Manufacturers' Monthly July 2011

CELEBRATING 50 YEARS Years

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July 2011

INSIDE Industry News >> Latest Products >> Industry Opinion Reducing Your Energy Costs >> Automation & Robotics Metalworking & Machine Tools >> Production Software

ENDEAVOUR AWARDS WINNERS 2011 >> The best of the best of Australian manufacturing!

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Inside JULY 2011

For daily news visit manmonthly.com.au

4 Editorial ■

22

Taking a thought-leadership stance on solar.

Endeavour Awards 2011 honour roll revealed!

6 Comment ■

Climate change and common sense.

8

8 Analysis News ■

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Shadow Minister Sophie Mirabella condemns carbon tax.

Latest manufacturing training and events.

Modular building booms.

CCA’s $57m self-funded factory.

12

14 Carbon Footprint ■

Bringing balance to sustainability.

46 What’s New

56 Maintenance

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Best product releases for the month.

New technology for your factory.

22 Endeavour Awards Winners 2011

50 Metalworking

58 Materials Handling

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Full winners’ coverage from the ceremony.

Tony Abbott’s shoot-down over the carbon tax.

We name the manufacturer of the year.

CELEBRATING 50 YEARS Years

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Est. 1961 July 2011

Print Post Approved PP255003/00324

Publisher Michelle Graves michelle.graves@reedbusiness.com.au Editor Sarah Falson Ph: (02) 9422 2480 Fax (02) 9422 2722 sarah.falson@reedbusiness.com.au Journalist Annie Dang Ph: (02) 9422 2964 Fax (02) 9422 2722 annie.dang@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 SA/NT & WA Sales Reed Business Information Ph: (02) 9422 2368 anthony.head@reedbusiness.com.au

INSIDE Industry News >> Latest Products >> Industry Opinion Reducing Your Energy Costs >> Automation & Robotics Metalworking & Machine Tools >> Production Software

ENDEAVOUR AWARDS WINNERS 2011 >> The best of the best of Australian manufacturing!

■

A shiny future in metal.

Clean machining at Ford.

54 Automation & Robotics ■ ■

Driving drilling accuracy.

Robotics replacement service.

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High-quality forklift range.

A fast supply chain future.

52 Products & Services Showcase ■

Manufacturing directory.

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Editorial

SARAH FALSON – Editor

editor@manmonthly.com.au

Giving it a red hot go The future is all bright and shiny when we think about solar, but how do we get a meaningful market off the ground without help? Sometimes a will doesn't always equal a way – especially when ‘thought-leadership’ is the driver.

F

RENCH car manufacturer Renault is undertaking the largest solar project in the history of the automotive industry, installing solar panels on the roofs of all of its French production plants.

Some 450,000m2 of solar panels are needed for the project, covering an area equivalent to 63 football fields.

Speaking to Manufacturers’ Monthly, Toyota Australia manager environmental policy Jon Ward said the company might consider covering its Australian manufacturing facilities in solar panels, if renewable energy technology was cheaper.

Ward took the opportunity to call-out to local solar technology suppliers and government bodies, urging them to make renewable energy systems like solar more commercially-viable for businesses.

“There is no question that solar can be effective in generating significant quantities of energy if the area is large enough, however the cost per megawatt hour of solar is still very high, even compared to other renewables such as wind,” he said.

“The challenge industry faces is how to make renewables com-

The kind of thought-leadership Renault is showing with its solar array is a step in the right direction for manufacturing.

mercially-viable given their current costs. This is on-going work and in the meantime Toyota Australia will continue to focus on energy efficiency to improve our carbon intensity.”

In France, Renault hopes to generate 60 MW of power per year using the solar panels, which is the equivalent annual electricity consumption of a town with a population of 15,000.

Renault plans to reduce its carbon footprint by 10% by 2013 and by a further 10% between 2013 and 2016. The solar panel project aims to reduce CO2 emissions by 30,000 tonnes a year.

Toyota Australia is also committed to reducing manufacturing emissions, setting itself a challenge to reach zero emissions throughout all of its business.

Which begs the question – if solar was affordable, surely Toyota Australia would take this thought-leadership stance and invest in the technology, too.

Which raises another question: why is renewable energy so expensive? In Australia, we have the landmass and the means to be a world-leader in solar energy technology. So why are we being trumped by countries like France when it comes to taking a leadership role and showing the world that we are at the forefront of emissions management?

Ward agrees, saying Renault’s solar power plan, though expensive, is still an important part of raising awareness of emissions reduction and the measures available to companies.

“It is important for companies

to show environmental leadership by demonstrating what is possible,” he said.

Locally, Toyota is all for cutting emissions, and is in the midst of commissioning a TriGen turbine at its corporate headquarters in Victoria to produce electricity, heating and cooling from gas and reduce its carbon footprint by 25%.

“This is on top of the 22% reduction in CO2 per vehicle in manufacturing from 2000 and 26% reduction achieved at our corporate HQ already from 2005/06,” said Ward.

Interestingly, Toyota in the UK has announced it will go the way of Renault and install a barrage of solar panels at its Derbyshire manufacturing plant, using all UK-made solar products.

Work has started on installing the ground-mounted system, where Auris hybrid, Auris and Avensis cars are built for the UK and export markets.

The solar array is located on 90,000m2 of industrial land within the plant and consists of around 17,000 panels – enough to cover almost four and a half football fields.

I’m sure Australian solar manufacturers including SilexSolar and Eco-Kinetics would jump at the chance to be part of such a visionary project – but then, Australian automotive manufacturers don’t have that kind of money to throw about at the moment.

Can we rely on the government to step in, or isn’t thought-leadership important to Australia?

sales

4 JULY 2011 Manufacturers’ Monthly

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Comment

HEATHER RIDOUT – CEO Australian Industry Group

editor@manmonthly.com.au

Adding some climate common sense It’s time to put some common sense in the climate debate, if government hopes to gain the support of industry. Heather Ridout writes for Manufacturers’ Monthly.

W

E need to take off the table ludicrous policy options such as a $40 starting price; an ongoing fixed price regime; a ban on all future coal mines; exclusion of credible offshore emission-reducing actions; and moving to an unconditional 2020 target of 25% below 2000 emission levels.

These options would be economically reckless, complicating an already diabolical policy debate.

As well, it needs to be understood that the timing of this debate is very tough, especially for manufacturing. The industry is facing potential new burdens from any approach to climate change at a time when it is under escalating pressures.

While it has been painted as trivial by some, Australia’s cur-

6 JULY 2011 Manufacturers’ Monthly

rent unconditional target of 5% below 2000 levels is a huge ask.

Australia’s emissions are currently on-track to be 24% above 2000 levels by 2020. Meeting the ‘5%’ target is equivalent to cutting emissions in 2020 by almost 30% below latest projections. This would be equivalent to the combined emissions of our transport and agricultural sector.

If, as the Government plans, Australia prices carbon from 2012, it needs to address the serious risks to the survival of big wealth generating and employing businesses in Australia. If carbon is to be priced we need to start low and provide strong and effective shielding for tradeexposed industries.

Any emissions reduction arrangement, including the

Opposition scheme, would only be viable if there was strong and effective shielding for businesses who would bear costs not imposed on their competitors abroad. For the Government, this means getting the emissions intensive trade exposed (EITE) provisions right. Adding a third tier would correct the inequitable and heavy burden imposed on businesses just outside the original CPRS arrangements, including upstream food processors; metal casting and fabricating businesses; some plastics and paper manufacturing activities and some metal smelting and refining operations.

These businesses and their employees are amongst the most vulnerable to the impacts of a carbon price.

To effectively and efficiently reduce emissions on an economywide scale, any proposal needs three other key components.

Firstly, it is essential to ensure continuity of electricity supply and new investment in the generation sector.

Secondly, the up to 550 existing state and federal emissions reduction regulations and programs should be removed as they become unnecessary under a carbon price.

Finally, any carbon pricing arrangement needs to be accompanied by a concerted effort to invest in research, development and low-emissions technologies.

We are approaching crunch time in this debate and any plan to address climate will need to allay these concerns if it is to get industry support.

Heather Ridout is chief executive officer of the Australian Industry Group.

Visit www.aigroup.com.au

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AnalysisNEWS EVENTS

United over carbon wreckage Industry is uniting against the carbon tax, Shadow Minister for Innovation, Industry

JULY 7–8: Federation of Automotive Products Manufacturers (FAPM) 2011 National Conference The Melbourne event will bring the industry together to examine ways to sustain the Australian automotive supply chain into the future. www.fapm2011.com 10–13: Foodpro 2011 The triennial Sydney event displays the latest food and beverage processing machinery, services, technical products, ingredients, flavourings, additives, food safety and testing equipment, and more. www.foodproexh.com 12–13: International Conference on Additive Manufacturing The 6th International Conference on Additive Manufacturing (AM) will focus on the research into and application of additive manufacturing as a technological approach for the production of end-use parts. To be held in Leicestershire, UK. www.am-conference.com 13: Food Challenge Awards 2011 In its 7th year, the Food Challenge Awards recognises and rewards best practice and innovation in food and beverage manufacturing in Australia and New Zealand. Hosted by MM sister magazine, Food, the night draws together newly-launched boutique operations and fully-established international enterprises. www.foodmag.com.au/awards

and Science, Sophie Mirabella MP, writes exclusively for Manufacturers' Monthly.

F

OR all of the disastrous ramifications of Julia Gillard’s carbon tax, there has at least been one positive consequence to emerge from the wreckage.

I say this because the debate on the tax has reminded Australians of the enduring spirit, passion and commitment of our country’s manufacturers.

To see manufacturing businesses and workers rising up so defiantly against this policy has been a moving experience.

Manufacturers are already feeling frustrated and angry that so many of the existing policy settings continue to operate to the detriment of Australian businesses, rather than to their advantage. But those sentiments have become even more intensely felt since the Government broke its election promise not to introduce a carbon tax.

Since I became the Shadow Minister for Industry in late 2009, I have been privileged to meet regularly with manufacturers across the country. But at no time have I sensed such disillusionment with the Government’s neglect of manufacturing as during the past three months.

The refusal of manufacturers to lie down and accept policies that threaten their existence has been gratifying to anyone who

Many of the existing policy settings operate to the detriment of Australian businesses rather than to their advantage, says Mirabella.

understands how important a strong and viable manufacturing sector is for our economy.

It has also been heartening in a number of other respects, too – not least because it has helped to sharpen the focus, at the national political level, on the future of manufacturing.

It has helped to revive a vital national debate by causing many people to consider critical questions about the kind of economy we want in the future. It has also forced them to contemplate what the loss of an Australian manufacturing capability might mean for us in 10 or 20 years from now.

Australian manufacturing workers are smart, innovative, hard-working people who know full well what a carbon tax will do to their international competitiveness. Especially in the absence of similar policies being adopted in other countries.

They also know that manufacturers are already trying to combat a range of pressures. And that the last thing they need right now is to be asked to absorb yet another substantial (and annually escalating) cost – let alone one that won’t be borne by their overseas rivals.

Whether it’s with car workers in Geelong and Altona, plastics makers in Dandenong, food producers on the Central Coast, or steel fabricators in Fremantle, these are among the messages that continue to resonate when I meet with manufacturers all around the country.

Another refrain is that the Government simply doesn’t understand that times are tough, and that Australians are now anxious about their livelihoods and about making ends meet.

There was already disbelief that our Government was doing so little to help Australian manufacturers. But now there is palpable anger at its attempts to club manufacturing out of existence.

In the national interest, the Coalition will continue to fight against this industry-destroying, job-destroying tax. And I would urge the same of anyone who wants Australian manufacturing to survive.

Comment at manmonthly.com.au

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8 JULY 2011 Manufacturers’ Monthly

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AnalysisNEWS

Not just another brick in the wall

BY SARAH FALSON

A

USTRALIAN building products manufacturers are being run off their feet this year, thanks to a new trend in housing components offering consumers more versatile products at a fraction of the price.

Nimble manufacturers have cottoned-on to the growing popularity of these ‘modular’ building systems, incorporating two or three previously separate housing materials into one convenient package.

These offerings, which are developed in a factory, can be built quickly, in exactly the colour and/or shape the customer requires, eliminating the long wait for a builder or engineer that is so often associated with building a house.

Plus, once the components are brought to the housing site to be fitted together, the bricks and mortar (so to speak) are in place within weeks, instead of months – or even years – and construction delays caused by bad weather are minimised.

One savvy manufacturer developing these components is Queensland-based thermal building products company, Bondor.

The firm is receiving such interest in its insulated roofing systems from customers in Australia’s South, that it recently started assembly of the solutions at its plant in South Australia, in addition to the original Brisbane-based facility.

Factory-made modular products, like this 3-in-1 roofing system, are cutting construction time and offering environmental benefits.

Ramped-up production of the SolarSpan composites roofing solution will mean additional shifts for employees at the South Australia plant, and jobs for three new staff members.

The company’s SolarSpan system – launched two years ago – is now being manufactured at the Salisbury South plant for the South Australia, Victoria, Northern Territory and Tasmania markets, while the Brisbane facility supplies the NorthEastern states.

SolarSpan is a three-in-one roofing solution, combining a trimdek-style Colorbond roof from BlueScope Steel, Colorbond Surfmist ceiling finish and a fire-retardant polystyrene core for insulation. The system is very strong and can be applied in up to 7-metre spans.

It allows builders to reduce the interior framework of a roof, eliminating rafters and battens, thence saving associated labour and material costs. Additionally, design elements, such as lighting, can be incorporated into the

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EF CTIVE COMPLIANCE EFFECTIVE EFFECT COMPLIA ANCE FOR F THE MANUFACTURING INDUST INDUSTRY TRY

• • • • • • •

ceiling finish at the factory level, reducing inventory costs.

“People are looking for a better and faster way of constructing their roofs and Solarspan allows them to make that happen,” Bondor sales/ architectural representative – SolarSpan, Kyle Bowes, told Manufacturers’ Monthly.

“With SolarSpan sales dramatically increasing over the last two years, we have found it necessary to commence the rolling of SolarSpan [in SA] to keep up with demand and improve our service to the building industry.

“The time saved in construction, the ability to cater to client’s individual needs and the pre-painted ceiling finish, I believe, is the reason for this.”

The system is manufactured using composites technology, which is the practice of engineering two or more materials together to form a new fibre or fabric

which is stronger, more flexible or more versatile than the sum of its parts. A typical example is brake pads, which are made of hard ceramic particles embedded in a soft metal matrix.

“Our manufacturing was originally based on the use of expanded polystyrene materials (EPS) however, through an extensive R+D process, Bondor now manufacture and supply composite panels with three different core materials for various applications,” said Bowes.

“More recently, combined with the development of its roofing panel Solarspan, Bondor has made in-roads into the commercial and residential marketplace through architects and builders.

The attraction to these parties increased, making it possible to add architectural finishes to the composite products, offer high energy efficiency, fast-tracked construction and a cost-effective means for a return on their clients’ investments.”

Ramped-up production of the SolarSpan will mean additional shifts for employees at the South Australia plant, and jobs for three new staff members. Bowes says it’s likely a second shift will need to be added mid-next year, creating a further five positions, if demand keeps increasing.

To prep the South Australian site for the onslaught, a new roofing roll former was installed to collaborate with Bondor’s existing panel machine, along with a computerised automation program, automatic core feeder and specialised cut-off machine.

protecting the

What you missed in June…

• Interest rates to rise despite manufacturing woes: http://bitly.com/fw1m7P • R&D Tax Credit to start 1 July: http://bit.ly/laHIDx • New Quickstep plant offers turn-key components: http://bit.ly/lXe8tS • 31 seriously injured with angle grinder in past year: http://bit.ly/jqrs55 Never miss out again! Follow us @manmonthly for all the latest news, product information and comment pieces from the industry.

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AnalysisNEWS

CCA funds $57m upgrade in lieu of grant

BY SARAH FALSON

A

LMOST 30 new manufacturing jobs will be created at Coca-Cola Amatil’s (CCA) new $57 million bottle preform and closure manufacturing facility, which was built to eliminate the food manufacturer’s reliance on third-party bottling companies.

The new facility, which was funded entirely by CCA in lieu of a suitable R&D tax grant, is built at the company’s $90 million automated distribution centre in Eastern Creek, New South Wales. It is the final stage in the ‘vertical integration’ of CCA’s manufacturing facilities in Australia and New Zealand, and will focus on CCA’s bottle lightweighting technology.

The site brings the company’s Australian bottling investment to a whopping $450 million.

“There was no government funding available for this manufacturing facility. Our CEO, Terry Davis, has repeatedly called on governments to assist the manufacturing sector with support in the form of accelerated depreciation and meaningful R&D allocation,” CCA director of media and public affairs, Sally Loane, told Manufacturers’ Monthly.

CCA’s new self-funded facility will use injection moulding

technology to manufacture plastic bottle enclosures (caps) and PET resin preforms that will be used to make PET plastic bottles for non-alcoholic drinks at CCA’s other manufacturing sites in Australia and New Zealand.

At these sites, the preforms will be fed into the blow-fill machines, blowing light-weighted bottles to CCA’s specific design.

This means the company will be bringing its intellectual property in-house, where previously its bottles were not exclusive.

“We have been reliant up until now on the design and weight specifications of our suppliers of our bottles, preforms and closures, and these were not exclusive to CCA. By bringing all the manufacturing in-house, we will be able to design our own packaging which will not be available to any other beverage producer,” said Loane.

The site will initially produce 1.4 billion preforms and 1.4 billion closures per year, however it could facilitate manufacture of almost twice this in the future.

The resulting bottles will incorproate 20% less PET resin.

The new business model will also reduce transportation costs.

The preforms will initially be supplied to CCA’s Northmead, Sydney manufacturing facility,

CCA group managing director Terry Davis (right) and the Mayor of Blacktown Alan Pendleton, at the sod-turning ceremony at the new plant last month.

which already has the blow-fill bottle manufacturing technology installed on its production lines.

“We are rolling ‘blow-fill’ out to our other manufacturing facilities in Australia and New Zealand, so eventually, this plant will supply all our six facilities in Australia and New Zealand,” Loane said.

(Though CCA was unable to garner government support for the project, a $1.8 billion R&D Tax Credit for new innovations started 1 July, in the form of a 45% refundable tax for companies with an aggregated turnover of less than $20 million, and a 40% non-refundable offset to all others.

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Skilling high-performing workplaces

BY ANNIE DANG

A

USTRALIA’S manufacturing industry may be staring down the barrel of a major skills shortage, but the push to build high-performing workplaces at a micro level could provide the solution manufacturers need to turn the skills issue around.

Speaking at the Western Sydney Manufacturing Leaders Forum and Innovation Technology Showcase, as part of NSW Manufacturing Week, Australian Industry Group (Ai Group) policy and projects manager, Lee-Anne Fisher, said developing processes and procedures around people-oriented frameworks can help companies resolve their skills issues, and put them in a better position to become competitive.

Such frameworks include

Participative Decision Making (PDM) Skills Development and Utilisation (SDU), which will form part of an on-going study conducted by Ai Group.

Due to be released in September, the ‘Building Productivity Firm-by-Firm: High Performing Workplaces’ study will provide contemporary, reallife examples and case studies of local manufacturing companies that are considered to be ‘highperforming’.

“By highlighting what it is that makes these companies highperforming workplaces, the study will provide a working example of what has been learnt from [these workplaces],” Fisher told Manufacturers’ Monthly.

The report is expected to provide some much-needed industry perspective to workplace structures and staffing, in order to help build more efficient work-

Lee-Anne Fisher, Australian Industry Group manager of policy and projects, says Australia’s skills shortage is set to intensify with the resurgence of the resources sector.

places by informing industry about the best approaches to take to become high-performing companies.

The report’s release will come at a time when manufacturers are expected to face a tough fight to retain skilled staff from moving across to better remuner-

ated sectors, such as mining and infrastructure projects, or to simply bulk-up the depleting skills ‘pipeline’.

According to Fisher, the next five years will prove to be interesting times for the Australian manufacturing industry.

“Australia has experienced a prolonged period of skills shortage which is set to intensify with the resurgence of the resources sector and the major infrastructure and reconstruction projects underway,” says Fisher.

“We need to look at all avenues to access the skills manufacturers need and to tap into underutilised skills in the industry. Notwithstanding reductions in overall employment levels in manufacturing, there are still deep and sustained skills shortages.”

Australian Industry Group 1800 648 859, www.aigroup.com.au

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Manufacturers’ Monthly JULY 2011 13

AnalysisMANAGEMENT Balancing the sustainability tripod Sustainability has become a key business driver for all sectors. To remain competitive in changing economic conditions, businesses must balance energy usage, resource consumption and safety. Michael Loke discusses.

S

USTAINABLE production has never been a more important goal for industry.

As new demands for environmental accountability are made, today’s manufacturers must monitor raw material usage, power and water consumption, and generation of waste, in order to operate their facilities in the most environmentally sustainable way possible.

Sophisticated, integrated control solutions – paired with production intelligence software – are essential to balancing the demands of environmental and economic imperatives of operating a business. Systems of this kind give companies the ability to collect data, process it and distribute it to the appropriate people at the right time.

The cost of energy is a significant business outgoing and a key environmental and sustainability metric. Knowing the amount of energy used in the production process is an important factor for any manufacturer.

Implementing systems to monitor energy usage at all stages of

14 JULY 2011 Manufacturers’ Monthly

Renewable energy is a major focus for sustainable production.

the production process can identify savings. It is important to know not just how much energy is used but also when it is used.

Integrated information-enabled control architectures, that monitor all stages of production, can be used to optimise the processes and manage energy usage to take advantage of off-peak supply and deliver cost reductions.

Such systems can transform a company from a passive energy consumer to a strategic manager of energy resources.

A by-product of utilising energy and consuming natural

resources is the generation of waste. Therefore, the amount of waste being sent to landfill is another factor driving the adoption of sustainability strategies.

Monitoring emissions and waste generated during processing is integral to a company’s ability to comply with the reporting requirements of government, along with new regulations that might be introduced in the future. For example, the waste created by the manufacturer during preparation and application of the packaging could be reduced. Such designs would

reduce the landfill requirements of end-users.

There are also processes – both internal and external – that manufacturers can implement to reduce waste. A comprehensive internal waste segregation system – which encourages re-use and recycling – and training staff to follow it correctly, can minimise the amount of material sent to landfill.

Sustainability needs to be driven from a company’s highest levels. Senior managers who appreciate that there are financial benefits in a sustainability strategy; that companies that do not implement progressive changes are taking bigger economic, brand and regulatory risks, are central to a company’s success.

Integrated automation control solutions can enable manufacturers to operate cleaner, safer and more efficiently, helping to continuously protect and fortify their brands, and improve the bottom line.

[Michael Loke is industry manager, Sustainability, with Rockwell Automation.]

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16 JULY 2011 Manufacturers’ Monthly

BY KEVIN GOMEZ

SCHNEIDER Electric has identified the food and beverage industry in Australia as a major growth opportunity for 2011 and will increase its business focus and expand its team in the sector in coming months.

"Improving the efficiency of operations is crucial if food and beverage manufacturers are to remain profitable in what's becoming an increasingly competitive market," Craig Roseman, newly appointed national segment manager, Food & Beverage, Schneider Electric Industry Business Australia, told Manufacturers’ Monthly.

"Best practice begins by conducting a detailed audit into the efficiency of operations at all manufacturing sites so that inefficiencies, such as motors running unnecessarily when systems malfunction, can easily be identified.

"This insight is most valuable when fed into SCADA systems that present information in an easy-to-digest dashboard. It gives operations managers complete visibility of plant systems and isolates and identifies problems early on before they become plant-wide issues. Once armed with this insight manufacturers can start to automate and optimise processes.�

Schneider Electric's increased focus in Australia is part of the group's wider strategy to strengthen expertise in this market internationally. It includes the global appointment of Carola Puusteli into a newly created role as vice president of Food and Beverage, based in France.

Schneider Electric believes that energy management is key to Australian food and beverage organisations remaining competitive.

Roseman explains: "In the food and beverage sector, rising consumer expectations are placing pressures on manufacturers to push sustainability higher up the business agenda."

At the same time, however, the food and beverage sector is trying to balance challenges such as

Craig Roseman, National Segment Manager, Food & Beverage, Schneider Electric Industry Business Australia.

falling profit margins, increasing compliance requirements, higher costs of raw materials and rising product complexity.

"Savvy manufacturers are addressing these challenges by adopting a strategic four-step approach to improve the efficiency of operations," notes Roseman.

"This involves measuring and analysing energy use, deploying efficient devices, automating and optimising performance and embracing a continuous program of monitoring and improving.

"Those that have followed this four-step process are able to 'do more with less' while at the same time achieve significant energy savings.

"Schneider Electric's experience globally shows organisations in the food and beverage sector typically reduce energy consumption by 30 per cent simply by optimising the systems they have in place," adds Roseman.

"Our model allows us to share technology and specialist process control knowledge with our partners, meeting the end-user's expectation of a well-coordinated system," he notes.

"Our focus on the food and beverage segment will include the associated businesses which currently provide expertise or technology and where our customers expect a single solution provider approach."

Schneider Electric 1300 369 233, www.schneider-electric.com.au Comment at manmonthly.com.au manmonthly.com.au

Cutting environmental emissions and energy costs Reducing environmental impact and driving business efficiencies have become the dual role of energy management systems today, and therefore a major item on the business agenda. Steven Kratsis writes.

T

ODAY we are witnessing a potent combination of factors, which together are driving organisations to optimise their energy consumption.

With energy often the largest component of operating expense for manufacturers, coupled with restrictions on greenhouse gas emissions, these issues are combining to be major items on the business agenda.

This trend is further strengthened by the ongoing global economic downturn.

Improving energy efficiency saves costs with no negative impact and therefore represents a particularly attractive option for businesses to follow at this time, especially given that in the near future many companies will also be faced with having to buy CO2 emissions credits.

Being more energy efficient therefore has a double impact on the bottom line – it reduces both operating expenses, and expenditure on CO2 credits.

However one of the key issues they are facing is that there are many different ways to reduce energy costs.

With the United Nations COP15 conference held in Copenhagen in 2009, interest has been growing in the role of Carbon Capture and Storage (CCS) in driving the reduction of CO2 emissions for energy intensive businesses.

The need to cut environmental emissions is certainly urgent. The International Energy Agency (IEA) predicts that by 2030 demand for energy will increase by 50% compared to today.

The increased demand will drive up carbon dioxide emissions and heighten the climate change problem, making the efficient use of energy key to resource conservation.

It is true that CCS has great potential as a method of addressing these issues. This is underlined by the fact that leading companies in the energy sectors are engaged in piloting promanmonthly.com.au

Improving energy efficiency saves costs with no negative impact.

grammes using technology.

One of the key challenges in CCS is carbon capture and many leading companies are using process modelling solutions for carbon capture modelling to find ways to make carbon capture viable and cost effective in the shortest amount of time.

However, the pilot programmes are in early stages and it will take time for these programmes to demonstrate commercial viability in meeting the carbon capture challenges.

The way in which organisations interpret energy management varies. Typically, the key challenge is to identify the combination of improvements that best meets the demands of the existing production processes and utility systems and maximises potential in line with business objectives.

An integrated approach to energy performance management can achieve significant savings in energy costs and hence greenhouse gas emissions both within the manufacturing units and in the utilities systems that support the manufacturing units.

An important component of the solution is provided by model-based energy management systems, which can be used to help take advantage of potential savings which have hitherto been largely unexploited in addi-

tion to providing optimised and consistent information about a site’s key processes and facilities for decision-makers.

This knowledge can be useful both in long-term, strategic decisions and in concluding energy

supply contracts, in preparing budgets and in drawing up investment plans, as well as in optimising the energy costs of ongoing operations – based on current demand, costs and plant availability.

Adopting best practice here can have a major bottom-line benefit since savings of between 5-10% can be obtained using operations planning and optimisation without needing to make any significant capital investment, even in the most sophisticated plants.

By implementing an energy management program with elements focusing on both supply and demand, organisations can achieve significant returns often over 15% of their annual energy costs with very attractive payback on the capital invested.

[Steven Kratsis is Country Director, AspenTech Australia.]

Manufacturers’ Monthly JULY 2011 17

TechnologyIT@MM The perfect tonic to rising energy costs

Measuring and understanding your energy consumption is critical to the environment.

With energy prices expected to rise by as much as 30% in the next few years, measuring your energy consumption should be a key strategic focus for any industrial business. Norm Hebron writes.

C

ARBON reduction dominates the political landscape at present with a huge divide over what is the best way to meet Australia’s proposed 5% emissions reduction.

As we move inevitably towards a low-carbon economy there will be implications for business regardless of the policy environment, not least because electricity prices are rising and will continue to do so – climate change or not.

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there are often energy reduction gains to be had and those gains can be really quite significant.

Take a typical three phase motor which is common place in manufacturing plants in all industries. If it is just one percent off its optimal phasing then energy costs can be as much as 50 percent higher and the machine’s lifespan can be reduced by as much as a half.

Over the long term, the energy costs of an asset can far exceed its upfront purchase cost.

Another example observed recently was the performance of a 500hp fan in a spray booth.

It was purchased at $30,000 and was found to cost over $600,000 in energy costs over five years. That's a huge variance.

Even worse, energy efficiency tends to degrade over time. Just because a piece of equipment hasn’t actually broken down, it doesn’t mean it’s not losing the business money.

So, if the filters on the air-conditioning unit become clogged, energy consumption soars, yet to the casual observer it is still cooling the building.

Spotting these variations is often difficult; it requires a far more granular understanding of energy usage than is typical.

However, in much the same way as smart meters are starting

to infiltrate the home and report on appliance level energy consumption, commercial grade appliances also need to report on their energy usage, consumption and wastage.

The challenge is capturing and analysing this data to understand how energy use can be actively minimised. Ask yourself the following questions: How committed are we to improving energy consumption?

Where is the majority of our energy consumed?

How much energy should we be consuming?

How much wastage is involved?

With the exception of number one, most organisations are unlikely to be able to answer them fully and accurately. The old adage that “you can’t manage that which you can’t measure” is true; if a company does not know which assets are inefficient, it is impossible to act to improve the consumption of energy.

To tackle the problem, there are a number of steps to take.

1. Monitor high energy consuming assets in your business.

Including energy consumption as part of the asset management process, with tools like Infor’s EAM Asset Sustainability, can provide complete picture of operating and maintenance expenses, including energy costs. manmonthly.com.au

2. Identify which assets are performing sub-optimally and automatically generate actions to remedy the issue(s).

Once you’ve got the visibility into your assets, it is possible to automatically detect and prevent energy wastage by pinpointing where and how to reduce environmental impact. It also helps the decision to replace the right assets at the right time with complete financial justification including energy usage.

3. Change the organisational culture Having an awareness of energy usage is one thing, but to effectively alter organisational behaviour it is important to first alter the cultural attitudes to energy usage. Make energy efficiency a cost issue first, rather than an environmental nice to have – some might argue with the science of climate change; it’s difficult to argue with bottom line savings.

Research by the Economist Intelligence Unit recently found

PLM, DCM and 3D CAD now integrated SIEMENS PLM Software and IronCAD have announced that IronCAD’s new 3D Connector software, part of IRONCAD Draft, is now integrated with Siemens PLM Software’s Parasolid software and three D-Cubed software components for constraint solving and collision detection.

According to IronCAD, users can now leverage constraint information from their 3D models in the context of a dedicated drafting and detailing tool.

IRONCAD Draft is a 2D drafting tool with a new 3D integration capability enabled by 3D Connector.

Leveraging its new integration with Parasolid, users can now import 3D model data – from suppliers, customers and colleagues – created with any software product capable of outputting the widely used Parasolid geometry format, such as

that 70% of Australian organisations are already taking steps to ready themselves for a transition to a low carbon economy.

This is a prudent measure if not for environmental reasons, then certainly to reduce costs.

IRONCAD or a wide range of third-party applications.

The company says data can be viewed, analysed, rendered and referenced as the user produces drawings using the various 2D mechanical drafting functions in IRONCAD Draft.

In addition, any 3D models imported from IRONCAD can be repositioned under the control of any existing dimensions and constraints using Siemens PLM Software’s D-Cubed 2D and 3D Dimensional Constraint Managers (DCMs).

This allows the user to reconfigure a constrained model to meet the requirements of a specific 2D drafting or detailing task.

Using the D-Cubed Collision Detection Manager (CDM) users can also quickly verify that new configurations do not result in colliding parts.

Siemens PLM 1300 519 144, www.siemens.com/plm

And in our experience, applying energy intelligence to assets throughout an organisation can realise in the region of 20 percent savings in energy usage.

With energy prices expected to rise by as much as 30% in the

next few years, that’s something every business should be looking at.

[Norm Hebron is from EAM Pacific, Infor.]

Comment at manmonthly.com.au

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Manufacturers’ Monthly JULY 2011 19

F•S•A/DEX0375

DEXION’S PROPOSAL TO LIFT STORAGE DENSITY, MEANT KIMBERLY-CLARK’S ROOF COULD BE LOWER.

Dexion’s warehouse design for Kimberly-Clark’s Erskine Park and Millicent National Distribution Centres featured a Multi-Deep storage system which doubled the number of stacked pallets to ‘four deep’.

This not only maximised storage capacity on the available footprint, it did so with a much lower roof height. A lower roof design achieved lower construction costs and resulted in a saving of more than 30% on equipment and whole-of-life maintenance.

One example of Dexion’s smarter thinking. We have warehouses full of them. www.dexionsmarterthinking.com.au

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EndeavourAWARDS

Read more online at manmonthly.com.au/awards

Bold steps make manufacturers brave After eight years and almost 100 times as many entries, the 2011 Manufacturers’ Monthly Endeavour Awards has reached a whole new level of prestige – and roused the interest of Canberra to boot. Sarah Falson writes.

O

VER 300 manufacturers gathered at the RACV Club in Melbourne on 25 May – the biggest turnout ever – to celebrate Australian manufacturing innovation and excellence. Not surprisingly, ‘carbon’ and ‘tax’ were the words of the night, and every guest speaker had their say.

Federal Opposition Leader Tony Abbott asked the industry to support him in his fight against the proposed tax; Innovation Minister Senator Kim Carr encouraged delegates to work towards leading the world in cheaper, cleaner production; and Holden executive director of manufacturing operations Martyn Cray claimed the government doesn’t throw enough support behind manufacturing.

“This is a very bad tax. It can’t be fixed, it has to be fought and if it’s not fought the manufacturing sector in this country, I regret to say, is almost certain to die and I think this is as stark as that, the choice you face: do you fight or do you die?” said Abbott.

“The introduction of the carbon price will attract investors to those opportunities. And every cent of the revenue we raise will be used to help our people and industries adjust to the new economy,” said Senator Carr.

“Manufacturing needs support from the government. I’ve worked around the world, and governments all around the world support manufacturing – don’t let this government tell you anything different,” said Holden’s Cray.

“The government is carefully considering the price of carbon to make sure there are opportunities for [Australian] manufacturers as the country moves to a low-carbon economy along with the rest of the world,” said Parliamentary Secretary for Climate Change, Mark Dreyfus.

But perhaps the most moving part of the evening was the story of Holden’s new small car, the Cruze, told by Cray. The Elizabeth plant in South Australia went from manufacturing the Monaro at 50% production levels in 2008 to producing the Cruze today – including plastic parts, precision parts, and main assembly – which has been so well-received by the Australian public that the factory will raise its output from 430 to 480 Commodores and Cruzes next month. A mighty positive story about Australian manufacturing.

“About two and a half years ago, it was a pretty dark time for the auto industry, and a dark time for people in Holden as well. But the Holden senior leadership team made a decision which some people thought we were absolutely

22 JULY 2011 Manufacturers’ Monthly

Federal Opposition Leader Tony Abbott calls for support in his fight against the carbon tax.

“To be successful, manufacturers have to take bold steps. I would encourage you to keep on taking those bold steps to ensure that manufacturing is secure here in Australia.” – Martyn Cray, executive director manufacturing operations, Holden. crazy to do. We announced that we were going to start making a small car in Australia,” he said.

“There were sceptics, there were critics, there were a lot of people saying we couldn’t pull it off. But General Motors and the Holden senior leadership team thought otherwise, and the result that we’ve just launched that car, with support from the government and our trade union colleagues as well, is testament to the confidence that the team has in this workforce.

“In late 2008, make no mistake, it was make or break time for Holden. Not many people know that, but it was tough. There were questions about whether we’d be part of General Motors; there were newspapers saying we were going to be bought by the Chinese. But the Holden leadership team had confidence in its workforce, it has confidence in Australia, and confidence in the Australian public that it would buy a small car that was built in Australia.

“It took a very bold step and my words to you are: to be successful, manufacturers have to take bold steps. I would encourage you to keep on taking those bold steps to ensure that manufacturing is secure here in Australia.”

From late 2008 to January this year, the Holden maintenance and engineering team completely remodelled the Monaro bodyshop for Cruze production. They installed 22 new robots, they refurbished 48 robots, and they installed an entirely new assembly line – an assembly line that now puts together a Holden Commodore, which includes 3,500 parts, in 100 seconds flat.

The refurbished factory works in one-piece flow, producing cars only to meet customer orders, meaning it is very lean and efficient.

The Holden Cruze saved Holden in Australia.

The story of Holden is testament to the ingenuity and power of Australian manufacturers.

The Endeavour Awards exist to bring these stories to the public.

Congratulations to all the winners of the 2011 Manufacturers’ Monthly Endeavour Awards, and thank you to all 300 guests, speakers and sponsors who helped make the 2011 Awards the best ever. The following 23 pages tell their stories. Together, we are raising the bar for Australian manufacturing. www.manmonthly.com.au/awards manmonthly.com.au

.

EndeavourAWARDS Environmental Solution of The Year Award – 2011 Winner

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Sick plant finds an energy-efficient cure The move to energy-efficient manufacturing has seen a major transformation at Longwarry Food Park, with the Saurin Group winning the Environmental Solution of the Year award. By Margaret Tra & Alan Johnson.

SAURIN’s decision to purchase the long-neglected Longwarry dairy plant from Bonlac Foods in 2001 and transform it into a modern energyefficient plant has won it an Environmental Solution of the Year award.

Rakesh Aggarwal, the Saurin Group’s managing director, accepted the award, thanking Manufacturers’ Monthly and sponsor Atlas Copco for recognition of this major upgrade.

“Longwarry Food is conscious of the environment and takes it seriously. We have implemented a range of measures to protect our environment,” he said.

“We as a company are determined to save water and reduce carbon emissions in our production processes, whether there is a carbon tax or not.”

Located in the regional part of Victoria, Gippsland, the plant had been closed since 1997 when Saurin bought it in 2001.

The plant was in poor condition, and according to Aggarwal, it was run down, using old technology, and was no longer economical to operate.

Since then, the plant has been upgraded from 2.3 million tonnes per hour of product to 4.3 million tonnes per hour, using in-house technology producing full cream milk powder, fat filled milk powders and a variety of dairybased products.

According to Aggarwal, Saurin has increased production at the Longwarry plant by 300%.

“We have reduced our greenhouse gases by 25% and water usage by 40% on unit consumption basis. Our cost of energy has decreased from $122MT in 2005–06 to $97.50MT. This is despite significant increases in cost of energy from our suppliers,” he said.

As part of its ongoing upgrade program, the company recently installed a fresh milk line under the Gippy brand, and will be promoted on the back of Gippsland’s clean and green image.

Longwarry Park also has a new UHT production line being installed, which is scheduled for commission this month.

At present the plant exports to 30 different companies around the globe. From a $1 million turnover in 2001 to 2002, it has grown to approximately a $75 million turnover in 2010 to 2011.

Surviving in a competitive industry, the company’s objective over the next three years is to grow the operation to be a $200 million business.

24 JULY 2011 Manufacturers’ Monthly

Saurin’s Rakesh Aggarwal, pictured accepting the Environmental Solution of the Year award from Chris Hunter, business line manager with Atlas Copco, which is this year’s official sponsor of the award.

Saurin aims to achieve this by expanding plant capacity from 4.3MT/hr to 6.0MT/hr utilising newly installed milk bottle line for the fresh pasturised milk and the installation of sweet condensed milk plant to occur in this month (July).

Amongst its changes reduction in wastage, plant optimisation, water consumption reduction, energy conservation have been Longwarry’s regular targets.

“We have been successful at reducing all these year after year,” said Aggarwal.

“We continuously invest in Research and Develop to improve plant efficiency, process automation and productivity,” he said.

In one year, the company has successfully improved and completed several tasks which include; control of viscosity for improving plant efficiency, control glass transition point to reduce the dryer temperature, increase efficiency by optimising temperature and improving product wettability.

Ausindustry has granted Longwarry Park with a $500,000 grant to reduce energy consumption to match the best practice; the company anticipates completing this in 18 months.

Several challenges were faced when the changes were implemented, Longwarry noticed

that the milk supply in Australia is declining and it currently competes with 13 companies for milk.

Despite this it has managed to grow its Compound Annual Growth Rate (CAGR) 30% in milk supply.

According to Aggarwal, milk powder is a commodity and the company has to manage the volatility of world markets.

Its solution is to have reliable customers and build long term contracts.

Aggarwal says the plant is being continuously upgraded and has achieved significant reduction in greenhouse emission.

“The 2008 BRW Award for Excellence in Environmental Practices, the Australian Greenhouse Office award for Environment and Energy Management and the SP AusNet Business award for Sustainability are recognition of Longwarry Food Park’s efforts,” Aggarwal said.

The judges said the decision to revive the plant and make it energy efficient has proved to be victorious. “Whilst competing with bigger industries, the Longwarry group are doing wonders,” said the judges.

Saurin Group and Longwarry Park 03 9646 6771, www.longwarry.com manmonthly.com.au

The environment is in safe hands with Atlas Copco Compressors

For the sixth 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.

As a founding member of the Endeavour Awards (currently in it’s 8th year), we are once again proud to be a sponsor of the Environmental Solution of the Year award and would like to congratulate the winner, Saurin Group and Longwarry Food Park.

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

EndeavourAWARDS Safety Scheme of The Year Award – 2011 Winner

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Paper mill’s focus on safety pays dividends A Victorian paper mill complex has been awarded this year’s Safety Scheme of the Year trophy at the 2011 Endeavour Awards for a smart new approach to safety in the workplace. Alan Johnson reports.

AUSTRALIAN Paper’s Maryvale Mill, Australia's largest integrated fine paper-making and packaging papers complex, has won this year’s Safety Scheme of the Year Award for its Refresher Training Toolbox 24/7 safety scheme.

Peter Freeman, Australian Paper’s MHF Compliance Officer, accepted the Endeavour award at the official ceremony on 25 May in Melbourne, saying he and his team were very proud of the decision made by the expert judging panel to recognise the measures the company went to to make a safer workplace.

“In fact all the finalists here in the safety category are winners; we all stop people getting hurt,” Freeman said on the night.

Located in the heart of Gippsland, Victoria, 160 kilometres east of Melbourne, the Maryvale Mill was built in 1937 and has been upgraded periodically over the years to improve efficiency and environmental performance.

The paper mill produces more than 500,000 tonnes of paper every year, with much of the fine paper output sold in Australia and New Zealand – including popular brands like Reflex and Australian Pure White.

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

“The problem facing Maryvale was how can we train and/or inform and reinforce basic knowledge from previous and new safety training sessions, 24 hours a day, seven days a week to a workforce of approximately 1000 personnel made up of 24 hour shift workers, day workers, administration staff,” Freeman told Manufacturers’ Monthly.

“For example, an employee has sustained a twinge in their back while carrying out a task and has reported the twinge to the First Aid centre. We report all injuries no matter how slight.

“The injury is recorded and the employee is deemed fit to return to work.

“However, before the employee returns to work, an employee has the ability to complete one of our new online Toolbox training and information sessions which show the employee the basics in musculoskeletal of basic handling techniques to reinforce previous training sessions.”

He explained the Toolbox session is recorded with the employee’s name, time and date of completion of the toolbox and automatically 26 JULY 2011 Manufacturers’ Monthly

Australian Paper’s Peter Freeman accepts the Endeavour’s Safety Scheme of the Year award from David Duncan, managing director of SICK and sponsor of the award, for the company’s Refresher Training Toolbox 24/7 scheme.

placed as a record of training in the employee’s training database. It also has the ability to printout the material contained within the program, with provision to make notes.

“A PRO Active application of this Toolbox training and information session is another OH&S tool for managers and supervisor carrying out their safety day training or a safety Toolbox sessions on area related OH&S concerns,” said Freeman.

“Let’s say the topic is eye safety. They can play one of the three toolboxes on a projector with the ability of pre-printed handouts for group discussion and this information session can also be recorded within each employees’ training database.”

Another advantage of the system is that sometimes – for whatever reason – an employee may not be able to attend a safety training day.

That employee can still complete the information from the toolbox on-line at a convenient time, with the results again recorded.

Freeman explained that there are 71 Toolbox sessions available live, 24/7, and that the Toolbox has had over 1,200 completions after just 12 months online.

“We have just added a number of videobased toolboxes, thanks to the kind people at

Worksafe BC who have given us permission to use some of their videos,” Freeman said.

“These are based on the same concept and record keeping and are committed in 2 to 3 minute video clips that can be viewed as a whole program over a full round of shifts, when employees have the time available. They are also online and available 24/7.”

Most Toolboxes have a printable PDF file of their content and where applicable questions and interactive answers are used.

According to Freeman, the cost-effectiveness of the programs has delivered a return on investment that is very high.

“Not only have we been able to recycle training material which in its original form can cost up to two to three thousand dollars in the time spent to putting a training package together, but we created the ability for each employee to do these Toolbox sessions online, without any overtime or cover required,” Freeman said.

The judges were impressed with the simplicity of the system, and its uptake, saying ”the Refresher Training Toolbox 24/7 takes safety to a new level“.

Australian Paper Maryvale 03 5136 0653, www.australianpaper.com.au SICK 03 9497 4100, www.sick.com/au manmonthly.com.au

EndeavourAWARDS

Australian Consumer/Trade Product of The Year Award – 2011 Winner

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Consumer wizard takes award Seeley International demonstrates that entering the Australian Consumer/Trade Product of the Year category at the Endeavour Awards on an annial basis really pays off, Margaret Tra & Alan Johnson report.

FOR THE second year running, Seeley International has taken-out the Australian Consumer/Trade Product of the Year award at the annual Endeavour Awards, this year for its Climate Wizard product.

Known for its technical innovation and product leadership, Seeley is Australia’s largest air conditioning manufacturer.

Seeley International’s Founder and Chairman, Frank Seeley, accepted the award at the official ceremony on 25 May in Melbourne from sponsor Phalanx Consulting Group, and acknowledged the judges’ hard work.

“Ladies and gentlemen, the first thing I would like to do – and I would like to do it from the bottom of my heart – is to thank the judges.

They have done a wonderful job,” said Seeley.

“It has nothing to do with the fact that we are the winner. It has to do with the high calibre of the entrants.

“We have a product which can provide air at the quality of air conditioner with the tenth of the price. We can do anything you want, if you want it domestic or industrial.

“We’re incredibly excited about Climate Wizard and what it means for the industry, so it’s fantastic to receive this level of recognition for the product, its innovation and its energy efficiency.

“The Climate Wizard is a new way of cooling and is like nothing the world has seen before.

For the first time, we can cool even the hottest climates in the world and reduce energy use.

“Climate Wizard is dramatically different to traditional, direct evaporative cooling, in that it is capable of delivering much colder temperatures without adding any additional moisture to the conditioned space.”

The Climate Wizard was released internationally for commercial sale in 2010. The unit is an indirect evaporative air conditioner which works by drawing in hot outside air and passing it through a series of wet and dry channels.

This allows for natural evaporation to cool the air, and warm air is then expelled while cool air is delivered into the building.

According to the company, this approach is similar to traditional evaporative cooling because it contains no synthetic refrigerants and uses only water and moving air to cool the room.

Climate Wizards uses a single, electric motordriven fan, a water management system and a water distribution system.

28 JULY 2011 Manufacturers’ Monthly

Seeley International’s Frank Seeley (left) accepting the Australian Consumer/Trade Product of the Year award from Michael Dietrich, managing director of Phalanx Consulting Group, and official sponsor of the 2011 award.

A revolutionary new technology, the ultra high-efficiency counter flow heat exchanger, allows the Climate Wizard to use natural evaporation to cool the air, but not to add any moisture.

The cold air produced by the product can be equivalent to that produced by refrigerated systems, with temperatures that approach the ambient dew-point temperature.

According to Seeley, the air delivered into the building is cold and has no added moisture.

The entering cold air removes the heat within the building and is then exhausted to the atmosphere.

It then can be used on its own, to provide stand-alone cooling, or in conjunction with existing refrigerated systems in a bid to slash energy use and reduce load on the plant.

Existing installations include data centres, food processing plants, offices, factories, warehouse, supermarkets, leisure centres and education facilities.

It can be used in three different configurations and a range of applications – whether it’s a new building or an existing one. All three configurations are said to deliver significant energy savings and reduce greenhouse gas emissions.

Since its launch in 2010, Seeley has sold an

astonishing 63 units with sales revenue of over $580,000.

Within the next few years, the launch of the new residential Climate Wizard should continue to contribute to company revenue.

The product has also facilitated installation in establishments such as Bolton University (UK), University of Adelaide and Australian National University Canberra.

Seeley said the company has always subscribed to the notion that a good portion of business turnover should be dedicated to product and process research and development.

“Over the years, this has typically been around 5% of turnover and, as a result, the technology base of the company has expanded to include many technical skills in innovation, design and manufacturing,” Seeley said.

The judges said the Climate Wizard was a great product as it is not only practical for consumers, but also for industrial applications.

“It not only saves costs and it is also energy efficient. Seeley’s ground breaking technology will see them succeed in this market,” they said.

Seeley International 08 8328 3850, www.seeleyinternational.com Phalanx Consulting Group 1300 731 245, www.phalanxgroup.com.au manmonthly.com.au

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EndeavourAWARDS Australian Industrial Product of The Year Award – 2011 Winner

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Hoshizaki heats-up at the awards Hoshizaki Lancer heated-up the Endeavour Awards this year with its Ecco Heat heat recovery system, winning the Australian Industrial Product of the Year award for its efforts. Margaret Tra & Alan Johnson write.

AN ADELAIDE-based manufacturer specialising in professional food service refrigeration units and heat recovery systems, Hoshizaki Lancer, has taken this year’s trophy for the Australian Industrial Product of the Year for its Lancer Ecco Heat system.

Managing director, Joe Thorp, accepted the award on behalf of Hoshizaki Lancer at the official ceremony on 25 May in Melbourne, claiming he and the company greatly appreciate being chosen for the gong.

“This product is very significant to our company. It’s free hot water from a system, providing less than one year payback,” he said.

Thorp made a special mention of Frank Seeley and Seeley Products International, winner of the Consumer Product of the Year award, during his acceptance speech.

“I worked with Frank Seeley for five years and I would like to thank him. He’s been an inspiration to me. He is a great leader. I would like to acknowledge him for what he has done,” Thorp said.

The Lancer Ecco Heat system is a de-super heater that captures the waste heat from refrigeration systems and converts it to free hot water through a tube-in heat exchanger.

According to Thorp, up to 20% of the energy input to the considering unit can be reclaimed through hot water generation.

“We have taken the de-superheat principle and applied it to existing refrigeration systems.

This is coupled to a circulation system designed to generate hot water,” said Thorp.

The product units match refrigeration units in cool rooms or air conditioners and are suitable for businesses ranging from small convenience stores to supermarkets, convention centres and hotels, according to Thorp.

The units are designed to have a rapid payback period, depending on the capacity of the refrigeration plant and the number of tanks to be heated.

“Ecco Heat provides an approximate oneyear payback, which is a significantly shorter period than solar hot water,” he said.

In addition, it can also be scaled up as businesses grow or add refrigeration capacity.

Though the principal behind the Ecco Heat product is relatively simple, significant work went into ensuring the units were easy to retrofit to existing air conditioning air units and compatible with new air conditioning products.

According to Thorp, the new unit fits a niche 30 JULY 2011 Manufacturers’ Monthly

Hoshizaki Lancer’s managing director, Joe Thorp (left), accepting the Australian Industrial Product of the Year award from Ian Stone, managing director of Advance Metal Products, and official sponsor of the award category.

in the market by exploiting an existing waste produce (heat). He says they also have a quicker payback period than other environmentallyfriendly water heaters on the market.

Lancer has recently signed an exclusive distribution agreement with Actrol for Australian distribution, while trials are also underway for deployment in Indonesia.

These distributions are expected to result in a significant increase in work; the Ecco Heat products are all produced in Adelaide.

Lancer employs 90 people at its Beverley, South Australia facility, which includes a factory producing some 120,000 machined parts a year together with tubing ‘python’ glycol chillers, founts and beer taps.

Customers include Coca-Cola Amatil, Schweppes, Lion Nathan, Fosters, Coopers and many more.

One of the company’s largest installations has been the Sydney Olympic Stadium (ANX Stadium), which has 42 four-way Multifills and 114 two-way Cobra founts, making a total of 396 beer taps. The system also includes 10 Glycol chillers and nine kilometres of tubing python.

On the Stadium’s opening night, the system comfortably coped with demand as patrons

consumed 90,000 litres of beer, or 1,800 50-litre kegs.

The company’s revenue is approximately $40 million-a-year, and Lancer recently achieved a rare ‘triple crown’ by simultaneously being awarded ISO 9001 accreditation for a quality management system, ISO 14001 for sound environmental performance and AS 4801 for safety management, following an independent examination of its Integrated Management System.

Thorp said the company has focused for many years on making its products and processes as environmentally compliant as possible.

“In particular, we have sought to reduce the energy consumption and carbon footprint of our flagship products, the Lancer S4 and S8 Soft Drink Superchillers and a heat exchange system designed to generate hot water from waste heat from refrigeration units, now known as Ecco Heat,” he said.

The judges described the Ecco Heat system as an innovative energy saving device.

“An excellent product to drive the industrial industry,” they said.

Hoshizaki Lancer 08 8268 1388, www.lancerbeverage.com Advance Metal Products 02 8796 6222, www.advancemetal.com.au manmonthly.com.au

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EndeavourAWARDS Australian Steel Innovation Award – 2011 Winner

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J. Smith & Sons steel the award J. Smith & Sons took-out the Australian Steel Innovation award for its Smith Hydrapede project, which was designed to fill a gap in the mining industry. Margaret Tra & Alan Johnson report.

J. SMITH & Sons’ Mk4 Hydrapede Dolly has filled a noticeable gap in the mining industry, in particular the mine haulage equipment market, and as a result has taken-out this year’s Australian Steel Innovation award at the Endeavour Awards 2011.

According to the company’s managing director, Kerren Smith, who accepted the award at the official Endeavour Awards ceremony on 25 May in Melbourne, the increasing number of satellite mines across Australia has increased the need for vehicles that are capable of hauling large amounts of resources over long distances.

Thanking Manufacturers’ Monthly and BlueScope Steel for the recognition, Smith also gave thanks to the company’s engineering team members for all their hard work.

“I am third generation and I am proud to say that we only use Australian made steel,” he said.

“With a wonderful sense of irony, the Mk4 Hydrapedes are hauling the rich Australian iron ore similar to that used to manufacture them.”

Smith said the company began developing the Hydrapede in 2000 after discovering that there was not a vehicle on the market that could adequately service the increasing incidence of satellite mines across Australia and the long distance haulage capabilities they demand.

“The mining industry was left with wide bodies which demanded larger, more expensive road infrastructure and maintenance, and short distance haulage capabilities due to larger tyres,” said Smith.

“The Smith Mk4 Hydrapede Dolly was designed to fill this market, to provide increased payload and faster average haulage speeds.”

According to Smith, the Dolly has four key advantages over other alternatives which include: high payload of 400t, narrow build, fast average hauling speed and long distance haulage capability.

The high payload capacity increases operational efficiencies; the narrow build decreases the required road width thus decreasing infrastructure costs; the faster average hauling speed further improves operational efficiencies; and the long distance haulage capability makes what was previously not possible, possible, Smith said.

The Dolly has been commissioned at the West Turner Syncline Mine in Western Australia, and is an improved design of the previous Mk3 concept which are operating in Queensland.

The project contributes 20% to the compa32 JULY 2011 Manufacturers’ Monthly

J. Smith & Sons’ Kerren Smith (left) accepting the Australian Steel Innovation award from Steve Gregson, acting general manager of Bluescope Steel, and also sponsor of the Steel Innovation award at the 2011 Endeavours.

ny’s profits per unit sold. It has reportedly ensured that employment has been maintained at J. Smith & Songs during difficult economic periods in recent years, and has actually made provision for additional employment of 10 staff members in 2011.

In addition, it has forged a vital network of sub-contractors within the local economic region as it required local third-party companies to undertake aspects of the project.

After several attempts, it has taken four versions of the Hydrapede dolly to get the Mk4 to what it is today.

The first Mk1 Hydrapede was developed with an east-west engine, mounted at the front of a trailer and transmission mounted underneath the trailer chassis.

According to the company, this configuration was used successfully as a pit haul unit, and modifications were later made to the unit to make it ‘high speed’ enough for long haul applications.

In 2007, a second Hydrapede was developed to improve the Mk1 dolly in regards to the long distance haul capability of the Mk1 unit.

Mk3 Hydrapede was introduced to the market in 2009, developed with a different engine and the addition of a lazy axle to improve the pay-

load capacity of the units. The new engine meant redevelopment of the system software was in order.

The Mk4 Hydrapede Dolly has been developed on the back of a successful take-up of the Mk2 and 3 Hydrapede Dollys. Orders were placed for four Mk4 units prior to the completion of their design, making provision for further research and development of the concept.

These units were successfully commissioned in 2010 and are currently operating in Western Australia, servicing the needs of bulk long-distance haulage in the harsh Australian outback.

According to Smith, the company’s sales team has recently received enquiries for the purchase of five more Hydrapede units.

A Mk5 Hydrapede Dolly concept is currently in design and this design concept will be taken to Western Australia’s Next Generation Mining Summit.

The judges described the Mk4 Hydrapede Dolly as a well though out and executed product. “The company found a hole in the market, and decided to fill it with an innovative dolly,” said the judges.

J.Smith & Sons 07 5482 1166, www.smithson.com.au BlueScope Steel 1800 800 789, www.bluescopesteel.com.au manmonthly.com.au

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At the core of Australia’s manufacturing future

At BlueScope Steel we believe in excellence. It’s at the core of our business and vital for Australia’s manufacturing future. That’s why we proudly support the Endeavour Awards; because through recognising and supporting excellence in Australian business we’re helping exceptional people achieve their very best. That’s good for Australia and the future of our manufacturing industry. © 2011 BlueScope Steel Limited (ABN 16 000 011 058). BlueScope is a trade mark of BlueScope Steel Limited. BIM0697 05/11

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EndeavourAWARDS Global Integration Award – 2011 Winner

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Quickstep fast on its feet with double wins Quickstep Holdings, specialist in advanced materials manufacturing, has twice as much to celebrate, winning the Global Integration Award, plus Manufacturers’ Monthly’s Manufacturer of the Year Award. By Alan Johnson.

BY TAKING-out the Global Integration Award, plus being crowned Manufacturers’ Monthly’s Manufacturer of the Year for 2011, Quickstep Holdings proves that Australian manufacturers can successfully compete against the best in the world.

As part of the F-35 Joint Strike Fighter program, the largest military aerospace program in the world, Quickstep has successfully overcome the many entry barriers faced by new participants in the defence manufacturing sector, possibly the highest of any industry in the world.

Managing director of Quickstep, Philippe Odouard, said the receipt of the Global Integration Award and the Manufacturer of the Year Award for 2011 was an outstanding achievement for the company, and a testament to the hard work of the Quickstep team.

“We are delighted to have been recognised for our work on the Joint Strike Fighter program, and would like to pay tribute to each of the company’s team members for their vital contributions,” he said.

The company has recently signed a long-term agreement with Northrop Grunman, providing a framework for the supply of JSF components.

“This contract will be the first of many to come,” he said.

Quickstep has significant capabilities and expertise in the production of aerospace-grade composite components using both conventional autoclave-based manufacturing and leading out-of-autoclave production technologies, including the company’s Quickstep Process.

At present, the company generates revenue from three distinct business streams: manufacturing advanced aerospace-grade composites at our Australian manufacturing facility; licensing its patented manufacturing technology for advanced composites – the Quickstep Process; and through R&D on new composite structures.

The company has a fully-commissioned aerospace-grade manufacturing facility located in North Coogee, Western Australia, and recently announced plans to relocate its manufacturing operations to Bankstown, in the western suburbs of Sydney, to a new facility that offers the scale, resources and utilities necessary to undertake large-scale, long-term aerospace manufacturing contracts.

In addition to its Australian operations, Quickstep also has facilities in strategic global locations including North America, Europe and the UK. 34 JULY 2011 Manufacturers’ Monthly

Quickstep’s Philippe Odouard (left) receiving the Global Integration Award from David McLachlan, ICN chairman, sponsor of the award. Quickstep also went on to win the prestigious Manufacturer of the Year award for 2011.

The company is currently partnering with some of the world’s largest aerospace/defence companies, including the US Department of Defense, Lockheed Martin, Northrop Grumman, Boeing, Airbus and EADS. Quickstep commenced targeting JSF manufacturing contracts in June 2009, and in November 2009 signed a Memorandum of Understanding with lead JSF contractors, Lockheed Martin and Northrop Grumman, for the supply of up to $700 million of components over 22 years.

Quickstep then embarked on prepartions to its manufacturing facility for JSF manufacturing, with Northrop Grumman stipulating that Quickstep must be fully enabled to manufacture demonstration and qualification panels for JSF

by October 2010.

Quickstep has since met every interim deadline set by Northrop Grumman, and in February 2010 signed a Long Term Agreement providing a formal framework for supply.

As well as overcoming the highest barriers to entry of any industry in the world – the qualification processes are exhaustive and new entrants generally take many years to gain approval as suppliers – Quickstep has other hurdles to jump.

With best practice procedures paramount, Quickstep had to achieve AS9100 international aerospace quality standard for its manufacturing facility and was subjected to rigorous quality control testing at every stage of the manufacturing process.

The company also had to meet all deadlines set by Northrop Grumman despite administrative delays from US Department of State.

Following an exhaustive approvals process, Quickstep signed a Long Term Agreement in relation to JSF manufacturing in February 2011.

Investment risk included the significant costs incurred in preparing the company’s manufacturing facility and training staff members for JSF manufacturing without a formal contract having been signed.

The Long Term Agreement provides a formal framework under which Quickstep will participate in an international supply chain for the production of F-35 composites subassemblies.

The Endeavour judges had high praise for the way the company has grown so quickly.

“Quickstep Holdings overcame overwhelming expectations triumphantly,” they said.

Quickstep Holdings 08 9432 3200, www.quickstep.com.au ICN 02 6285 2033, www.icn.org.au manmonthly.com.au

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EndeavourAWARDS Exporter of the Year – 2011 Winner

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Exporter’s one-stop-shop in Asia The Aunew Group’s one-stop-shop program, designed to help exporters tackle the Asian market, has won the Endeavour’s 2011 Exporter of the Year award for excellence, writes Margaret Tra & Alan Johnson.

AUNEW Group Holding’s ‘One Stop OEM services’ concept, designed to help exporters reach the booming Asian market, has seen the company win this year’s Endeavour Exporter of the Year award from Manufacturers’ Monthly.

Currently, the company is focusing on six categories of Australian and New Zealand products including health foods, bee products, infant and baby care, wine and foods, skin care, wool and leather.

Under Aunew’s franchising plan, these products are organised into six Aunew promotional shelves as a package and introduced into Chinese retail outlets such as shopping malls, supermarkets, airports and gymnasiums.

Managing director Karl Ye who accepted the Exporter of the Year award at the ceremony in Melbourne in May said it’s a big encouragement to receive the award.

“Selling Australian-made products overseas can be hard. Regulation, distribution and logistics are some of the issues,” he said.

“We have successfully developed a system to fix the issue, which is much easier. It’s to show companies the resources that are available.

“As most of the products have very complicated regulation issues to export to China, we have a professional regulation team acting on behalf of those who intend to develop their products into the China market to get their brand/products registered with authorities.

“As well, our professional team work closely with Chinese customs, inspection and quarantine offices to make clearance and smooth pathway and logistics in a fluent function.

“We also have tailor-made bonded warehouse for the protection of goods. Some of these products are very climate- and environmentsensitive, and need very dedicated care during each step of export and distribution.

“Aunew arranges dedicated warehouses in Australia, New Zealand and China, with temperature-controlled and monitored warehouses and container or airfreight to China, which minimises the quality climate impact during long-distance transport.”

The company consists of its Therapeutic Goods Administration (TGA) licensed pharmaceutical plant – GMP Pharmaceuticals Australia located in Girraween, Sydney and GMP Pharmaceuticals located in New Zealand.

It also has offices and wholesale/retail stores in Beijing and Shenzhen, a bonded warehouse in Tianjin port, a regulation and distribution team 36 JULY 2011 Manufacturers’ Monthly

Aunew’s Karl Ye (left) accepting the Exporter of the Year gong from Jonathan Reso, managing director of EFIC and sponsor of the 2011 award, for making it easier for Australian businesses to export to China.

in Beijing, a distribution office in Hong Kong and a new office set up in Yiwu city in China.

Aunew is an exclusive distributor for many Australian and New Zealand brands including Edenvale alcohol-removed wine, Mothernest health foods, NZVE Honey, URAS dairy and Mindell health foods.

The number of SMEs to export their products to China supported by the company’s One Stop Export to China system has increased from last year’s 40 companies to the current 60, a 50% jump forward.

One Stop Export to China has also officially launched its franchising program at CISMEF (China Int’l SME Fair) in Guangzhou China, with a target to set up 1,000 Aunew stores to market and sell a range of Australian-made products.

“By using One Stop Export to China, we have not only increased export of our own products but also products from other Australian companies such as Penfold’s wines, wool quilts, UGG boots, kangaroo leather hats, and Australian honey/bee products,” said Ye. At present there are over 20 stores planned in major cities including Beijing, Shanghai, Tianjin, Dalian, Zhengzhou, Fuzhou and Yiwu.

Aunew employs approximately 300 people, which is a 19% increase compared to last year,

with most of them in Australia and New Zealand. The company is the largest contract manufacturer in Australasia for the Chinese and other South East Asian health food/supplement market.

The total turnover of the company has now reached $50 million, a 25% increase compared to last year, with export to Asia (directly or indirectly) also increasing accordingly.

The two factories in Sydney and Auckland were set-up for the main purpose of contract manufacturing for those interested in buildingup their own brands of products for sale locally or in South East Asia.

With strong beliefs in marketing and promoting Australian made products, Aunew in collaboration with Australian Made Australian Grown Campaign, launched and published the first edition of ‘Directory of Australian Made Products in China 2010’ at CISMEF and various Austrade offices in China.

The judges said Aunew Group Holdings has a smart strategy from end to end.

“Exporting to China is no easy feat. The company is to be congratulated on a fine achievement,” said the judges.

Aunew Group Holdings 02 9264 1199, www.aunew.com EFIC 1800 887 588, www.efic.gov.au manmonthly.com.au

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EndeavourAWARDS

Enterprise Connect Significant Achievement Award – 2011 Winner

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Integra Systems bigger and better The decision to re-locate to a bigger facility has won Integra Systems the 2011 Enterprise Connect Significant Achievement gong at the Endeavour Awards. Margaret Tra & Alan Johnson write.

WITHIN nine months of re-locating to larger premises, an essential strategic move after an Enterprise Connect review, Integra Systems has won the Enterprise Connect Achievement of the Year award at the 2011 Endeavours.

Integra Systems, an engineering and manufacturing solutions provider, supports customers with product development and manufacturing services which focus on steel.

Managing director Paul Hughes, who accepted the award at the ceremony, said he was humbled to receive the award.

“Just to become a finalist, I was happy with that. For over 20 years we have been a mechanical engineering design company. We design and manufacture for the Australian industry with innovative products,” he said.

“Over the past three years we have seen strong growth, moving forward with all the challenges and risks. Enterprise Connect went out of its way to identify our strengths and weaknesses. Through their program we have been able to take control of this business, and not be controlled by others.

“We have achieved our goal of combining our design business and manufacturing into one, with a whole range of innovative products.”

Paul Smarrelli of Enterprise Connect conducted the review in October 2009. He made various recommendations, some implemented from internal resources, and others through Tailored Advisory Services. In 18 months, the company successfully implemented the changes recommended, these included; optimising workflow in the factory, reduced lead times, innovative use of manufacturing technologies and embarking on the Skills for Growth Program.

“Within 18 months there has been a dramatic improvement in the business performance and robustness through: Innovative new products, quality, reliability, flexibility and continuous improvement,” said Hughes.

According to Hughes, this was a key driver in implementing all its strategic business actions.

Currently all the staff at Integra are undertaking Certificate 4 in Competitive Manufacturing.

Integra has also employed a young apprentice who is undertaking Certificate 3 in Process Manufacturing and a welding course.

The company also saw significant transformation in the workforce when managerial changes were made. This was done by increasing management privacy in a partitioned office environment to effectively undertake management 38 JULY 2011 Manufacturers’ Monthly

Integra Systems’ Paul Hughes accepting the Enterprise Connect Achievement of the Year award from Judith Zielke, Head of Division, Enterprise Connect, sponsor of the award.

meetings and private strategic planning and review sessions.

“The company aims to be an ‘Innovative complete solution provider,’ a differentiator by providing the space to undertake a larger volume of high-value-add work, and still allow component manufacturing to continue as our ‘bread and butter’ revenue,” Hughes said.

Integra has invested in new machinery to increase supply capacity, meeting shareholders’ targets for profitability and return on capital employed. According to Hughes, Integra would not have been able to progress with many of the Enterprise Connect recommendations without the relocation.

Under Enterprise Connect’s advice, Integra is currently implementing Activity Based Costing to ensure that all costs are captured correctly and managed. This will ensure the company improves accuracy and competitiveness.

“We have re-structured the chart of accounts to more accurately measure margins and control EBIT. This has been supported by Tailored Advisory Services through consultants Phalanx Resources,” said Hughes.

To gain a further understanding of its target markets it conducted a thorough customer base analysis.

“We did this by withdrawing support to customers that did not meet our strategic direction, in order to focus on core business development drivers that supported our strategy. But at the same time we strengthened and grew our existing customer base, in addition to identifying and converting new customers,” said Hughes.

The Endeavour judges explained that the Enterprise Connect Significant Achiever award is given to a firm that has implemented its Business Review recommendations, increased its capacity and capability, demonstrated improved business processes and embedded these improvements throughout its organisation.

“Transforming the business and moving from increased productivity into an accelerated growth cycle was also a consideration,” the judges said.

“Integra Systems displayed all these characteristics including some radical re-thinking of the way and with whom they do business.”

The judges strongly commended Integra Systems on its abilities to embrace business innovation, a key driver of the Enterprise Connect initiative.

Integra Systems 03 9359 3133, www.integrasystems.com.au Enterprise Connect www.enterpriseconnect.gov.au, 131 791 manmonthly.com.au

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Young Manufacturer of the Year - 2011 Winner

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Young manufacturers taking control Turning Automation Control Systems’ bottom line from a loss position to a month-by-month profit sees Jason Ko win the Young Manufacturer of the Year Award. Margaret Tra & Alan Johnson report.

AT JUST 27 years old Jason Ko is already the chief executive officer (CEO) of Automation Control Systems (ACS).

Over the past six years, Ko has had a positive impact on the company and it is his commitment that saw him take out the Young Manufacturer of the Year award at the 2011 Endeavour Awards in Melbourne.

Ko said it was an honour to accept the award.

“This means a lot to me. I am very fortunate because I love technology,” he said.

“I love inventing things. I am lucky to be in the position I am in, to continue to learn and continue to grow.”

Having signed a new contract, Ko hopes to attend the Endeavour awards next year in the exporting category.

“I hope I come back here next year. We recently signed a new contract and would like to come back if the bankers don’t get me first,” he joked.

In 2005, Ko was ACS’s first engineer, responsible for the company’s products sold in the domestic Australian market.

With the growth of a thriving business, Ko established engineering teams to achieve ACS’s technology products and quickly became the head of R&D and a key decision-maker in the strategic direction of the products.

According to the company, while trying to establish export businesses overseas in 2009, Ko was placed in the position of CEO by the board to reduce company operating costs, and set-up the business to be completely focused on professional engineering, IT and manufacturing.

Ko dissolved the then management structure, slashing the company’s expenses by half.

Since then, he has established overseas distributorship agreements allowing ACS to focus on what it does best which is innovation and removing its need to market and sell the products in a foreign territory.

Within the first calendar year, Ko has turned ACS’s bottom line from a loss position to a month by month profit position, with healthy projections in the coming years.

With a clear strategic direction, hitting financial targets, Ko focused on the company culture of a professional engineering firm, with a strong focus on autonomous, personal success, tapping into the young enthusiastic engineering culture, while ensuring a successful professional environment that cultivates learning and new 40 JULY 2011 Manufacturers’ Monthly

Jason Ko receiving the Young Manufacturer of the Year award from Damian Bridge (right), who is the general manager, southern region, of Skilled, and also official 2011 sponsor of the Young Manufacturer category.

ideas and commercial success.

Outside of industrial projects, Ko was also passionate about profiling work, continually driving the automotive road safety technology effort.

This is shown with his involvement with ACS in the Victorian state government’s ‘Commercial Ready’ project to develop the Intelligent Speed Adaptation technology.

The outcome of the project (SSV4 ISA technology) is now being used in trial projects with the NSW Road Traffic Authority, VicRoads, Transport Accident Commission, and Main Roads Western Australia.

According to the company through ACS, Ko has developed skills in business acquisitions, employment, business-to-business agreements, and government grants, with examples of each area demonstrated in the global arena.

Ko’s specific achievements include managing a $2 million government grant for the development of Intelligent Speed Adaptation Systems, acquisition of Australian Motive Power Systems as the energy division for ACS, acquisition of high-frequency traction battery charger Intellectual Property, plus negotiating a distributorship agreement for ACS products to be exported to worldwide including the US, Canada and the UK.

Today, as CEO of the company, he is responsible for strategic and financial performance of the business.

His role oversees the management team, its direction and objectives of each area covering departments of software development, engineering, production, finance and administration.

Ko sees the position of CEO as far more than just strategic direction and financial performance.

His challenge is to cultivate a fun, innovative, yet commercially-successful culture. He sees this as of the upmost importance to reducing staff turnover, ensuring the company is able to be involved in global negotiations due to its professionalism.

His personal objective is to set up the company in a way which promotes the cultivation of new leaders and new professionals.

The judges were impressed with Ko’s hard work and dedication to the company and said Ko is a natural born leader.

“He has worked his way to the top, and is now reaping the rewards,” they said.

Automation Control Systems 03 8585 9012, www.speedshield.com SKILLED 1300 361 582, www.skilled.com.au manmonthly.com.au

Targeting Excellence has its Rewards.

SKILLED is proud to continue a long tradition as a sponsor of the 2011 Manufacturers’ Monthly Endeavour Awards, Australia’s premier national awards for manufacturing excellence.

We understand the essential role manufacturing plays in Australia’s economy, and for more than 40 years have provided support, expertise and know-how to this important industry sector.

Just like the award winners, targeting excellence is not just a goal, but an action we engage in actively and with over 20,000 people employed daily, we have the experience and capacity to get the job done.

In these changeable economic conditions, it pays to be flexible. SKILLED can deliver strategic workforce solutions that will allow manufacturing companies to reduce fixed overhead costs and increase production levels fast.

To the winners of the 2011 Manufacturers’ Monthly Endeavour Awards, we congratulate you on hitting the bulls eye.

www.skilled.com.au NCASK644

Lifetime Achievement Award – 2011 Winner

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A lifetime achievement for Colin North Colin North takes out this year’s Lifetime Achievement award at the Endeavours for his contribution to Australia’s manufacturing industry. Alan Johnson reports.

MAJOR Furnace Australia was established in 1912, supplying thermal and mineral processing equipment and related services to customers in Australia and overseas.

It designs and supplies large-scale furnaces and process equipment for steel, aluminium and solar grade silicon, cremation and incineration equipment.

Unfortunately, Colin was unable to accept the award in person at the ceremony on 25 May in Melbourne, as he was overseas raising funds for juvenile diabetes research.

However, the company’s managing director, Andrew North, his son, was available on the night to accept the award on his father’s behalf.

“When I was told he had won the Lifetime Achievement award, I was delighted. Over 40 years working in manufacturing and engineering is a long time and to be recognised is welldeserved,” Andrew said.

Colin North joined Major Furnace Australia in December 1970 as a project engineer; his duties involved design, installation and commissioning of specialised furnace equipment.

In ten years he worked on several projects, including the invention of an energy-saving assembly and operating technique for a large industrial afterburner and heat recovery system.

This assembly and operating technique was installed on three pieces of equipment at the same time and found to be highly-successful.

A fourth assembly was also installed several years later.

In 1981, he was appointed project manager and successfully landed the company a multimillion dollar contract with Bechtel to supply aluminium holding and melting furnaces to Boyne Smelters and New Zealand Aluminium.

After these contracts were completed, Colin was then appointed to the role of chief engineer at the company until June 1986, when the descendents of original founders of Major decided to close the business.

Colin’s decision to purchase the business from the shareholders and continue to employ the remaining 22 staff kept Major Furnace Australia in business.

He restructured the company shortly after the acquisition, and with great determination from North, the company was awarded significant industry contracts.

The contracts involved designing and supplying 80-tonne-capacity aluminium tilting for Portland Smelter Services and later, the No 6 42 JULY 2011 Manufacturers’ Monthly

Andrew North (left) receiving the Endeavour’s Lifetime Achievement award, on behalf of his father Colin, from David Delany, managing director, ifm efector, and official sponsor of the 2011 Endeavour award.

continuous Annealing and Galvanising for BHP at Western Port, Victoria.

In 1990, under Colin’s direction, the company developed a new-generation furnace to enable it to re-enter the Australian Cremation market.

Subsequent development has produced models to meet the differing requirements of International Markets in Europe and Asia.

In late 2005, Colin handed day to day operation of the company to Andrew, however Colin continues to have an active role in the company as mentor and senior consultant. Andrew said his father has the rare ability to be both technically excellent and also possess a first rate business sense.

“Whether it be a technical discussion or a contract negotiation, his ability to sum up a situation, logically think through the issues and then provide the necessary resources either himself or via delegation to achieve the result have been an enormous asset to the business,” said Andrew.

“Colin’s mantra to all within the company has been ‘attention to detail’ which is an essential element when designing innovative equipment, especially one off pieces of equipment.”

Under Colin’s leadership, the company has

survived economic cycles by growing and contracting while competitors disappear in the manufacturing market.

Over the years, he has provided a working environment for his staff that sees them stay with the company for decades.

This also provides an opportunity for people to grow both technically and commercially within the company.

The company has had a peak workforce of approximately 250 people, located across five sites, four of which were service branches, with the bulk of the workforce being located at the Clayton facility.

According to Andrew, Colin’s leadership has resulted in the organisation re-inventing itself to better serve the needs of the rapidl- changing manufacturing community in Australia.

The judges noted that without Colin, there would be no company.

“His decision to purchase the company means that the company survived and staff were kept, which contributes to the success of Major Furnace Australia,” they said.

Major Furnace Australia 03 8558 1800, www.majoreng.com.au ifm efector 1300 365 088, www.ifeefector.com.au manmonthly.com.au

Technology Application of the Year Award – 2011 Winner

EndeavourAWARDS

Proudly sponsored by

Read more online at manmonthly.com.au/awards

Robotic system improves safety The Dulux Group has won the Endeavour Awards’ Technology Application of the Year gong for recognition of its robotic hazardous chemicals handling system from Robotic Automation. Margaret Tra & Alan Johnson write.

THE introduction of an automated robotic system to handle hazardous chemicals and improve staff safety has seen Dulux Group, in collaboration with Robotic Automation, win the Endeavour’s Technology Application award.

The Dulux Group has several business units including Decorative Coatings, Selleys, Cabot's, Yates and Powder & Protective Coatings.

While accepting the award, David King, project manager with Robotic Automation, said the robotic system has improved safety by redeploying nine employees from a hazardous and uncomfortable work environment, eliminating OH&S incidents in the process.

As well, through-put has increased by approximately 20% and has allowed Dulux to accept smaller custom batch orders of less than 500kg while remaining profitable.

The previous system involved staff handling and decanting loose, heavy bags of powders in

different sizes weighing 20 to 25kg each in an environment saturated with fine powder dust.

Working together with the engineering team at Robotic Automation, Dulux developed a centralised make-up facility. This facility consisted of a major materials robotic loading system, a minor materials robotic loading system and a SCADA system.

The system is connected to Dulux’s SAP system and staff operated Human-Machine Interface (HMI) touch-screens. The process begins as the SAP system pushes the production schedule down to the database from where the managers can manipulate the batches. The recipes are then pushed to the control system which checks the stock of each powder.

The robots were enhanced with extra body and sealing protection to safely work in a combustible ‘Zone 21’ hazardous environment.

“These three Robotic Chefs (Motoman

Robotic Automation’s David King, receiving the Technology Application of the Year award from Thomas Anderson from Siemens PLM, sponsor of the award.

HP165-100 models) now set about their tasks to stock, handle, pour, mix a perfect powder-coating product to order,” said King.

Robotic Automation 02 8748 6500, www.ragroup.com.au Siemens www.siemens.com/plm

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44 JULY 2011 Manufacturers’ Monthly

innovation becomes that much easier.

Learn more at siemens.com/nx. © 2010 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. NX is a trademark or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks usedherein are the property of their respective holders.

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Most Innovative Company 1961-2011 Award – 2011 Winner

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ANCA remains sharp Leading manufacturer of precision CNC grinding machines, ANCA, takes out the special Manufacturer’s Monthly 50th Anniversary: Most Innovative Company 1961–2011 Award, celebrating longevity. Alan Johnson reports.

THIS year’s special 50th Anniversary: Most Innovative Company 1961–2011 Award was won by the world’s leading precision CNC grinding machine manufacturer, ANCA. Formed in 1974 with just two founders, ANCA now employs over 600 people and is recognised world-wide as the leading manufacturer of precision CNC grinding machines. Company cofounder and joint managing director, Pat Boland, accepted the award in Melbourne on 25 May. ANCA began as a manufacturer of technologically-advanced CNC systems in 1974 with a diversity of customers and applications, including high-speed control systems for packaging machines and complex lathe machining centres.

From this diversity of product ranges, ANCA discovered a niche market in tool and cutter grinders to aggressively move into superior CNC control systems. With this advantage in world class CNC technology ANCA could adapt its

own tool and cutter grinder to many complex applications where competitors with their bought CNCs could not. Such early complex applications can be seen through an ANCA machine for precision grinding automotive steering input shafts, which are a key component in determining the ‘feel’ of a car’s steering.

From this evolution in technology advances, ANCA has marketed itself as a highly robust and flexible manufacturer that will take on almost all complex applications requiring precision grinding throughout the world.

Such an attitude has seen ANCA shift into the medical market, developing and selling machines for highly-accurate knee joints, bone rasps and dental burrs. It has also moved into mining, manufacturing diamond buttons for drill rigs.

“This current financial year is shaping to be the best year in terms of both machines built and revenue since ANCA was formed,”

ANCA’s co-founder Pat Boland (right) accepting Manufacturer’s Monthly’s 50th Anniversary: Most Innovative Company 1961–2011 Award from Alex Coslovich, director – product quality & engineering, NHP, sponsor of the award.

Boland told Manufacturers’ Monthly.

Modern solutions with a timeless service.

ANCA 03 9751 8202, www.anca.com NHP 02 9748 3444, www.nhp.com.au

INDUSTRIAL SWITCHGEAR AND AUTOMATION SOLUTIONS.

NHP has been innovating the electrical industry since 1968.

We provide our customers with the world’s best products, from the best global manufacturers - then customise solutions to suit the local market.

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At NHP we aim for our customers to find “what they want, when, where and how they want it”.

8 196 Sales 1300 NHP NHP

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nhp.com.au

Manufacturers’ Monthly JULY 2011 45

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

High-heat safety gear

Built-in PAC for compressor control

WELD Guard has brought-out a protective winter range of flame retardant clothing, made for workers in industrial settings.

Made from Egyptian cotton, the new range is designed for welding, and is reportedly lighter and more comfortable to wear than traditional frame-retardant clothing on the market.

The range includes jackets, bibs, welder caps and neck flaps, and each model comes in either navy, yellow or grey colour.

For heavier industrial jobs, Weld Guard has a line of heat-resistant clothing made from leather, Parrawool and an aluminised range that can reportedly resist temperatures of up to 400°C. The aluminised range is specifically designed to resist radiant heat and includes jackets, overpants and aprons. The jackets are lined with a wool-blend blanket to further enhance the heat resistance.

BOC 03 9287 8203, www.boc.com.au

The range is designed to protect welders.

Small, oil-free compressor BOGE has released a new oil-lubricated screw compressor called the S 40-2 BLUEKAT, with a built-in converter, designed specifically for small and medium-sized compressor applications.

The new model is said to be a more cost-effective solution than other, larger units on the market.

BLUEKAT’s built-in converter reportedly removes all residual oil aerosols contained in the compressed air, while breaking the hydrocarbon chain into carbon dioxide and water.

The residual compressed air produced meets the quality requirements of ISO 8573-1 Class 1 and Class 0.

The compressor is available in the standard pressures of 8-, 10- and 13bar, with output capacities ranging from 3.71–5.01m3/min, and motor power at 30kW. BOGE Compressors 08 9528 2157, www.boge.net.au

CAPS Australia is now offering a range of R-Series 90-160kW rotary screw air compressors from Ingersoll Rand, with built-in PAC technology.

The PAC protects the equipment and prevents unnecessary or emergency shutdowns of production lines caused by extreme situations or maintenance oversights.

PAC continually monitors key components and operating parameters and adjusts these to prevent unexpected downtime.

The R-Series comes in four standard variants, designed to suit the load profile and duty required. A fixed-speed and variable-speed model is available, the latter incorporating a Nirvana Hybrid Permanent Magnet motor.

CAPS 03 8527 6815, www.capsaust.com.au

Inventory control software The compressor removes all oil aerosols in the compressed air.

Press fit monitor for complex machining processes A NEW range of Burster Press Fit Monitors called the DIGIFORCE 9307 provides automatic monitoring, logging and signalling on a PASS/FAIL basis for complex machining processes.

The unit can be housed in either a compact panel or bench-mount case, which includes a front panel with a high-definition graphics and alpha numeric display, with button pads.

The DIGIFORCE 9307 has a maximum sampling rate of 46 JULY 2011 Manufacturers’ Monthly

The compressors come in fixed- and variable-speed models.

10kHz, its evaluation rate is 20 to 30ms, and the precision grade is 0.05%.

The monitor is said to be compatible with different sensor technologies including incremental and absolute encoders, strain gauge-based transducers, potentiometric, piezoelectric, and piezoresistive-based sensors and transducers.

The unit stores up to 128 measurement programs for 128 different product processes.

Bestech Australia 03 9540 5100, www.bestech.com.au

THE new JDA Planogram Generator is an inventory control software system that can be tailored across various manufacturing sites.

The system is reportedly powerful and scalable, automating the highvolume production of optimised, storespecific ‘planograms’, giving suppliers and retailers an easy way to respond to customer requirements.

The software takes into account user-defined merchandising instructions, fixtures, assortments and performance data.

It enables users to update their merchandising rules based on performance data.

JDA Software 0401 149 735, www.jda.com manmonthly.com.au

Radiant heating system GAS radiant tube heaters suitable for heating warehouses and large industrial environments are now available from Schwank.

The overhead systems use radiant heat, heating people and objects instead of air, which is reportedly a more cost-effective means of generating heat.

A patented system called ‘ceramic

burner technology’ creates a long and laminar flame leading to a uniform transfer of heat to the tube. This is said to ensure an even distribution of radiant heat, and is a key element in achieving a high degree of energy efficiency in the factory.

Multiple Schwank tube heaters can be installed in different areas of a site and, using zoning controls, can be set

No spills dolly

web server, and a PROFINET status display. Optionally, fibre optic lines are also supported.

The bus module can be mounted either directly on the inverter’s interface unit or separately from the inverter by means of an optional wall-mounting kit. The PROFINET bus line is connected to the box via an RJ45 plug connector.

ENWARE is now offering the Poly-Dolly from Enpac, which provides protection against spills and leaks of industrial fuels, chemicals and hazardous fluids.

The unit is a tough, light and ergonomic mobile dispensing station for 205-litre drums, engineered to reduce drum handling and improve safety.

According to Enware, the design of the Polly-Dolly ensures workers involved in mobile dispensing use their correct major muscle groups to support and propel the load from a correct distance.

Traditionally, workers have been known to strain smaller muscle groups by being hunched over, too close to the load in materials handling applications.

The unit also includes a built-in secondary containment unit to prevent accidental spills landing on the floor.

Built-in drain plugs conveniently discharge excess liquid.

NORD Drivessystems 03 9394 0500, www.nord.com.au

Enware 1300 369 273, www.enware.com.au

The tube heaters cost-effectively heat large and small industrial areas.

to different temperatures through a central building management system.

Three models are available: calorSchwank, infraSchwank and novoSchwank.

Devex Systems 1800 636 091, www.devexsystems.com.au

PROFINET box connectors with integrated ethernet NORD Drivesystems is now supplying PROFINET boxes for the integration of frequency inverters into industrial PROFINET environments.

With no need for repeaters or additional master interfaces, the new boxes are said to cost-efficiently connect a large number of inverters to a single bus line.

The technology box supports realtime data transfer and features an integrated ethernet switch, an integrated

manmonthly.com.au

The connector box can be mounted onto the inverter interface or on the wall.

Manufacturers’ Monthly JULY 2011 47

What’sNEW Hydraulic power units

The ducting is resistant to -40 °C to +100 °C temperatures.

Clean, clear food ducting NEW ducting from Eximo is designed specifically for the clean environment required in food manufacturing operations in Australia.

FoodFlex is a medium-weight, flexible polyurethane ducting that is clear of colour, allowing constant inspection of product as it travels along the system.

Typical applications include suction and transport of lightweight materials

in most food and beverage manufacturing sectors.

FoodFlex ducting contains an organic compound that is resistant to mould, fungus microbes and hydrolysis.

The ducting is said to offer good oil- and abrasion-resistance and has a smooth bore. Its temperature resistance ranges from -40 °C up to +100 °C. Eximo 02 9757 1233, www.eximo.com.au

THE HYBOX concept from HYDAC is a complete solutions driven power unit package.

It utilises HYDAC components including tanks, pumps, electric motors and a specially designed tank mounted manifold that incorporates the return filter, accumulators and valving, The HYBOX Flex basic has up to 60L/min, 250/350 Bar. Oil tank sizes available include 25, 50, 100, 150, 200, 300 and 400L. A valve block concept comprising of a multi-flexible block which offers users the possibility to attach other blocks, including HYDAC’s ML series and multi station manifolds for NG 6 valves and others is included.

The HYBOX features ultra-low noise

The HYBOX has integrated cooler and accumulator options.

options, integrated cooler and accumulator options, fully optimized power unit with condition monitoring integration and return and pressure filter integration.

It also comes with a fully itemised circuit diagram, 24 months warranty and an optional environmental tray.

HYDAC 03 9272 8900, www.hydac.com.au

Food-grade liquids handling CEVA offers a range of demountable liquid bulk handling solutions to simplify storage and handling.

The Optimum Food Container, features a patented split lid design that slides back and locks into place, eliminating the need to manually remove

the lid. The system's graduated sight glass gives a clear view of the level and quality of the product inside.

The system is being marketed as a great alternative to 205-litre drums.

CEVA Logistics 1300 550 868, www.au.cevalogistics.com

Acra Machinery Pty Ltd

20 Fowler Road Dandenong, Victoria, 3175

ph. (03) 9794 6675 www.acra.com.au

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EUROPES NO.1 FABRICATION MACHINERY SUPPLIER AVAILABLE IN AUSTRALIA 48 JULY 2011 Manufacturersâ&#x20AC;&#x2122; Monthly

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Mongrel SP Range Because what you do makes a difference to the boots you wear Our Mongrels SP Series was designed to incorporate the most significant technological, comfort and safety features into one premium range. Now Mongrels have expanded the SP designation to meet the requirements of different work conditions.

For example the mining industry and light manufacturing industries have very different needs. Now, along with SP>P Originals we offer SP>R, SP>S, SP>Z, SP>T and SP>N ranges. Take a look on our website or call for a Mongrel salesman for more information.

Features many of the original and popular styles of our SP Premium Range launched in 2006.

The high tech rubber-soled work boot that’s built to take the heat no matter how rugged the conditions – heat resistant soles up to 300˚C

The lightweight, work boot with aluminium toe-cap and advance Sport technology soling.

The revolutionary ZipSider style allows for great ankle support with easy on and off features required by many trades.

Our Trade range featuring high spec features matched with a comfort innersole and value for money rugged leather uppers.

Many workers don’t require a steel toe cap. So Mongrels has provided a number of non-safety styles from riding boots to classic elastic sided boots and a security range.

SP RANGE The Aussie born and bred work boot designed to work best for you

Victor Footwear 15 George Young St. Auburn NSW 2144 p: 02 8667 2555 f: 02 8667 2500 e: sales@mongrelboots.com.au w: www.mongrelboots.com.au SPZ 002

Metalworking& MACHINE TOOLS

Record Austech 2011 attendance signals growth in the metals industry in Australia.

A shiny future in metal The future is looking bright for Australiaâ&#x20AC;&#x2122;s advanced manufacturing industry, with record attendance at Austech 2011 suggesting investment. Annie Dang writes.

A

USTRALIAâ&#x20AC;&#x2122;S manufacturing sector might be facing challenging times with a patchy economy and a looming carbon tax, but record attendance at Australiaâ&#x20AC;&#x2122;s advanced precision manufacturing and machine tool exhibition â&#x20AC;&#x201C; Austech 2011 in Melbourne in May â&#x20AC;&#x201C; suggests a bright future is in store for the industry.

Figures released by exhibition organisers Australian

Manufacturing Technology Institute Limited (AMTIL) show visitor head-count grew 10 to 15% compared to 2009 â&#x20AC;&#x201C; a result which AMTIL says is the â&#x20AC;&#x153;best outcome since the showâ&#x20AC;&#x2122;s inception in 2000â&#x20AC;?.

Held alongside National Manufacturing Week (NMW) and Ausplas, Austech attracted over 80 exhibitors across a floor-space of 6,000 square metres. The three co-located shows attracted over

600 exhibitors from Australia and overseas.

Among them was welding and cutting machine producer, ESAB, which showcased its new portable MIG/MAG welding unit â&#x20AC;&#x201C; the Caddy Mig C200i â&#x20AC;&#x201C; a lightweight, easy-to-use inverter power source suited for repair, maintenance and assembly welding of mild steel applications.

Speaking with Manufacturersâ&#x20AC;&#x2122; Monthly during the five-day exhi-

HEAVY DUTY DRILLING PCS DRILL.

bition, ESAB Australia country manager, Damian Cann, said the launch of the new MIG/MAG welding unit marks the companyâ&#x20AC;&#x2122;s return to the Australian metal industry â&#x20AC;&#x201C; a market which has been indentified as a source for solid returns.

According to Cann, the companyâ&#x20AC;&#x2122;s renewed focus on the local market is not only a vote of confidence for our metalworking industry, but also a sign that manufacturers are once again looking to invest in new heavy metal equipment.

One company looking to take advantage of the burgeoning growth is leading machine tool manufacturer DMG/Mori Seiki Australia, which reported sales of more than 10 machines at Austech this year. The strong sale figure is a positive sign for the joint German-Japanese company, which expects to increase its market share in Australia and New Zealand by more than 50% within the next three years.

DMG/Mori Seiki chief executive officer of cooperation markets, Dr Jens Hardenacke, said there is huge growth potential for the companyâ&#x20AC;&#x2122;s high-end and low-end machines in the local market. Having already gained 50% growth per year over the past two years in the Asia-Pacific region, the company is in good stead to continue this positive streak. DMG/Mori Seiki Australia recorded over 1,000 trade visitors at its Austech stand, which featured six machines including the newly-developed DMU 65 monoBLOCK simultaneous >>

100%

AUSTRALIAN

MANUFACTURED

Â&#x2021; 'ULOOLQJ 7DSSLQJ 0DFKLQLQJ Â&#x2021; +3 +ROHV 8S 7R PP Phone: +61 (03) 9305 2555 50 JULY 2011 Manufacturersâ&#x20AC;&#x2122; Monthly

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

Metal cutting coolant management unit CC TECHNOLOGIES has developed a coolant management unit designed specifically for use in the metalworking industry: the Antibacterial Unit (ABU). The unit reportedly reduces microbial growth in water-based machine coolants.

By topping or filling up machines with water passed through the ABU along with good concentration control and regular tramp oil removal, the company says the unit can eliminate coolant odours and reduce skin irritation caused by contact with coolant.

The unit is part of CC Technologies’ research in Silver Ion Technology, an electrolytic mineral ion process developed to treat water against bacteria, mould and fungi.

continued from p50

5-axis machining system.

Also drawing in visitors at Austech and NMW was welding gases and safety equipment supplier, BOC. The company’s Austech stand featured the Mini Bulk Gas Supply – a supply system designed for the Australian laser cutting market – while its NMW stand featured the new GMA arc weld projector.

According to BOC South Pacifc's market manager for welding and industries gases, Kyle Scott, the one-of-a-kind GMA arc weld projector was an exhibition winner.

“The GMA arc weld projector unit has been designed for training staff, apprentices, semiskilled welders as well as welding supervisors and inspectors about the benefits of using shielding gases in real arc time,” Scott said.

“It can be used for live demonstrations on the workshop floor or at educational institutions to help train staff and apprentices about specific changes to arc parameters.” manmonthly.com.au

The unit reduces microbial growth in water-based machine coolants

Reported benefits for the metal cutting industry include: increased duration between coolant changes; reduced storage of waste; reduced cost to dispose of water/oil waste; reduced downtime due to mould and fungus blocking pumps, lines and filters; and no change in the physical or chemical properties of water/coolant.

CC Technologies 03 9701 7089, www.cctechnologies.com.au

The unit is connected to a projector which simultaneously shows the GMA welding arc with the corresponding welding parameters, such as wire feed speed, voltage, stick-out, current, pulse frequency and shielding gas composition.

“As soon as the parameters are changed, users can observe how the arc is affected by looking at the projection which uses a selfcontained PC measuring system, combined with a standard beamer to project the image of the arc onto the screen,” says Scott.

According to Scott, the company’s success at the show demonstrates a trend to up-skill workers to remain competitive.

“With equipment like the GMA arc project, manufacturers can not only lift the industry’s national welding skills level, but also help to strengthen the sector by providing welders with the knowledge and understanding of best practice,” Scott said.

ESAB 1300 372 228, www.esabasia.com BOC 131 263, www.bocworldofwelding.com.au DMG/Mori Seiki Australia 03 85 404 602, www.dmgmoriseiki.com Manufacturers’ Monthly JULY 2011 51

Metalworking &MACHINETOOLS

Clean machining at Ford

BY DEREK KORN

F

ORD’S Van Dyke transmission plant in the US implemented minimum quantity lubrication (MQL) as it lowers machining costs by eliminating not only the large volume of coolant used in conventional wet operations, but also all the ancillary equipment and electrical power necessary to maintain a big, central coolant system. MQL also creates a cleaner, safer manufacturing environment, which is beneficial to the health of both the equipment used on the shopfloor and the employees who work there.

Switching to MQL to machine three types of aluminium components for the company’s 6F line of front-wheel-drive transmissions has ultimately boosted the plant’s flexibility and efficiency, allowing it to more quickly adapt to today’s rapidly changing market demands for different types of vehicles.

The Technology of MQL In short, MQL delivers a very small amount of coolant to a cutter’s edge in the form of an oil mist or aerosol, as opposed to traditional techniques of flooding the work-piece and tool with a substantial volume of liquid coolant. Just a tiny bit of that aerosol is left on the chips, workpiece and machine during the cutting operation.

52 JULY 2011 Manufacturers’ Monthly

Significant MQL benefits MQL has delivered on the two prime drivers for its adoption at Van Dyke. From a total cost of ownership perspective, which considers machine cost, downtime, maintenance, floor space, electricity usage, coolant management and related factors, MQL has yielded a 13% improvement versus comparable wet operations. As for environmental impact, MQL has been a key factor in the plant’s successful efforts in delivering no manufacturing by-products to landfill.

But consider these other interesting ways the Van Dyke plant has benefitted from implementing its MQL strategy.

Lessons learned The Van Dyke team faced an inherent learning curve when it moved from wet machining operations to MQL. For instance, when you’ve historically flooded a work zone with a large volume of coolant during machining, there’s a natural tendency to believe that more oil is better with MQL. In many instances, however, the team learned ‘less is more’ in this respect.

MQL machining operations at the plant include drilling, milling, boring, reaming and tapping. The amount of oil used for specific operations is different and largely depends on tool diameter and feeds and speeds.

Lighter cuts, such as boring oper-

Because MQL eliminates airborne mist and contaminants, the Van Dyke team has seen a remarkable reduction in electrical nuisance faults and electronic component failures.

ations on valve body spool bores, don’t require much oil. In fact, milling operations are often performed completely dry. On the other hand, drilling and tapping require more oil because greater friction between the tool and work-piece generates more heat.

Van Dyke doesn’t skimp on cutters for MQL, either. It uses primarily high-end tools from Emuge, Guhring, Mapal and Unimerco. This allows the machines to run as fast as or faster with MQL than it could with traditional flood-coolant operations while producing products with exceptionally tight tolerances. For instance, valve body spool bores are held to micronlevel precision, and the MQL

processes have proven their ability to consistently produce at that accuracy level.

The plant has also adapted new machining operations for use with MQL. One example is a spline shaping operation for converter housings that uses shaping tools with conventional geometries. Had it not developed this process, converter housings would have to be delivered out of the MQL cell for wet machining of the splines. Now, all machining operations are performed inside the cell.

[Article originally appeared in Modern Machine Shop. Derek Korn is senior editor.]

Unist Australia 02 8850 2022, www.unist.com/australia

manmonthly.com.au

Mini bulk gas supply BOC’s new Mini Bulk Supply and service system provides liquid laser nitrogen and liquid oxygen for industrial applications including laser cutting of stainless steel, carbon steel and aluminum, process purging and oxy fuel cutting.

The solution provides a costeffective and space-saving system for specialty gas customers who use between 100 and 400 cubic metres of gas per week and are looking save on costs and space.

The gas supply is reportedly more convenient and safe than a common system using multiple linked cylinders or ‘manifold packs’, as it is compact and doesn’t pose the same risk of han-

The system is perfect for companies using laser cutting for stainless steel.

dling injuries associated with manually changing-over cylinder packs on older systems.

Once the compact, high pressure vessel is installed on-site, the gases are delivered by BOC in small, rigid road tankers designed for easy site access.

BOC 13 1262, www.boc.com.au

Improving joining preparation LINCOLN Electric has introduced VERNON Tool’s pipe and tube cutting and profiling solution ideal for high-production/ high-volume handrail and fencing fabricators.

The VERNON Tool MasterTubeCutter (MTC) and MasterPipe Profiler (MPP) models are ideal for small- to medium-sized shops that require efficiently-cut profile tubes or pipes to improve joining preparation.

The 5-axis MTC offers the capacity for 1–8 inches round (1–12 inches outside diameter) and rectangular (7.5 inches across) pipe and tube cutting with either plasma or oxyfuel.

With a servo-driven rotating chuck, the MTC provides rotation and longitudinal motion, with its two additional profiling axes allowing for torch angle and linear motion.

The 2-axis MPP is capable of handling cutting and profiling operations for pipe with an outside diameter of 1–12 inches and a length of up to 40 feet.

Lincoln Electric 02 9772 7222, www.lincolnelectric.com.au manmonthly.com.au

Two New Powermax Plasma Cutting Systems Now Available in Australia Powermax 65® and Powermax85® are the two new systems that come with more torch options, industry leading technological innovations and a more rugged torch design for greater durability in harsh cutting environments.

A number of technological advances offer improved cut performance, reliability and ease of use. Smart Sense™ technology boosts efficiency by automatically adjusting gas pressure to the cutting mode and torch length, while Spring Smart™ technology in the electrode increases reliability by eliminating moving parts in the torch body. Despite these new features the new systems are 30% smaller and up to 20% lighter than the systems they will replace in the Powermax line up.

New torch options including an ergonomic 75 degree hand torch and a 15 degree hand torch for gouging and cutting in tight locations. In addition the torches which are part of the Hypertherm new Duramax™ series are up to five times more rugged and durable than before.

Westgate Hi-Tech Machinery stocks the full range of Hypertherm Powermax hand held plasma systems with consumables ready for your cutting applications.

ACN 087 591 044

Ph: 03 9391 1133 Fax: 03 9391 1244 5 Sutton St. South Kingsville Vic 3015 sales@westgatehitech.com.au www.westgatehitech.com.au

Manufacturers’ Monthly JULY 2011 53

Automation&ROBOTICS in the surface. Traditionally, a single polymer foam sheet was placed on a cutting machine to form the grooves, and then transferred to a second purpose-built machine to be drilled. This long process often resulted in low throughput and high wastage, as the registration â&#x20AC;&#x201C; the alignment of the holes in the grooves â&#x20AC;&#x201C; was not accurately executed.

The entire system is controlled using one MOVI-PLC.

Driving drilling accuracy An automatic sawing/drilling machining centre optimises accuracy and virtually eliminates waste. Richard Tuft writes.

I

N the development of sophisticated drilling and cutting tools, one Australian company leads the way in the design of innovative automated machining equipment.

Apex Automation and Robotics, located in the northâ&#x20AC;&#x201C;western suburbs of Sydney, designs and builds factory automation machinery and robotic systems. All of Apexâ&#x20AC;&#x2122;s designs are engineered to max-

imise product quality and production throughput. This was demonstrated clearly with one of the companyâ&#x20AC;&#x2122;s most recent developments, an â&#x20AC;&#x2DC;automatic machining centreâ&#x20AC;&#x2122; (AMC) for polymer foam panels.

Apex Automation teamed up with well-known motors and drives company, SEW-Eurodrive, to design a servo motor-based system with faster throughput and greater precision.

Foam to fly and float Industrial polymer foam is a critical element of a wide variety of structures where lightweight rigidity is required, for example in ship hulls.

The polymer foam is supplied in sheet form in sizes up to 1.2m by 2.6m and thicknesses of 5mm to 50mm. To help the resin infusion process and maximise adhesion, the sheets must have holes drilled through and grooves cut

Precision perforation The AMC forms grooves spaced 20mm apart along the length of each sheet. The largest sheets can have up to 8,320 holes drilled into the 64 grooves. Halfsize sheets can be processed at 100 sheets per hour, resulting in more than 300,000 holes being made each hour.

Apex Automation and Robotics was chosen to design and build the machine against international competition. According to the companyâ&#x20AC;&#x2122;s general manager, Dany Seif, it was the speed and precision of the Apex design that secured the project. â&#x20AC;&#x153;The traditional processing of the foam sheets incurred lots of rejects and needed multiple machines to get the same output.

We were able to meet the throughput requirement on a single machine and provide the required accuracy of 0.2mm,â&#x20AC;? he said.

Registration is key A sheet of foam is now placed in the AMC and motor-driven saw modules then cut up to 64 grooves in one pass on the upper and lower surfaces. Following

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this, a bank of drill bits is positioned and then raised to create holes of a pre-determined depth.

The drills are repeatedly moved along the length of the sheet until all the holes are made. All motion processes within the AMC are managed by a single SEW-Eurodrive MOVI-PLC. Combining both conventional sequential PLC control and motion control, it links all of the AMC’s motion control elements.

The saws and drills each move in their allotted sequence to produce the precisely aligned grooves and holes. The components communicate using S-Bus. “This is the brains of the operation where the sequence of movements required for a particular size and weight of PVC foam sheet is programmed and stored. Once the parameters are entered, the MOVI–PLC then choreographs the motion of the saws and drills,” said Apex project manager, Angelo Di Lorenzo.

SEW-Eurodrive 03 9933 1000, www.sew-eurodrive.com.au

manmonthly.com.au

Headland will pick-up old robots and replace them with a suitable KUKA model.

Robot replacement service HEADLAND Machinery is offering a new service called the Robot Exchange Program, in which one of Headland’s ‘Robot Integrators’ pick-up an old and

tired robot from the factory, and replace it with a suitable KUKA robot.

The Robot Exchange comes with a 5-year warranty on the

robot itself and is packaged up into a monthly fee including parts, labour and retraining of the staff so there isn’t a strain on the immediate cash flow.

An integrator will identify the right KUKA robot to replace the existing model, and in many cases swap the robot over in just a few days.

Headland developed the program to alleviate the risks associated with using old robots in the factory, including breakdown and lack of spare parts, both of which cause expensive downtime.

If the robot is part of production that is worth $2,000 per hour or more, then a five- or sixweek delay while spare parts are sourced could cost a typical Australian business up to half a million dollars in lost production, Headland estimates.

Headland suggests manufacturers using robots from the 1990s or older should take advantage of the program.

Headland Machinery 03 9244 3524, www.headland.com.au

Manufacturers’ Monthly JULY 2011 55

Factory MAINTENANCE Reversible wet vacuum EXAIR’s Reversible Drum Vac, a powerful liquid vacuum designed for 205-litre drums, is the ideal way to vacuum coolant, hydraulic oils, spills, sludge, tramp oil and waste water, says Compressed Air Australia.

According to the distributor, with the turn of a knob, the same stainless steel pump can quickly empty the drum, and coolant sumps can be easily refilled; floor spills vacuumed; or contaminated liquids transferred to filtration tanks in minutes.

The compressed air powered Reversible Drum Vac reportedly offers maintenance free operation and is covered by a fiveyear built-to-last warranty.

The Model 6396-205 litre Premium Reversible Drum Vac

The 12v optima battery has a one-hour run time.

Two-way clean machine NILFISK has launched the innovative SC350 walk behind cleaning machine which cleans in both forward and reverse motions.

The 37 cm scrub deck is reportedly fully adjustable providing complete traction control and allowing access to confined spaces.

With a low rating of 64dB(A), the unit is ideal for noise sensitive areas and day time cleaning.

The unit incorporates an on board charger as standard making charging as simple as park

and plug, Nilfisk says.

It features a small and light 12v optima battery with a one hour run time, 27 kg of brush pressure and a reportedly high vacuum power for drying.

According to the company, all components are immediately accessible without tools making maintenance quick and easy.

Classed as ‘start and go’, the new machine is considered easy to operate with minimal training required.

Nilfisk 1300 556 710, www.nilfisk.com.au

The vacuum has been designed for 205-litre drums.

System includes the two-way pump assembly, shutoff valve, 3-metre flexible vacuum hose, drum dolly, ABS Spill Recovery Kit, aluminum wand, 11-inch and 24-inch aluminum crevice tools, skimmer tool, magnetic tool holder and 6.1-metre compressed air hose.

Compressed Air Australia 1300 787 688, caa.exair.com

Tough, portable cooling keeps quiet BIG Ass Fans has introduced the Yellow Jacket, a portable fan designed for flexibility, quiet operation and durability.

It has a heavy-gauge steel carriage engineered to withstand the harshest environments, a Powerfoil-inspired blade for maximum efficiency and airflow coverage and an acoustically designed fan, motor and carriage

for quiet operation.

Other features include oversized wheels and ergonomic handle for superior maneuverability, multiple speeds and an easy-tooperate locking position mechanism for greater airflow control.

According to Big Ass Fans, the unit cuts energy use by 50%.

BigAssFans 07 5500 0690, www.bigassfans.com.au

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www.kerrick.com.au 56 JULY 2011 Manufacturers’ Monthly

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MaterialsHANDLING The sorting system is high-tech enough to inspect the nuts and take out any immature kernels.

Getting to the kernel of the job Intelligent sorting solutions boost output and lower materials waste by cutting accidental rejection of nut kernels at Australia’s Stahmann Farms.

‘T

RAWALLA’, an Aboriginal word for ‘flood waters’, is the name of Stahmann Farm’s 700hectare property in Moree, New South Wales. The farm is the company’s main source of pecan kernel in Australia.

The nuts are harvested every June and are transported to North America, Europe and Japan. But first, they are shipped to Toowoomba, Queensland, where 80 fulltime employees handle all cracking and processing on three sorting lines, each line working three shifts, 48

58 JULY 2011 Manufacturers’ Monthly

weeks a year. According to Ross Burling, general manager of Processing at Toowoomba, kernel quality can vary depending on post-harvest handling, weather and picking damage.

“We have lab specialists with over 25 years’ experience looking for kernel defects, insect damage and grading of the different kernel types,” he said.

It’s from these assessments that parameters are determined for proper, large-batch sorting of raw product, where the overall kernel value is defined.

“This drives the need for high-

ly sophisticated sorting equipment that can be easily configured to accurately process each run based on parameters set by lab analysis,” said Burling.

An older automatic sorting system at Toowoomba was not reliable, flexible or operator-friendly enough for this important step. It created big production delays because the sorter took so much time to correctly program.

Despite these efforts, the result typically was the accidental and unacceptable rejection of too much good product with the bad.

The team chose to invest in the

BEST Helius freefall laser sorter three years ago. With up to 12 individual laser signals, the equipment is able to analyse structure, size and shape of the kernels in a single pass, and within milliseconds, uses its sensitive air guns to precisely eject any defect while allowing good product to continue its natural free fall.

The sorting system is also able to inspect the nuts and take out immature kernels. Because the ejection system is at the rear, air valves can be placed extremely close to the product which facilitates highly-targeted defect ejection. Since purchasing the Helius, the firm’s output has increased by 30% (900kg/hour average).

“Our firm differentiates itself by heavily focusing on reducing accidental rejects to increase profitable yield,” Burling says.

The company credits the easyto-use Helius operator interface as crucial to its success. A big advantage of the technology is its software is designed on a personal computer (PC) platform so an operator can intuitively perform very complex manipulations. This includes entering precise sorting parameters for each batch based on the hand crack assessment and instantly translating them to the processing platform.

“Prior to Helius, either mysef or one of my specialist operators would spend hours holding up the line actually working on the factory floor programming the

manmonthly.com.au

sorter. Now, the operator performs this vital task quickly, which takes me out of the loop entirely. However, if necessary, there’s a remote monitor with identical displays in my office that lets me check unit settings or even execute the same processes. It’s a great backup system,” he says.

BEST service engineers can also access the Helius processing platform remotely using the same interfaces from PCs anywhere in the world.

“The company’s PAX remote diagnostic system is available 24 hours daily. I can logon and talk to BEST’s European technical staff anytime. Having instant access to technical support is great peace of mind, and sets BEST apart from other companies that eagerly support the sales but not the post-sales support,” said Burling.

“We see payback on this unit in two years.”

Heat and Control 07 3877 6333, www.heatandcontrol.com

manmonthly.com.au

The forklifts feature top specifications at affordable prices.

High-quality forklift range POWERLIFT Material Handling’s Powerlift HC Range of industrial forklifts, manufactured by Chinese company

Hangcha, are now available for purchase by manufacturers across Australia.

The machines come in a range

of engine models including: 1.8 to 10 tonnes in gas, diesel and petrol forklifts; 1 to 5 tonnes in electric; and reach truck models ranging from 1.2 to 2 tonnes.

The units come standard with tilt adjust steering wheels, suspension seats and LED rear lights for safety.

All forklifts also incorporate Nissan-made engines and solid tyres, and offer LCD displays of all machine functions along with high-capacity radiators.

The Nissan engines reportedly comply with EU stage III control regulations, ensuring low fuel consumption and low emissions output for a cleaner working environment.

According to Powerlift Material Handling, all models in the new HC range of forklifts and reach trucks are manufactured of the highest quality materials, offering top features at an attractive price.

Powerlift Material Handling 1800 353 312, www.powerlift.com.au

Manufacturers’ Monthly JULY 2011 59

Materials HANDLING Picking stations

Lean and digital = a fast supply future

improve order speed

BY DR JOHN BLAKEMORE

RAPIDPICK ergonomic split case picking stations are capable of increasing operator productivity rates to over 1,000 items per hour, supplier Dematic claims.

The configuration of the picking stations, which can be set-up to process multiple orders concurrently, are tailored to match operators’ individual requirements, including height-adjustable operator platforms and work tables.

Height- and rake-adjustable display screens provide simple, step-by-step management of the picking process. The highresolution screen displays symbols for order volumes, along with photos of the products to be picked. Check weighing can also be integrated. With Dematic’s RapidPick, order fulfilment is said to become just like an assembly line.

Dematic 02 9486 5463, ww.dematic.com.au

60 JULY 2011 Manufacturers’ Monthly

BUSINESS is about people, process and precision. Precision of process in all business functions at 'Six Sigma' tightness of control, creates a strong competitive advantage.

A key question is how do small manufacturing operations take advantage of the new and more efficient ways of satisfying customers, using digital data?

The first three fundamental characteristics of good business practice are quality, cost and delivery aimed at exceeding customer expectations. Added to this is innovation and speed with a special focus on continuous improvement.

It is clear that to achieve best practice, we should have total cooperation in all of the supply chain to achieve maximum benefit for all participants.

Cooperating to compete is a strong competitive advantage.

Digital connections to suppliers and customers will assist in

Continuous research and development of both process and product is fundamental.

making companies more agile.

With the new digital cooperative lean approach, value-adding by decreasing waste in planning, process and expenses increases as innovation of process and product continues. Digital connections allow any enterprise in the chain to more accurately

forecast, or make to order only.

Such ideas will not work to advantage if the processes are not operating at a high degree of precision. To achieve maximum benefit, the five functions of business; people, operations, marketing and sales, innovation and finance; need to be integrated both internally and if possible, externally.

Concentration on the technical aspects of these factors alone will not yield the desired results.

The reason is that the most important part of all business is people.

Companies must plan for the long-term and plans should be continually updated. People must be rewarded for creativity, communication skills and continuous improvement. With continuous innovation, we can release the full intellect and power of the people.

[Dr Blakemore’s book, 'Velocity', expands on the above challenges and gives advice for management.]

Email: masc@blakemore.com.au

manmonthly.com.au

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Delays cost you thousands of dollars a day.

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