Manufacturers' Monthly April 2012

April 2012

Making Manufacturing

Print Post Approved PP255003/00324

INSIDE Industry News >> New Technology >> Industry Opinion >> Manufacturing for Mining >> Welding & Profile Cutting >> NMW 2012 Preview >> Benefits of ERP >> Cranes & Lifting

ENDEAVOUR AWARDS FINALISTS >> Shortlisted nominations for our 2012 manufacturing awards announced!

Dexion速, 速 Speedlo edlock k and k速 d Ke Keyl K yylock k速 arre k e all a re eg e gis iste s red trade ste emar ema arrks a s of of D Dexion (A (Au Austra stralia) lilia)) Pt Pty y Li L ited Lim itted d. FSA/D SA/DEX05 EX0537 EX05 37

®

TODAY’S DEXION ENSURES FULL COMPLIANCE WITH THE NEW AS4084:2012 STANDARD.

The new AS4084:2012 requires racking manufacturers to determine the material properties of their components by conducting independent testing. Within a six month period, the University of Technology, Sydney has conducted over one thousand tests on all Dexion’s racking components.

The thoroughness of this testing ensures both our Keylock and new Speedlock racking systems perform to their stated loads. Even more importantly, they meet the world’s most demanding racking codes.

Can your racking manufacturer provide you with the same assurance?

For more information about new Speedlock, Keylock or the requirements of the new AS4084:2012, visit racking.dexion.com.au

Publisher Michelle Graves michelle.graves@reedbusiness.com.au Group Editor Sarah Falson Ph: (02) 9422 2480 Fax (02) 9422 2722 sarah.falson@reedbusiness.com.au Deputy Editor Annie Dang Ph: (02) 9422 2964 Fax (02) 9422 2722 annie.dang@reedbusiness.com.au Journalist Angela Welsh Ph: (02) 9422 2898 Fax (02) 9422 2722 angela.welsh@reedbusiness.com.au Editor-at-large Alan Johnson Ph: (02) 9422 2325 Fax (02) 9422 2722 alan.johnson@reedbusiness.com.au Graphic Designer Ronnie Lawrence ronald.lawrence@reedbusiness.com.au Creative Director Julie Coughlan Production Co-ordinator Mary Copland Ph: (02) 9422 2738 mary.copland@reedbusiness.com.au VIC/Overseas Sales Michael Northcott PO Box 3069 Eltham VIC 3095 Ph: 0448 077 247 michael.northcott@reedbusiness.com.au NSW Sales Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067.

Ph: (02) 9422 2368 Fax: (02) 9422 2722 Mobile: 0414 644 664 anthony.head@reedbusiness.com.au QLD Sales Sharon Amos PO Box 3136, Bracken Ridge QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@reedbusiness.com.au NSW, SA/NT & WA Sales Reed Business Information Ph: (02) 9422 2368 anthony.head@reedbusiness.com.au Head Office Tower 2, 475 Victoria Avenue, Chatswood NSW 2067 Locked Bag 2999 Chatswood DC Chatswood 2067 Ph: (02) 9422 2999 Fax: (02) 9422 2966 Published 11 times a year Subscriptions $140.00 per annum. (inc GST) Overseas prices applyPh: 1300 360 126 Printed by Geon Impact Printing 69 – 79 Fallon Street, Brunswick VIC 3056 Ph: (03) 9387 7477

Inside 6 Editorial ■

16

End of an era

4 APRIL 2012 Manufacturers’ Monthly

Publication of Australian Industry Participation Plans will shed some light on some company claims.

8 Comment ■

Moves to increase skilled

8 workers pool.

10 News ■

10 minutes with Byron Bay Cookie Company’s Gordon 8 Slater.

■ Manufacturing a skilled future.

■ OHS Harmonisation: What’s 8 really different?

54

■

16 Management ■

More transparency to boost

8 manufacturing.

20 IT@MM ■ ■

Where analysis is not paralysis The shift to cloud computing

56

25 What’s New ■

8 lead up to May’s gala dinner.

Latest products for

8 manufacturers.

56 NMW Preview ■

54 Welding

Innovators to star at NMW in

8 Sydney.

32 Endeavour Awards

■

■

8 technology to lower costs.

60 Materials Handling

■

■

Finalists revealed for 2012 8 22 pages of nominations in the

April 2012

Print Post Approved PP255003/00324

INSIDE Industry News >> New Technology >> Industry Opinion >> Manufacturing for Mining >> Welding & Profile Cutting >> NMW 2012 Preview >> Benefits of ERP >> Cranes & Lifting

Advances in welding Protecting welders’ eyes.

ENDEAVOUR AWARDS FINALISTS >> Shortlisted nominations for our 2012 manufacturing awards announced!

New storage standard.

Behind the cover NMW brings Australia’s manufacturing industry together to showcase new capabilities while addressing issues affecting the industry’s future.

Making Manufacturing

ABN 80 132 719 861 Average Net Distribution Period ending September 11 15,273 ISSN 0025-2530

For daily news visit manmonthly.com.au

APRIL 2012

Australia’s largest integrated manufacturing industry event, NMW 2012 will occupy most of the Sydney Showground with industry showcases across 12 specialist zones: including health & safety, sustainable manufacturing, engineering, IT and automation

& robotics. NMW 2012 brings customers, suppliers, innovators and industry experts together under one roof. It’s industry’s best chance to see new solution demonstrations – compare technologies from around the world – and source new opportunities for gaining a competitive edge.

Registration now open! Visit nationalmanufacturingweek.com.au for more information.

manmonthly.com.au

TRANSMIG MULTI-PROCESS WELDING INVERTERS

The right tool for every job.... big or small

The CIGWELD complete range of TRANSMIG multi-process welding inverters, come loaded with features sure to satisfy any trade professional in any industry regardless of the welding application.

SINGLE PHASE INVERTERS Multi process; MIG, Stick & Lift Tig Voltage Reduction Device (VRD) Light weight and compact power sources Robust 50mm twist lock connections Quick connect shielding gas connection Digital voltage and amperage meters Power Factor Correction in 200i and 250i models for up to 50% savings in power.

Compliant to AS 60974.1 & AS 1674 3 year limited warranty*

*Refer to CIGWELD website for further warranty details.

1300 654 674

I

www.cigweld.com.au

3 PHASE INVERTERS Multi process; MIG, Stick & Lift Tig Voltage Reduction Device (VRD) Welding setup program storage (10 programs) Fan on demand Digital Voltage & amperage meters Gouging capability (550i model only) Compliant to AS 60974.1 & AS 1674 3 year limited warranty* Pictured:

power source with optional wire feeder.

Editorial

ALAN JOHNSON – Acting Editor

editor@manmonthly.com.au

End of an era The start of 2012 sees two of manufacturing's most influential players leave centre stage; one with flowers, the other one with knives in his back.

A

ny punter will tell you that if you put your money on the wrong horse you will take a hit.

Senator Kim Carr probably Australia’s most dedicated and influential industry ministers since John Button has certainly learnt that lesson the hard way, with his questionable support of Kevin Rudd.

Politics, like the manufacturing industry, can be ruthless.

And this year we have lost one of our strongest advocates.

In policy terms, Carr was able to reshape the debate within the Labour Party and Government about the importance of manufacturing.

Speaking to him last month, as minister for human services, it was clear the scars of his demotion are still red raw.

However he remains optimistic he will return to his favoured role, one day.

I remember my first meeting with Carr, when he was shadow industry minister, at Carlos Broens’ official opening of his second factory in Ingleburn in South West Sydney.

I was immediately impressed with Carr’s knowledge and passion for the industry.

When he became the industry minister, with the fall of

the Howard government, Carr was quick to act and suddenly manufacturing had a voice in Canberra.

Probably one of his most important first moves was renaming his department to Innovation, Industry, Science and Research.

“This was quite deliberate.

It highlighted a new approach to the modernisation of the Australian industry and the critical role that science and research play in the transformation of Australian business and the concepts around co-investment,” Carr told me.

While probably better known for his high-profile work with the contentious automotive industry, he suggests the establishment of Enterprise Connect was his biggest achievement and believes one day it will be compared with the CSIRO regarding its contribution to innovation.

“Enterprise Connect has allowed us to draw from the best in the world and develop unique Australian characteristics about supporting management of Australian manufacturing companies.”

A strong supporter of the Made in Australia campaign, Carr is invariably seen in Australian made suits and ties

Carr will always remain a strong supporter of Australian Made.

and can still be seen proudly wearing the Australian-made badge despite his change of role.

“You can never get enough Australian Made, and I will continue to argue that case within Government and in the Parliament.”

Heather Ridout Another of industry’s driving forces has also left the industry recently, but Heather Ridout, former Chief Executive of the Australian Industry Group, left under her own steam.

After 33 years with the organisation and approaching eight years as CEO, Ridout also had,

and still does, a very strong passion for the manufacturing industry, starting under the guidance of the venerable Bert Evens, CEO of the powerful MTIA (Metal Trades Industry Association) of the day, which morphed into today’s Ai Group.

Coming up through the traditional male bastion of industrial relations set Ridout with the skills needed for the bare-knuckle bearpit that is federal policymaking.

Ridout has contributed to some of the most fundamental and hotly contested policy overhauls in Australia’s recent history – tax reform, tariff reduction, industrial relations changes and now the climate change response – all while juggling the competing demands of a string of prime ministers, business leaders, and union heavyweights.

When Ridout, then 23, accepted the MTIA position, she was the first woman with a degree to do so; and the only other women working there were secretaries.

We have certainly come a long way since then.

On behalf of all the team at Manufacturers’ Monthly, a sincere thank you to both inspirational leaders for their valuable contribution to the manufacturing industry.

sales

6 APRIL 2012 Manufacturers’ Monthly

manmonthly.com.au

24 hours a day 7 days a week 52 weeks a year

Noel McConnachie Residential Service Manager Dematic

DEM915

Another logistics result.

Your DC represents a substantial capital investment and you need it to deliver the goods day in, day out. At Dematic we share that goal. Behind every Dematic system is the largest service organisation of its type in ANZ. With more than 170 highly trained specialist technicians, you can count on Dematic to see that your system consistently meets your customers’ delivery expectations. From preventative maintenance, operational support, real-time monitoring and diagnostics, through to full rebuilds and system upgrades, the Dematic team is right there with you – 24/7. That’s what we call a logistics result.

Scan for more

Ask us.

02 9486 5555 www.dematic.com.au

Logistics Solutions | Service & Support | Software & IT | Voice Picking | Wireless Networks | Storage Solutions | Conveyors | AS/RS

Comment

INNES WILLOX – CEO Australian Industry Group

editor@manmonthly.com.au

Moves to increase skilled worker pool Government changes rules relating to 457 visas to overcome skills shortages.

D

espite the slow growth seen in employment over the past year, businesses across the economy are still experiencing skill shortages in key occupations and many continue to rely on the immigration program to fill skill gaps.

This is especially so for those skills in demand by the resources sector such as in engineering and the skilled trades.

In this regard, recent changes announced by the Federal Government to the immigration program should help employers to better access overseas skilled workers in this tight labour market.

One of the key changes relates to making it easier for existing 457 visa holders to transition to permanent residency.

Almost half of the permanent skilled migration program comes

8 APRIL 2012 Manufacturers’ Monthly

from the 457 worker cohort.

They make particularly good additions to our labour market because they have all have local experience and have put down roots here and by definition have the skills in demand in our economy.

An important change was the removal of the need for language testing of current 457 visa holders applying for permanent residency.

This is very sensible and will remove the possibility of rejection for those who may have failed to meet what are still arduous language requirements.

Another change is raising the upper age limit to 50 for permanent applications.

This is also a sensible move which will increase the pool of potential migrants.

Critics of the temporary migra-

tion program often forget that we are not the only country experiencing skill shortages and we are in a highly competitive global market for skilled labour.

There will also be a consolidation of the lists used to identify those skills which qualify for the various programs.

However, while a consolidated sponsored occupation list will simplify administration, we would be concerned if it resulted in a narrowing of eligibility, particularly for the important skilled trades for which demand is so strong.

We continue to engage closely with the Government on the immigration program including on the size of the intake for the next financial year, which will be announced in the Federal Budget.

It is Ai Group’s view that the

current planning level for the 2011–12 Migration Program, which is set at 185,000 places, is below what is required to avoid pressure on capacity and its attendant impact on costs.

We have proposed to the Government a modest increase in the 2012-13 planning level to 190,000 places with a continued emphasis on skilled migration.

Innes Willox is the new CEO of the Australian Industry Group, taking over from Heather Ridout who has joined the Board of the Reserve Bank of Australia.

Willox was previously Director of International and Government Relations for the Ai Group, with policy and advocacy responsibility across federal and state governments including economics, trade, defence, climate change, industrial relations and communications and technology issues.

manmonthly.com.au

AUSTECH1039

See what’s new in Advanced Manufacturing Connect with large numbers of key industry contacts in one place Learn about the latest products and services designed to help grow your business

Austech 2012 Australia’s Premier Advanced Manufacturing & Machine Tool Exhibition

Combining with National Manufacturing Week to create your total manufacturing solution

8th – 11th May 2012 Sydney Showground Sydney Olympic Park, Sydney

PARTNERS

www.amtil.com.au

Register at austechexpo.com.au

AnalysisNEWS EVENTS APRIL 16-20: Fundamentals of Process Safety This 5-day course in Perth is designed to benefit all staff keen to develop or improve their knowledge of process safety, hazards, risk and their management. www.icheme.org 17-19: Safety In Action/Melbourne Materials Handling These two exhibitions will be held concurrently at the Melbourne Exhibition Centre, providing an effective way to keep track of the latest safety products and services. www.thesafetyshow.com.au www.materialshandling.net.au

MAY 7-10: AUSPACK PLUS The largest biennial packaging and processing machinery and materials exhibition in Australia will be heading to Sydney Olympic Park. www.auspackplus.com.au 8: Manufacturers’ Monthly Leaders Summit Bringing policy-makers, industry leaders and other key stakeholders together at NMW 2012 to discuss The Future of Manufacturing in Australia. www.manmonthly.com.au 9: Manufacturers’ Monthly Endeavour Awards The 2012 winners of Australia’s premier national awards for manufacturing excellence will be announced at a dinner ceremony in Sydney. www.manmonthly.com.au/awards 8-11: NMW 2012 Brings Australia’s manufacturing industry together in Sydney to showcase new capabilities. www.nationalmanufacturingweek. com.au 18: Manufacturing Skills Conference and Awards Based in Queensland, the event brings together industry, government, academia and training organisations to address the challenges facing the

10 APRIL 2012 Manufacturers’ Monthly

10 minutes with the Byron Bay Cookie Company

BY SARAH FALSON

G

ORDON Slater, chairman of local manufacturer Byron Bay Cookie Company, speaks to Manufacturers’ Monthly about the company’s transition from hand-made to machine production, and its future growth plans.

Q. What’s the best thing about being chairman of Byron Bay Cookie Company?

The best thing about being the chairman of Byron Bay Cookie Company is getting involved in all aspects of the business, from product development to operations and sales & marketing.

Plus I get to try a lot of different cookies!

Q. How much time do you spend at your manufacturing facilities?

I split my time between our bakehouse in Byron Bay and our new head office in Sydney. !

We employ between 50 and 100 staff; this fluctuates throughout the year.

Q. What’s the one piece of technology/equipment that Byron Bay Cookie Company could not manufacture without?

Our cookies were originally hand made which gave us a certain point of differentiation, however limited us in terms of long term growth. We’ve since made key equipment purchases enabling us to scale up production whilst remaining true to our traditional baking methods.

Q. Byron Bay Cookie Company began in a farm-style kitchen and is now recording 17% yoy growth. Was this the plan from the get-go?

Our plan has always been to manufacture a superior quality product but more importantly, we understood very early on that we had found a niche for a greattasting treat that can be enjoyed with a coffee and uses natural, locally-sourced ingredients. As

such we were the “original café cookie” and pioneered the concept of cookie jars in cafes and delis across Australia.

Whilst the café market remains at the core of our business, we’ve managed to maintain growth by expanding into the retail market and by acquiring other brands such as Luken & May biscuits and Falwasser crispbread.

Q. How important are export markets to the longevity of your business?

Export markets have been key to our expansion from day dot.

The very first export market we conquered was the UK over 10 years ago. We first started shipping our cookies from Australia; however as customer demand grew we made the strategic move to embark into a joint venture with a local bakery so Byron Bay Cookies are now made in the UK for the European market.

The next market was Japan and it’s interesting to see how each market reacts to different products. Whist the Dotty is our number 1 seller in Australia and in the UK, it’s our Fig & Pecan that tops the list in Japan, and the Triple Choc Fudge in the US. We’re always on the lookout for new export markets, and as such are planning on increasing our presence at key tradeshows overseas.

Q. Byron Bay Cookie Company is a classic example of what Australian manufacturers do best: quality over quantity. Can you comment on this?

From the very beginning our mission was to bake great cookies using the finest quality ingredients. By enforcing quality through each step of the production process, we managed to create a highly loyal customer following and we grew from there.

The challenge over the years has

Pioneering a product idea and finding a niche market for it is crucial to the company’s success - Slater.

been to remain innovative whilst maintaining the same quality and taste that took us where we are today.

Q. Do you think the Australian government does enough to help the manufacturing industry?

The Australian government has put in place some great programs which we have taken advantage of over the years. At the end of the day, it’s up to us entrepreneurs to keep challenging ourselves and continually push for more innovation and creative ways to take the business further.

Q. Which other Australian manufacturers do you admire, and why?

Australian fashion manufacturers have done a tremendous job with growing their brands overseas; Billabong is the perfect example. A great product will only take you so far; ultimately it’s about creating and nurturing a strong brand that will take us that extra mile and deliver returns.

Q. You know the saying, ‘never trust a skinny chef’? You own a cookie company: how come you’re so slim?!

I have my personal trainer to thank for this! The biggest challenge is the constant travelling that I do (and the constant product testing!). It’s all about balance and great time management. manmonthly.com.au

EFIC DID MORE THAN FINANCE OUR EXPORTS

THEY TOOK US TO THE NEXT LEVEL. Michael Lavis, Managing Director, JML Engineered Facades Pty Ltd

Winning another contract in the Middle East was an exciting step for our business. After working on the Dubai Airport we won the contract to manufacture the glass façades on the Doha International Airport. However our bank required full cash cover for the million dollar bond demanded under this latest contract – locking up valuable funds that could otherwise be used on other business ventures.

So we turned to EFIC for support. EFIC focused on what it would take for us to succeed. They were able to draw on their relationships with international banking networks to establish a structure for a local bank in the Middle East to issue a bond to us in Qatar, secured with a guarantee by EFIC. EFIC’s assistance allowed us to use our capital to keep expanding our operations while fulfilling a key contract that helped us gain an even stronger position in the Middle East.

Overcoming financial barriers for exporters.

Visit efic.gov.au/mm

AnalysisNEWS

Building a skilled future

T

The agile supply chain

26-27 June 2012 Melbourne Exhibition & Convention Centre For more information visit www. supplychain2020. com.au or call 1300 789 845

Endorsed By

Supported By

Education Partner

12 APRIL 2012 Manufacturers’ Monthly

Media Partners

he 2012 MSQ Skills Conference and Awards, to be held in Brisbane on Friday 18 May, will address many of the challenges facing manufacturing businesses today, including: • How to attract and retain skilled talent • How to turn around the resource skills drain from manufacturing • Skilling strategies to ensure businesses have the capacity and capability to grow • What is diversity and how will it benefit a business • Programs to assist with upskilling and training the workforce for the future Organised by MSQ, a division of QMI Solutions, the conference will also look at how industry can retain mature-aged workers to pass on their valuable skills to the next generation.

The conference will also investigate the success of the mining and construction in particular how they have managed to attract and retain women in the workforce.

QMI Solutions’ CEO Jim Walker encourages every-

MSQ consultant John Colegate with Varley Specialised Vehicles’ GM Anthony Dore.

body involved in manufacturing in Queensland to attend the conference.

“The industry is moving from a process engineering background to a focus on R&D, product innovation and design, which means the workforce needs to be trained not only with engineering skills, but also problem solving and creativity to make manufacturing the cradle of innovation,” he said.

“We are facing demanding times but have the opportunity to secure and embrace the future of Queensland manufacturing if we act now.

The industry must focus on innovative manufacturing

and nurturing the next generation,” Walker said.

The 2012 Manufacturing Skills Awards, taking place on the night of the conference, are a chance to recognise young talent rising through the ranks of the manufacturing industry. Categories include Manufacturing School of the Year, Trainee/Apprentice of the Year, Manufacturing Indigenous Student of the Year, Manufacturing Trainee of the Year, Manufacturing Apprentice of the Year.

Applications for nominations for the awards close on 18 April. For more information visit: www.msq.org.au

Win for local manufacturer Australian advanced materials company, Quickstep Holdings has secured its second major aerospace manufacturing program, announcing it has been awarded the tender to manufacture wing flaps for the C-130J Hercules military transport aircraft.

Quickstep was selected as sole source supplier for the C-130J flaps following an international commercial tender program by Lockheed Martin which attracted bids from numerous manufacturers from around the world.

Representatives of Lockheed Martin are scheduled to visit Quickstep’s Australian

headquarters this quarter to finalise contract details, which are expected to include a multi-year term and will see Quickstep as sole source global supplier for these part sets.

Managing Director of Quickstep, Philippe Odouard, said that securing the contract represented an outstanding achievement for the company’s contract manufacturing division.

“It is good news for manufacturing in Australia demonstrating that we can keep manufacturing work in country through innovation and high-end capabilities.

“I would like to pay a particular tribute to the NSW government that supported us in developing the Bankstown facility which will become one of the most advanced in the world. This win could create 60+ new jobs at the Bankstown facility in NSW,” Odouard said.

First orders for non-recurring activities for the manufacturing program (such as planning, tooling, training and project management) are expected in Q2 2012 with early cash flows following shortly after. First aircraft parts are scheduled to be delivered in 2014. manmonthly.com.au

Meet us at AUSTECH 2012 !

8th – 11th May 2012 Booth: B040

simply more success

CTX 310 ECOLINE

ECOLINE – Top Seller in a new design with the largest selection of control options available DMG SLIMline® Panel with SIEMENS 840D solutionline

NEW // Functional Design: with a 35% larger safety glass for better viewing, Planon LED plus for optimal work area lighting // PROGRESSline – Clear display of remaining machining time and number of pieces* // Highly dynamic servo turret with a synchronous motor, hydraulic clamping and 50% faster tool changing. // Larger bar passage up to 65 mm* (90 mm)* / ** for more flexibility // Circular diameter over the bed: 330 / 680 mm**; Turning diameter over the cross slides: 200 / 465 mm**; Max. longitudinal path (Z): 450 / 1,050 mm** // User-friendly control range * Optional, ** Data for the CTX 510 ECOLINE, *** Only available on the CTX 310 ECOLINE

DMG SLIMline® Panel with HEIDENHAIN CNC Pilot 620

All the latest news available at: www.dmgmoriseiki.com DMG / MORI SEIKI Australia: Melbourne Head Office Unit 6, 6 Garden Road, Clayton VIC 3168, Australia, Tel.: +61 3 8545 0900, Fax: +61 3 9561 4999 Sydney Office: Tel.: +61 2 8844 9700, Fax: +61 2 9638 6111 If your phone is equipped with QR-code recognition software, you will be directed to our homepage.

Authorized DMG / MORI SEKI Dealers in Australia: Qumac Engineering Services – Queensland, Tel: +61 7 5547 5066 / HS CNC Machines – Victoria, Tel: +61 3 9763 8207

MAPPS IV*** from MORI SEIKI

AnalysisNEWS OHS Harmonisation: What’s really different?

The new laws make the duties of OHS officers very clear.

By Angela Welsh

T

HE recent OHS Strategy Summit on the Gold Coast highlighted a number of concerns regarding the now in force national OHS harmonisation laws; probably the most significant reform to OHS legislation in the past 30 years.

The new model Work Health and Safety Acts (WHS) came into effect on 1 January, 2012, with the exception of Tasmania which is waiting to 1 January 2013, South Australia which is currently debating the Bill, and Victoria and Western Australia who are likely to defer implementation until later in the year.

Essentially, each of the current state and territory OHS laws will be replaced by national laws based on a model Work Health and Safety Act. The most obvious advantage is consistency of laws across Australia.

Tracey Browne, Ai Group’s manager of national OHS policy believes the outcome has been a set of laws that can work.

“It is clear the laws do not have to be identical to be harmonised. When the Bill was out for public comment there were many concerns about the number of jurisdictional notes that were in there, allowing the jurisdictions the opportunity to make changes,” Browne said.

However, the jurisdictional notes are not about allowing divergence from the laws, she explained.

“Instead, they are there to allow the regulators or the

Parliaments to implement these laws within the complex legal systems in which they operate,” she said.

Applying the new laws Browne said a key factor in making the laws effective is how employers or persons conducting a business or undertaking (PCBU) adopt the new legislation.

“From Ai Group’s perspective, large organisations that operate across multiple jurisdictions have the opportunity to highlight where the issues are, raise

them back with the regulators, raise them through Safe Work Australia so we can have them addressed.”

“It’s not actually the courts that will determine whether harmonisation works or not.”

Browne said the different additions each state has made so far will not be a barrier to harmonisation.

“Right from the start, harmonisation was never about identical laws.

“Part of the issue that we’re seeing in the media debate is concerns that if four jurisdic-

tions aren’t there yet, and can’t be convinced that we’re actually going to have harmonised laws, maybe we should just let them all fall over,” she said.

“There was even a comment made recently that New South Wales was actually the start of the failure of harmonised laws because of the amendment that was put in to allow a much more narrow application for unions’ rights to prosecute.”

However, Browne believes that from the perspective of what the harmonised laws mean within a workplace, that detail is not

Positive Displacement Dosing Pumps from Accurate and Easy to Install Features: 1.5 to 20 LPH 220/240 VAC

$203 +GST

Reseller enquiries welcome.

Tel: +61 (03) 9769 0666

14 APRIL 2012 Manufacturers’ Monthly

Fax: +61 (03) 9769 0699

Email: hannains@hannainst.com.au

Web: hannainst.com.au

manmonthly.com.au

as significant as workers and unions might have feared.

“That’s something that might get applied by the unions at some stage if they want to prosecute a particular employer,” she said.

looking to influence the officers of their organisations - the opportunity to have the discussion in the first place, and to then bring in what the new laws actually mean for those officers,” Ward said.

Safety: on the agenda Konekt principal of health, safety and compensation Nicholas Ward said now is “a time like no other” for workplace OHS. “We actually are seeing a national debate about Workplace Health & Safety.

“If that is the sole outcome of harmonisation then I think the harmonisation project has achieved a great deal already.”

Ward said he has certainly noticed the paradigm shift in the way employers and officers of organisations have been embracing work health and safety.

“And a lot of the impetus has been these laws,” he said. “[The laws] have given health and safety managers - who are

manmonthly.com.au

Defined responsibilities Ward explained that the new laws make the duties of officers extremely clear, in regards to what they do and what they have to achieve.

“So there’s no ability to hide from what their duties are anymore. There’s no delegation back to the OHS manager.

They are responsible, they know that,” Ward said.

“They also know that in that context they’ve got massive increases in penalties and they’ve just got more skin in the game. So essentially what I have seen… is that the engagement of officers has certainly increased,” he said.

Top Tweets in March (chirp!)

What you missed last month on Twitter...

• Water products supplier to build $8m water-friendly factory <Visit: bit.ly/wZilu1> • Participation agreement makes it easier to export to Vietnam <Visit: bit.ly/ziIRku> • Brisbane firm enters $300m pile repair game with joining systems contract <Visit: bit.ly/wdFm2t> • Food producers slash more than 100 jobs in Victoria <Visit: bit.ly/xKPQ1C> Never miss out again! Follow us @manmonthly for all the latest news, product information and comment pieces from the industry.

The question is…

Safe Work QLD associate director general Barry Leahy said the key question in the whole harmonisation debate is: ‘Why do it?’

Leahy said the simple answer is that there are just so many different sets of regulations that the situation has become unwieldy.

“In a country with a working population of about 10 million people, why on earth do we have

nine or 10, or far more than that, sets of regulations around Workplace Health & Safety?” he said.

“It just doesn’t make sense to me, and particularly when our economy, as it develops, will have more and more national companies with employees in each of the jurisdictions,” he said.

So, in a sense, “harmonisation is a no brainer,” Leahy said. www.ohsstrategy.com.au

Manufacturers’ Monthly APRIL 2012 15

AnalysisMANGEMENT More transparency to boost manufacturing While some Australian manufacturers are riding the present mining industry wave, many are missing out. However that could change with more openness. Alan Johnson reports.

WA’s Matrix Composites and Engineering has invested heavily in new equipment to take advantage of strong demand.

NMW 2012: a stronger response to challenges If there’s one thing you can be certain of in business, it’s that things change and good businesses adapt.

To help you respond to industry challenges, NMW will host a one-day conference focusing on practical strategies for a range of topics: including managing the coming carbon tax, manufacturing in a high cost environment and the broader quest for a competitive edge.

The NMW 2012 Conference – Wednesday May 9,

16 APRIL 2012 Manufacturers’ Monthly

M

UCH has been said and written about the manufacturing industry’s lack of involvement in our resources boom; however the sector is not going down without a fight with moves for more government involvement and transparency.

AMWU National Secretary, Dave Oliver, says the mandatory publication of Australian Industry Participation Plans is an obvious move to improve local manufacturers’ involvement in resource projects, and “will help shine a light on the reality of some of the claims about local content or the lack of local capacity to provide it”.

He claims the industry uses statistics to mask how little engineering and fabrication work is performed locally for our major resources projects.

“Industry lumps expenditure like earthworks, catering, travel and entertainment in with skilled expenditure like engineering and fabrication to arrive at a higher local industry participation percentage,” Oliver told Manufacturers’ Monthly.

“They then add expenditure over the 30-year life of the project to the design and construction expenditure to further inflate the local industry partici-

a part of NMW and Austech (May 8-11, Sydney Showground – Sydney Olympic Park) - will feature executives from Boeing Aerostructures, Bluescope Steel and CSIRO as well as from smaller businesses and government agencies. It will also include round-table discussions on how companies can step up their “can do” approach to build a vibrant, prosperous business.

The conference program is on the NMW website – I am sure you’ll agree that it’s well worth attending as a source of new ideas for your business.

Meanwhile, the NMW exhibition itself is shaping up as a world-class platform of industry capabilities. From what exhibitors tell me, there will be new products, new services and ‘firsts’ across NMW 2012 – making it a true

pation percentage.

“This would presumably include expenditure on items like catering, travel, accommodation and communications expenditure over the full 30 years,” Oliver said.

“Industry and Government appear unable to provide figures that tell us how much engineering and fabrication is being performed locally for WA’s major resources projects now, but appears able to predict how much money the projects will spend feeding workers that are not even born yet, and how much their phone bills will be.

“This is like someone not knowing how much it was costing to design and build their house, yet being able to predict how much it was going to cost to mow the lawn and clean the gutters over the next 30 years.

“So far the AIIP’s companies have filled out haven’t had much transparency or accountability. The decision by the Prime Minister late last year, to make them mandatory and public is a good step forward. It will allow the local industry to scrutinise them and contest them,” Oliver said.

However, the AMWU is calling for governments to do more, pointing to the Skilled Local

showcase of the best that industry has to offer.

Please make sure you don’t miss out! Register now at nationalmanufacturingweek.com.au – it’s fast, free to industry – and it’s the best way to make sure you get to see the innovations and ideas that could give your business a competitive edge.

Paul Baker Exhibition Director National Manufacturing Week

manmonthly.com.au

Jobs Bill 2011 proposed by the WA Labor opposition.

In part, the Bill calls for any firm engaging in an Australian resources project to do the following: â&#x20AC;˘ detail procurement practices that will provide a fair opportunity for WA industry to participate; â&#x20AC;˘ detail information on methods by which WA businesses will become part of the supply chain of the mine developer; â&#x20AC;˘ detail how local suppliers will be given equal opportunity to participate as existing interstate and overseas suppliers; â&#x20AC;˘ provide information on the expected percentage of local content; â&#x20AC;˘ wexplain why local manufacturers are being overlooked for work not done here that could be done in WA. According to Oliver, the Bill is an option that the Barnett Government should take. â&#x20AC;&#x153;Experience shows that major resources companies always

Lack of transparency means statistics can be used to mask how little engineering and fabrication work is performed locally for our major resources projects - Oliver.

comply with the laws of the land in which they operate. â&#x20AC;&#x153;This is true in the case of environmental regulation and industrial relations law and it is also true in the case of local content requirements. â&#x20AC;&#x153;In WA however, the government has demanded very little and we are increasingly getting very little in return. â&#x20AC;&#x153;The Bill does not propose mandating an arbitrary one-sizefits-all percentage for local content on major resources projects, and nor should it. Mandated levels of local content are unworkable and could actually sell the continued on page 18

WORK HEALTH AND SAFETY 2012 NATIONAL CONFERENCE Getting a grip on work health and safety risk management MELBOURNE 3 May ADELAIDE 4 May SYDNEY 8 May BRISBANE 9 May

For further information visit whsconference.aigroup.com.au

:H¡YH *RW <RX &RYHUHG 0DQXIDFWXULQJ (53 WKDW EHQHILWV WKH HQWLUH RUJDQLVDWLRQ

(&L 0 LV SRZHUIXO (53 VRIWZDUH IRU PDQXIDFWXUHUV ZKR ZDQW WR UHGXFH RSHUDWLRQDO FRVWV LPSURYH SURGXFWLYLW\ DQG LQFUHDVH SURILWDELOLW\ ZLWKRXW LQFUHDVLQJ RYHUDOO KHDGFRXQW Â&#x2021; $GYDQFHG SODQQLQJ DQG VFKHGXOLQJ

Â&#x2021; %DU FRGHG VKRS IORRU GDWD HQWU\

Â&#x2021; -RE FRVWLQJ DQG DQDO\VLV

Â&#x2021; 4XDOLW\ PDQDJHPHQW DQG UHSRUWLQJ

Â&#x2021; 4XRWLQJ DQG HVWLPDWLQJ

Â&#x2021; $FFRXQWLQJ DQG 3D\UROO

Â&#x2021; &XVWRPHU 5HODWLRQVKLS 0DQDJHPHQW

Â&#x2021; ([HFXWLYH GDVKERDUGV

%RRN D )UHH 'HPR 7RGD\

ZZZ (&L6ROXWLRQV FRP 0 &RYHUHG PP

RU VSHDN ZLWK VRPHRQH WRGD\ 1= TXRWLQJ 00 ZZZ (&L6ROXWLRQV FRP Â&#x2021; (&L0 #(&L6ROXWLRQV FRP (&L 0 DQG WKH (&L 5HG %R[ ORJR DUH WUDGHPDUNV RU UHJLVWHUHG WUDGHPDUNV RI H&RPPHUFH ,QGXVWULHV ,QF $OO ULJKWV UHVHUYHG

manmonthly.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly APRIL 2012 17

Analysis MANAGEMENT Over 80% of AGi Engineeringâ&#x20AC;&#x2122;s work is now for the mining industry.

continued from page 17 State short,â&#x20AC;? Oliver said.

Riding the mining wave One WA manufacturer taking advantage of the boom in the oil and gas sector is Matrix Composites and Engineering who recently opened a 20,000m2 manufacturing plant in Henderson, said to be the largest and most technically advanced composites syntactic plant in the world.

The facility, which cost $80m, also houses a hydrostatic pressure testing facility, capable of qualifying and testing buoyancy systems to a depth of 17,500 feet.

Employing close to 400 workers, the plant operates three shifts per day, six days a week, and produces a range of buoyancy systems and related equipment for off-shore operations.

According to Matrixâ&#x20AC;&#x2122;s CEO Aaron Begley, the new plant will provide the company with a significant competitive advantage in the marketplace. â&#x20AC;&#x153;By doubling the production capacity of the old plant we can deliver a greater number and type of product. Plus with the increased automation, we now have shorter production timeframes and cost savings, and with superior technology we have even better quality products which closer meet clientsâ&#x20AC;&#x2122; needs,â&#x20AC;? Begley told Manufacturersâ&#x20AC;&#x2122; Monthly. â&#x20AC;&#x153;We also now have the ability to manufacture other composite products for different markets, increasing revenue and reducing risk â&#x20AC;&#x153;This, along with our com-

petitive pricing made possible through our many efficiencies has allowed us to compete effectively on a global scale,â&#x20AC;? he said.

Regarding Australian manufacturers being locked out of many tenders for resource sector construction projects, Begley says the issue needs to be addressed via legislation. â&#x20AC;&#x153;There should be a minimum level of Australian content, but we do need to build local capacity at the same time in high value goods. â&#x20AC;&#x153;A minimum level of local content shouldnâ&#x20AC;&#x2122;t be across the board, it should be in specific areas where we can sustain an ongoing competitive advantage,â&#x20AC;?

Begley said.

On the other side of the country, Queenslandâ&#x20AC;&#x2122;s Minister for Manufacturing and Small Business, Jan Jarratt, says the Mackay area is fast becoming an industry hub for the Queensland state.

â&#x20AC;&#x153;The whole region with the Bowen Basin, the Galilee Basin, is just booming and the potential employment generation and wealth generation out of this area of Queensland is huge,â&#x20AC;?

Jarratt said.

Earlier this year, Nepean Mining announced a new massive mining equipment facility will be built at the port of Mackay for the coal mining industry The new $50m manufacturing plant is expected to generate 400 new full-time jobs, and will produce a range of equipment, including above-ground conveyors and in-pit crushing and conveying systems.

The 5.8-hectare facility will have dedicated lines set up to manufacture conveyors, transfer stations and other mining related infrastructure and will include an R&D division that will focus on developing new mining technologies.

Andrew Kisten from AGi Engineering in Wollongong says his company is also taking advantage of the coal mining boom on the East coast of Australia. â&#x20AC;&#x153;Today the mining industry is over 80% of our business, while five years ago it was probably less than 30%,â&#x20AC;? Kisten told Manufacturersâ&#x20AC;&#x2122; Monthly. â&#x20AC;&#x153;We presently do a lot of work for Joy Mining Machinery in Mossvale; mainly fabrication and machining work.â&#x20AC;? â&#x20AC;&#x153;However lead times for the mining industry are much shorter, which sometimes creates a bit of pressure as companies can often be penalised if the part is late. â&#x20AC;&#x153;However, to meet these deadlines we have an afternoon shift, plus we often work on the weekends. If the customer says itâ&#x20AC;&#x2122;s urgent, then we will work to make the part on time,â&#x20AC;? he said.

Despite the mining industry booming, Kisten says price still plays a big part in getting the business, especially in the past couple of years. â&#x20AC;&#x153;Now we have a lot more competitors, with more manufacturers tendering for the same job. â&#x20AC;&#x153;Before it was quite a niche market, with only a few people involved, but today we often have 10 to 15 competitors tendering for the same job.

Everyone wants to get on the mining industry bandwagon.â&#x20AC;?

However Kisten warns lead times are critical. â&#x20AC;&#x153;We are able to meet the deadlines so we have plenty of work at the moment.

But if it wasnâ&#x20AC;&#x2122;t for the mining industry, things would be pretty tough.â&#x20AC;?

DRAGON SOURCING INTERNATIONAL

reduce your costs... compete in Australia & overseas

THE CHINA SPECIALIST SINCE 1992 There are three options when considering your China strategy:

Work with China Fight against China Ignore China

The choice is yours, but remember the last two could prove to be fatal.

www.dragonsi.com.au 1800 333 182

Australia:

China: Shanghai Hangzhou :

18 APRIL 2012 Manufacturersâ&#x20AC;&#x2122; Monthly

manmonthly.com.au

ITW Polymers & Fluids, the manufacturers of GalmetÂŽ, MolybondÂŽ, RocolÂŽ, DevconÂŽ, EpirezÂŽ and ScrubsÂŽ is now offering PrematexÂŽ to the Australian market!

Finally an alternative for all your Threadlocking, Retaining, Gasketing & Threadsealing needs!

Since 1909, PermatexÂŽ has provided industry with a comprehensive line of the most RELIABLE maintenance products available anywhere, at an affordable price, in easy ready to use packaging.

Providing on-the-job solutions to tough everyday problems.

PermatexÂŽ offers a wide range of highly VERSATILE threadlocking, retaining, gasketing and threadsealing compounds, multi-purpose lubricants, time-saving cleaners, fast-acting adhesives, and specialty maintenance products. PermatexÂŽ products help PREVENT repair and downtime costs and PROLONG equipment life.

! " #

$ % &

&

' % '&

PermatexÂŽ products are designed to help solve industrial problems and improve the reliability of maintenance operations.

Come see us at stand 2000 at National Manufacturing Week!

PERMATEX KEEPING INDUSTRY MOVING!

www.itwpf.com.au

www.itwpf.com.au

TechnologyIT@MM

An ERP system should be able to grow with the business, for the life of the business.

Where analysis is not paralysis Donâ&#x20AC;&#x2122;t allow your dated enterprise resource planning (ERP) system to become the proverbial tail wagging the dog, reports Mike Lorge, managing director of Sage Business Solutions.

T

ODAY, when it comes to ERP systems, businesses are looking for scalable solutions that are able to grow with the company.

The freedom to grow a solution and customise it to meet specific needs is critical, but at the same time manufacturers are looking for the following: 1. Improved ability to operate and trade quickly and easily across multiple markets and geographies while maintaining the same degree of accuracy and security.

2. Streamlined processes.

20 APRIL 2012 Manufacturersâ&#x20AC;&#x2122; Monthly

3. Interoperable systems to ensure they have a single view of every customer across the business.

4. Adherence with regulatory compliance standards for reporting and record keeping, all of which are imposing increasing pressure on businesses.

5. Improved data to deliver productivity and efficiency increases.

While every business is different, an ERP gap analysis checklist can help you identify key issues your business may face, and determine whether the

systems and technology in place have the capabilities to meet your current and future needs.

Consider the following: Do you need to comply with government regulations? Does your existing technology integrate the capabilities necessary to improve the organisationâ&#x20AC;&#x2122;s regulatory compliance? Do you need to streamline your operations to improve productivity and profitability?

By automating business processes, which in turn improves accuracy of information and accelerates data flow, an ERP system can help your company

streamline day-to-day tasks and free up staff to focus on more complex issues. As a result you can improve productivity and dramatically reduce operating and overhead costs.

Your ERP should offer a fully integrated set of applications, from front-end customer-relationship management to backend financial analytics and business intelligence.

It should also offer a common repository; this is where all the data required by all of your applications and processes is kept giving your employees

manmonthly.com.au

access to the information they need when they need it.

Donâ&#x20AC;&#x2122;t forget process orientation, which enables processes to be evolved naturally over time, rather than orientated to discrete tasks.

You might also need to enhance your decision-making capabilities by implementing software that integrates all your information and processes into one coherent environment.

Does your current ERP offer critical BI capabilities including integrated BI, integrated CRM, enhanced visibility, ease-of-use, reporting, and security?

As market conditions fluctuate and competitive pressures increase, you may need to team with multiple geographic partners and rely on contract manufacturing and third-party logistics providers. Do your existing IT systems support collaboration with partners?

Do they have capabilities that include: a web-native platform, automated workflows, Web 2.0 capabilities and security?

manmonthly.com.au

Do your processes and systems adapt and scale with you?

Are your solutions flexible?

Are they scalable so they support your business today, but can accommodate your needs and requirements in the future?

They should have configurable workflows, multi-site support and customisation features.

Are you planning to grow your business globally?

If you plan to operate your business outside Australia, will your systems support international operations including: global currencies, multiple languages and global regulatory requirements?

Looking to the future, as businesses continue to choose between on-premise and cloud delivery models when it comes to business software purchasing, you can expect to see continued developments in ERP solutions to suit each preference, providing customers with greater freedom of choice.

Sage Business Solutions 02 9921 6500, www.sagebusiness.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly APRIL 2012 21

TechnologyIT@MM Sheet metal and steelwork software LANTEK’S 2012 versions of its CAD/CAM, management and ERP software for sheet metal and structural steelwork applications are said to bring even more powerful software tools to engineers.

The Lantek Expert CAD/CAM software now includes a manufacturing browser which optimises the selection of tool options, while algorithms for automatic machining of multi-parts and the 3D simulation of punching operations improve efficiency and clarity.

For pipes and steelwork, the company has improved the way in which Lantek Flex3d links with CAD. Its new customisable ribbon menus and advances in STEP, IGES, DSTV, CAM and XML interfaces make it easy to import pipe assemblies and work with 3D data.

For production monitoring and planning, Lantek Manager and Lantek Wos offer real-time control and monitoring of the manufacturing process.

7 - 9 May, 2012 Melbourne Convention & Exhibition Centre

The ONE event that connects the Air Conditioning, Refrigeration and Building Services industry Register online at www.arbs.com.au

22 APRIL 2012 Manufacturers’ Monthly

Software for the sheet metalwork and steelwork industries.

New features in 2012 include data input control to avoid typographical errors, configuration enhancements to make it easier to customize the software to meet individual requirements, controls for optimising cutting, and XML for intelligent data sharing both import and export.

Lantek, www.lanteksms.com

ARBS 2012 is Australia’s ONLY International HVAC & R and Building Services trade exhibition.

Showcasing the very latest innovations and technology ARBS connects local, national and international manufacturers and suppliers with decision makers, specifiers, engineers, contractors, technicians and service professionals.

Save the date for this HVAC & R and Building Services mega event held over 3 days and featuring the trade exhibition, an informative seminar program and the national awards gala event.

manmonthly.com.au

The shift to cloud computing

Cloud computing is a shift that enables businesses to purchase IT as a service.

BY KEITH BUCKLEY

I

N the last five years, cloud computing has evolved from a buzz word to one of the biggest IT movements to transform the industry.

When we consider that the manufacturing sector accounts for more than 10% of Australia’s economic output, it’s little surprise that these companies are investigating cloud computing as they look towards the next big thing to improve their IT infrastructure.

So what is cloud computing exactly? Simply put, cloud computing is a shift that enables businesses to purchase IT as a service.

Rather than managing their computing infrastructure in house, they can outsource this to an expert third party provider.

This way data storage, applications (such as email) and software services (such as security) are hosted offsite rather than on physical machines in your company.

In essence, computing becomes a service rather than a product that needs to be managed and maintained in house.

Cloud computing offers numerous business benefits, including cost efficiency and predictability. Businesses no longer need to invest in hardware such as data storage infrastructure.

They can also avoid purchas-

ing and managing software such as email, office applications or security solutions. Instead they pay a set fee to a cloud provider who delivers these solutions.

Cloud computing also frees up staff by removing the need for day-to-day management of IT reports, software updates, technical support and help desk assistance. These IT services are outsourced, allowing staff to focus on developing new processes and innovation.

Despite the benefits, a move to the cloud requires confidence.

Many organisations want to test the waters before they move their full IT infrastructure to the cloud.

Therefore, it can be useful to take a staggered approach to the cloud and begin by adopting a cloud service. If we take a look at the issues facing the manufacturing industry, security is a good place to start.

Manufacturing targeted In November 2011, the manufacturing industry was found to be the third most frequently targeted industry for cybercrime.

An average of 13.6 targeted attacks were blocked every day, making security a major issue for companies in this sector.

Targeted attacks are specifically designed to provide cyber-

criminals with access to manufacturing networks, enabling them to access this confidential information, gather intelligence and, in some cases, disrupt operations. 2011 was home to two high profile attacks on the manufacturing and related sectors, dubbed Nitro and Duqu.

These attacks were designed to collect intellectual property such as design documents, formulas and manufacturing processes at least 48 organisations.

A cloud-based security solution can be a major advantage for businesses in the manufacturing sector. Given the complexity and frequency of the threats targeting these organisations, manufacturing forms can achieve peace of mind by putting their security posture into the hands of industry experts.

Cloud security providers have a real-time view of the threat landscape, enabling them to deliver superior protection against both established and emerging threats.

They redirect email, web and Instant Messaging (IM) traffic through the service provider, which enables security threats to be identified and blocked before they enter the organisation.

[Keith Buckley is Regional Director, Symantec.cloud, Australia and NZ.]

www.colby.com.au

“

ColbyRACK is backed by an expert design service

“

manmonthly.com.au

Manufacturers’ Monthly APRIL 2012 23

TechnologyIT@MM

CAD software drives car design faster

BY ALAN JOHNSON

I

N the world of the Australian V8 Supercars Championship, there is only one thing that matters: faster lap times.

The challenge for the racing teams of the 28 cars on the grid is to squeeze as much speed as possible out of a Holden Commodore or Ford Falcon; yet stay within the series’ regulations.

Roughly three years ago, the Kelly Racing engineering team entered a long-term relationship with Autodesk to supply the team with digital prototyping software for all the team’s CAD development.

Kelly Racing, recently named Autodesk’s Inventor of the Month for its innovative use of software, uses it to design and validate new car components to give the team a racing edge - all without hitting the track for physical testing.

With the period between races often a window of less than three weeks, Autodesk’s Inventor Professional, Simulation CFD/Multi-physics and Vault Professional software are crucial to enabling Kelly Racing to turn around new components in a timely manner.

“It is critical for us to be fast and efficient in every facet of our business,” said Rick Kelly, team racer and co-owner.

Many readers might not realise that Kelly Racing has close to 50 full-time staff members.

“We run four cars in the Championship and each car has

two dedicated mechanics. Other staff are across roles such as subassembly, fabrication, engine department, team management, commercial and other specialist roles like auto electrical, CNC machinists, truck drivers, spray booth painter, and of course our engineering department,” Kelly told Manufacturers’ Monthly.

“We have eight full-time people in the engineering department - at an event we have race engineers who effectively run the cars, determining the set-up and managing the race strategies, then back at the workshop we work on designing new components, monitoring quality control, refining processes and planning for upcoming events,” But he says the numberone skill needed is teamwork, “because each team needs lots of different people with different skill sets, the driver included”.

“You need clever people and then you also need to get them to all work together and pull in the same direction,” Kelly said.

Following a race weekend, the drivers brief Kelly Racing’s in-house design and engineering team on what precisely went right and wrong during the race.

The designers then set to work with Inventor software to make modifications to the existing car parts that can enhance performance and save the team time.

For example, improvements to the front end of the car, in particular the suspension assembly, has increased traction and grip by 8%, leading to faster lap times or shaving 1% of total car

Teamwork and smart engineering the keys to Kelly Racing’s success.

weight through design and material optimisation.

Even the most minor modifications play a vital role in a sport, in which a fraction of a second can be the difference between first and twenty-first place.

Engineers then test revised designs with Simulation CFD to optimise aerodynamic performance and ensure the components are able to perform at speeds of up to 300kph.

Vault Professional data management software helps manage the design process from initial concept to final release, providing the engineering team with greater control over the design process right up until the component or part is manufactured, released to the race department and put on the car.

The Autodesk solution for digital prototyping enables engineers to create a single digital model that can be used in every

How Much is Compressed Air Costing You? Did you know that more than 75% of the lifetime cost of an air compressor is in energy costs?

Southern Cross Compressors Australia can offer industry leading products and services to maximise efficiency and ‘lower the cost of compressed air’.

Call 1300 735 768 or visit www.sccompressors.com.au 24 APRIL 2012 Manufacturers’ Monthly

stage of production, bridging the gaps that usually exist between conceptual design, engineering, and manufacturing teams.

This single digital model simulates the complete product and gives engineers the ability to better visualise, optimise and manage their designs before producing a physical prototype, in turn allowing them to get to market faster with better product innovation.

Embracing digital prototyping has been a winning strategy for Kelly Racing.

A new racing team typically takes six or more years to register its first win, but just barely into its third season, Kelly Racing has already scored two victories along with nine podium finishes.

“We design everything on the car using Autodesk,” said Kelly.

Autodesk, www.autodesk.com Kelly Racing, www.kellyracing.com.au

•Rotary Screw Compressors •Reciprocating Compressors •Used Compressors •Air Receivers •Air Dryers •Aftercoolers •Filters •Servicing •24hr Breakdown Service •Hire Compressors •Repairs & Rebuilds •Spare Parts •Energy Audits •Air Leak Audits •System Design & Installation

See Us @ NMW Expo Stand 1120

manmonthly.com.au

What’sNew See more new products at manmonthly.com.au

Mobile personal GPS security and tracking system EziTrak Nano Mobile is a low cost high performance Personnel Tracking System designed for remote and field workers.

It is described as a small, durable, reliable real time tracking device with fast acquisition and update rates with features such as man-down detection, SOS notification, auto-vehicle connection detection and logging.

It can be used as a tracker in any vehicle or for personal use.

The user simply plugs the unit into a vehicle’s cigarette lighter and details of each journey undertaken by that vehicle will be recorded including street address, speed, heading and duration of journey.

For personal use, the unit is placed in the Belt Cradle and worn by the user as he/she goes about his/her duties. A RED panic button can be used to signal an emergency situation.

The system is designed for remote and field workers.

Rojone 02 8796 7888, www.rojone.com.au

Compact automation terminals WITH its narrow design, the analogue Inline terminal IB IL AO 2/UI-PAC from Phoenix Contact is a compact option for outputting current and voltage signals.

The analogue terminal is just 12mm wide, has two channels, and offers precision and performance at an affordable price.

Two analogue outputs operate in

Rugged mobile computer/server Backplane Systems Technology has released Octagon System’s rugged mobile computer/server, the RMB C2 designed for applications where severe environments and high performance meet.

It is said to tightly integrate the electrical, thermal and mechanical components into a complete system with no compromise to any one segment.

The RMB-C2 is a fully-developed platform designed to accelerate user’s

design process. It can be supplied with Windows XPe or Linux installed.

It can be used as a central server, a stand-alone CPU, or a remote terminal, with a full complement of I/O provided: 2 x USB2.0, CAN Bus, VGA, serial, video, audio, odometer and digital I/O ports.

Additional functionality can be implemented via expansion cards in the PC/104 and Mini PCI formats.

synchronism with the local bus with a resolution of 11 bits plus sign and a precision of 0.1% of the measuring range final value.

The compact Inline terminals are

fast and reliable, reduce the amount of space in the control cabinet, and at the same time lower costs.

Phoenix Contact 1300 786 411, www.phoenixcontact.com.au

PC & PLC Programming Video Image Processing Cost Effective Solutions for your automation technology needs Australia wide.

We specialise in Systems Integration and Projects Big and Small.

Industrial Software & Electronics Tel: (07) 3856 2232 Fax: (07) 3355 1012 Email: info@industrialsoftware.com.au

Backplane Systems Technology 02 9457 6400, www.backplane.co.

www.colby.com.au

“

ColbyRACK is designed for safety even in earthquake zones

“

manmonthly.com.au

Manufacturers’ Monthly APRIL 2012 25

What’sNEW Elastomer-free transducer Automated Control Engineering (ACE) and STS have released a pressure transducer that is free of elastomers.

For applications in which O-rings are either undesirable or impermissible, a measuring cell with a fully welded process connection is now available.

As the standard welded version is designed only for pressures up to a maximum of 250 bar, STS has developed a new elastomer-free version that incorporates a metal to metal seal that is capable of withstanding higher pressure ranges.

The new metallically sealed transducer is suitable for a configurations covered within the TM, ATM and PTM product groups.

Safety boot range

The measuring cell features a fully welded process connection.

Mack Boots has launched a new range of safety boots for a variety of industrial environments and work conditions.

The new boot range includes the Aero, Boss, President, Freeway, Wolf, Venus, Kelpie, Heeler, Peak, Terra, Zero, Jupiter, Barb, Blast, Earth, Tradesman and Saturn boots.

All the boots in the range are said to have high durability and are slip and heat-resistant.

The safety boots are also said to be able to withstand extreme conditions and are very comfortable for those that need to wear their boots all day long.

Automated Control Engineering 02 4954 5004, www.aceg.com.au.

Mack Boots www.mackboots.com.au.

“No-frills” utility forklift available in 1.5 to 3.5t models Nacco Materials Handling has released the new Utilev range of forklift trucks which are designed for users who require materials handling equipment without the need for advanced functionality or attachments.

The IC-powered counterbalance forklift trucks are said to offer users a no-nonsense, uncomplicated approach to materials handling, providing affordable, reliable and cost-effective handling solutions.

The new range consists of 1.5 to 3.5t forklift trucks and is available in six different capacities with either diesel or dual-fuel power.

Each forklift truck in the range is said to feature an ergonomically-designed

Focusing Made Easy.

Automatically blend visible and infrared images Get focus-free imaging with IR-OptiFlex ™ Troubleshoot with multi-mode video

26 APRIL 2012 Manufacturers’ Monthly

Build a complete picture of your environment with IRPhotoNotes™

Colour alarms highlight problem areas

operator compartment, with a familiar automotive layout which is designed to keep drivers comfortable and prevents tiredness during handling operations.

Nacco Materials Handling Group 02 9795 3812, www.nmhg.com

New from Fluke: Our easiest-to-use thermal imagers ever.

IR-OptiFlex™ delivers pointand-shoot imaging with full IR-Fusion capabilities.

AutoBlend™ mode blends partially transparent infrared and visible images into a single view for precise reporting.

With portrait or landscape mode—your preference.

Thermal imaging has never been easier.

See the new imagers in action: www.fluke.com.au

manmonthly.com.au

Industrial pumps

Automated and manual lifting devices

HURLL Nu-Way, authorised distributor for Dover PSG pumps in Australia & NZ, has released the EnviroGear range of pumps onto the Australian market.

Dover Pump Solutions Group (PSG), said to be the world’s largest provider of sliding vane (Blackmer) and eccentric disc pumps (Mouvex), has acquired EnviroGear, a premier magdrive internal gear pump manufacturer.

While the EnviroGear pump is designed to eliminate operational concerns found in old-style mechanical seal gear pumps, its simple design— which consists of only seven primary parts: a magnet housing, containment canister, casing, rotor magnet assembly, idler gear, eccentric spindle and head—greatly reduces maintenance and environmental costs.

The pumps are said to offer a 50% reduction in maintenance costs, lowest overall cost of ownership, and increased environmental and fluid handling safety

The pumps are said to offer a 50% reduction in maintenance costs

Hurll Nu-Way 1300 556 380, www.hurll.com.au

Protection from impact hazards AUSTRALIAN safety products company Safepad has introduced a range high visibility impact protectors, including tube-ends, cylinders, safety pads, and edge protection.

The product range is intended to help prevent impact hazards on site, in order to avoid the risk of forceful collision with open ended pipes, scaffolding joints or other jutting, sharp-edged objects.

This problem has often been dealt with using rags and duct tape or paint to draw attention to the hazard.

However, this is time-consuming to apply; it also looks unprofessional and only highlights the hazard without reducing its consequences.

Built to function in heavy-duty industrial work environments, Safepad products offer flame-retardant and static-resistant materials which have

been site-tested in offshore, corrosive and temperature extreme environments.

Safepad products are used on and offshore in the construction, mining, marine and oil and gas industries in Australia and in South East Asia by contractors and multinationals, including Shell, BHP, ASC, Alcoa and Apache.

ACTISAFE has released a range of heavy duty automated and manual lifting devices for safer work with pallets, skids, bins and stacks.

Known as Actilift, the range includes the premium product, the automated Quickstak Smart Stacker, as well as a series of manual and automated lifting trolleys.

Actisafe is a defence preferred supplier, so its product range is heavy duty in order to sustain a long operating life in demanding sites such as military depots.

The Quikstak Smart Stacker has automatic height adjustment during loading and unloading to keep the work height at an optimised set position for better ease of use and reduced potential for injury.

This in-built height adjusting sensor keeps the unit positioned at pre-determined heights whether it is loaded with palletised goods, bottles or large sheet material.

Optional built-in digital scales allow the operator to calculate the exact product weight while working.

Actisafe 1300 852 397, www.actisafe.com.au

Safepad 08 9474 6886, www.safepad.com.au

www.colby.com.au

ColbyRACK is no problems, just solutions

manmonthly.com.au

“

“

Manufacturers’ Monthly APRIL 2012 27

+P[JO [OL LUJSVZ\YL 4HJOPUL 4V\U[ 0 6 0UJYLHZL `V\Y Ă&#x2026;L_PIPSP[` ^OPSL YLK\JPUN `V\Y LUJSVZ\YL JVZ[Z

Whatâ&#x20AC;&#x2122;sNEW Infrared thermometers with IP65 sealed sensor Ircon has introduced the Modline 7 Series of infrared thermometers said to provide best-in-class solutions for demanding industrial environments with a rugged, IP65 (NEMA 4) sealed sensor system and the flexibility to meet most continuous temperature monitoring and control requirements.

The thermometers are suitable for a wide range of industrial applications, including semiconductor manufacturing, metals processing, furnace refractory, primary and secondary glass, as well as plastics thermoforming.

With extended temperature ranges (-40ÂşF to 5432ÂşF/3000ÂşC), high-resolution optics and fast response times, the thermometerâ&#x20AC;&#x2122;s sensing head can operate as a stand-alone sensor, providing simultaneous analogue and digital outputs of process temperatures.

Motorised focus control and both through-the-lens and laser sighting are standard on all thermometers.

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

Compact safety light curtain module

0 6 )SVJRZ Â&#x2039; +L[HPSLK KPHNUVZ[PJZ Â&#x2039; 9\NNLK M\SS TL[HS OV\ZPUN Â&#x2039; /PNO KLUZP[` 0 6 Â&#x2039; OPNOS` ]PZPISL Z[H[\Z 3,+ÂťZ )HSS\MM 3L\aL 7;@ 3;+ )\Y[VU *V\Y[ )H`Z^H[LY =0* ; ^^^ IHSS\MM SL\aL JVT H\

28 APRIL 2012 Manufacturersâ&#x20AC;&#x2122; Monthly

The new ReeR EOS4 compact safety light curtain is designed for the protection of machine tools and with its small-size housing and minimal dead zone, it is suited for applications where space restrictions exist.

With a very small dead zone, which is only present on one side, this allows the safety curtain to maintain resolution up to 30mm if installed on a plan, and up to 40mm if installed at 90° against another EOS unit.

The safety curtain can be used for the protection of presses, punches and dinking machines, cutters and shears, robotised areas, assembly lines and assembly machines, including those with a small size.

The units feature selectable maximum scanning distances of 4m or 12m, and have two PNP safety

static outputs protected from shortcircuits and overloads.

Treotham Automation 02 9907 1778, www. treotham.com.au .

Temperature control skids TERALBA Industries has recently released the Thermaster range of heat transfer systems.

Thermaster combines the product features of Dimpleflo and Teralba heat exchangers, delivered with a range of control equipment such as pumps, valves, resistance temperature detectors (RTDs) - with provision for thermal

expansion - into a skid mounted system.

Thermaster systems are compact, minimising the use of floor space. They are also transportable.

The heat transfer systems incorporate removable panels for protection from hot surfaces and adjustable levelling feet to allow

positioning in different locations.

The systems are suited to demanding applications such as controlled water heating with steam, isolation of ethylene glycol from temperatures above its flash point, and refrigeration duties with inbuilt control requirements.

Teralba Industries 1300 207 020, www.teralba.com manmonthly.com.au

Protective coveralls 3M has launched a comprehensive range of disposable coveralls that provide protection for a variety of applications ranging from light-duty industrial cleaning to asbestos removal, painting and coating, pesticide spraying and chemical spills, decontamination and tank cleaning.

The 3M protective coveralls contain no components made from natural rubber latex or silicone and are designed with extra material in the arms and legs for enhanced mobility.

Two-way zippers provide added on/off convenience while storm flaps help provide additional protection and

15/12/11

The range also includes accessories such as mob caps and disposable overshoe and overboot covers.

seamless shoulders and sleeve tops translate to fewer entry points for contaminants.

3M 136 136, www.3m.com/au/ohs.

High-pressure ball valve HYDAC has released a 15,000psi stainless steel high-pressure ball valve.

The valve is made of high strength, corrosive resistant materials. The 1â&#x20AC;?

(2.5cm) full bore valve is designed to increase flow rates in order to allow deeper oil/gas drilling capabilities.

The trunion ball design reduces the amount of torque required, and the

manmonthly.com.au

compact design minimises space, piping and weight, which is critical for offshore applications. According to HYDAC, the ball valve is maintenancefree due to proprietary design. The process of exchanging valves is simple, as welding is not required due to Grayloc design or Butt Weld.

! "

!

#$ %!& $ "'

2:44 PM

Page 1

Electrical & Electronic Components Catalogue

2012

Switches Connectors Sound & Visu al Enclosures Power, Protect ion & Contro l Computing & Display

( )*++ ,-. /)) #" ( " 0 $ 1 #1" 1 $ 1 #1"

HYDAC 1300 449 322, www.hydac.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly APRIL 2012 29

What’sNEW Reach forklifts USB isolators to Toyota Material Handling Australia protect from surges has releasee the new Raymond 7000 B&B Electronics has developed one-port Ulinx UHR401 and two-port Ulinx UHR402 USB isolators, designed to protect connected equipment from surges, spikes and electrostatic discharges carried on USB cable.

The isolators also protect themselves due to their tough construction. Ulinx hubs are built to withstand industrial networking hazards like shock, drop, vibration, electromagnetic interference (EMI) and temperature extremes.

They are equipped with high retention ports that hold USB cables firmly in place to eliminate data loss, and in extreme cases, the risk of fire caused by loose cables and arcing.

Applications would include industrial control and manufacturing, remote sensing and metering, instrumentation, point-of-sale, test and measurement, laboratory information systems (LIMS) and medical applications requiring 60601-1 certification.

Key features include a temperature range of -40 to 80°C, Level 4 ESD protection (15kV air, 8kV contact), and 4kV isolation between upstream and downstream USB ports.

Downstream ports provide full 500mA power to connected devices, and high retention ports require 3.2lbs (1.45kg) of force to dislodge a cable.

The included external power supply has US, EU, and UK blades.

B&B Electronics, www.bb-elec.com

Series reach forklifts.

The new stand-up 7500 and sit/ stand 7700 forklifts, which supersede the 7400 and 7600 models, are said to include new “Eco-Performance” benefits.

The forklifts are said to provide the latest in economic and ecologic technologies, and include regenerative braking to save energy and reduce component wear.

All high capacity 7000 Series models offer regenerative lowering technology (optional on other models) that creates power, with up to 10% of the amps returned back to the battery when the truck is lowering its load.

According to the company, Raymond’s ac motors, unlike dcpowered trucks, deliver the same level of performance until the battery wears down with considerably less maintenance requirements.

Toyota Material Handling Australia 1800 425 438, www.toyotamaterialhandling.com.au.

Forklifts feature “Eco-Performance” benefits.

Handheld terminal with built-in printer UNIQUE Micro Design (UMD), a distributor of “edgeware” devices and solutions, has released the Casio IT-9000 Rugged Handheld Terminal with built-in printer.

The Casio IT-9000 is targeted for use in mobile ticketing, mobile pointof-sale (POS), meter reading, parking enforcement, traffic citation and route sales.

With a built-in printer, local area

network (LAN) and near field communication (NFC) as standard, and options including wireless area network (WAN), global positioning system (GPS), 2D imager, magnetic card reader and 2 megapixel colour camera, this unit aims to meet the demands of today’s mobile workforce.

The unit is suited to outdoor usage with high durability (1.5m drop, IP54

rating, operating temperature -20 to 50 degrees C), long battery life (up to 15 hours) and high LCD visibility in sunshine.

Desktop and vehicle mounted charging cradles are available along with Ethernet or USB communications cradles, battery chargers, screen protectors and cables.

Unique Micro Design 03 9582 7000, www.umd.com.au

Established in 1986 Robot Technologies-Systems Australia Pty Ltd is Australia’s foremost integrator of robotic automation.

Celebrating 25 Years

SPEAK WITH AN EXPERT TODAY ABOUT OUR WIDE RANGE OF APPLICATIONS, PROCESS AND AUTOMATION CONSULTATION, TURN KEY PROJECTS, 24/7 TECHNICAL SUPPORT AND TAILORED TRAINING COURSES.

RA series Arc Weldng Robots

ROBOT TECHNOLOGIES-SYSTEMS AUSTRALIA PTY LTD Head Office: 2 Silicon Place (P O Box 118), Tullamarine, Victoria, 3043 Telephone +61 3 9330 3511 Web: www.robots.com.au E-mail: sales@robots.com.au 30 APRIL 2012 Manufacturers’ Monthly

manmonthly.com.au

Servicing the Manufacturing Industry for over 30 years Hydraulic and Industrial hose and fittings 92 Service and Supply Centres Australia wide National fleet of 320+ fully stocked mobile service workshops Rapid response time, 24 hours 7 days All Service and Supply Centres ISO9001:2008 accredited NATA certified hose testing facility Registered training organisation Nationally accredited and certified technicians National pricing policy

EndeavourAWARDS Enter online at manmonthly.com.au

Celebrating manufacturing success The 9th annual Endeavour Awards will celebrate Australia’s manufacturing excellence. Annie Dang writes.

N

OW in its ninth year, the Manufacturers’ Monthly Endeavour Awards is the only national awards program specifically for Australia’s manufacturing industry that celebrates and recognises the achievements of industry leaders in their drive to achieve ‘best practice’ and excellence in manufacturing.

This year, the Manufacturers’ Monthly team received an influx of quality nominations – 92 award entries – to be exact, which goes to prove that manufacturing is still thriving in Australia.

“The number of finalists this year reflects the strength and diversity of Australia’s manufacturing industry and proves to the doomsayers that the industry is alive and well, and is in fact booming in many areas,” says Manufacturers’ Monthly’s editor-at-large Alan Johnson.

To read more on the nominations, look to the following pages to find summaries about the outstanding products, projects and people from this year’s thirteen award categories, with three more to appear in the May issue. The categories reflect Australia’s broad range of manufacturing excellence and that Australian companies are on par with the best in the world.

Last year the Endeavour Awards celebrated Manufacturers’ Monthly 50th birthday with over 300 manufacturers gathering at the RACV Club in Melbourne on 25 May – it was the biggest turnout for the Endeavour Awards ever had.

The awards celebrated over 99 local manufacturing success stories; proving that despite an unstable global economic market, and the off-shoring of local production by some big manufacturers, Australian manufacturing is strong, resilient and adaptable to change local and global conditions.

Comedian Vince Sorrenti keep guests last year entertained, while keynote speakers Parliamentary Secretary for Climate Change and Energy Efficiency 32 APRIL 2012 Manufacturers’ Monthly

professional MC. This year we have one of Australia’s leading comedians and media personalities, James O’Loghlin joining us on this special night of night for industry.

Most recognised as the host of the ABC program, The New Inventors, O’Loghlin is well verse in the necessity, innovation and creativity that goes into development new technologies and products that help to Quickstep’s Philippe Odouard (left) receiving the shape and reshape how we do Global Integration Award from David McLachlan, things.

ICN chairman, sponsor of the award.

Judges for this year’s Quickstep also went on to win the prestigious awards include Manufacturers’ Manufacturer of the Year award for 2011.

Monthly’s editor-at-large Alan Johnson; Dr John Blakemore, CEO and Principal Consultant Mark Dreyfus, who introduced Senator Blakemore Consulting International; Kim Carr’s video, Opposition Leader Dr Ivan Cole, Research Team Leader Tony Abbott and Holden Australia’s for CSIRO Materials Science and executive director of manufacturing Engineering (CMSE); Mark Goodsell, operations, Martyn Cray addressed NSW Director of the Australian Industry more pressing concerns for Australian Group; Derek Lark, executive director manufactures and drew attention to the of the Industry Capability Network; strengths of the industry. and Stephen Johnson, Acting Manager While ‘carbon’ and ‘tax’ was the hot Industry Team For Manufacturing topic for the night, it was Quickstep and Electrocom, NSW Department of Holdings’ claim to Manufacturers’ Education and Communities.

Monthly’s Manufacturer of the Year for Thank you to all our 2012 awards 2011, as well as winner of the Global sponsors: ABB, Atlas Copco, BOC, Integration Award, which highlighted BlueScope Steel, EFIC, Enterprise how Australian manufacturers can successfully compete against the best in the Connect, ICN, IFM, Sick and SMC. Thank you also to all the companies world. who entered the awards. The nominaAs part of the F-35 Joint Strike tions this year has been outstanding; Fighter program, the largest militruly proving that there is a manufacturtary aerospace program in the world, Quickstep has successfully overcome the ing future on this island continent.

The winners from each of the 16 catmany entry barriers faced by new paregories will be published in the June ticipants in the defence manufacturing issue of Manufacturers’ Monthly and will sector, possibly the highest of any indusalso be announced on our website at try in the world. www.manmonthly.com.au.

This year’s Endeavour Awards gala The Endeavour Awards program is dinner will be held in Sydney on 9 designed to breed innovation and sucMay 2012, at Doltone House at Darling cess, please join us on 9 May 2012 to Harbour and will bring manufacturers celebrate the best Australian manufaclarge and small together for Australia’s turing has to offer. largest manufacturing industry awards program.

To buy tickets to the Endeavour Awards, email Sarah We can’t reveal too much about the Bateman on sarah.bateman@reedbusiness.com.au. night because we want to keep it a surFor Endeavour Awards news and updates, prise! What we can share with you is go to www.manmonthly.com/awards that the awards will again be run by a manmonthly.com.au

TICKETS NOW ON SALE FOR THE 9TH ANNUAL ENDEAVOUR AWARDS The Endeavour Awards, hosted by Australia’s leading manufacturing magazine Manufacturers’ Monthly, is the pinnacle event for Australia’s manufacturing industry where innovation and achievement is recognised.

JOIN US IN CELEBRATING THE BEST OF AUSTRALIAN MANUFACTURING! WEDNESDAY 9 MAY, 6.30PM DOLTONE HOUSE, PYRMONT, SYDNEY

TICKETS $130 PER PERSON OR $1,100 FOR A TABLE OF 10*

BOOK TICKETS

at www.manmonthly.com.au/awards or contact Sarah Bateman on (02) 9422 8994.

*PRICES EXCLUDES GST

Proudly brought to you by Manufacturers’ Monthly and the following sponsors:

.

FOLLOW US ON:

Twitter: @manmonthly Facebook: Manufacturers’ Monthly Linkedin: Manufacturing Australia

EndeavourAWARDS Safety Scheme of the Year Award - 2012 Finalists

.

Proudly sponsored by

Enter online at manmonthly.com.au

Keeping industry workers safe AUSTRALIAN PAPER MARYVALE MILL Creating a safety frame of mind.

The Maryvale Mill has three pulp mills, five paper-making machines, an elemental chlorine free bleach plant, pulp lapping machine, finishing facility and a waste paper processing plant.

When it came to safety and reminding employees who had been on leave or contractors of the importance of safety it decided to implement a Video Display Unit (VDU) at its two pedestrian entrances.

Maryvale now display 200 plus inhouse safety posters that it created over the past four years and due to WorkSafe Victoria and WorkSafe BC a number of safety video commercials have been allowed to be used for this purpose.

The VDUs at the gates run 24 hours a day seven days a week and are designed so that none of the 887 employees or over 2000 plus contractors who enter the site annually should see the same group of posters or commercials for at least a 12 month period.

BALLANTYNE SAFETY BSS (Ballantyne Safety Systems) Ballantyne Safety offers a complete height safety system that includes equipment sourced from manufacturers and Australian accredited training specifically designed for working on roofs.

As part of its R&D program, the Ballantyne design team integrates the opinions and suggestions of safety experts into the product development process. An example of this is the new adjustable off-load T bolt. This allows the roof anchors to be in a fixed position before attempting to enter a roof space.

Market research has shown a strong need for a secure, safe and reusable roof anchorage system. The Ballantyne roof anchors comply with all Australian testing standards and requirements.

The implementation of BSS manufactured equipment and training courses offers the potential to reduce serious injuries due to falls from roofs to zero.

OPTALERT Optalert Fatigue Risk Profiler (FRP) Optalert is said to be the only alertness monitoring technology in the world that can accurately measure a driver’s alertness in real time and detect the early 34 APRIL 2012 Manufacturers’ Monthly

Protecting workers a key focus for manufacturers.

onset of drowsiness to prevent an accident.

The Optalert System is the culmination of more than 15 years of research into the physiology of drowsiness by Optalert founder and Chief Scientist, Dr Murray Johns.

Dr Johns and the team of Melbourne researchers spent many years developing the proprietary drowsiness detection algorithm based on new methods for measuring eye and eyelid movements.

This led to the development of the “Johns Drowsiness Scale”; the world’s first validated scale of drowsiness in active people.

Since that time, Optalert has gone through a series of design perfections to deliver to the transport and mining sectors a behavior based safety tool that constantly supports the need of the driver to remain safe during their journey.

With the development of the Optalert Fatigue Risk Profiler, Optalert can now make a driver’s level of alertness visible to management via the Internet.

In doing so, Optalert assists those in the ‘control room’ to share in the responsibility of safe driving, while also improving safety for all road users.

TRADIEZRACK TradiEZrack Safety Tradiezrack uses a patented rack to hold the weight of boards to make it easy to shift each board at no risk to the tradesmen. It can also be locked so there is no chance of them falling when the site is closed after hours.

Currently, plasterboard, gyprock and timber are placed in the middle of the site, or more commonly leaned against the wall. When a tradesman wants to select a certain piece they commonly lean all boards against themselves and slide out the correct piece. This has resulted in injury and even death Tradiezrack can be placed on site by the manufacturers of the board and the sheets placed in them when they are delivered, this will negate any injury caused currently by the boards. manmonthly.com.au

Technology Application of the Year - 2012 Finalists

EndeavourAWARDS

Proudly sponsored by

Enter online at manmonthly.com.au

Technology investment the key Improving production efficiencies the key to companies’ successes.

BOC BOC South Pacific GMA and TIG Arc Projectors BOC in conjunction with Linde Group has introduced to Australia the GMA and TIG Arc Projector. The Arc Projector training and demonstration tool which displays the difference BOC shielding gases can make to various welds, helping manufacturers optimise results and cut costs.

BOC shielding gas can deliver savings of more than $3 per metre of weld by keeping traditional cost drivers such as labour and welding wire lower, depending upon the specific application.

The Arc Projector produces an optically-magnified image of the welding arc which changes in real time as the operator changes welding parameters such as wirefeed speed, voltage, stickout, current, pulse frequency shielding gas composition.

BOSCH CHASSIS SYSTEMS Casting Supply Cassette Bosch Chassis Systems (BCS) is the only OE brake caliper manufacturer, supplying local car manufacturers with brake callipers, park brakes and knuckles.

Previously the cast iron castings of caliper bodies and brackets, weighing between 1.2 to 3.8kg weree supplied in bulky Ropaks from Sydney. They were decanted into 12.5L bins at 3rd party Logistics next door and supplied to processes. Smaller bin and smaller lot size were chosen to aid lean material flow on site.

The solution was a casting supply cassette that eliminates the need to lift any parts or bins with parts.

Users now place eight 12.5l bins in a ‘cassette’ which becomes the Kanban.

The cassettes can be stacked in a truck to be transported.

The system has helped with the safe transportation of castings, elimination of manual handling which has cut costs.

Minimised stock has also been a benefit from improved technology.

FOCUS PRESS Commonwealth Bank of Australia/Focus Press Lean Enterprise Project Number 1 Focus Press offers a full range of offset and digital printing, pre-press, design and creative services, finishing and fulfilment, direct mail with data management and comprehensive warehousing 36 APRIL 2012 Manufacturers’ Monthly

and distribution services.

Focus Press has developed a new CBA Specialty yellow which eliminates the need for Process Yellow therefore reducing the 6-colour job to just five colours: Paper has been reduced by 27%, and make-readies, plates and blankets are all reduced by 17%. The process produces less waste paper, plates, ink, chemicals, ink cartridges and printing blankets.

If CBA adopt this technique for the majority of their offset printing, the monetary, resource and environmental savings would be considerable. The next stage of the project includes a feasibility study to investigate a broader application of this new technique.

MATRIX COMPOSITES Hydrostatic Pressure Testing Facility Matrix manufactures and supplies subsea buoyancy systems, and is leading the field in composites and syntactic foam technology for use in advanced engineered products. It opened a new manufacturing facility in 2011 which is the world’s largest and most technically advanced composites syntactic plant.

Matrix also houses a hydrostatic pressure testing facility which is capable of qualifying and testing buoyancy systems to a depth of 17,500 feet. This has been advantageous due to the structural trend towards deeper sea drilling which requires superior buoyancy modules.

The new changes have increased its ability to manufacture other composite

materials and expand its marketplace Increased automation has shortened production timeframes, reduced labour costs and wastage as well as reduced plant downtime and costs due to improved OHS standards and procedures.

ROBOTIC AUTOMATION Robotic End-of-Line Solution Robotic Automation in conjunction with Amcor Cartons has created a global packaging solution supplying a range of packaging products.

The Robotic End-of-Line Solution consists of three main component technologies including robotic palletising, automatic guided vehicles and automatic pallet wrapping.

The design and integration, including R&D, manufacture, build, testing and final on-site installation & commissioning was performed by Robotic Automation to increase staff safety, product quality, and reduce costs while providing a 235% boost to productivity Each robot performs at the equivalent rate of two manual staff per shift, in up to three shifts per day, without need for break-times or shift changeover time etc.

With seven lines in full operation to six cells, the six robots can do the work of more than 42 staff per day.

Automatic Guided Vehicles have allowed a more efficient and flexible use of current floor-space and cost-free adaptability to changing needs. manmonthly.com.au

Enterprise Connect Significant Achievement Award - 2012 Finalists

EndeavourAWARDS

Proudly sponsored by

Enter online at manmonthly.com.au

Raising the bar CHOCOLATIER Chocolatier Australia specialises in manufacturing for the chocolate market to retail and specialty stores, foodservice outlets, contract manufacturing and logistic services.

Since the Enterprise Connect review, Chocolatier has proceeded to address all of the major recommendations including sales and channel management, new product development, inventory and working capital management as well as productivity improvement in the factory.

ECOYA ECOYA is an Australian home fragrance and body care business. Since joining the Enterprise Connect Program, Ecoya’s manufacturing productivity growth has increased by 40% and sales turnover has increased from $10m to almost $16m this financial year.

The ECOYA team has grown from 25 to over 60 staff and although the Australian market still accounts for more than 60% of sales, it has expanded its export market to the US, (including Bloomingdales and Macy’s ), the UK, (including Harrods and Liberty’s), Asia and the Middle East.

EDLYN FOODS Edlyn Foods is a family owned and operated company focused on the food service and hospitality industry.

Since completing the Enterprise Connect program sales have grown from $18.7m in the year ending 2008/09 to $24.8m in 2010/11, with an increase of 32.6% over the two years.

LUXMY FURNITURE Luxmy Furniture is a family owned and operated business which focuses on office furniture and being environmentally sustainable.

Under the recommendations of the Enterprise Connect program, Luxmy launched the Evolvex which is a modular system of furniture which can be designed online by the consumer to fit their specific needs.

ELECTRA-LOOM Electra-Loom is a manufacturer of wiring assemblies ranging from single wires to complex harnesses, ribbon cable assemblies, lighting assemblies, electronic assemblies & data cables for the rail, automotive, lighting, electron38 APRIL 2012 Manufacturers’ Monthly

Enterprise Connect assists Australian companies to introduce improved business practices.

ics and communications manufacturing industries.

The first full month of operations after completing the Enterprise Connect program resulted in an immediate jump in gross margin of 3%. There was also a dramatic reduction in work in progress with works orders “in production” falling by between 50-75% depending on the nature of work LONGWARRY Longwarry is a producer of full cream milk powders, fat filled milk powders and a variety of other dairy based products.

In the past year of being on the Enterprise Connect program, cleaning time has been reduced from 3.5hrs to 2hrs using new technology, packaging material wastage has dropped by 98% and new software has been implemented to improve logistics, access to information and reduce costs.

THERMA TRUCK Therma Truck builds refrigerated truck bodies and vans.

Through Enterprise Connect, Therma Truck adopted the Lean Manufacturing principle with results that included labour hour variations reduced by half from 30% to 15%, average hours per job reduced by up to 35% on previous jobs, profitability positive on all jobs, delivery lead time reduced by 25%, on-time

delivery performance improved and a reduction in overall inventory.

TOP CAT INSTALLATIONS/KITCHEN INNOVATIONS Kitchen Innovations is a manufacturer of kitchen and bathroom cabinets for domestic dwellings.

Since being advised by Enterprise Connect, the company has been customer satisfaction, employee capability and commitment, product innovation and financial performance Kitchen Innovations has relocated to larger premises so as to further expand the business and implement newer technology and another new plant has been commissioned.

VIP PACKAGING STEEL VIP Packaging Steel is a supplier of rigid plastic and industrial metal packaging in Australia and NZ. VIP identified two areas in need of improvement through Enterprise Connect which were firstly the need to develop a holistic set of performance measures involving all departments in an integrated manner and secondly to create a culture change of continuous improvement The VIP Packaging Steel Quality Management System is now a fully integrated system, centrally located on the company intranet which supports all five Australian sites. manmonthly.com.au

Global Intergration Award - 2012 Finalists

EndeavourAWARDS

Proudly sponsored by

Enter online at manmonthly.com.au

Linking with the world AUNEW GROUP HOLDINGS Franchised Distribution Program AUNEW has initiated and participated in a large number of promotion and marketing events in Asia, including trade shows and expos in Hong Kong, Malaysia, South Korea, and China.

The company has also grown its overseas presence with a new factory completed last year in NZ as well as 10 new shops opened in China.

There is also a bonded warehouse in Tianjin port (one hour drive from Beijing), a regulation and distribution team in Beijing, an office in Hong Kong and a newly opened branch in Seoul.

Since AUNEW has consolidated enough products to support its own store, it is now building distribution channels through a franchising program in China.

AUTOMOTION CONTROL SYSTEMS FM1 Fleet Management Telemetry Automotion Control Systems (ACS) has developed the FM1 ‘black box’ for forklifts which measures operational data such as a vehicle’s odometre, hours, metres and time in use (traction) versus idle, operator driving habits, use and abuse of the asset through collision and impact detection.

The Development & Supply Agreement with NMHG means ACS has access to over 750,000 trucks worldwide which steadily grows as they have a lifespan of between 5-7 years which is the length of the lease agreement with the customer. ACS’ current manufacturing volumes stands at less than 10,000 units per year.

The company has factored in response time and cost of shipping in deciding upon suppliers for its telemetry products. Harnesses and brackets are specific to the regional range of forklift truck sold in that market, and the cost benefit analysis showed a US or Mexico based supplier for such parts provides the most advantages in both cost and customer responsiveness.

MATRIX COMPOSITES ENGINEERING Matrix Global Supply Chain Matrix Composites & Engineering (Matrix) is involved in the research, design, testing, manufacturer and service of engineered products for use in the oil, gas and resources industries.

40 APRIL 2012 Manufacturers’ Monthly

Australian companies are playing key roles in many OS supply chains.

The company manufactures technically advanced buoyancy systems and related equipment for off-shore operations using composite and polymer materials that originate from the aerospace and defence industries.

The materials are used in the creation of engineered products that are durable, lightweight, economical and reliable: drilling products, well construction equipment upstream SURF ancillary equipment, downstream cryogenic insulation systems, offshore and site services.

Matrix has developed a global network of sales offices, manufacturing plants, service facilities, warehouses and agents in Australia, UK, US, Brazil, Norway, Korea, Singapore, Malaysia and India.

It also has plans to expand its presence into West Africa in the near future.

Besides its own networks, Matrix has entered into agreements with agents in Malaysia, Korea and India. This is the most commercially effective arrangement as the agents have established contacts and the correct licenses to operate within that country.

With a long history in the export market, Matrix has established a solid supply chain that allows it to successfully compete in the global marketplace.

TAE GAS TURBINES TAE Aluminium Vacuum Brazing

Manufacturing Capability TAE is an aerospace engineering company providing a combination of aerospace manufacturing, gas turbine engine maintenance and engineering support services.

It works with multiple products and the technology is used in a growing number of applications such as advanced liquid-cooled electronics enclosures, cold plates, waveguides and radar assemblies.

TAE has engaged with a number of international supply chains predominantly within the global aerospace and defence arena.

The focus for this engagement has been primarily with TAE’s Aluminium Vacuum Brazing manufacturing capability.

TAE is said to be the first Australian company to have developed this technology and one of only a very small number world-wide able to offer the capability.

Over the last 12 months TAE has signed long term agreements and winning production contracts from international multi-national aerospace companies such as Harris Corporation and BAE Systems.

Included among these contracts have been situations where TAE is now the sole, global supplier for complex components on the F-35 Joint Strike Fighter.

manmonthly.com.au

All the right connections for the manufacturing industry.

When it comes to finding new business opportunities, one of the biggest challenges can be breaking into new or expanding supply chains.

Industry Capability Network (ICN) is an organisation that introduces local suppliers to the supply chains of major projects.

Even if you’ve never imagined your business supplying goods and services to a major state or national project, ICN could uncover an opportunity that’s just right for your business.

With more than 25-years experience helping Australian and New Zealand manufacturers find opportunities in major projects, ICN is a great place to start when looking to expand your business. ICN consultants have a thorough knowledge of existing and planned projects.

So, if you’re looking to expand your business opportunities go to www.icn.org.au or call your local ICN office on 1300 961 139

EndeavourAWARDS Lifetime Achievement Award - 2012 Finalists

Proudly sponsored by

Enter online at manmonthly.com.au

Withstanding the test of time BRIAN MCLEAN Tri-Nature Brian McLean is MD of Tri-Nature and the Director in charge of technical services. He is directly responsible for all research, development, product manufacture, and quality control of the companies involved.

Brian is still very much involved in the general operations of the company, taking responsibility for all factory functions right through to dispatch and delivery to customers.

Brian’s dedication to this industry has broadened beyond Tri-Nature as he has made himself available to customers and other advice-seekers as a form of ‘educator’.

FRANK SEELEY Seeley International Frank Seeley AM founded Seeley International in 1972 when it began manufacturing portable evaporative coolers.

Frank is still the Executive Chairman of the company, and has fostered a culture of innovation and creativity that has delivered products across all heating and cooling categories.

He continues to be the driving force in all aspects of the business from the design and engineering of world leading product developments such as Climate Wizard through to the commercialisation of new technologies.

Frank has aggressively pursued a policy of vertical integration, manufacturing almost all products in-house.

He has also had a strong focus on supply chain management ensuring flexibility and responsiveness to meet fluctuations in market demand.

PAT BOLAND ANCA ANCA was formed in 1974, one of them being Pat Boland who now serves as MD and Chairman.

Pat along with his business partner Patrick McCluskey have lead ANCA into a worldwide success in designing, developing and producing technologically advanced computer numerically controlled systems and went on to develop their own cutter grinding machines.

In 1990, Pat developed a new machine for precision grinding automotive power steering input shafts which is the key component in determining the ‘feel’ of a 42 APRIL 2012 Manufacturers’ Monthly

Manufacturing is part of their NA.

car’s steering.

Pat has been involved in all areas of ANCA, having particular interests in research and development and is still continuing to make significant contributions.

ROBERT FERNANCE Tri-Nature In 1989 Tri Nature was formed to bring to the marketplace natural cleaning solutions for industrial, household, and personal care including the manufacture of phosphate-free powders.

Robert OAM is MD of Tri-Nature as well as being the director of financial operations.

Whilst managing the financial aspect of the business, Robert is still very active in the sales and customer service areas of day to day business.

RUSSELL HUGHES Integra Systems Russell began his engineering career in 1957 as an apprentice and is now the Engineering Director and joint founder of Integra Systems.

With over 35 years of engineering, innovative product development and senior management experience.

Russell joined Integra Tooling Systems (now Integra Systems) in 1993 as joint director to develop the harnessing of innovation and engineering solutions for

Australian industry.

Hughes was behind the world’s first high speed Coil Processing Line (PunchIT Coil Processing), which was ultimately built as Integra’s first production machine.

His hands-one and mentoring approach at Integra Systems’ allows him to oversee engineering design, prototyping, all manufacturing functions and supply chain management.

He is the key driver for all new product development undertaken within Integra Systems for the product range.

SYLVIA TULLOCH Dyesol As a co-founder and founding MD of Dyesol, Sylvia has 25 years experience in the establishment and management of high technology businesses with a particular interest in the commercialisation process.

She has contributed to the invention of several of Dyesol’s patents, including the key patents for the SureVolt flexible DSC panel and the Combined Energy Generation and Storage (CEGS) devices.

Sylvia is currently a member of the Future Manufacturing Industries Innovation Council, which advises the Australian Minister for Industry, and is also a non-executive director of four other clean tech and advanced technology companies in addition to Dyesol. manmonthly.com.au

ifm offers solutions to application challenges.

Position sensors and detection systems for all applications, including robotics, handling, production and logistics.

Fluid sensors suitable for food and hygienic areas, as well as environments with aggressive oils and coolants.

Networking, identification and control systems. AS-interface to easily transmit sensor signals to a controller at a low cost. Robust control system ecomatmobile is the perfect solution of mobile applications.

1300 365 088 sales.au@ifm.com www.ifm.com

efector

Exporter of the Year Award - 2012 Finalists

EndeavourAWARDS

Proudly sponsored by

Enter online at manmonthly.com.au

Tapping into overseas markets ARMSTRONG Eco – Terazz End of Life Tile The Eco - Terrazz End of Life tile was created as a way of lessening environmental impact by recycling old EcoTerazz flooring which was aimed at the export only market.

By offering a freight paid end-of-life take back program, customers avoid landfill charges and the freight cost to get it there.

The concept of End-of-Life VCT was to offer a product that could be priced to offset higher FX (foreign exchange) but still maintain margin percentages.

The move was initially defensive, to protect existing customer bases, but would become a means for further export market penetration when FX and pricing eased.

COOK MEDICAL World Exports in 2011 Cook Medical is an Australian medical device manufacturer of endovascular grafts used in minimally invasive vascular surgery and products for In-Vitro Fertilisation, including IVF needles, culture media and benchtop incubators.

The medical devices serve the needs of customers (physicians, hospitals, patients) in over 135 countries around the world. Outside of Australia, Cook Medical’s largest markets are Denmark, Ireland, Japan, United States and China with plans for market growth in Asia Pacific as well as Eastern Europe, Latin America and the Middle East.

HOMART Health Supplements Export Homart specialises in the manufacture, wholesale, and export of health supplements and skin care products.

It currently manufactures over 100 products and launches 7 to 10 new products every year Homart exports its brands of products throughout various Asian countries, especially to China, Hong Kong, Macau, Taiwan, and Korea. Homart’s export has expanded 850% (8.5 times) in the last three financial years since July 2008.

HOSHIZAKI LANCER Beverage Dispense Systems Export Hoshizaki Lancer is an Adelaide-based manufacturer of draught beer, soft drink and frozen beverage dispenser systems, ice machines, professional food service 44 APRIL 2012 Manufacturers’ Monthly

Despite the strong Australian dollar, many manufacturers are successfully exporting.

links with overseas markets.

MAJOR FURNACE Taganito High Pressure Acid Leaching Nickel Project Major Furnace provides products and services in the fields of thermal and mineral processing, combustion, refractory, fluid power and lubrication technology, equipment automation and safety.

The company supplied two High Pressure Acid Leaching Autoclave Seal Systems for nickel leaching autoclaves at Taganito Mine project at Surigao Del Norte in the Philippines.

The project was a subsequent order after the initial development of the systems supplied to RioTuba in the Philippines in 2003 and 2007.

refrigeration units and heat recovery systems.

Lancer’s export objective was to secure employment for its Adelaide engineering and production employees against declining domestic sales resulting from market saturation.

The company has been developing three export markets in particular – NZ, Philippines and US and now represent 24% of total sales with eight employees now placed in NZ, Hong-Kong, India and the US. LONGWARRY FOOD PARK Milk Powder Export The disused Longwarry plant was purchased from Bonlac foods in 2001 and since then an unviable business has been converted from old technology and an overall uneconomical operation into a profitable and energy efficient business.

Longwarry’s export success can be shown in its increase of exports from $47m to $90m over one year, there has also been a launch of a new UHT milk and an increase in employment from 32 to 52 in one year.

Marketing has been a key to the success of Longwarry’s exporting as the company has participated in trade shows in Dubai, Hong Kong and Korea in a bid to increase brand awareness and create

MANUFACTURING SOFTWARE AUSTRALIA Manudyn ManuDyn is a modular MRP system covering the complete range of manufacturing activities from job quoting, through production control, stock and inventory control, cost tracking and onto product dispatch.

The company has long-standing markets in Australia and the UK and now, with the advent of ManuDyn, it has taken its unique system to the world through an online rollout, distribution, and technical support platform – particularly in North America. Its international online rollout is now underway.

MATRIX COMPOSITES AND ENGINEERING Engineered Products Matrix Composites & Engineering (Matrix) is involved in the research, design, testing, manufacturer and service of engineered products for use in the oil and gas, and resources industries.

Matrix exports over 85% of its products and services with a global network of sales offices, manufacturing plants, service facilities, warehouses and agents. The company is headquartered in WA and has a presence in the UK, US, Brazil, Norway, Korea, Singapore, Malaysia and India.

Matrix manufacturers and supplies drilling products, well construction equipment, upstream SURF ancillary equipment, downstream cryogenic insulation systems and offshore and site services. manmonthly.com.au

EFIC DID MORE THAN FINANCE OUR EXPORTS

THEY BACKED THEM ....AGAIN. Rod Sawyers, Managing Director, Bronx International

It was an opportunity 20 years in the making. A leading steel company in Latin America awarded us a large contract to upgrade an old galvanising line provided to the original buyer almost 20 years ago. They were willing to provide an advance payment as part of our contract terms, but naturally required an advance payment bond to protect both parties.

We knew where to turn for support. EFIC has a history of financially backing us on successful contracts in Turkey, Ukraine and Argentina. The outcome of working with them this time was just as positive.

EFIC supported us by issuing the bond to the buyer on our behalf. This allowed us to hold onto the working capital we needed to deliver on a contract we saw as key for our growth in Central America.

Overcoming financial barriers for exporters.

Visit efic.gov.au/mm

Australian Industrial Product of the Year Award - 2012 Finalists

EndeavourAWARDS

Proudly sponsored by

Enter online at manmonthly.com.au

Locally made products keep industry moving ABB AUSTRALIA SynRM Synchronous Reluctance Motor The SynRM motor and drive package is available in two configurations, one that maximises efficiency, the other maximising output.

Because the motor and drive package is designed specifically for variable-speed drive operation it is said to lead to further energy savings. These savings create a pay-back time which in many cases can be less than two years.

Typical applications include fans; pumps; compressors; conveyors; hydraulics; cranes; extruders for industries like pulp and paper; metals; ventilation; power plants; water and wastewater; food and beverage; mining; OEMs. AUSTRALIAN INNOVATIVE SYSTEMS Ecoline on-site in-line fresh-water chlorine generator The Ecoline on-site in-line fresh-water chlorine generator can work completely without salt plus it can convert small amounts of minerals (naturally available in the fresh water) into chlorine.

Ecoline technology has been tested/approved by NATA Accredited Laboratories and meets Australian Drinking Water Guidelines.

There are three types of chlorine generator available from AIS: Chlorogen, Autochlor and Ecoline. In addition to chlorine generators AIS equipment is installed for various water disinfection applications such as drinking water, waste water, industrial process water, agriculture, pharmaceutical, decorative lagoons, aqua parks and competition swimming pools.

AUTOMATION CONTROL SYSTEMS FM1 – Fleet Management Telemetry At the heart of ACS’ technology is the use of real time telemetry with web technologies to provide levels of information for fleet operators to manage their operating efficiencies.

FM1 is a ‘black box’ that sits on the forklift measuring operational data such as the vehicle’s odometer, hours, metres and time in use (traction) versus idle, operator driving habits, use and abuse of the asset through collision and impact 46 APRIL 2012 Manufacturers’ Monthly

The CP9 was developed to improve on existing halogen/ xenon work-lights commonly fitted on mining machines.

The high power LED luminaire is designed to provide superior luminous output in a compact size enclosure that rivals competitor product.

Innovative features are said to include the use of solid state LEDs, heat management, multiple lens configurations, cool operating surface temperature and precision dimming.

A diverse range of industrial products are still made in Australia.

detection.

The system also allows equipment dealers to access their information via web service – extracting valuable telemetry data when it’s available, and integrating it with their existing business system.

CKAS MECHATRONICS CKAS “Cranky” Full Motion Wharf Crane Simulator The CKAS “Cranky” Full Motion Wharf Crane Simulator provides full scale replication of a typical crane cabin and includes an array of switches, lights, gauges and other specialised instruments.

The simulator can be used to engage the driver in initial familiarisation and introduction as well as direct hour accumulation for crane driver training.

The hardware was developed in house with the resources available to a small engineering innovation company and overcame the problem of the very large set of multidisciplinary engineering skills required to develop this product.

The key to success in this project was that all engineers involved in the development were selected for their very high level of skill in many facets of engineering, but it was also crucial that the engineering staff selected had a track record of working successfully on high pressure projects together in the past.

COOLON LED LIGHTING CP9 (Coolon Projector 9) Coolon is an LED luminaire manufacturer with roots in the electronics industry whose products are primarily industrial, focusing on mining.

CASWA Access Pack AccessPack is an access control system that ensures equipment can only be used by authorised personnel.

According to the company, it can be fitted to any type of electrically powered device (including mobile, remote and battery operated equipment).

Machines will work only when the user swipes with a valid card. AccessPack requires users to have current and appropriate ‘tickets’ including qualifications, accreditation, training and/or inductions in order to operate the equipment. People with an expired ticket or those without the appropriate ticket are ‘locked out’.

The system is designed to increase accountability, which leads to changes in operator behaviour thereby reducing the amount of downtime and breakdowns as well as equipment abuse.

MARATHON GROUP Ruggedised waste tanks for remote locations Marathon’s point of difference with their tanks lies in the use of all-polyethylene rather than stainless steel as well as heavy duty galvanised steel frame, these units are specifically designed to go underneath an ablution block rather than beside it and perform in the roughest of conditions and locations where no sewer connection is available.

One of the key features of Marathon Group’s ruggedised waste tanks is these units are flat on the bottom of the tank to ensure no sewage remains in the tank when pumped clean. The poly tank itself is a high-density UV-stabilised unit that is easily removed from the steel frame when required. manmonthly.com.au

Supporting innovation & success

Australian Industrial Product of the Year /*)/ $ % $ &

#

$ % $ &

!

"

BOC Limited ' ( )* + , ' ,-. /))0 1

www.boc.com.au 2 $ !

2 3 4 2 /*)/

$()/5*67/5)6*0

EndeavourAWARDS Australian Steel Innovation Award - 2012 Finalists

Proudly sponsored by

Enter online at manmonthly.com.au

Aussie steel; Aussie tough DEMATIC Precision Storage Systems for Automated Materials Handling Dematic is a supplier of logistics automation, warehousing, materials handling and automatic storage systems. The company has a turnover of $160m and employs 385 people in Australia and NZ. The company’s systems configurations are built around process and supply chain improvements and may be manually operated, mechanised or automated.

Dematic’s single source, vertically integrated capability can reduce time, cost and risk - achieved through ownership and control of design services, real time WMCS software, material flow technologies and engineering, project management and customer services.

Steel components in Dematic storage products are manufactured from high tensile grades of steel supplied by BlueScope at advanced production facilities in Australia and incorporate the latest innovations in production technologies.

The high precision steel racking components within Dematic Multi-shuttle and Mini-Load solutions are used extensively across a wide and varied range of applications which require automated materials and storage handling.

Key features of Dematic’s innovation in Australian steel storage components include their modularity, patented components, being globally standardised and the design being optimised with regard to steel content and structural efficiency.

The components can be used within standalone automatic crane storage retrieval systems and in-rack shuttle systems and have been designed to be used in storage systems destined for both non-seismic and seismic areas.

Dematic has successfully utilised the components recently in a mini-load ASRS storage system in the heavy seismic area of Palmerston North, NZ. 48 APRIL 2012 Manufacturers’ Monthly

MELVELLE EQUIPMENT CORP Seized Rail Fastener Remover (Pandrol PR & E Clip) Melvelle Equipment Corp is an Australian owned and operated company established in 1982.

The company has 22 members of staff who specialise in the design and manufacture of light-weight, high-powered products, principally for railway track maintenance, small drilling rigs and hydraulic power packs.

Its client base has extended to all states of Australia and overseas.

Melvelle has a fully equipped workshop where products are manufactured and at times certain elements are sublet in order to meet scheduled requirements.

Melvelle has over 250 products and a range of new products being prototyped,

mers to create the impact force needed to vibrate and impact the fastener.

This cyclic vibrating load, breaks the rust or “chemical” bond between the railway sleeper “cast shoulder” and the spring clip and the whole process is completed without damaging the sleeper itself.

The Melvelle Equipment Corp Clip Remover has an Australian Provisional Patent in place and an International Patent is pending.

LEUSSINK ENGINEERING Steel rolling mill refurbishment An alliance between German company Corts and Australian company Leussink Engineering was formed to use high level steel fabrication expertise to refurbish ageing Australian rolling mills (ferrous and non-ferrous) and extend their lifespan.

Corts-Leussink, an active technological collaboration between German flat bearings and engineering company Corts and Australia’s Leussink Engineering, is a partnership that places both companies to be at the centre of large refurbishment projects.

The challenge was to provide a complete engineering service at world’s best practice.

Australian-made steel designed Basically, the qualfor Australian conditions. ity of the refurbishment is a combination of several key factors including a patenttested, field trialled and finally released ed precision flat bearing known worldas an ongoing development programme. wide as a CORTS Precision Flat Bearing, Melvelle’s rail customers required a solution to remove seized railway fasten- a Corts patented lubrication technology (Lubtech). ers from concrete sleepers and concrete Lastly is the precision engineering of slab railway track. Initial enquiries for re-machining the mill stand, parallel and a solution were received in 2008 by perpendicular to dimensions critical to KiwiRail before extending to Australia. the longevity of equipment without comThe Clip Remover is designed to remove weathered railway fasteners and promising the structural integrity the mill stand. eliminate the risk of OH&S injuries by This level of restoration decreases preventing rail personnel from being downtime, maintenance and running struck by flying clips and debris as well costs. as reducing the labour effort and the The partnership allows Leussink and need for dangerous practice of using Corts to be at the centre of projects not hammers. just in Australia but around the world.

The machine uses two hydraulic hammanmonthly.com.au

EndeavourAWARDS Environmental Solution of the Year Award - 2012 Finalists

Proudly sponsored by

Enter online at manmonthly.com.au

Sustainable manufacturing key to our future ARMSTRONG Eco – Terazz End of Life Tile The Eco – Terazz End of Life Tile grew from a strategic objective to minimise the environmental impact at Armstrong.

A review of local and export markets regulations uncovered restrictions in the use of some raw materials which necessitated strict material testing.

After PVC bottles and other recyclable materials were explored and proved not to have enough useable materials, Armstrong decided that the most cost neutral way of being more environmentally sustainable was to recycle their own flooring products at the end of their life.

Challenges which arose that returned multi-coloured materials could not be easily sorted for use.

Since Armstrong has made environmentally aware changes within the business, potable water usage has dropped by 30% and CO2-e emissions have been reduced by 40%.

At higher recycle content rates, offset savings from material substitution gave positive return on investment and permitted some price relief for export customers.

HEANEYS Sustainable Management System Heaneys has implemented an environmental management system (EMS) to reduce its carbon footprint across all business aspects.

The EMS is in accordance with the Sustainable Green Print initiative rolled out by Printing Industries Australia.

Consultants have been brought in to reduce electricity use through a comprehensive assessment of energy consumption, timing of consumption around peaks, and energy waste through ‘electricity leaks’.

Major environmental impacts including solid waste production, water use and electricity consumption form the foundation of the EMS. As the first printing company to go through many of these processes the company has worked directly with Printing Industries to ensure that the entire industry can maintain sustainability and adopt Heaneys practices to 50 APRIL 2012 Manufacturers’ Monthly

sors suited to the supermarket’s needs, thus reducing the money spent and CO2 emissions from lighting left on unnecessarily.

Sedac identified all savings options available related to lighting and showed the client how these could be achieved through a series of trial sites.

The trial sites proved the effectiveness of the control system, showed the results of the different options and encouraged an open discussion on how to move forward and narrowed down the best works and switchboard design.

After considering different installation and pricing options, all parties agreed on the thirteenth scope revision which simplified the control, ensured Green savings often equate to $$$ savings. great paybacks, simplified project management and administrative requirements, and had a miniachieve its own sustainability goals mal affect on store staff whilst maintaining enormous energy savings.

LONGWARRY FOOD PARK Milk Powder Production SULO Longwarry has aimed to become a more SULO 360L Kompakt MGB (Mobile environmentally sustainable company Garbage Bin) by reducing wastage, increasing plant SULO recognised a major problem facoptimisation, water consumption reducing Australian waste management, in tion and also trying to conserve energy that 33% of all weighted household recywherever possible. clables currently end up in landfill.

The company has put in place practiThe alternative options of more bins cal routines in order to reach regular or more frequent collections were targets such as reducing cleaning times thought to be too costly and environmenfrom three and a half hours down to two tally unsustainable. by using newer technology.

The company decided larger capacPlant productivity has also been ity was the solution – a 360L Australian improved and the installation of a new designed and manufactured MGB. technology machine has meant material The larger capacity allows for waste wastage was reduced by 98%. minimisation by reducing the leakage of Longwarry has received a $500,000 recyclables into landfill. grant from AusIndustry for reducing As a consequence, it also reduces energy consumption to match best landfill costs to local councils (and practice as well as a $50,000 grant from ultimately ratepayers) and contributes South East Water in Victoria to reduce significantly to local council compliance water consumption. with national waste reduction targets set by the Federal Government.

SEDAC The design of the MGB has been certiLighting Reduction Project Sedac approached a nationwide superfied tested and the 50% larger bin takes market retailer with an energy manageup a similar amount of space on the ment initiative which would take control nature strip as the smaller model. of its lighting system.

It is also manufactured using up to The company designed and manu35% recycled content and they are factured a control system to eliminate currently being used by Brisbane City user inefficiencies and enable enhanced Council which has seen a 20% increase control through time schedules and senin recycling. manmonthly.com.au

The environment is in safe hands with Atlas Copco Compressors

For the seventh consecutive year, Atlas Copco has been named one of the world’s most sustainable companies.

In addition to social indicators, companies were measured against an objective ‘sustainable path’ standard for energy, carbon, water and waste ratios.

We are proud to be the major sponsor for the Environmental Solution of the Year award and wish all the finalists the best of luck!

Atlas Copco Compressors Australia 1800 023 469 ausairinfo@au.atlascopco.com www.atlascopco.com.au

EndeavourAWARDS Young Manufacturer of the Year Award - 2012 Finalists

Proudly sponsored by

Enter online at manmonthly.com.au

Employees punching above their years BRENDAN BUTLER Astral Pool Australia Astral Pool is a manufacturer and wholesaler of swimming pool appliances including pumps, filters, chlorinators, chemical measuring and dosing appliances and gas heaters.

As Operations Manager, Brendan oversees product development, quality control as well as all aspects of manufacturing and distribution of products and parts to the wholesale warehouses.

He reports to the GM and has direct responsibility for two production supervisors, the production planner, product development manager, production engineer, quality control inspector, warehouse manager and toolmakers/fitters.

Brendan has been responsible for the sourcing, acquisition, installation and commissioning of more than $2m of robotic and CAD/CAM machinery in the last three years.

DAVID MICHEL Automation Control Systems David Michel began at Automation Control Systems as a graduate in 2006 and has worked his way up to his current position as Engineering Manager.

He is now in charge of design of hardware, firmware and programming as well as managing a team of four staff and two contractors.

He deals with international heads of design and has worked to develop a strategy that ensures his team develops on time, in rhythm and shows consistent performance.

As well David designed the Fleet Online device which is a telemetry product which sells over 200 units annually.

He also helped in the development of Speedshield which controls speed in large and heavy equipment.

JESSE CE ZHENG Dyesol As Dyesol’s chemical engineer, Jesse is responsible for developing processes to commercialise DSC (dye solar cell) in particular by taking DSC manufacturing processes from the laboratory scales to pilot and semi-industrial scale, thus ensuring processes can be applied in larger manufacturing projects.

Jesse has contributed to increasing the output of processes by minimising waste and optimising chemical reaction condition, and optimising or eliminat52 APRIL 2012 Manufacturers’ Monthly

With an ageing workforce it is critical that industry has young manufacturers ready to fill the gaps.

ing labour intensive bottlenecks which allows the material to be manufactured more economically both from an environmental and productivity perspective.

Jesse graduated with a Masters of Engineering majoring in Chemical Engineering (Second Class Division A) from the Australian National University in 2007 and has been employed with Dyesol since 2008.

KYLE DIX Redarc Kyle is Surface Mount Technology (SMT) Supervisor at Redarc which involves him ensuring the safe and efficient operation of the assembly line.

Kyle has ten operators and technicians working under him as well as fulfilling a range of roles in the areas of innovation, customer satisfaction, teamwork as well as maintaining the integrity, quality and protection of the environment in line with Redarc’s policies.

His most significant achievement to date has been the designing and then implementing a cleaning program to facilitate quality improvements in PCB cleanliness following the SMT process.

This was a significant gain and occurred ahead of schedule, within budget and achieved the required cleanliness result.

MATTHEW ARBLASTER Bayer Material Science In his role as Production Engineering Co-ordinator, Matthew is responsible for the management of the maintenance team, design and execution of engineering plant improvement projects as well as coordinating production.

He also coordinates the production team supporting the operations manager and team leaders.

In this role, Matthew manages the reliability of the plant which is benchmarked against all Bayer plants globally and during his time managing the maintenance team, total plant reliability has increased by 5% and mechanical and electrical breakdowns have been reduced by 16%.

Matthew spent over 18 months successfully managing the implementation of a new $6m solid sheet line including designing the supporting infrastructure.

OWEN BET Leussink Engineering Owen began his working career at Leussink Engineering seven years ago at age 20 and completed a fitter/machinist apprenticeship.

He is now studying his Bachelor of Mechanical Engineering.

Owen is currently involved in the reconditioning of the Hot Strip Mill at BlueScope Steel Port Kembla as part of a refurbishment program completed as an international partnership with Corts Engineering PRIYANKA RAO Luxmy Furniture Luxmy is a furniture company and a commercial contract manufacturer which has just launched a consumer line of flat pack furniture.

Priyanka manages Marketing and Strategic Management projects at Luxmy.

Her responsibilities include managing the marketing for Luxmy Furniture, managing the online presence, implementing the Lean Management program as well as working on audits and creating processes and strategies for improving its environmental impact across the company.

She is also in charge of managing a new online, modular furniture line.

Since being in her role, Luxmy has been a finalist in several business awards. manmonthly.com.au

Your network.

Anytime, anywhere.

°

There are many ways to get the best out of ABB, its products and services.

Talk directly with us or make contact through our ABB authorized value providers or any other member of our network. We are all here to listen and meet your needs. This convenient network delivers high quality ABB services and product-speciďŹ c authorization, knowledge and local expertise. Our promise is to be near you, for you.

Please visit www.abb.com to learn more about our sales and service network near you, and our unique ABB authorized value providers.

ABB Australia Pty Ltd Phone: 1800 222 435 www.abbaustralia.com.au

Welding& PROFILE CUTTING Advances in welding technology to lower costs

By Hartley Henderson

A

dvancements in digital controlled power sources are resulting in new welding process variants that can bring fabricators and manufacturers significant opportunities to improve weld quality, consistency and productivity.

According to BOC product manager automation and welding, Peter Kuebler, these new GMAW (MIG/MAG) variants and enhancements provide opportunities for cost savings in material preparation, welding times and post weld finishing, as well as energy consumption.

Kuebler points out that with the shortage of skilled welders, there is a growing need for welding equipment that requires less operator intervention to achieve acceptable weld quality.

“In recent times welding equipment designers have concentrated on harnessing the versatility and energy efficiency of inverter power sources by manipulating their outputs using digital technology,” Kuebler told Manufacturers’ Monthly.

“For example, modified short circuit transfer, such as BOC’s coldArc system can reduce the risk of lack of fusion defects by controlling power surges during arc re-ignition after each short circuit.

“This is achieved by continuously monitoring the arc voltage and switching the machine

Latest welding equipment requires less operator intervention.

output current precisely at the point of arc re-ignition using a high speed digital processor.

“As material thicknesses decrease with the trend to light weight, higher performance vehicles and components, the system has found extensive application in the automotive industry, particularly for MIG brazing.”

Kuebler says that compared with conventional GMAW welding, the use of this technology has resulted in cost reductions related to faster joint completion times, reduced finishing requirements, lower power consumption, and reduced distortion.

“Importantly, these savings assist in maintaining the competitiveness of automotive and sheet metal industries in advanced economies with high labour costs,” he said.

“Another significant proc-

ess variant that has emerged is modified spray transfer for deep penetration and narrow joint geometry, such as forceArc. By monitoring the arc voltage and rapid intervention, it provides a combination of powerful, stable spray transfer with lower heat input and deep penetration without undercut or spatter,” Kuebler said.

Ensuring accuracy Accuracy in fabrication and assembly is a continuing issue in many industries where tight tolerances are required.

Leussink Engineering’s demmeler fixturing tables are designed for assembly, testing and welding processes where the maintenance of tight tolerances is critical.

Company director and design engineer, Jason Leussink, explains that the heart of the system is a solid steel block-like

work table designed to provide a sturdy platform for mounting weldments with a variety of angles, blocks and accessories.

“With this system of positioning and clamping in any horizontal or vertical plane, making custom welded fixtures is no longer a cumbersome, time consuming challenge,” he told Manufacturers’ Monthly.

“During welding, any changes in the fixture that are needed to compensate for weld pull can be made easily.”

Leussink points to NZ’s Trimax Mowing Systems, manufacturer of tractor powered grass mowing equipment (branded Howard in Australia) as an example of an industrial company that was using flat tables and moved to demmeler.

“By sourcing the demmeler fixturing tables, it gained higher accuracy in all job processes and now uses them right across the board.

“It is an item used in tooling processes as well as production and welding as it provides flat surfaces and datums everywhere,” he said.

“All tooling and checking of production is done on these; as is inspection to see how straight bases are; general level of accuracy is measured in case of misalignment; plus the fixturing tables are used to build spindle mount surfaces,” Leussink said.

BOC 02 8874 4400, www.boc.com.au Leussink 02 4260 7777, www.leussink.com.au

WORLD CLASS PLASMA CUTTING PCS4000HD

100%

AUSTRALIAN

MANUFACTURED

+HDY\ 'XW\ &RQVWUXFWLRQ 'XDO 6LGH $& 'LJLWDO 'ULYHV $XVWUDOLDQ 0DGH Phone: +61 (03) 9305 2555 54 APRIL 2012 Manufacturers’ Monthly

Website: www.profilecuttingsystems.com manmonthly.com.au

Protecting welders’ eyes

By John Allen

WITH light travelling at around 299,792 kilometres a second, the reaction speed of the lens in a welder’s helmet is critical when a welding arc is struck.

Today, welders rely heavily on their auto-darkening welding helmets to protect their eyes from the painful and often debilitating effect of welder’s flash burn or ‘arc eye’.

Professional welders understand that flash burns are like sunburn in the eye and if not treated, an infection may start which can lead to vision loss.

That is why Robert Clarke, senior metal fabricator with champion V8 Supercar constructor Triple Eight Race Engineering, insists on fast auto darkening welding helmets from Miller for himself and his fellow welders.

“Importantly, the lenses are quick to darken, plus they have a very large viewing area which means we can see clearly when we are welding.”

However, Clarke said one of the most important features of the Digital Elite Miller welding helmets is the X-Mode, which can impact the team’s productivity, weld quality and operator comfort.

“Often we have two or more welders working on the same vehicle, which with other welding helmets could cause false activations.

Lens reaction time critical for welding helmets.

“By adjusting the sensitivity of the X-Mode, our welders are able to continue welding without incessant false activations,” said Clarke.

Research shows that the quality of finished welds can be seriously reduced as a result of false activations.

Constant flickering can put the operator’s focus on the performance of the helmet instead of the job at hand. The result is substantially more time taken to complete the job and lost productivity.

Reduced operator comfort is another side effect of false activations. Fatigue and headaches can result from the increased need to blink frequently while welding when subjected to con-

stantly changing or inadequate light conditions causing false activations.

However, with the introduction of the latest digital lens technology, featured in Miller’s Digital Elite Auto-Darkening helmets, false activations are all but eliminated.

When in X-Mode, the lens operates through electromagnetic arc sensing technology. The detection of welding current, as opposed to reliance on light intensity, is used to trigger the operation of the lens.

The result is improved operational reliability of the lens. The major advantage of this feature is that external light conditions, physical barriers or adjacent operator activity does not negatively impact the operation of the lens, enabling it to switch on and off with absolute precision.

Laser welding – did you know?

HEADLAND Machinery has expanded its range of laser welders with a laser spot welder where users can create single joining spots or weld in a continuous wave mode dependant on the required strength of the weld and the maximum amount of heat input into the component.

According to the company, becoming more popular is automated laser deposition welding.

For thicker materials laser deep penetration welding requires extremely high power densities of about 1 megawatt per square centimetre. In this process, the laser beam not only melts the metal, but also produces vapour that exerts pressure on the molten metal and partially displaces it. The result is a deep, narrow weld.

Headland Machinery 02 9638 4463, www. robotintegrators.com.au/robot-integratorblog/laser-welding-did-you-know/

WIA 1300 300 884, www.welding.com.au

3D 5Axis Dedicated Tube Laser Cutting Up to 8.5M lengths processed by the pack or singles

RHS, Tube, Angle, Channel

P: 1300 134 462

E: sales@laserworld.com.au

W: www.laserworld.com.au

Fast,Accurate, Reliable,Affordable - Based in SA servicing the nation - Drawing on 15 years experience in Flat Bed Laser Cutting manmonthly.com.au

Manufacturers’ Monthly APRIL 2012 55

Preview NATIONAL MANUFACTURING WEEK: 08-11 MAY 2012

Innovators to star at NMW in Sydney

P

acked with the manufacturing industry’s leading suppliers showcasing their latest innovations, this year’s National Manufacturing Week (NMW), co-located with Austech and held at the Sydney Showground, Sydney Olympic Park on 8-11 May, will once again be Australia’s leading integrated industry event.

More than 450 companies are exhibiting across NMW and Austech. Within NMW, each of the 12 Product Zones is strongly represented with leading Australian companies as well as specialist exhibitors showcasing new technologies and innovative products.

This year’s event will include API Pneumatic and UBEECO, both exhibiting for the first

This year NMW will feature a record 12 product zones, including two new zones focusing on sustainable manufacturing and metals & composites.

time. Other ‘firsts’ will include Henkel, unveiling a FDA approved threadlocker for

food and beverage manufacturing; Industrial Measurement Solutions’ new, high accuracy

Storage systems

Thermal imaging camera FLIR Systems will showcase its recently released E30 thermal imaging camera range designed for electrical and mechanical maintenance inspections at NMW 2012.

The camera is equipped with a 2 Megapixel visual camera which enables the operator to clearly reference the exact position of the identified problem with a visual image.

By pressing one button the camera stores the thermal image and the visual image simultaneously.

A LED-lamp at the front of the camera is said to ensure good quality visual images can be taken in dark environments.

The camera is equipped with

The camera can detect temperature differences as small as 0.1˚C.

a laser pointer to help the user to associate the hot spot on the thermal image with the real

Advanced metal forming Woodland Metal Spinning (WMS), on stand 2508, will be showcasing new capabilities in advanced metal forming manufacturing that are said represent a ‘first’ for Australia.

Among these is the capacity to 56 APRIL 2012 Manufacturers’ Monthly

laser inspection device, a raft of new welding options from Machinery Forum and many more.

Paul Baker, Exhibition Director says NMW will also provide a great opportunity to network and learn new ideas.

“There will be rolling demonstrations and displays of new technologies, and, in addition, a one-day high level conference focusing on practical strategies for addressing broader industry challenges.

“In a nutshell, NMW is an outstanding opportunity for professionals to keep up-to-date with developments in and for their changing industry.”

For more details – and to register – visit nationalmanufacturingweek.com.au

physical target in the field.

BAC Systems will be displaying its multi Design-Award winning range of workplace equipment on stand 3000 at NMW. The company’s drawer storage systems will be the feature in this year’s display, demonstrating the important shift in the industry from 2D shelf storage to the space-saving 3D drawer storage systems.

According to the company, the drawer storage modules will compliment any workplace, having applications in the defence, health, automotive, education, manufacturing and mining industries. BAC will also feature its tool trolley and its award winning rack storage system.

Flir Systems Australia 1300 729 987, www.flir.com.

BAC Systems 02 9832 2777, www.bacsystems.com.au

Fully embedded ERP software

accurately form mild steel up to 8mm and stainless steel to 6mm, plus new technologies, including the Leifeld CNC metal spinning lathe that completes multiple operations in one.

WMS 02 98245677, www.woodland.net.au

Cogita will be showcasing Epicor’s ERP software on stand 6310. The software is fully embedded, and can provide the basis for companies to manage ordering, engineering, making and distributing products.

The software is designed to scale from basic manufacturing operations to complex multinational, multi-site businesses, and extends to product life cycle maintenance and forecasting.

Cogita 02 9413 4339,www.cogita.com manmonthly.com.au

Delivered to your Workplace

March 2012

Request your copy of the

2012 Blackwoods Catalogue at blackwoods.com.au/catalogues Tools

Safety

Electrical

Hygiene & Janitorial

Welding & Abrasives

Fasteners

and much more

Preview Robots, motors and low voltage drives ABB will be showcasing a wide range of products on stand 1106 including industrial robots designed to provide intelligence, accuracy, productivity and safety across various applications.

High performance low voltage drives with a flexible and seamless interface for complete machine control solutions will also be on display as well as wash-down grade motors and bearings for processing applications.

ABB 1300 782 527, www.abbaustralia.com.au

Industrial adhesives released at NMW At NMW, on stand 100, Loctite will be launching Loctite 3038.

The polyolefin bonder is said to open up new possibilities in the joining of difficult to bond substrates The company will also showcase Loctite 2046, the first FDA approved threadlocker designed to prevent nut and bolt failure in food and beverage industry.

The company will also be featuring new general purpose silicones, and a range of new maintenance cleaning products.

Structural steel software AceCad Software, on stand 6114 at National Manufacturing Week, is inviting readers in the structural steel industry to visit its stand to see StruM.I.S, described as an ‘invaluable’ information management system that provides industry with total accountability across

Loctite 2046 threadlocker, designed for the food/beverage industry.

Loctite www.loctite.com.au

Gears and racks

multiple locations.

According to the company, the software can follow a job from the estimation process, through ordering, procuring, production and finally on-site delivery and erection - inception through to completion.

AceCad Software 08 9284 1555, www.acecad.net.au

Ronson Gears will be showcasing its Stock Gear range on its stand 0820 at NMW. Said to have the country’s most extensive range of gears and racks, the company says it is certain customers will find the solutions they are looking for.

Supplied by KHK Stock Gears from Japan, there are said to be

over 9,000 gears and associated products available to choose from.

Ronson Gears says it keeps approximately 2,000 different line items on the shelf; from spur gears, helical gears, bevel gears to gear racks, spiral bevel gears, worms and worm wheels.

Ronson Gears 03 9555 9822, www.ronsongears.com.au

Leadership has a class of its own

FLIR E-Series: Picture Perfect A new generation of FLIR hand-held ‘point & shoot’ thermal imagers is here. Packed with class leading features, the E-Series is designed for applications including electrical, industrial, mechanical, HVAC and building.

Take your pick of three pixel resolutions – all with 60Hz frame rate and a 3.0 Meg visual camera built in.

The new FLIR E-Series. It’s all class.

Get Connected!

Connect to iPhone or iPad via Wi-Fi to use the FLIR ViewerApp for processing and sharing results.

◊ Mobile Device Wi-Fi Connectivity ◊ Large Bright Touchscreen ◊ Built-in Digital Camera & Laser Pointer ◊ Groundbreaking Performance & Affordability ◊ Superior Point & Shoot Thermal Imagery

FLIR Systems Pty Ltd. 10 Business Park Drive, Notting Hill, VIC 3168, Australia VIC: 03 9550 2800 NSW: 02 8853 7870 WA: 08 6263 4438 QLD: 07 3861 4862 SA: 08 8274 3747 Tel AU: 1300 729 987 NZ: 0800 785 492 Email: info@flir.com.au www.flir.com Disclaimer: Images for illustrative purposes only, subject to change. ISO No. FLIR20837

58 APRIL 2012 Manufacturers’ Monthly

manmonthly.com.au

Vacuum tube lifter

Ready made or Custom made

At NMW this year, Millsom Materials Handling will have on display, on stand 7300, the JumboFlex 35 vacuum tube lifter.

The vacuum lifter is able to lift and move a huge range of products weighing up to 35kg including boxes, bags, sacks, drums and rolls of film along with many other items as well.

With single handed, user friendly operation the lifter can

tilt to 90° and rotate continuously.

The company specialises in all areas of vacuum lifting equipment, vacuum gripper systems and vacuum components along with a complete range of jib cranes, bridge cranes and low friction track systems manufactured in-house.

Automation

Dust/gas control

John Hart Automation will be exhibiting advanced automation solutions technology on stand 4100. On display will be the new M-3iA High speed ‘Genkotsu’ robot with integrated line tracking function, the LR Mate 200iC High Speed mini robot with automatic camera calibration and recovery functions, simulation software and more.

On stand 7518, Nederman will be introducing new products and services designed to help manufacturers reduce the impact of harmful particles, fibres, dust, gas, smoke and oil mist.

The company describes its products and services as both ecologically and economically efficient under a common name: eco-efficiency.

www.ronsongears.com.au VISIT US AT STAND 0820

Millsom Materials Handling 1800 99 22 11, www.millsom.com.au

John Hart Automation 03 9542 6262, www. johnhart.com.au

...exclusive distributors for KHK

Nederman 03 9702 3233, www.nederman.com.au

THIS MONTH’S PRODUCT FEATURE’S ARE ‘CRANES TO SUIT ANY APPLICATION’ Millsom manufacture & install jib cranes, bridge cranes, monorails and low friction track systems, they are available from our standard range of capacities or can be manufactured in-house to suit your specific requirements.

To complete your solution we also have a wide range of electric chain hoists, pneumatic hoists and vacuum lifting equipment to suit almost any application.

Millsom’s also have a great range of vacuum lifters capable of lifting up to 2000kg and jib cranes, bridge cranes and low friction track systems to suit most applications.

LIFT & MOVE

JUMBO FLEX

EASY LOADING OF YOUR CNC

WOOD INDUSTRY

WORKSTATION CRANE

SHEET STEEL OR WOOD

The Right Advice, The Right Solution,The Right Choice MELBOURNE, SYDNEY, BRISBANE, PERTH, ADELAIDE & NZ

manmonthly.com.au

FREECALL 1800 99 22 11

www.millsom.com.au email - sales@millsom.com.au

Manufacturers’ Monthly APRIL 2012 59

MaterialsHANDLING

New racking

standard moves from a “permissible stress” design philosophy to a “limit states” design approach.

New storage standard

By Dr Murray Clarke*

A

NEW standard covering the design of steel storage racking systems was released on February 29th 2012 and will bring Australia up to date with the latest international knowledge and experience in the design of storage systems and cold-formed steel structures.

Compliance with the new standard, AS4084-2012 Steel Storage Racking, is a rack-byrack, application-dependant proposition.

It is the designer’s task to create steel racking systems that are fit for purpose, meet the

60 APRIL 2012 Manufacturers’ Monthly

user’s requirements and budget, and provide acceptable safety margins to ensure safe, longterm operation.

However, when it comes to day-to-day operation, the onus of responsibility to ensure the systems are being properly used and maintained, and continue to meet the standard, falls squarely on the user.

The major change contained in the new Australian standard for steel storage racking is the switch from using a “permissible stress” design philosophy to a “limit states” design approach – a move which brings Australia into line with most

of the advanced rack designs codes in the world, including the European racking standard EN15512: 2009 and the Rack Manufacturers Institute Specification from North America.

It also brings the standard into line with the relevant cross-referenced companion Australian standards, including AS/NZS4600: 2005 Cold Formed Steel Structures and AS41001998 Steel Structures.

From a structural design perspective, the limit states approach offers advantages over the permissible stress format.

It allows the designer to con-

sider the application of different margins of safety to different types of loads (dead loads, storage loads, live loads, seismic loads) to facilitate design optimisation, while guaranteeing a prescribed level of safety across different combinations of loads.

Limit states design also provides the designer with greater insight as to how the structure will behave in the event of an overload that approaches the true collapse load of the system.

Other significant changes in the new standard include vastly expanded and improved testing provisions, including statistical evaluation, and the inclusion of advanced methods of structural analysis and finite element analysis.

Compared to the old standard from 1993, the new standard has the potential to result in more structurally efficient and finely tuned designs.

The result is that the storage racks of today are generally lighter and cheaper than those of yesteryear, while still possessing the required minimum level of structural safety – and that’s good news for end users.

For a full list of changes contained in AS4804-2012 Steel Storage Racking, view this article online at http://bit.ly/xKmrTo Dr Murray Clarke is a member of the Standards Australia committee for steel storage racking, Structural Design Manager and Structural Design Manager at Dematic.]

02 9486 5555, www.dematic.com.au

manmonthly.com.au

Overhead crane features sway control VEYANCE Belting of Bayswater, Victoria, manufacturer of Goodyear-branded conveyor belting for the Australian mining and materials handling industry, is enjoying the benefits of a new Konecranes 55t double girder multi-featured overhead crane, featuring sway control.

“Our new overhead crane is typically lifting 32 to 36 tonne loads of coiled conveyor belting on and off our processing machinery and onto delivery trucks,” said Veyance Plant Engineer Hong Koh. The new crane’s sway control minimises swinging or swaying of the load. It modifies the crane operator’s speed command so that the requested speed is reached without end swing. The operator spends less time worrying about load sway and adjusting it during the operation. The most accurate and efficient load positioning is thus achieved.

Sway control modifies the crane operator’s speed command so that the requested speed is reached without end swing.

“With sway control, the crane movements will definitely be safer for our operators. Speed isn’t so much a benefit for us, as our crane travel is small, but we’re aware that we can move the load more quickly with sway control,” Koh said.

He said that all Veyance’s operators learn to use the 55t overhead crane as part of their

standard training. It is company policy that they are skilled on all the production machines at the factory.

The double girder overhead cranes are said to have excellent hook approaches at both ends of the crane and the headroom requirement is minimal.

Konecranes 1300 937 637, www.konecranes.com.au

Counterbalance electric forklifts ADAPTALIFT Hyster’s J4.0-5.OXN electric counterbalance forklift in capacities from 1.5 to 5t provides low cost of operation and is designed for use in industries such as metal, timber, breweries, paper and automotive, the company says.

The new series incorporates features of the J-XN range, including the ECO-eLo and HiP settings for optimum environmental performance.

The Energy Low setting (eLo) is said to offer users low energy consumption while maintaining competitive performance.

Compact dimensions and manoeuvrability are achieved through the combination of the dual drive front axle and zero turn radius steer axle.

Adaptalift Hyster 1300 880 335, www.aalhysterforklifts.com.au

DID YOU KNOW? HYSTER R VOTED #1 FOR LOWEST WEST COST OF F RSHIP OWNERSHIP

DID YOU KNOW?

HYSTER FORKLIFTS ARE RANKED #1 FOR LOWEST TOTAL COST OF OWNERSHIP In an independent survey, urvey, Hyster forklifts ranked No.1 in the ca category ategory of total cost of ownership. Based on current U.S. customer ratings, ®

®

Hyster led all full-line forklift manufacturers.* *Based on an independent survey conducted by Peerless Media Research Group.

STRONG PARTNERS. TOUGH TRUCKS.

manmonthly.com.au

1300 880 335 | aalhysterforklifts.com.au Manufacturers’ Monthly APRIL 2012 61

ProductSHOWCASE FASTENERS & ADHESIVES

Increase productivity in your manufacturing process by pre-coating all your threaded fasteners.

Stop the shake, rattle and roll….

Microencapsulated coatings available for: every type of threaded fastener all applications every assembly process Dry finish, Easy handling No drips, no mess, no fumes, NO WORRIES Extensive range includes: Loctite, 3M, ND …

Ask Belmatic to provide the ideal solution for your needs.

Belmatic Industries Pty Ltd 12 Kylta Rd, Heidelberg West VIC 3081 P: 03 9459 8097 W: www.belmatic.com.au

APPLIED FASTENER COATINGS • SPECIALISED PRECISION ENGINEERING

FASTENERS & ADHESIVES

Premium products and services Manufacturers’ Monthly’s bi-annual Products & Services Showcase features an array of new products and services available to help Australian manufacturers work smarter.

To promote your product or service in the Products & Services Showcase, contact Michael Northcott on 0448 077 247 or email michael.northcott@reedbusiness.com.au FASTENERS & ADHESIVES Belmatic Industries Jacmor Engineering FLOORING Flowcrete Australia FOUNDRIES T P Castings GRINDING Henry Engineering

62 62

HEALTH & SAFETY Priority Supplies

63

PNEUMATICS Nitto Kohki Australia

63

PUMPS & VALVES All Pumps Supplies

63

SENSORS Semmler Technologies

63

TRAINING Interpoint Events

63

63

63

9463 0888

63

62 APRIL 2012 Manufacturers’ Monthly

manmonthly.com.au

FLOORING

PNEUMATICS Dem

and Get with

the F low ~

PUMPS & VALVES

FOUNDRIES

TP CASTINGS PTY LTD

www.tpcastings.com.au

03 9768 3255 Chemical & Acid Drum Pumps • Metallic & non-metallic versions.

• Electric and pneumatic models.

• Lightweight and safe.

• Available with a range of accessories including flowmeters and dispensing nozzles.

LARGE ALUMINIUM CASTING FOR ROTATIONAL MOULDING - 2MT X 1 M DIAMETER.

Global Pumps 42-44 Dunorlan Rd, Edwardstown SA 5039 Ph: 08 8275 8000 Fax: 08 8275 8099 Email: sales@globalpumps.com.au Web: www.globalpumps.com.au

GRINDING

SENSORS

HEALTH & SAFETY

TRAINING

SET TING THE WITH STANDARDS AFE INNOVATIVE S TIONS STORAGE SOLU

THE AGILE SUPPLY CHAIN

EF CTIV EFFECTIVE EFFECT IVE COMPLIA COMPLIANCE ANCE FOR F THE MANUFACTURING INDUST INDUSTRY TRY

• • • • • • •

26-27 June 2012

Relocatable bulk stores Safety cabinets Gas cylinder stores Lube stations Bunding Safety showers Custom design to suit your situation

DESIGNED AND MANUFACTURED IN AUSTRALIA

1300 134 223 1300 307 895 sales@storemasta.com.au www.storemasta.com.au manmonthly.com.au

Melbourne Exhibition & Convention Centre For more information visit

www.supplychain2020.com.au protecting the

or call 1300 789 845 Endorsed By

Supported By

Education Partner

Media Partners

Manufacturers’ Monthly APRIL 2012 63

A Member of The Linde Group

At BOC, we understand the challenges your business faces everyday. If we can help you increase production and keep costs down, then weâ&#x20AC;&#x2122;re doing our job.

Donâ&#x20AC;&#x2122;t forget that BOC can also supply a comprehensive range of

provide your business with a wealth of technical expertise.

Thatâ&#x20AC;&#x2122;s why weâ&#x20AC;&#x2122;re proud to introduce the mini bulk gas supply

is ideal for customers who use between 100m3 to 400m3/week but are also looking to save space onsite.

!

local Gas & GearTM

"#" 262.

A mini bulk gas supply makes it easier to manage variable

BOC will be exhibiting at National Manufacturing Week in ! $ % "" '("' )

8400.

Oxygen.

BOC Limited * + ) , "( - * !5 '""#

contact@boc.com 79+

79+ : $ : ; < 79+ : '("'

MP12-0439-3|MA|MM|0412

Introducing the mini bulk gas supply option