journey began about three years ago, when it was one of the first companies to participate in the Researchers In Business program.

Having a CSIRo researcher embedded in the business for a year did not bring immediate results, but began the R&D process that led to ultraAbsorb.

“And that’s from the initial inception through to creating and building the new equipment, all the design work associated with redeveloping the product,” said Butler.

Again, it’s all to do with the high dollar.

The strategy to cope is twopronged: invest in the most productive equipment in the world - which has actually been assisted by the dollar’s strength - and match this with a technologically advanced product.

The latter was enabled by R&D investment.

Butler credits the R&D tax incentive as a major help in the process, and advises other businesses to explore the option, with the paperwork surprisingly straightforward.

“We decided to put in our first application and we were surprised at how easy it was to make those applications,” he said.

According to Butler, “the results speak for themselves,” and all that was required was a bit of discipline.

“And what will keep us afloat on a longterm basis is more investment in research and development.”

It’s all necessary, he believes, to stay relevant through innovation. ultraAbsorb might be a successful product, but Textor is already thinking about generation two and three. And then there’s the massive upgrades to the plant, which should be finished in March next year. It all matters, and at the heart of it, it’s all to do with one very basic motivation.

“The most important incentive is survival,” said Butler.

Textor Technologies 03 9330 8100 textortechnologies.com manmonthly.com.au

MA0814_000_KRE

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2014-07-09T08:30:07+10:00

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MA0914_040

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Made in AUSTRALIA Nobody Denim: keeping it local our final Hidden Champion, Nobody Denim has built itself into a brand known for quality and style. Co-founder John Condilis told Brent Balinski about the company’s journey and its plans to grow.

“

I guess it’s a passion of mine to have control and the ability to experiment,” explained John Condilis, managing director at Nobody Jeans, which he founded with his brother in 1999.

“And I don’t mean that in a negative way, it’s in a positive way. What we’ve established, is that we’ve had a vision of how we create our own mad scientist laboratory in which we develop and innovate and progress, in our space.”

Having control over everything - in the form of a fully integrated design, manufacturing, and distribution site - came about after an Enterprise Connect business review towards the end of the last decade.

Condilis told Manufacturers’ Monthly, “In order for it to progress and work efficiently, we needed to have the best structure with all activities planned under one roof.”

Everything has been done out of the Fitzroy facility since 2011, with the benefit of greatly shortened lead times and increased responsiveness to customers’ needs.

The decision to keep things [very] local was a response to the uncertainty in the textiles, clothing and footwear industry, said Condilis, who avoided the lure that saw many in the industry move offshore. others simply folded, unable to be competitive as tariffs lowered to around ankle height.

“The trend was to find a manufacturing partner outside of Australia,” explained Condilis of his contemporaries.

“No-one in the fashion space, or in the clothing space, knew where things were going. It was all about margin and cost. The value-add of quality and being a little bit more innovative almost went out the door” John Condilis and brother Nick followed in their father’s footsteps (he ran a denim laundry for Dachet 40 SEPTEMBER 2014 Manufacturers’ Monthly

jeans) running a denim laundry in the 1990s, before beginning their own jeans label in 1999.

“Nobody” retained a laundry service for local companies, though had to cut staff drastically in 2000 (to five) as clients’ local textile manufacturing evaporated.

Condilis said he learned from the industry’s difficulties, adding of his company that, “I guess I was on a mission” to bring Nobody back to good health.

“It was about us developing a value-add product that focussed on quality and focussed on the right fit,” said Condilis.

“And with the right style.”

The company has developed a reputation for stylish, premium denim products, with everything manufactured in Fitzroy. The emphases are on quality and customisability.

Due to an absence of local suppliers, material is sourced from global denim mills.

Nobody Denim has gained a lot of attention in the fashion world.

Having close control over and visibility of the company’s supply chain is deeply important, believes the managing director.

The company gained Ethical Clothing Australia accreditation in July 2010.

“We - all employees - like to have our head held up high saying we’re doing the right thing and we’ve got nothing to hide,” he said.

The focus on desirable, well-made products has gained a lot of attention in the fashion world, with Nobody’s jeans seen on the likes of Rihanna, Naomi Watts and Miranda Kerr.

Condilis puts Nobody’s domestic and export sales at about a 90/10 breakdown, and aims to bolster exports, but not before the company is structurally able to cope with this.

Without the correct infrastructure, it is impossible to properly service demand.

“If your back-of-house is not functioning properly and the correct

infrastructure for global distribution is not in place, any company would find it very difficult to meet demand,” he said.

Condilis believes there’s a need for all Australian manufacturers, especially those in textiles, to think in terms of a global market.

“It’s no longer just Australian or Victoria or Melbourne,” he said.

“Everything is quite transparent and there are greater opportunities.”

Nobody Denim 03 9486 9477 nobody.com.au manmonthly.com.au

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Local knowledge forges success Family-owned tool company Mumme Products is in its third generation, and sets itself apart through its understanding of local customers’ needs. Brent Balinski reports.

C

oMPANIES able to perform well in the difficult environment for local manufacturers have often done so due to emphases on value, an understanding of and closeness to their customers, and flexibility.

Mumme Products has been making hand forged and other tools since the 1930s, and are quick to mention that, being manufacturers themselves, they are aware of the challenges their industrial clients face.

“In-house research and development is ongoing,” Chris Mumme, the company’s business development manager, told Manufacturers’ Monthly.

“We face the same problems as our customers and are constantly developing new products for our own use, so we often already have the solutions to a customer’s problems.”

M Acompany 0 9 1 4 enjoys _ 0 0 0significant _ REC The exports, with about 20 per cent of

its products sold overseas, including first and foremost we are manufacturdestinations such as North and South ing in Australia, keeping Australians America, Asia, and even, they proudly in jobs. It’s all about educating the note, Antarctica. customer and remaining innovative.”

The family-owned business is in its The company offers a range of third generation, and has remained in hand tools, such as chisels, digging Adelaide for the last 78 years. tools and hammers, and has customers It has grown in the last generation in industries including mining, manuthrough acquisitions in 1989, 2001, facturing, defence and utilities.

2002 – and last year gained a partA deep understanding of the nership to distribute uS electrical needs in its domestic markets is tools specialist Klein’s products in another point of difference compared Australia. to cheap imports. In addition, consistIn the local environment, inexpenent quality and flexibility are things sive imports and the higher dollar importers do not address effectively. have meant highlighting points of “Both of which we address, unlike superiority are more important. some of our overseas competitors,” “For us to remain viable in this said Adam Mumme. climate, we have to spend time and “In particular we have the abilmarketing dollars,” managing director ity to address site-specific issues, Adam Mumme told Manufacturers’ because we can do small production runs. We can customise products to Monthly.

1 “We 2 0 use 1 4 first - 0 grade 8 - 0 materials, 5 T 0 9 : our 1 2 : 5 suit 0 + a1particular 0 : 0 0 application, such as tools are consistently high quality, and making a longer or shorter version

PROUDLY AUSTRALIAN • • •

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of a product, or adding a hanging loop or safety collar to an existing product for a particular safety issue on a site.”

Mumme is currently developing a new range of wrecking bars for release later in 2014.

Its newer products include a bursting chisel (a wedge with chisel handle) and a pit bar. “used for splitting cases, flanges and mating surfaces (similar to our fox wedges), the head of the chiseltype handle is normalised for safety and the blade is finely tapered and ground,” explained Chris Mumme of the bursting chisels.

“The Pit Bar is a digging tool used for trenching, squaring up holes and cutting through tree roots.”

+61 2 9621 8988

CUSTOM MADE REELS ARE OUR SPECIALTY

sales@recoila.com.au Manufacturers’ Monthly SEPTEMBER 2014 41

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SKILLSTRAINING & RECRUITMENT The old, the new and the future TAFE Queensland SkillsTech has a wide-angle view on Australia’s skills, training and recruitment landscape: clients range from single subscribers to multinational conglomerates, while courses and programs are equally diverse.

Everything old is new Growth in traditional trade training continues apace at TAFE Queensland SkillsTech, with its light and heavy automotive schools undergoing something of a renaissance, leading to the development of heavy/large engine reconditioning capability and auto mechanical/electrical dual trade qualifications.

Stonemasonry is another trade poised to flourish. Originally based at Eagle Farm, the school recently relocated to TAFE Queensland SkillsTech’s flagship Acacia Ridge Training Centre, occupying a custombuilt workshop space featuring new equipment and tools.

As at 8 August 2014, stonemasonry was listed by the Queensland Department of Education, Training and Employment (DETE) on its Skills Shortage List and this is also reflected nationally. According to stonemasonry teacher Steve Sullivan, the new workshop will be one of the most advanced training facilities globally when it officially opens in November.

“It’s a big call I know, but the scale and scope of our capability will be unparalleled. For training, it means we will be able to take a more hands-on approach for masonry applications used in manufacturing, such as kitchen bench tops, to monumental and heritage restoration work,” Mr Sullivan Said.

Developing existing workers The recently launched Registered Trade Skills Pathway (RTSP) program is a fully-funded program giving existing workers in manufacturing and engineering industries an alternative to traditional apprenticeship, Certificate III qualifications and formal recognition as a tradesperson.

Stephen Gates, recognition services assessor at TAFE Queensland SkillsTech, said it’s important to create pathways to trade qualifications 42 SEPTEMBER 2014 Manufacturers’ Monthly

Programs on offer range from niche, specialised and emerging industries to traditional and artisan. for workers that build on a worker’s existing trade-based skills, knowledge and experience.

“The nature of employment in the manufacturing, engineering and heavy auto industries can make it difficult for unqualified workers such as labourers and trades assistants to formalise their skills and experience and access extra training where needed,” Mr Gates said.

“Those who are currently employed and for a variety of personal or employment reasons may not be able to access the traditional apprenticeship way. This pilot program recognises a broad range of work and life experiences, with the availability of training for persons who may have small ‘gaps’ in the skills and knowledge required at a trade level.”

Delivered in partnership with DETE, more than $1 million is being invested to subsidise 100 training places for those with existing skills and experience in the manufacturing and engineering industries.

“The manufacturing and engineering RTSP pilot has only just been launched and we’ve already filled 10 out of 100 positions. I’m confident we won’t have any trouble filling the 100 positions available,” Mr Gates said.

Enhancing skills While talk around town dwells on the changing nature of skills, training and recruitment in the mineral and resource sectors, TAFE Queensland SkillsTech is already experiencing a ramp-up in demand for niche, highly specialised training options to ensure Australian resource companies stay ahead of the skills game.

High density polyethylene (HDPE) welding is a prime example. Developed through collaboration with key partners Queensland Gas Company (QGC), Iplex Pipelines and GF Piping Systems, TAFE Queensland SkillsTech’s development of HDPE welding courses addressed a twofold problem: challenges faced by QGC in terms of HDPE pipe infrastructure and critical skill shortages in Queensland’s natural gas sector more broadly.

As a result of the collaboration, TAFE Queensland SkillsTech developed nationally recognised competencies and statements of attainment under the Australian Qualifications Framework (AQF) national training system, namely: • Butt weld polyethylene plastic pipelines (PMBWELD301B) • Electro fusion weld polyethylene pipelines (PMBWELD302B)

• N on-accredited: Hot tapping and squeeze off - Statement of Participation contextualised under electrofusion welding (a national competency).

This delivery of nationally recognised qualifications/statements of attainment gives graduates transferable competencies – a training first for Queensland’s energy sector – and consistency in training.

The HDPE welding training and delivery model, established by TAFE Queensland SkillsTech, has been eagerly adopted by other key players, including Murphy Pipe and Civil and Origin Energy, and leading vocational teacher Danny Platt hasn’t been busier.

Delivered in the field and in a simulated workshop environment at TAFE Queensland SkillsTech’s HDPE PE100 Centre of Excellence at the Acacia Ridge Training Centre in Brisbane, Mr Platt is regularly engaged to train, assess and verify HDPE competencies all over Australia.

“Last week I was at Miles and Roma, then it was down to Tasmania, and next week I’m at Dalby and Chinchilla,” Mr Platt said.

With applications beyond oil, gas and natural resources (think water and other infrastructure) Mr Platt attributes TAFE Queensland SkillsTech’s success at HDPE welding to continued partnerships with co-providers like Iplex and GF Piping Systems.

“Hot tapping and squeeze off has certainly generated the biggest industry response and this means we have access to the latest technology and equipment and plenty of it, with our industry co providers sharing the latest trends and strategies. I believe we are also one of the very few offering training in hot tapping and squeeze off of HDPE,” Mr Platt said.

TAFE Queensland SkillsTech 1800 654 447 tafeskillstech.edu.au manmonthly.com.au

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Australia Pty Ltd

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2014-08-27T07:40:20+10:00

BodyPROTECTION New executive safety boots reviewed For those who don’t necessarily have to trudge through the dust and mud every day, but still need to step out on site fairly regularly, Blundstone have released a new style of executive safety boot. Ben Hagemann reports.

W

here the last model featured elastic sides and visible seams to the toe, the new executive Style 783 improves on their dress safety boot with a molded leather toe, and inside ankle zippers.

It’s a great looking boot, very simple in style and perfect for maintaining polish with no seams over the toe, which is steel-capped to ensure that whenever you step on site you are covered for personal protective footwear.

The best thing about these boots is the comfort factor. Many types of men’s dress shoes have a very thin sole, which is murder on your feet if you have to spend much time walking around.

People who have spent years wearing work boots around site get used to the comfort, especially with the way boots are designed these days.

But people who get off the tools and wind up at a desk in office attire can find that ordinary dress shoes have nowhere near the level of support and comfort afforded by regular steel capped boots. even if you don’t need the safety toe, the 783 is one of the most

There’s no breaking-in time, so there’s no problem with getting a comfortable wear from day one. comfortable dress shoes available.

Like all good work boots these days, there’s no breaking-in time, so there’s no problem with getting a comfortable wear from day one.

To illustrate the point, a journalist friend has whinged relentlessly about having sore feet since changing from work boots to office wear, so it was with no small degree of scepticism that he road-tested a pair. however, after only 24 hours of wear he’s already remarked that his feet aren’t nearly as sore as they were

after a hard day at the office in dress shoes, slaving away at the keyboard to bash out the news, or trudging through the city to the next heartattack inducing business lunch.

This kind of orthopaedic protection comes down to the Shock Protection System (SPS) Max, dual density sole, with Poron XrD for up to 90 per cent step impact protection in the heel strike area.

This reduces shock impact through the legs, which means they’re not so tired at the end of the day, and

cushions the lower back from hard impact on heel strike.

The lightweight sole also has a nylon shank which ensures the correct step flex point, which assists with the torsional stability of the sole.

The inner sole is a comfort arch footbed made from soft polyurethane, incorporating an airflow and moisture wicking system to reduce sweatiness during wear.

The Poron XrD material is also impregnated with Microban, an anti-microbial agent which will stop bacteria and fungus, and reduce odour.

The steel cap is a broad toe with 200 joule impact resistance, and the sole is resistant to temperature (up to 140 degrees) and electrical hazards.

The sole is also slip resistant, oil and acid resistant and organic fat resistant, which makes it a great choice even for kitchen staff in camp.

All in all, the 783 executive is a great pair of boots for looks, comfort and safety, even if you never set foot on site another day in your life.

Blundstone Australia 03 6271 2222 www.blundstone.com

Lightweight, oil-repellent gloves ANSELL’S HyFlex 11-926 glove employs Ansell’s Ripel liquid repellence technology and Ansell Grip technology, and is the first lightweight HyFlex style to combine protection against knuckle abrasion, oil exposure and oil grip in a single flexible glove.

Many manual tasks across a range of industries may be completed with greater hand protection and efficiency with a new comfortable, light duty oil repellent multi-purpose glove that provides protection, while helping retain grip on small, oil coated parts and assembly components.

Featuring a durable three-quarter dip coating to ensure full protection to the back 44 SEPTEMBER 2014 Manufacturers’ Monthly

of fingers, the glove is designed to provide all-day comfort, thanks to a soft liner made from a very fine gauge nylon fibre.

According to Ansell’s David Nicholls, the unique blend of protection, performance and flexibility features incorporated in the HyFlex 11-926 glove bridge the gap from previous generation palm dip style oil repellent general-purpose gloves built on cut and sew cotton liners, to the latest seamless palm dip gloves.

“This lightweight multi-purpose glove is ideal for operations such as cutting,

Features durable threequarter dip coating.

sorting, inspection, uploading and downloading parts of the line; inspection of machine parts and components of metal working as well as assembly of components and machinery,” Nicholls said.

Ansell Industrial Healthcare 1800 518 687 ppe.ansell.com.au manmonthly.com.au

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High-visibility tape for safety helmets HIGH visibility clothing has come a long way since the turn of the millennium, but we haven’t seen a lot of major changes since 2010. Generally a fluorescent colour and some 3M reflective tape seems to the acceptable industry standard.

However, a new type of high-visibility tape may become a game changer, one that will have us spotting our co-workers from miles away.

For the better part of a few years, Scott Safety has been in the R&D phase of implementing an electronic neon tape on their safety helmets, which may be available on the market by the end of the year.

David Starbuck said there’s been a lot of research that’s gone into finding the most visible colour, which happens to be blue.

“We’re always keen to develop new accessories for our safety helmets: customisation and adding value to the helmets is huge business for us,” Starbuck said.

“We already have High-viz tapes that go on our helmets, but they require artificial light.”

The tape is able to take an electric current which causes it to light up in bright neon blue, charged by a 30g battery pack on that back of the helmet.

The tape is also able to flash and strobe for higher visibility settings.

Enables high-visibility for people who are working in dark areas

It enables high-visibility for people who are working in dark areas where there is little light, underneath loading docks, roadworks at night, and general nightshift work done outdoors, where traditional reflective tape would be of little assistance without artificial light sources.

Starbuck showed off the prototype helmet at the Queensland Mining Expo in July, but he says that development has been ongoing since then.

“We’ve now developed it to be wider and brighter,” he said.

“We’re at the point where we’re nearly ready to present the finished product. For people who really see a need for it right now we can start to release some units, all we have to do is complete the branding, and although there will be some early sales to specific customers, the new high-viz helmet will be ready for the shelves by November.”

The high-viz tape cannot be retrofitted to old helmets as the difficulty of installation is high.

The rechargeable lithium-ion battery pack life is around 10-11.5 hours, or 20 hours on the strobe function, and the pack is waterproof to ensure it will survive any weather.

The tape is manufactured by EL Australia, who have been fitting the tape to safety vests and motorcycle helmets, and now Scott is bringing it to industrial uses.

“We wanted it to be as low profile as possible, and we were also very cautious to ensure that the weight on the helmet would be limited,” Starbuck said.

“We frequently add a lot of accessories to our helmets, A Dand _ Fthey D Mwould ET APR_ 1 3 whether face shields or hearing protection, weigh more than the battery pack.

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Safety glasses

UGLY FISH was born in 2003, launching its fashionable and functional sports polarised sunglass range in the fishing and boating markets.

Ugly Fish’s Flare series is designed to be useful in any industry or on any jobsite, while still holding their own on the drive home.

The safety glasses are available with or without a ventilated positive seal. This seal has the ability to shelters eyes from wind, dust and other air-born particles on the worksite. The glasses also have unique rotating arms allowing the lens to adjust to fit most heads and even accommodate the use of ear muffs and hard hats.

The series is built for comfort and durability, with shatterproof lenses and manmonthly.com.au

Limited lifetime warranty against manufacturer’s defects. an anti-fog and anti-scratch coating.

These glasses are also certified to the Australian Safety Standard. Features include Polycarbonate Decentred Safety Lens (PC-DS) which complies with Australian Safety Standards for medium impact, smoke, clear, yellow or indoor/ outdoor shatterproof lenses. A fixed arm option is also available.

Ugly Fish Eyewear 1300 369 574 www.uglyfisheyewear.com Manufacturers’ Monthly SEPTEMBER 2014 45

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Materials HANDLING A fork in the road With a growing pool of options now on the market, forklift selection is becoming more and more compelling. Sarah Falson offers some tips on how to select the right piece of equipment for your business.

C

hoosing the right materials handling equipment is just as important as selecting the appropriate production systems; both are crucial elements of manufacturing and need to be considered carefully.

Manufacturers today demand a lot from their forklifts, and equipment suppliers are responding by providing vehicles developed specially to meet their industry-specific requirements.

Competitive edge According to Lencrow Materials handling managing director, Ross grassick, local manufacturers require forklift products that help improve workplace safety, handling and operating efficiency.

“They have to play against a world market and if they can save by increased performance and more efficacy this will make their products more competitive,” he told Manufacturers’ Monthly. “in this we look at ways to reduce product damage and increase duty cycles of units between charges or refuelling. This can be achieved by both better handling practices and more efficient equipment. “over the past few years the improvement of both batteries and AC operating systems is giving electric forklifts the performance they need to make them competitive against fuel-driven models.

The up-side of electric vehicle operation is the improvement to the environment as well as a substantial reduction in fuel costs.” grassick says safety is a crucial element in forklift development, and advises manufacturers in the market for new vehicles should check new models meet local safety and quality standards before making a purchase. selecting a forklift based on its competitive price alone can also end up costing a manufacturer more in the long run, he warns.

“The problem today is there are various brands on the market that look similar, but in many cases do not comply with the safety features required in Australian standards, and the quality of the prod46 SEPTEMBER 2014 Manufacturers’ Monthly

Toyota’s new 8-Series Large Forklifts incorporate technology to help reduce the likelihood of lateral or longitudinal rollovers. ucts are not suitable for the Australian manufacturing environment,” he explained.

“Many businesses are faced with having to cut costs to compete with other local manufactures as well as imported products, so in their endeavour to save money they could make the error of choosing equipment by price, thinking that they are saving money.”

According to grassick, longevity in the business is usually a good indication of the reliability of a forklift brand.

“Customers need to ask how long the product has been sold in Australia, and check the supplier offers after-sales service and is responsible for the

“

There are things we can do today that we only dreamt about a few years ago… warranty on repairs if required,” he advised.

“The second requirement is that they get the right advice about the best solution available for their application. We as suppliers are not just selling equipment; we offer materials handling solutions. There is no substitute for the right advice.”

Technology development Toyota Material handling Australia (TMhA) national sales and product manager, Jim Lobow, told Manufacturers’ Monthly that customers are demanding high-quality, durable and reliable

materials handling products that are backed by effective customer service and support.

“Customers are also looking for lowest total cost of ownership through quality fleet management systems,” he noted.

Lobow says manufacturers are constantly searching for techniques to raise production efficiency, and are looking to the latest technology to assist.

“Driverless forklifts or automated guided vehicles (AgV) with repetitive travel paths are currently in development, and suit specific applications in manufacturing,” he pointed out.

Lobow agrees that safety is a key component in forklift development, and Toyota has recently launched a new breed of 3.5- to 8-tonne forklifts designed specifically for use by manufacturers.

Called the 8-series, each model incorporates stabilising technology known as the system of Active stability.

“This ground-breaking technology helps reduce the likelihood of lateral or longitudinal rollovers, and works in conjunction with Toyota’s Active Mast Controller Function – which automatically matches lift height and load weight to help prevent dropped loads or tip-overs,” Lobow explained.

Smart systems According to Crown Equipment general manager marketing & Crown insite, Crown Asia Pacific, greg Facer, the benefits of warehouse system integration are becoming increasingly prevalent, with forklifts now incorporating sophisticated software capable of offering a holistic view of the floor.

“Just as a company’s sales department has integrated various software solutions for manmonthly.com.au

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prospecting, up-selling, cross-selling, customer retention and billing into a single platform accessible via a range of devices such as PCs, laptops, tablets and smartphones, that same company now has the opportunity to undertake a similar program with all the disparate software solutions running on the warehouse floor,” he told Manufacturers’ Monthly.

“This is a world where the technology in the truck – such as Crown’s InfoLink – can record and report on the health of the vehicle and the performance of the operator connects seamlessly, in real-time, with management software. In turn, this software integrates with maintenance and operating training databases to give a holistic view of each shift, each operator and each vehicle, so that better business decisions can be made.”

Crown InfoLink gives warehouse and operational managers real-time insight into a huge range of data that leads to better business decision-making.

Customer savings ForkTrack system allows businesses to take control According to Adaptalift Hyster chief executive ofof their forklift fleet with features such as safety ficer, Andrew Satterley, manufacturers today need interlocks, prestart checklists, impact alerts, and greater visibility across their forklift fleet. real-time online reporting.”

“As fleet sizes grow, so does the need to manage Safety and cost-saving features are also high on them in a more efficient way. Our customers want the needs list, Satterley says: “Safety has always to know what is happening to their fleet, as well as been a hot topic and is still extremely important what may happen, so they can avoid any problems MA 0 9arise,” 1 4 _ he 0 0told 0 _Manufacturers’ ADA 1Monthly.

2 0 1 4 - when 0 8 - it1comes 2 T 1 to 3 :designing 3 3 : 4 our 9 + forklifts.

1 0 : 0 0We also before they offer a range of add-on safety products including “Fleet management technology such as our

manmonthly.com.au

the Hyster Blue Warning Spot Light for alerting pedestrians,” he explained.

“We are continually looking at ways we can save our customers money. Even a small change can go a long way to reducing the total cost of ownership. This all starts with choosing the right piece of equipment for the application, configuring the machine properly, reducing aisle widths for more storage space, and even offering one unit that can do the job of two.

“It is a very exciting time to be a part of the materials handling industry. Technology is advancing so fast that there are things we can do today that we only dreamt about a few years ago.

“For example, battery management is getting smarter every day, with advanced queuing systems telling you which forklift battery to use next.”

Lencrow Materials Handling 1300 245 993 www.lencrowgroup.com.au Crown Equipment 1300 072 752 www.crown.com/au Adaptalift Hyster 1300 758 188 www.aalhysterforklifts.com.au

Manufacturers’ Monthly SEPTEMBER 2014 47

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Materials HANDLING Reach trucks A warehouse can only perform as effectively as its trucks and their drivers.

Reach trucks especially are a partnership of driver and machine. That’s why the new Mitsubishi SENSIA is specifically engineered to take any operator’s performance to the next level.

Available in 11 different models with a maximum lift height of 13 metres, the reach trucks are generous on operator space and comfort and are designed to ensure operators stay focused, safe and productive at all times.

The average reach truck operator mounts and dismounts the truck up to 100 times per day. These reach trucks are designed to make that easier and more comfortable through a lower seat position, ergonomic hand 0 9 non-slip 1 4 _ 0 step, 0 0 _ LE bars,LaM wide and an adjustable steering

Hunt for the forklift champ console that folds neatly out of the way. The key is to have your drivers concentrate on the job at hand, not the truck.

According to the company, the reach trucks have the strength to lift bigger loads to higher heights than most other trucks its size, allowing drivers to operate in smaller aisles and tighter spaces.

With 360-degree electric steering and good visibility through the mast, carriage, overhead guard, and uncluttered cabin, the operator knows exactly what’s going on at all times.

Furthermore, the mast is the strongest and most stable Mitsubishi has ever made, allowing for accurate work at heights of up to 13 meters.

Skilled operators are an important investment and Nneed - to1be protected 2 0 1 4 - from 0 8 - 1 1 the physical and mental

48 SEPTEMBER 2014 Manufacturers’ Monthly

The reach trucks offer good visibility for the driver.

stresses of a challenging job. With this range of reach trucks, the driver can be as fresh and productive at the end of their shift as they were at the start.

MLA Holdings T 1 5 : 2 2 : 5 8 + 1 0131 : 0652 0 www.mlaholdings.com.au

The 2014 Forklift championship is set to find out who is Australia’s best forklift driver in November.

The Australian Warehousing Association will host a number of companies and individual operators to compete for the coveted title in Brisbane.

The Forklift championship is focused on safety and safe operation in a small area where eye and hand skill coordination are tested to the max. Every contestant starts with a score of zero and points are added when an error is made. Not wearing a seat belt will be a penalty of 3 points to the competition contestant as an example. Could your workers benefit from participating and testing their skills?

Every year the number of female forklift contestants grows.

The judges have been very impressed with the quality of driving with only a few points’ variation between the top male and female. The number of female of warehouse managers has increased significantly, in what was “male dominated” in the past.

Forklift operation is now classed by the government as HIGH RISK WORK. As part of this push there are more compliance checks by Inspectors. The current assessment tools to obtain a forklift are very different to the past and include WHS legislation, calculations and wide and varied forklift theory and practical operation. Gone are the “old days” where a wink and a nod got a licence.

If you want to test your forklift operational skills or your workers against the best drivers based on the national standard conditions, register by emailing AusWA on admin@auswa.asn.au.

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Modular goods-to-person storage and retrieval system This modular goods-to-person (GTP) storage and retrieval system from Dematic is said to deliver a picking rate improvement of 500% compared to a traditional environment. it is a flexible, off-the-shelf picking solution for a wide variety of small to medium-throughput order fulfilment applications, ideally suited for businesses distributing from 200 to 1,000 or more order lines per hour.

According to the company, in operations where the system is employed one operator is capable of achieving the same sort of picking rate as up to five people in a traditional picking environment.

The Modular GTP system is designed to deliver high pick accuracy with only one sKU presented to the operator at a time. An integrated weighscale at the pick location checks expected weights in real time further enhancing accuracy and ensuring that any errors are identified and corrected on the spot.

M A 0stock 9 1 4being _ 0 delivered 0 0 _ ML A “With to picking stations in the precise

manmonthly.com.au

The Modular GTP System requires minimal customisation. other’s pace, and pick stations can be sequence required for order assemopened and closed according to busibly – heavy items first, fragile items ness volume on a particular shift. The last, by family group or in whatever system also provides full redundancy sequence needs dictate – pickers can achieve very high productivity rates of as orders can be processed at any location with all pick stations operatmore than 1000 items per hour,” said ing independently.

Dematic’s Wholesale and Distribution The Modular GTP system requires Logistics Manager, Darren Rawlinson. minimal customisation, as all of the With the Modular GTP system, 1staff2 can 0 1 work 4 - 0in8parallel - 1 2 Tat1 multiple 3 : 1 3 : 3 hardware 4 + 1 0 :including 0 0 storage systems, Multishuttle and GTP picking stapicking stations, unaffected by each

tions, and software are pre-configured – which enables rapid installation and start-up. The system’s compact configuration also uses space efficiently, potentially reducing building or leasing costs and providing the opportunity for better utilisation of space in existing distribution centres.

The only systems integration requirements for the Modular GTP system are connecting the high density Multishuttle buffer store to a conveyor network to transport orders out of the system, and to interface the system’s software and controls with the user’s warehouse management system.

Given the seasonality of many businesses, if more sKUs are added or order volume increases over a period of time, the Modular GTP system can be expanded to accommodate new requirements by adding additional Multishuttle storage aisles and/or pick stations.

Dematic 02 9486 5555 www.dematic.com.au

Manufacturers’ Monthly SEPTEMBER 2014 49

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Energy& POWER MANAGEMENT Solar option helps sow the seeds of success Burder industries, a Victorian manufacturer of agricultural machinery, has made the switch to solar energy. What’s more it is banking on the move to help ensure its long-term success.

Y

ingli green Energy Australia (also known as Yingli Solar) is the world’s largest manufacturer of solar photovoltaic (PV) modules. The company has supplied Burder industries with a 355kWp solar PV system through its distribution partner, Envirogroup, a specialist provider of renewable energy products and systems for commercial applications, government clients and residential home owners.

Burder industries is a regional manufacturer that produces customised tractor and earthmoving equipment for the agricultural industry. its facility in Wangaratta, Victoria has been equipped with 1,420 250W YgE High Efficiency Polycrystalline Yingli A DPV _ Ppanels.

A C E P L A MA R _ 1 2 . p Solar The installation will generate ap-

50 SEPTEMBER 2014 Manufacturers’ Monthly

proximately 467MWh of solar energy per year and is expected to provide for 90 percent of the company’s daily energy consumption. Solar power will reduce the company’s electricity costs by over 70 percent each year and provide a 25 year hedge against future electricity price increases.

This will reduce Burder industries’ carbon footprint by up to 607 tonnes annually; an equivalent of taking 145 cars off the road. The company’s investment in solar PV is expected to generate an internal Rate of Return of over 25 per cent annually.

Operating in the agricultural sector, Burder industries competes directly with imported equipment that is produced overseas at a lower dcost. f itPisanot g eprotected 1 1 5by/ trade 0 2 /bar1 2 , riers or import tariffs. The company

Burder’s facility in Wangaratta has been equipped with 1,420 250W YGE Polycrystalline Yingli Solar PV panels. needed to reduce its operating costs 1 : 2 9 competitiveness : 5 2 A M Aand E Dto T to1 increase protect local jobs in the regional area.

As a large user of electricity, Burder industries saw solar power as an effective way to increase its competitiveness and reduce its operating costs.

Adam Fendyk, general Manager, Burder industries said, “While making the switch to solar has been a large capital investment for our business, we see it as a wise investment decision. Turning to solar power will be critical to the long-term success of our business as it will enhance our domestic competitiveness and the longevity of our operations.”

Daman Cole, Managing Director for Yingli green Energy in Australia, new Zealand and the Pacific said, “Solar power is vital for energy intensive companies like Burder industries as it will help to reduce their operating costs and carbon footprint. A quality solar PV system plays a vital role in ensuring their investment in solar pays off over the expected lifetime of a system and reduces their potential of experiencing bill shocks.”

Cameron Munro, CEO, Envirogroup said, “Burder industries can be confident with the complete solution we have installed. We have assembled high quality components

and carefully crafted the delivery of this project with Yingli Solar panels.

When combined, this will go a long way towards helping Burder industries reduce their operating costs and it will ensure their business remains competitive over the long-term.”

Envirogroup managed all aspects of the project including solar power system design, installation, high voltage connection design and upgrade, 500kVA substation sourcing and installation, grid connection and metering. Fendyk said, “Envirogroup surpassed our expectations completing a neat and professional installation within a short time frame, without disruption to our business operations. They also found creative solutions, including writing our company name ’BURDER’ across the roof of the building with the high quality Yingli Solar panels which has helped to promote our commitment to sustainability.”

The world’s largest solar panel manufacturer, Yingli Solar has delivered over 30 million panels or the equivalent of over nine gigawatts of solar energy to homes, businesses and utilities in over 50 countries.

Yingli Solar 1300 309 489 www.yinglisolar.com/au manmonthly.com.au

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Solar energy digs tractor parts manufacturer out of financial hole.

Energy bills were becoming a bottomless pit for Burder Industries, a regional manufacturer of customised tractor and earthmoving equipment. Solar seemed the obvious solution to lowering costs, and allowing them to remain competitive against cheap foreign imports.

Leading commercial installer, EnviroGroup, designed and fitted a custom system for Burder’s Victorian facility. Comprising of 1,420 High Efficiency Yingli Solar panels, it’s capable of generating 467MWh per year, which should reduce Burder’s energy costs by an earth-shattering 70%.

“Turning to solar will be critical to the long-term success of our business, as it will enhance our domestic competitiveness and longevity of our operations”, said Adam Fendyk, General Manager Burder Industries.

If you’re looking to reduce costs and future-proof your energy strategy, you should follow in Burder’s tyre tracks and visit yinglisolar.com/au or call 1300 309 489. As the world’s largest solar panel manufacturer, we’ll move heaven and earth to help you achieve your targets.

YGEAUS_BurderBlackMag_a4_v20140807_bigger.indd 1

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What’sNew All-in-one rotary screw compressor packages KAESER Compressors recently launched the new generation of its SXC series all-inone rotary screw compressor packages.

Ideal for light industrial compressed air users, these ‘plug and play’ systems deliver performance in a compact, quiet and energy efficient package.

Each SXC series compressed air package includes a rotary screw compressor, refrigeration dryer and air receiver, making them the ideal solution for workshops and smaller production facilities requiring an all-in-one compressed air system solution. This compact design further ensures a small footprint presenting a solution in cases where space is at a premium.

These high performance compressor packages boast a number of energy

efficient characteristics.

At the heart of each package is a Kaeser rotary screw compressor featuring a specially designed airend with flowoptimised Sigma Profile rotors. This enhanced airend design is intended to deliver more compressed air per kW of input power for less energy consumption.

In addition each compressor package includes the basic Sigma compressor control system as standard.

The all-in-one rotary screw compressor packages emit sound levels as low as 65 dB(A). This makes them ideal at point of use.

Sturdy dual-axle trailer built from 5mm steel.

Linear guides

Solar powered safety shower and eye wash SPILL STATION AUSTRALIA has designed and built a fully mobile solar powered safety shower and eye wash, a world first. It complies with all aspects of the Australian Standard for safety shower and eyewash equipment, AS4775.

The trailer mounted unit can be transported with the 1500 litre water tanks full.

Once the location is reached the unit is operational within 5 minutes.

This Australian made solar safety shower is constructed with 50mm aluminiumskinned insulation panels to ensure compliant water temperatures. It is also fitted with water level and temperature gauges.

Water temperature tests were conducted in WA over a three month period to demonstrate the effectiveness of the insulation.

52 SEPTEMBER 2014 Manufacturers’ Monthly

These high performance compressor packages boast a number of energy efficient characteristics.

Kaeser Compressors Australia 03 9791 5999 www.kaeser.com.au

Over 89 days there were 60 days over 30°C and the water temperature, which started at 20°C did not vary over 4°C. The pumps on this unit are powered by a 235 amp hour deep cycle battery. Even without the twin 120W solar panels fitted, the maintenance free battery battery can power the water pumps for up to 7 hours.

Spill Station has already exported units to Malaysia and the Philippines with further projects currently in development.

Because it is Australian made, Spill Station can customise your unit to suit needs and budget.

Spill Station Australia 1300 664 266 www.spillstation.com.au

IGUS’ DryLin W linear guide is now available in size 25 with lubrication free, dirt resistant linear technology that can withstand the weight of a mid-size car.

The linear guide was originally developed as a lubrication free, inexpensive alternative to The guide rail is linear guide systems that run on ball bearavailable in two ings. The flexible, modular design, available configurations. with various accessories, allowed for more design freedom than traditional linear guide systems.

The systems all rely on igus’ proven plastic linear plain bearing materials, the most common being J200, which was specifically formulated to achieve the best wear resistance and lowest friction against hardanodized aluminium guide rails.

Like all members of the DryLin W family, the new size 25 model consists of three basic elements: a guide rail made of hard-anodized aluminium, the bearing housings made of a zinc die casting, and the plastic bearing liner, made of the tribo-optimised plastic iglide J200.

The guide rail is available in two configurations: the first is a singlesided 25mm bearing rail that spaces the two guide shafts 129 mm apart.

The advantage of the double rail is that it eliminates the need for shaft alignment, easing assembly. The single rail offers the customer the ability to place them wherever the application demands.

Rails are available from stock in lengths up to 4m and compared to the other sizes, these new dimensions allow for a higher load capacity.

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

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Brought to you by

Pendant control stations

Thermal imaging iPhone app

NHP has introduced the Mike pendant station range from TER. The range is intended to complement their existing Charlie range of ergonomic, hand-held pendants.

The range is ideal if there is a requirement for several machines to be controlled using one pendant or for other auxiliary commands to be sent such as slew left/right, with the capability to facilitate up to 14 buttons in a single row.

A comprehensive range of operator symbol inserts and label/ symbol sheets are available to describe every combination of functionality required.

The contact arrangement has also been simplified in the new range of pendant stations with dual speed operation achieved via the pushbutton actuation rather than multiple versions of contact blocks (early make, etc).

A reliable and efficient method for the auxiliary control of lifting elevators, hoists, conveyors, and many other industrial lifting and motion applications, the range of pendant stations is designed to ensure minimum machine downtime.

FLIR Systems’ FLIR ONE thermal imaging accessory promises to turn iPhones into thermal imagers and allow users to do things like detect household energy or water leaks.

According to the company, the accessory will also allow users to see in the dark; and observe abstract patterns and create artistic images.

It can detect a broad range of temperatures and has a spot temperature measurement display. Users can capture either photos or videos and share them The app detects a broad range via text, email, or social media through the app. of temperatures and has a spot Other FLIR ONE apps scheduled for release temperature measurement display. include ‘TimeLapse’, which turns a series of thermal images into a seamless time-lapse video, revealing changes in temperature through time; ‘Paint’, which allows users to share photos that selectively display colour and thermal elements; and ‘Panorama’, which turns a series of contiguous imagery into a single panoramic image.

NHP Electrical Engineering Products 1300 NHP NHP www.nhp.com.au

The range of pendant stations is designed to ensure minimum machine downtime.

FLIR Systems Australia 1300 564 230 www.flir.com/AU/

Doors for temperature, dust and noise control for thermal and sound insulation, with ABS or vinyl surface, DMF International manufactures and supplies specialised and can be protected using PE teardrop bumpers. doors for temperature, dust and noise control.

Optional double glazed windows can be included.

The company’s impact traffic doors are designed New to DMF, the option of an internal venetian within the for use in high traffic pedestrian, trolley or forklift areas. windows allows for see through or privacy when required.

Customised to suit clear opening sizes up to 3000mm H x 2500mm W using a pair of swing doors, the traffic doors have a 180° swing with automatic closing by fully DMF International concealed and adjustable torque spring.

1800 281170 The door panels feature 40mm thick compressed foam www.dmf.com.au MA 0 8 1 3 _ 0 0 0 _ K E R 1 2 0 1 3 - 0 7 - 0 9 T1 0 : 3 3 : 3 2 + 1 0 : 0 0

Optional double glazed windows can be included.

KERRICK...the quality is built in for powerful performance

Pressure Cleaners Hot Water Cleaners Big Vacuum Range Sydney 98 Carnarvon Street, Silverwater, 2128 Melbourne 41 Pacific Drive, Keysborough, 3173 Brisbane 126 Robinson Road, Geebung, 4034 Perth 23 Belmont Ave, Belmont, 6104 Adelaide 31 West Thebarton Rd, Thebarton, 5031

Carpet Cleaners (02) 8737 9200 (03) 8769 1500 (07) 3865 2551 (08) 9277 9651 (08) 8340 8060

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sales@kerrick.com.au | www.kerrick.com.au manmonthly.com.au

Manufacturers’ Monthly SEPTEMBER 2014 53

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The lastWORD Metal matters: innovate or perish While steelmaking may have stabilised, there could be more pain in store for aluminium. Materials processing specialist Geoffrey Brooks shares some observations with Brent Balinski.

I

f you spend your professional life thinking about a subject, you’ll notice esoteric connections it has to various patterns in the world.

Geoffrey Brooks leads the High Temperature Processing group at Swinburne University, where he has been a Professor of Engineering since 2006.

One of his specialisations is steelmaking.

In recent years he has pointed out the link between steel production and economic and political might. He has even applied mathematical modelling to get an understanding of planetary formation through the cooling habits of molten steel.

Another relationship he has noticed is that between a successful country and a healthy steel industry.

“If you look at countries that we admire, countries that we respect for being clever and nice places to live, with good environments, wealthy etc. - they invariably have strong steel industries,” he told Manufacturers’ Monthly at a recent event hosted by the University of Wollongong’s Global Challenges Program.

“A lot of Northern European countries are in that category,” he noted, conceding that the relationship isn’t exact, but is apparent.

The biggest contributor to the world’s steel output is China, which contributed 779 megatonnes (Mt) to the 1,606 Mt produced last year, according to the World Steel Association. Global production has grown steadily since 1970 (595 Mt) and last year the overall increase was 3.6 per cent.

Australia’s contribution is a modest one, ranking 30th with 4.7 Mt. The difficulties faced by the country’s base metal manufacturers are wellknown, with the inflated dollar due to the commodities boom buffeting the industry in recent years.

After a disastrous period (which saw the country’s major steel company, BlueScope Steel, announce billion-dollar back-to-back losses in 2011 and 2012) Brooks believes things have stabilised.

According to the Professor, the country’s steel future is in high-value, innovative products.

“I think what BlueScope is doing more of now is smart... they’re trying to get into specialised architectural products,” he said.

“And I particularly like what they’re trying to do at the moment with integrating solar photovoltaic energy and roof panels for thermal energy recovery.”

He also singles out the success Arrium has had in grinding media, a specialised product that saw great demand during the mining boom. Again: a specialised, high-value, non-stock standard prod54 SEPTEMBER 2014 Manufacturers’ Monthly

uct. Being “smart” or “clever” is a constant theme when Brooks is asked his opinion on what metal companies need to do to be successful.

“There are some promising signs of companies Arrium is getting into some new grades of rail steel, and I hear BlueScope investing in new flat products and new coatings on their steels,” he added. “So that’s promising.”

When asked for global examples worth learning from, he points to the commitment of South Korea’s Posco to R&D (its CEO Park Tae-joon founded the tech-focussed Postech University), Nucor’s transformation under former president Ken Iverson, and Belgium’s Umicore.

Metals processing is sometimes seen as oldfashioned, unsophisticated and environmentally damaging. Umicore – which rebranded in 2001 and formed as Union Miniere in 1989 after a union of four mining and smelting companies – puts itself forward as the opposite of those things.

“Can you imagine anything less fashionable than being a lead smelter?” asked Brooks.

The company now has businesses in precious metals management and battery recycling, and re-

“

Can you imagine anything less fashionable than being a lead smelter?

claims material from industrial residues to e-waste sourced “from a truly global supply base”.

There is a lesson in Umicore’s transformation, from something simple and stooped in another era to a modern, technologically advanced company.

“They have become a world-leader in the recovery of valuable metals from waste electronics,” said Brooks.

“And they decided also to make their plant a showcase. A place you show off about. So it’s still a lead smelter, but they show schoolkids around it and show how they’re using all this clever science and technology.

“And they have a fashionable shop in Antwerp where they show mobile phones and all the things they’ve recovered and made from them, and they sell them back to the public. So it’s turned the issue on its head.”

An area in which there has been little in the way of innovation, according to Brooks, is Australia’s aluminium industry.

While some in steel are moving to a more sustainable future, there is little progress in aluminium.

Brooks has been pointing out for a long time that an aluminium industry which makes low-grade products is not a formula for success.

Australia’s aluminium industry has been ranked the fifth-biggest in the world, and exported nearly $4 billion worth of products in 2012.

However, it has seen a great deal of pain lately, with the energy-hungry (it takes nearly ten times the amount of energy to make a tonne of aluminium compared to steel) industry to see the Point Henry smelter to close in August. This will leave five smelters operating.

Brooks believes that the aluminium sector is destined for further bad news. One of the major problems, he believes, is the production of stock standard products.

“There is definitely a lack of innovation in the Australian aluminium industry,” he said.

“It’s in our long-term interest that they move to more sustainable products... I don’t see them being very responsive. And of course it’s complicated by a lot of the smelters being overseas-owned, so the priorities of a company aren’t necessarily the priorities of Australia.”

[Geoffrey Brooks is Professor of Engineering and ProVice Chancellor (Future Manufacturing) at Swinburne University. Contact him at gbrooks@swin.edu.au]. manmonthly.com.au

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2014-08-27T13:55:51+10:00

SponSored content

New generation lightweight robots UNIVERSAL ROBOTS, the Danish manufacturer of flexible industrial robot arms, has presented its third generation of the lightweight robots, the UR5 and UR10.

Special features of the revised robot arms are the true absolute encoders, the eight new adjustable safety rated functions, twice the number of builtin I/O’s, and the improved possibilities for connecting equipment to the control boxes.

Since the first UR robot entered the market in December 2008, Universal has seen substantial growth with the robotic arms now being sold in more than 50 countries worldwide. The company is headquartered in Odense, Denmark where all development and production is carried out.

According to the company there is a continuation of the safe human – robot collaboration in the new generation; additionally, the safety system of the new generation is now certified by TUV. Well-known characteristics such as the ease-of-use and the quick ROI remain.

The robot arms UR5 and UR10 are equipped with numerous new features. Still, Universal Robots remains true to its approach of userfriendly lightweight robots. The visual appearance of the six-jointed arm with a payload of 5/10 kilos remain unchanged.

“We are the only manufacturer of lightweight robot arms which already has a long lasting experience in a wide variety of industries,”

manmonthly.com.au

said Enrico Krog Iversen, Universal Robots CEO, on the latest developments.

“Our R&D department worked hard in order to integrate input and feedback from end users in our product development” The technical innovations at a glance:

True Absolute Encoder A central innovation of the new generation of UR robots is the True Absolute Encoder. This technical improvement enables a faster startup of the robot arms. The absolute position is recognised right after the switching-on, eliminating the need for jogging during initialisation of the robot arm. For this reason UR5 and UR10 are now suited for an automatic start-up – even though no battery is needed for this function.

“With the integration of the True Absolute Encoder, our robot-arms can be integrated even more easily into other machineries while startup also becomes much faster and simpler for all applications”, explained Esben H. Østergaard, Universal Robots CTO.

Patented: Adjustable Safety System The safety settings of the latest generation of Universal Robots’ lightweight robots can be adjusted for each specific solution. The robot arm can run in two operating modes of the safety functions; a normal and a reduced one. A switch between safety settings during the robot’s operation is also possible. To achieve this, eight

safety functions are monitored by the new patented safety system: Joint positions and speeds, TCP positions, orientation, speed and force, as well as the momentum and power of the robot.

The settings can only be changed in a password protected area. All these safety functions are safety rated PL d and certified by TÜV. “Our new patented safety concept is a logical development of our previous robot arms. The revised UR5 and UR10 can be operated in different modes depending on the context. For example, when a human enters the robots work-cell, it can continue to operate in reduced mode, and then resume full speed when he leaves again.

Or the robot can run full speed inside a CNC machine, and then reduced speed when outside”, says Østergaard.

TÜV Certification of UR safety 3.0

Focus on flexibility and user-friendliness The six-jointed, cost-efficient robot arms UR5 and UR10 are especially suited for small and medium sized businesses. Thanks to their light weight and their user-friendly handling via touch pad, a wide range of applications can be programmed quickly without complex training or deep technological knowhow.

“With our flexible robot-arms, we address a broad target group – whether it is (un-)loading of CNC machines in a ten-man firm or a gluing-process at an automotive manufacturer, everyone benefits from our robots. Because they perform the dull or harmful jobs that needed to be done by humans before”, said Iversen.

Auto Control Systems 08 9258 4555 www.autocontrols.com.au

The safety system UR Safety 3.0 of the new generation UR5 and UR10 from Universal Robots is certified by TÜV Nord and tested in accordance with EN ISO 13849:2008 PL d and EN ISO 10218-1:2011, Clause 5.4.3.

Further innovations Sixteen additional digital I/Os, which are easy to configure either as digital signals or as safety signals, a revised design of the control box and a rebuilt controller are further improvements.

Manufacturers’ Monthly SepteMBer 2014 55

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2014-06-23T08:48:49+10:00

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