Manufacturers' Monthly May 2011

Anniversary

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EDITORIAL Good as gold

Comment A credit to our history

IT’S not every day you turn 50 in today’s fast-moving publishing world. But we must have done something right, because 50 years ago we made you a promise, and today we are still here keeping that promise, month-by-month, issue-by-issue.

A

MILLION manufacturing

for the fivefold increase

workers clocked-on

in the productivity of our

in 1961. A million

manufacturing industries in the

will clock on today.

They are the heart of the

In May 1961, Manufacturers’ Monthly

They cannot account

space of the last five decades.

They cannot understand why

(MM) was developed to fill a hole in the

great story of Australian

manufacturers invest more

industry. Business was booming, and

manufacturing – a story that

in research and development

investors needed a reliable journal to

Manufacturers’ Monthly is

than any other industry sector.

show them where to spend.

rightly proud to chronicle.

They cannot explain why

People in manufacturing

Australian manufacturers have

to present you with this special Gold

tend to respect their history.

emerged resilient through the

50th Anniversary issue. From the entire

They value the insight that

booms and busts of a volatile

team, we’d like to thank our advertisers

comes from decades of

global economy.

who have supported us over the past

endurance in a tough global

50 years; our readers who have given

market. They know their debt

a million workers determined to

us such valuable feedback; and you,

to the workers of the past, and

ensure their story lives on for

the industry, for welcoming us into your

they repay it by investing in the

generations to come.

workplaces for half a century.

workers of the future.

Half a century on, it is our honour

They do not hear the voice of

We stand shoulder-to-

Manufacturing has an exciting future in

That’s why, when markets

Australia, and MM will be there reporting

shift, and technology moves

in that mission. Our stories

on these developments for the next 50

on, manufacturers don’t flinch.

were twined together in their

years – and another 50 after that. In

They make sacrifices. They

earliest chapters. They will

1961, we made you a promise, and we

make changes. They learn

never be untied.

just happen to be the sort to keep our

to thrive – not just endure –

word. Now, here’s to the future!

through innovation.

Those who have not lived

shoulder with the workers

I know there are difficult times ahead. I see the impact of rising energy costs

SARAH FALSON

that story cannot do justice to

and currency fluctuations. I

Managing Editor

the resilience and ingenuity of

recognise how hard it can be

Manufacturers’ Monthly

those million Australians.

6 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Senator Kim Carr congratulates Manufacturers’ Monthly on its 50-year contribution to Australian manufacturing.

Continued on page 8

Senator Kim Carr Minister for Innovation, Industry, Science & Research

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Comment A credit to our history

(Continued from page 6)

to secure the capital and skilled workers to innovate. Glib answers won’t ring true to people who know their history.

The Government offers instead its commitment to face the realities of the twenty-first century squarely, with confidence in our greatest asset – the workers of Australia.

We have been working with manufacturers and unions to turn their ideas into commercial returns. Through the carbon

– and the assurance that every

price, we will help them prepare

cent of the revenue we raise

incredible story – a story that

for a clean energy future. We

will be redirected to keep our

deserves to be told. I trust, in

will give them the certainty to

industries strong and our living

fifty years’ time, Manufacturers’

invest in cost-cutting technology

standards secure.

Monthly will still tell it with pride.

8 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

We take up the threads of an

“Manufacturers make sacrifices.

They make changes.

They learn to thrive – not just endure – through innovation.”

Senator Kim Carr Minister for Innovation, Industry, Science and Research

Growing stronger every year.

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Comment Consultation will take us forward Sophie Mirabella MP outlines manufacturingâ&#x20AC;&#x2122;s crucial role in our economy.

O

N THE occasion of

great skill in doing so. Clearly, the

player in advancing research and

its 50th anniversary,

nature of Australian manufacturing

development activity, and generates

I congratulate

has evolved dramatically since

products that are essential to

Manufacturersâ&#x20AC;&#x2122;

those times, and we can only begin

Australiansâ&#x20AC;&#x2122; everyday lives.

Monthly and everyone who has

to imagine how much more it may

played a role in that achievement.

change in the centuries ahead.

Any contribution that advances

Australiaâ&#x20AC;&#x2122;s manufacturing future.

Throughout its history, the sector

understanding of the importance of

constant that manufacturing has

has shown that it is resilient, smart,

manufacturing to Australia should

played a vital role in shaping our

innovative and hard-working. Although

be celebrated â&#x20AC;&#x201C; and there is no

economic destiny. I firmly believe

it faces many cost disadvantages,

doubt that Manufacturersâ&#x20AC;&#x2122; Monthly

this must also remain the case for

its entrepreneurial spirit, skill and

has made a substantial one over

many years to come.

resourcefulness still make it a

the past half-century.

Despite substantial recent job

From the earliest days of our

Sophie Mirabella Shadow Minister for Innovation

It has, nevertheless, been a

I havenâ&#x20AC;&#x2122;t lost optimism in

losses, the sector still employs

formidable international competitor.

I earnestly hope that the

settlement, Australians have

nearly a million Australians. It also

Government shares those views,

possessed an instinctive desire to

remains a crucial driver of innovation

too. It simply must halt its approach

make things, and have displayed

and new technology, a central

Continued on page 12

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10 | May 2011 Manufacturersâ&#x20AC;&#x2122; Monthly | Celebrating 50 years

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Comment Consultation will take us forward (Continued from page 10)

The manufacturing industry generates products that are essential to the everyday lives of Australians, and it will continue to do so for the next 50 years, at least.

of burdening manufacturing

labour costs, OH&S laws and

businesses with too many costs

environmental standards.

and pressures – especially in the

more heed to the needs of our

the high Australian dollar.

manufacturing community; there

Both sides of politics must

must be more consultation, and

recognise that the decisions we

there must be a greater focus on

make over the next few years

what kind of economy we want

will be critical to the future of

in 10, 20 and indeed another 50

Australian manufacturing. Many

years from now. Frankly, there’s

manufacturers are already

too much at stake to do otherwise.

struggling on wafer-thin margins,

12 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Governments must pay

face of rising interest rates and

There has rarely been a time

and are confronting increasingly

(even over the past 50 years)

intense competition from

when such discussions have

overseas. In such circumstances,

been so crucial, and I know that

more must be done to address

Manufacturers’ Monthly will be

our growing disadvantages

continuing to assume an important

against countries with lower

place in taking the debate forward.

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For 2011 around 70% of the exhibit space features displays of processing equipment in operation, plus a vast range of ancillary equipment, new materials and applications.

A feature at Ausplas this year will be the participation of numerous companies bringing new developments in the field of plastics fabrication for industrial users in mining, building and manufacturing. Also exhibitors showing their expertise in the production of large and complex mouldings.

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Analysis News A lean way of thinking

BY ANNIE DANG

“You can read books and

‘LEARNING by sharing’ is not

listen to lectures, but when

a phrase you often hear in

you visit a place you can learn

the manufacturing industry.

about the company itself, its

‘Competing interests’ and

processes, the sort of technology

‘trade secrets’ may sound more

and software they use, why they

familiar. But, according to Brian

have chosen these technologies

Levitan, public officer for the Lean

and processes and how that is

Network, the new industry group

working for them,” Levitan told

offers a different kind of culture.

Manufacturers’ Monthly.

Made up of industry

Ian Storey, production planner

practitioners looking for new ways

for Dunning Industries – a family-

to learn practically about Lean

owned engineering manufacturing

manufacturing processes, the

SME, specialising in CNC mills

Sydney-based Lean Network is a

and welding systems – says

not-for-profit organisation that hosts

that access to the on-site visits

panel discussions and on-site

has provided a practical way to

visits to encourage and promote

develop new ideas to increase

processes will suit Dunning

signage, clearer descriptions of

discussion about Lean thinking.

business efficiency.

Industries they provide a

and improvements to workflow,

foundation which we can build

optimisation of materials

In the Network, members

“The site visits are extremely

A first-hand look inside a production site using Lean principles is crucial to understanding the Lean message.

“Even though not all of the

Network, including improved

voluntarily share information about

valuable because you get to see

on and adapt to suit our

placement and workspaces, and

their Lean implementations in a

first-hand the people who are

particular purposes.”

improved mobility through the

spirit of cooperation and willingness

using Lean and are often on the

to help each other improve their

leading-edge,” Storey said.

production processes. One major

“You also get to see people who

Dunning Industries has made a number of small

purchase of additional trolleys and mobile benches.

improvements to the efficiency

appeal of the Network is the access

are just starting out on their Lean

of its operations as a result

• LEAN NETWORK

to on-site visits.

manufacturing journey.

of Storey’s membership to the

www.leannetwork.com.au

14 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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Austech 2011 Australia’s Premier Advanced Manufacturing & Machine Tool Exhibition 24th – 27th May 2011 Melbourne Convention & Exhibition Centre South Wharf, Melbourne RN8930

ONLINE MEDIA PARTNER

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Analysis News Manufacturers flock to Queensland

BY SARAH FALSON

“It was clear that there was a

PROFESSIONALS involved in

gap in the Queensland market

manufacturing technologies

leaving manufacturing and

and engineering industries

process professionals without a

will welcome the launch of the

forum to keep up-to-date with the

Queensland Manufacturing Show

latest technology,” Kinsella told

when it hits Brisbane in June.

Manufacturers’ Monthly.

The event, to be held at the

“We look forward to showcasing

Brisbane Convention & Exhibition

the latest in a vast array of

Centre from 21–23 June 2011

products including CNC machine

alongside the Queensland Safety

tools, CAD/CAM software,

Show, will showcase manufacturing

instrumentation, robotics,

technology and services to

programming systems and general

help local companies become

industrial engineering products.”

Queensland was in need of a trade show for manufacturing and process professionals: Kinsella.

“Approximately 28% of our

• QUEENSLAND

visitors to the most recent show

MANUFACTURING SHOW &

according to Australian Exhibitions

at the show, with the majority

were manufacturers so we start

QUEENSLAND SAFETY SHOW

& Conferences (AEC) managing

coming from the manufacturing

from a very strong base point,”

03 9654 7773

director, Marie Kinsella.

industry and related sectors.

said Kinsella.

www.qldsafetyshow.com.au

more ‘Clean, Lean and Clever,’

Over 5,000 visitors are expected

16 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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Analysis News Counting down to success

BY SARAH FALSON

was developed to harbour a culture

to the economy and provide

WITH the manufacturing industry

of competition and innovation

consumers with a choice of locally-

counting down to find out the

among local manufacturers and,

manufactured goods. Australian

winners of the 8th annual Endeavour

eight years later, close to 100

manufacturers employ and train

Awards at a dinner ceremony

finalist companies prove Australian

Australians, and support other

in Melbourne on 25 May, major

manufacturing is among the best

businesses who supply goods and

sponsor BlueScope Steel wishes all

in the world.

services to your company,” he told

99 finalists ‘good luck’ on the night,

According to BlueScope Steel

Manufacturers’ Monthly.

and marvels at the extremely high

acting general manager – Industrial

calibre of entries for 2011.

Markets, Steve Gregson, it is

manufacturer and supplier of flat

BlueScope Steel is a

The Manufacturers’ Monthly

not just the large firms that are

steel products in Australia, and is

Endeavour Awards program was

at the forefront of manufacturing

once again the major sponsor of the

designed to reward Australian

innovation, as the smaller players

2011 Endeavour Awards.

companies that have excelled in

continually show their worth in

developing new manufacturing

competitions like these.

technology, or instigated new

“No matter how big or small

According to Gregson, this year’s

Your manufacturing organisation makes a vital contribution to the Australian economy: Gregson

hardest few years on record.

Join us on the night!

Endeavour Awards is particularly poignant as it comes at a time

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18 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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t n e m e g a n a M is s ly a n A Trade finance delivers positive results

BY KEN RICHARDS

be a time-consuming prospect

MANY manufacturing corporations,

to investigate the many finance

as well as SMEs, are turning to

options available. In many

specialist equipment finance

instances, business-owners

brokers to negotiate the terms

approach their bank to organise

and conditions of trade finance

their commercial finance and, in

facilities required for the

doing so, find that the bank grants

acquisition of machinery and other

the facility – but at what cost?

capital equipment necessary to increase productivity.

Finding a staff member within a bank with expertise in the

Trade finance facilities offer

importation of capital equipment

Letters of Credit for the importation

can be difficult and, invariably,

of machinery or equipment, along

every bank or financier has

with hire purchase agreements,

different requirements and

lease purchases with varying

limitations which can lead to

balloon or residual options,

delays and issues with machinery

followed by a letter of credit

unsecured loans and working

manufacturers or agents.

issued for anything up to one

capital lines of credit.

Added to this, most purchases

For business-owners, it can

require a deposit to be paid,

Securing capital credit can be confusing, however financiers offer industry-specific programs.

shipping in a currency other than

year for manufacture, and usually

Australian dollars.

require a substantial payment for

Continued on page 22

Our isolators are very flexible and so are we.

Mackay has the largest range of rubber vibration isolator and equipment mounts in Australia.

We are the first choice for both original equipment and replacement parts.

More importantly, our design and manufacturing facility is capable of producing mounts for delicate electronic equipment to very large engine mounts.

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E X C E L L E N C E MAC009/A

20 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

I N

R U B B E R

T E C H N O L O G Y

t n e m e g a n a M is s ly a n A Trade finance delivers positive results (Continued from page 20) Next, GST will be required at the

specialist. Payments can also be

security to support equipment

professional specialist equipment

time the equipment enters Australia,

structured to suit projected cash

acquisitions. It is much more

finance broker to negotiate terms

often in addition to freight and other

flows, all without collateral security.

prudent to minimise the security

and conditions of your commercial

offered, and hold this for any future

equipment finance will help deliver

working capital requirements.

positive results for your business.

customs charges. There are often

Not only will most banks overly-

other costs too, such as tooling and

complicate this process, but in

associated equipment and, finally,

today’s economic climate, most

Business owners understand

payment of any retention following

have restricted their commercial

the situation in which real estate

interest rate, terms and conditions

the successful commissioning.

finance lending. Though in the past

is taken as security, however few

will be more favourable than those

they would have provided trade

realise the impact of providing their

you might negotiate directly with

producing income throughout this

finance facilities, these are now

bank with a fixed and floating charge

your bank, it is also more likely

time either, and may take further

considered ‘additional’ security by

over the assets of a company to

that the trade finance facilities will

time to be fully-integrated.

way of real estate, or through a

secure trade finance facilities or

be approved with minimal, if any,

fixed and floating charge over the

commercial finance. Such charges

collateral security required.

company’s assets.

give the bank significant control

[Ken Richards is the director of

over a business and can severely

Interlease.]

The equipment usually won’t be

Expand your options Few businesses realise that

Though this may be a reasonable

Not only is it more likely that the

this entire process, along with

position to take in a company’s

the associated foreign currency

start-up phase, once a business is

hedging, can be managed by

well-established there should be no

Reap the rewards

1300 859 429

a suitable equipment finance

need to tie-up additional collateral

Choosing an independent and

www.interlease.com.au

limit future borrowing capacity.

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E X C E L L E N C E MAC011/A

22 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

I N

R U B B E R

T E C H N O L O G Y

Authorised by the Australian Government, Capital Hill, Canberra.

Printed by Geon Impact Printing, 69-79 Fallon Street, Brunswick, VIC, 3056

t n e m e g a n a M is s ly a n A Priceless advice boosts business

BY SARAH FALSON NEW research conducted by the

component of business success.

Since 2008, Enterprise

Australian Government’s small

Connect has been working with

business assistance service,

small and medium businesses

Enterprise Connect, shows that

around Australia to review and

businesses that adopt a strategic

improve their performance. Each

approach to their operations

Business Review is conducted by

experience significantly better

a Business Adviser with years of

business outcomes.

relevant private sector experience.

According to the research, conducted among Enterprise

Review leads to rewards

Connect clients, the improvements

A case in point is legendary

were equivalent to increasing the

Tasmanian footwear company,

labour force by 25% or increasing

Blundstone. Blundstone has been in

capital expenditure by 65%.

business since 1870, but like every

The research supports the findings of a recent international Management Matters survey which pinpointed strategic planning as a vital

Enterprise Connect business adviser Steve Turner (L) and Steve Gunn, chief executive officer of Blundstone.

business it had to take a strategic

with what he achieved with the

from Enterprise Connect was

view to stay ahead of its competitors.

support of Enterprise Connect.

swift and I was impressed by the

Blundstone’s chief executive officer, Steve Gunn, was pleased

“The Business Review application process was easy and the response

professionalism of our business Continued on page 26

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24 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

t n e m e g a n a M is s ly a n A Priceless advice boosts business (Continued from page 24) adviser Michael Turner and state

Review, saying the company had

the business, however, we were

director Keith Calvert,” Gunn told

already started acting on the advice.

lacking the systems and procedures

Casa will be run by a management

necessary to support company

team with my involvement being

growth,” said Claude Cicchiello.

very much based around overall

Manufacturers’ Monthly.

“One of the valuable insights

Specialised service

“Ideally, in five year’s time, La

we gained through the Business

The emphasis on strategic planning

Review was that, to increase our

has also made a big difference to

the company has utilised the Tailored

market growth, we needed to shift

Adelaide-based cheese manufacturer,

Advisory Service grant to introduce a

that have traded in Australia

our focus from being manufacture-

La Casa Del Formaggio. The family-

culture program incorporating systems

for at least three years, are

driven to being market-driven.

owned business was opened by

and procedures. A new management

financially solvent, and operate

Gerardo and Rose Cicchiello is 1988

structure and incorporated systems

in specific industry sectors, may

and is now run by their children.

have also been put in place.

be eligible for assistance from

“The Business Review highlighted that we needed to beef-up our marketing expertise

Enterprise Connect business

As a result of the Business Review,

“Business growth has never been

business strategy and direction.”

Small and medium businesses

Enterprise Connect.

and focus more on our brand

adviser, Michael Cain, conducted

better. We now feel we are beginning

positioning and product marketing

a top-to-bottom Business Review

to support our operational strength

businesses in industries including

as well as refresh our sales

which pinpointed areas for

with systems and procedures. We

manufacturing and defence.

channel strategies to better target

improvement and growth and again,

have become more strategic in

our customers.”

strategy was underlined.

investing capital into the business

• ENTERPRISE CONNECT

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26 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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IT@MM Getting connected to CAD for growth: Part 2

BY ALAN JOHNSON

and think about the community

EVERY year, attendees at

platforms for 3D Swim and the

SolidWorks World are treated to

additional data management

sneak previews of the upcoming

products online, you really start to

release of SolidWorks (see

get these network effects where

below), plus an indication of the

you benefit as more and more

company’s general direction.

people use the platform, with

This year’s event, held in

customers interacting more, and

San Antonio Texas earlier this

more intense than SolidWorks

year, was no exception with

alone does,” O’Malley said.

connectivity and collaboration

Another tool expected to be

high on the agenda with the

of interest to readers will be

company’s recently released

SolidWorks Post3D. Based on the

n!Fuze (see April issue of MM).

existing 3DVIA technology, Post3D

Bertrand Sicot, SolidWorks’

creates virtual collaboration

newly appointed CEO, says

spaces or posts for designers to

connectivity is becoming more

upload CAD assets and review

and more important for engineers.

their work with partners in a fully

“Designers don’t work in a vacuum.

interactive and realistic context.

There is a shift to more and more

Max Piper, CEO of local

collaboration within communities;

SolidWorks reseller Intercad, says

they share designs, information,

each post can be shared publically

and images.

As seen in San Antonio. Is this the ultimate CAD operator’s chair?

or privately and allows users to

visualise in a 3D environment all

“We will provide the ‘Facebook’

meet virtually, in real time through a

within the confine of their own

product based on Enovia’s V6

for designers. Because today the

personalised URL set by the author.

offices,” Piper said. (Post3D will

platform that offers designers

be available in mid 2011.)

and planners an immersive

Live Buildings is an online

internet is much more than just

“Basically this incorporates

email, it’s a place where users

product design within a virtual

share and discuss ideas,” Sicot

setting. This will reduce the need

at SolidWorks World 2011 was the

structure, floor layout and even

told Manufacturers’ Monthly.

to travel great distances for

announcement of SolidWorks Live

place furniture and other decor.

presentations and all.

Buildings, a SolidWorks offering for

Austin O’Malley, executive VP R&D and strategy with SolidWorks agrees, “If you look forward

“Engineers, designers and their clients can now communicate and

30 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

But probably the biggest news

the AEC (Architecture, Engineering and Construction) industry.

environment to quickly design

The user interface has the community aspect for Continued on page 32

Make Your Vision a Reality.

Discover how the latest 2012 Autodesk速 Product Design and Manufacturing Portfolio, including Autodesk速 Inventor速 software, can help you create and deliver your most innovative work.

Visit www.autodesk.com.au

Image courtesy of Dynamic Structures Ltd.

IT@MM Getting connected to CAD for growth: Part 2 (Continued from page 30) collaboration and online libraries

SolidWorks 2012

of commonly used models that

Like many years in the past, a sneak

can be searched and dropped into

preview of some of the new features

the design quickly.

for SolidWorks 2012 was revealed

It is an initial conceptual design tool, like a SketchUp on steroids with the ability to exchange data

in the form of a “skit” in Texas. This year it was the CAD Cops.

While the skit ran for quite a

with DraftSight, the new free 2D

while, not all the new features were

AutoCAD clone from SolidWorks.

shown. O’Malley said the company

In Texas, SolidWorks showed DraftSight running on the iPad, which will be released later this year.

What with a clone for AutoCAD

was still working on some of them.

“We are working on new features all the time, but there are some significant things we

and a clone for AutoCAD WS, it’s

have announced this year,” he told

clear Dassault/SolidWorks has

Manufacturers’ Monthly.

Autodesk in its sights and are just

As an example O’Malley said

Amazing designs on show in San Antonio.

gives breakdowns of cost by

adjustments can update the

manufacturing process.

individual component cost.

getting started with AEC. It will be

SolidWorks 2012 will include

interesting to see where all this

a brand new Costing Tool,

machine setup costs can

link in some information from their

leads and how Autodesk reacts.

which analyses the model and

be input so that quantity

Continued on page 34

32 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

It will include areas where

Whether users will be able to

IT@MM Getting connected to CAD for growth: Part 2 (Continued from page 32) ERP system is not clear at this

as well. File properties, functions,

adjustments to the balloon

stage, but O’Malley was adamant

and global variables will all be

sequencing on the fly with all

it will not be too difficult to put the

available from drop down boxes.

associated Balloons and Bills of

SolidWorks will be the first 3D

Materials dynamically updating.

CAD tool to incorporate the ability

information needed in the system.

“There will be some base

Users can also utilise the Measure tool from within the

and New Zealand market.

“Plus, the announcement that

Balloons will also now have

for users to generate accurate

information and templates, and we

Equation Editor to create a reference

magnet lines allowing them to be

costs for their designs, will be very

will have some way to hook it up

dimension on the fly which can be

positioned along a magnet line

much of interest to our customers

to a data management system to

used as part of the equation.

with users having complete control

who must tightly manage costs to

over the spacing along that line.

ensure sustainable competitive

extract the information,” he said.

SolidWorks 2012 will

Another new feature will be

see balloons with several

There is also a new Large Design

Equation Editor which is a single

enhancements. Users will be able

Review mode in SolidWorks 2012

dialog box with the software

to Auto-Balloon sequentially which

which allows users to open large

automatically calculating the

will allow users to pick the location

assemblies very quickly.

solve order.

of item 1 balloon and then other

There are several different views incorporated such as category,

Solutions, Australia’s other

number order around the view.

reseller of SolidWorks says the

According to O’Malley, the

Manufacturers’ Monthly.

• INTERCAD

Shane Preston, CEO of Solidtec

balloons follow in sequential item

advantage,” Preston told

1300 CAD CAM www.intercad.com.au

customer driven enhancements

• SOLIDTEC

Users will be able to access all

whole setup is very configurable

for SolidWorks 2012 will be

1800 824 883

dimensions of a part from a list

and will allow users to make

particularly useful in the Australia

www.solidtec.com.au

dimension, and ordered view.

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www.chandlermacleod.com 34 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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IT@MM Shifting manufacturing design

BY KARSTEN HOJBERG

share and simulate the models

MANUFACTURING in Australia has

with their customers before

undergone significant shifts in

manufacturing is started.

the last 50 years. However, the

Today more than ever, design

one constant is the mandate to

is king, and ugly doesn’t sell.

do more with less while becoming

To produce concept design

more innovative in order to stay

that fits to purpose, as well as

ahead of the competition.

being aesthetically pleasing –

The most significant changes over

such as with consumer product

the last 25 years have been around

manufacturing and special

process and technology, enabling

purpose machinery manufacturing

manufacturing design to evolve into

– forward-thinking manufacturers

a more holistic expression of all

are turning to 3D models. Made

resources required to create the

using specialised design software,

end product, including materials,

these digital prototypes of highly-

energy, manpower, processes and

complex products maximise

going to the building industry,

industry, with Maserati allowing

of course, cost.

accuracy of designs and develop

the architecture and construction

customers to custom-design the

models which are much easier to

industries now want to understand

body kit.

view and understand.

the engineering and manufacturing

Where previously product design happened through paper sketches that were then translated to the

3D models provide a clear and

Profile view of an automobile prototype produced using design software.

process and participate.

It won’t be too long before other car manufacturers follow

production process in a linear

accurate presentation of how the

step-by-step process, it became

end-product will appear, which

in customers and end-users

customers’ needs and being able

increasingly necessary for design

is very useful when dealing with

contributing to manufacturing

to ‘render emotion’ into what

to be more engineering-driven.

customers that may not understand

design. With what is termed

is physically built. We call this

the engineering processes.

as the ‘maker’s movement’,

the ‘democratisation of design’.

bespoke products are becoming

[Karsten Hojberg is director of

Today, that engineering-driven approach has become even more

This technology is especially

There is also an increase today

suit, taking into consideration

sophisticated, adopting 3D design

useful today as manufacturing

more commonplace due to the

manufacturing solutions, Autodesk

simulations and digital prototyping

is not solely the domain of

affordability and accessibility of

Australia & New Zealand.]

to ensure that the designs are

manufacturers anymore.

design tools and technology.

created with as much detail as

With approximately 30% of

possible so that the designers can

manufacturing done in Australia

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g n i t a r b e l Ce th

SPECIAL FEATURE

A lifetime of experience Celebrating 50 years | Manufacturersâ&#x20AC;&#x2122; Monthly May 2011 | 37

Celebrating th

SPECIAL FEATURE

A lifetime of experience Celebrating 50 years | Manufacturersâ&#x20AC;&#x2122; Monthly May 2011 | 37

y they have helped – and hindered – development of our industry.

Over the following 50 pages, we hear from each of our specialist editors working alongside MM today, presenting their view of how manufacturing has helped shape their respective industries.

The editors from Electronics News, PACE, Australian Mining, BPN and Food magazines each share their thoughts.

Looking to the future, we paint a picture of the next 50 years, and where our industry is likely to be. From technology to social trends, we raise the most An assembly line in 1966 (far left) compared to an assembly line today (above). Robotics, automation and safety are just some of the advancements making production quicker, cheaper and more precise today. Image: GM Holden.

the most in-depth, and the most engaging monthly publication for the Australian manufacturing industry – and we will continue to do so for another 50 years after this.

Cause for celebration In keeping with the theme of our 50th anniversary, the following 50 pages of special 50th birthday coverage present a retrospective of Australian manufacturing from 1961 to the present. This section features decade-by-decade analysis of Australian manufacturing over the past 50 years. From 1960s gogo dancing, to 1970s bad hair and bellbottoms, right up to today’s top trends and technology, we cover the ‘whos’, ‘whys’ and ‘wheres’ of Aussie manufacturing, and how

important questions facing our industry today: Is mining the new manufacturing? Is globalisation killing our industry? How can local businesses get ahead?

“From now on, remember that in your business life you must have the 2M’s – ‘Manufacturers’ Monthly’ – to keep you informed of what is happening to the 4M’s – Money, Men, Machines and Materials – of industry.”

– MM May, 1961

What’s so good about Australian manufacturing anyway?

Australian Industry Group chief executive, Heather Ridout, gives her insight into today’s manufacturing industry in Australia, and provides some tips for the industry and government to work together to ensure the future of our industry.

Now sit back, relax, and let us entertain you. A whole lot has happened during the past 50 years, for the better and worse for Aussie manufacturing. What matters is that you’re still with us, reading our stories, listening to our opinions, and heeding our advice.

Let’s hope we continue to enthral you for another 50 years. Happy

Flashback to 1961 • Prime Minister, Julia Gillard, is born • Oral contraceptives first sold in Australia • Last electric tram service runs in Sydney • Parkes radiotelescope opened • Four Corners first screened on ABC TV • IBM introduces Selectric typewriter • Former NSW Premier, Morris Iemma, is born • The First electric toothbrush is produced • Lady Chatterley’s Lover banned from sale • Niagara Falls produces hydroelectric power • Former Prime Minister, Earle Page, dies • Dame Joan Sutherland announced Australian of the Year • Australia defeats England 2-1 and retains The Ashes • First in-flight movie is shown on Trans World Airlines • Manufacturers’ Monthly was born!

birthday Manufacturers’ Monthly!

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 39

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1960s a peak of 7,000 people from 35 nations. At the time, it was

Fast Facts 1960-1969

the only plant in Australia to

• Manufacturing expansion

manufacture the complete vehicle.

It introduced to Australia the in-line transfer machining of engine blocks, the “rotodip” paint process, automatic conveyor assembly processes and major advances in just-in-time and flexible manufacturing concepts.

In the inaugural edition of Manufacturers’ Monthly, an article headlined “Fuss about automation decried by BMC expert”, highlights the prominence of the car company

was double the rate of the rest of the economy • One in every 16 workers was employed in the automotive industry • Unions were powerful and lobbied successfully for better wages and conditions • The UK teamed-up with the EU and access to the British market tightened.

at the time, and how automation was viewed in the 1960s. In the

in the 1960s. They are still

article, Mr NH Humphries, chief

operational today, but are probably

manufacturing engineer with BMC,

less than 10% of the shop.”

warns that many people were fed-

panels were bolted together and

word ‘automation’.

then painted by hand” Phillips said.

“I think it’s a pity the word

“For general assembly in the

was coined in the first place,

1960s, we used a ‘chain-on edge’

otherwise there would not

production line, which was a

have been half as much fuss

single chain that transferred the

about this natural evolution of

cars through 140/150 stations

mechanisation,” he said.

through general assembly.”

Despite the arrival of serious

Keith Moss, now in his 80s,

competitors – namely, the Ford

remembers working for Holden in

Falcon, Chrysler Valiant, and

the 60s well.

Japanese cars – in the 1960s,

Moss said safety was already

Holden’s locally-produced, large six-

an issue in manufacturing. “I

and eight-cylinder cars remained

remember when I was manager

Australia’s top-selling vehicles.

of the press shop in Woodville;

Richard Phillips, present director

I started safety meetings with

vehicle assembly operations, said

shop stewards. We worked in

the Elizabeth assembly plant in

consultation in those days,

South Australia was put in place

with the unions becoming more

in the mid 1960s and at the time

powerful,” he said.

it was well-advanced in production

“At this stage there was very

techniques. “In fact, some of that

little automation, but we did

equipment is still in use today,” he

have air tools. It was all hand

told Manufacturers’ Monthly.

spot welding on the general

“Even today if you go into the

46 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

“In the 1960s, most of the body

up with the controversy over the

assembly then. For different

press shop you will see a couple

colours in the paint shop it was

of press lines that were installed

just a case of changing guns.”

1970s

The shocking seventies

By the 1970s the global economy had changed dramatically, and Australia’s ‘stagflation’ reflected the greater world recession.

Alan Johnson writes.

R

ECESSION, war, civil rights and feminism set the scene for Australian society in the 1970s,

and the manufacturing industry was forced to abandon the ‘she’ll be right, mate’ attitude it had enjoyed during the previous prosperous decade.

But although the sector struggled to compete with cheap imports, the 1970s signified the beginning of environmental consciousness in manufacturers.

The trend for star-rated equipment, carbon reduction schemes and energy management systems can all be traced back to Australian supplier ANCA, formed in 1974, developed some of the first CNC controllers for the local market. The company is still going strong today, and has expanded into the complex cutting and grinding market, employing 280 across the country.

a new social consciousness about the world as a single organism that needed to be preserved, as a result of new images of the Earth from afar taken during the first

developments, led to dramatic

Moon walk in 1969.

change in the Australian workforce

In Australia, the manufacturing sector experienced substantial decline in employment levels

quantitative import restrictions.

On the export front, firms

and production across all sectors –

turned to export, and the share

manufacturing in particular.

of manufacturing production that

The campaign by trade unions

was exported in the 1970s had

between 1973 and 1980, down

for equal pay and sharp rises in all

increased gradually to 15% by the

by 80,000. Manufacturing’s

real wage costs caused a squeeze

early decade and then experienced

share of employment fell from

from rapidly-escalating costs and

a plateau until the mid-1980s.

25% in 1970 to 18% in 1985; as

intensified import competition.

well, its proportion of total GDP

Tariff cuts in particular

a difficult period for many in

fell from a high of 29% in 1960 to

compounded the problem and,

heavy industry, with BHP closing

18% in 1985.

accordingly, import quotas were

its Whyalla (South Australia)

imposed on those goods most

shipbuilding works in 1978,

Australia’s international

affected by competitive external

forced out of business, it was

competitiveness was affected by

producers. The clothing industry,

argued, by foreign competition.

both external and domestic issues.

for example, was in sharp

Increasing competition from

decline after its peak in 1971,

huge uptake by manufacturers

newly-industrialised Asian nations

and this industry, along with the

of computer technologies to

and fluctuating exchange rates,

textiles, footwear and whitegoods

lift production efficiencies.

together with domestic workforce

industries, was the subject of

CNC machines were starting

Throughout this period,

48 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

It’s clear the 1970s was

However, the 1970s saw a

to be in common use in

supply all the data for the BOM

We said in 1971

machine shops in the 1970s,

(Bill of Materials), the heart of

Exports, tariffs, pollution, trade

with manufacturers faced with

MRP, which then worked-out when

unions and industrial relations were

shortages of skilled machinists.

stocks of these items needed to

the main themes of Manufacturers’

The introduction of CAD/

be replenished. It automatically

Monthly’s May issue in 1971.

CAM allowed further increases

reordered quantities to be made

Editor of the day, John Keenan,

in design ability and less time

and gave the dates they should

used his editorial piece to blast the

needed and with more accuracy.

be made. MRP appeared to

treasurer of the day, Billy Snedden,

But the greatest level of progress

be a boon for manufacturing,

for having special tax concessions

of computer application was in the

eliminating the hundred of stock

for the rural sector – which were

areas of process control and, by

cards, together with their tedious

apparently being exploited – while

error prone updating.

ignoring the important mining and

the late 1970s, this technology was appearing everywhere. Computercontrolled processing had its

“Man still makes war on man, and industry and Government are still at loggerheads,” Managing Editor, Norman B Rydge, MM May 1971.

But with the arrival of MRP

manufacturing sectors.

something else disappeared from

Describing the department

the production office, beside the

as “Canberra manipulators”, he

processing trades, and in processes

stock card – the simple but very

said export industries should be

where heat, speed, and dimensional

effective Gnatt chart. This was a

encouraged in the same fashion

control is critical. The computer was

huge board that showed all the work

as the rural sector so that

also now in the office of the 1970s,

centres and the orders due on them

valuable foreign exchange could

for the current and forward periods.

be earned. He went on to argue,

Planners had this easy-to-understand

”It is obvious that in the years to

board in front of them on a wall,

come these sectors [mining and

which was accessible to all who

manufacturing] are where our

walked into the production office.

export future lies.” How profound.

This effective planning tool

Trade unions, with a youthful-

greatest impact in the primary metals

first in accounts and payroll.

The biggest change came with MRP (Materials Requirement Planning) programs. They appeared in the early 1970s and promised a production planning paradise for inventory managers and production planners.

Production engineers would

“We are strong enough to take what we want. If you don’t take it our way you can take the consequences.”

– ACTU Leader Bob Hawke.

became part of history and was

looking Bob Hawke in charge of

dumped as soon as an MRP

the Australian Council of Trade

system was installed.

Unions (ACTU), were also making

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 49

1970s air pollution, manufacturing was

in Australia looked to start

1970 we had as good as high

Fast Facts 1970-1979

being challenged to lift its game.

manufacturing smaller, more

volume assembly, pressings and

• Manufacturing employment

The 1970s article suggests

economical cars. However,

sub-assembly, as the US,” Moss

manufacturers be charged for the

this was the decade BMC, now

told Manufacturers’ Monthly.

amount of pollution they create

British Leyland Motor Corp,

in the water, air, soil, and the

decided to introduce the near

to Japan, I saw first-hand how

environment.

legendary Australian big car:

it should be done. Once back,

the Leyland P76. A couple of

we started tidying up the plant,

said, “industries that used water

years later though, following the

painting floors, and generally

heavily, but returned the water in a

worldwide collapse of British

improving the plant; better

clean state would not be charged,

Leyland and its associates, the

housekeeping and so forth.

while small charges would be

Victoria Park/Zetland factory in

applied to companies who pollute

Sydney was closed by 1975.

1970-1985 down 25% • Growing competition from newly-industrialised Asian neighbours • Import restrictions put on clothing and textiles • Australian exports rise to 15% • CNC and process control emerges.

“For example,” the article

slightly, rising as the degree of

During the 1970s, Chrysler

“However, later on, when I went

“Their equipment was not as good as ours, but they had higher efficiencies. Even now, Japan

contamination rose.” However the

began working closely with

has no raw materials, they have

author argues this would be too

Mitsubishi Motors Corp with the

to import everything so waste in

the headlines in the 1971 issue,

complicated and too difficult to

result that Chrysler Australia began

Japan is minimal, unlike us and

with one headline reading, ‘Labour

regulate and police. Today’s carbon

building Mitsubishi-designed,

the Americans who just frittered it

watches Hawke to see how far

tax conversation comes to mind.

Chrysler-branded vehicles such as

away,” Moss said.

he will fly’. As Hawke spread his

It was a similar story with calls

the Galant and the Sigma.

A new entry to car making in

wings (pun intended), many people,

for recycling of end waste and used

including some union leaders, were

materials. The author argues that “it

as usual with the Falcon, but with

Motors who set-up factories in

critical about his role in forcing a

is cheaper to produce goods freshly

the oil crisis came the Cortina and

Australia to build small 4-cylinder

showdown on a big issue of the

made from new materials than it is

the Escort, which were adapted for

cars in the wake of the 1973

time; price maintenance, and the

from re-cycled waste materials”.

the Australian market from 1972.

oil crisis. Models produced in

The start of the 1970s saw

Australia included the Pulsar,

need to legislate against it.

“Until we can devise a system

For Ford Australia it was business

Australia in the 70s was Nissan

Hawke must have impressed

of either taxing new materials or

Holden launch the new HQ

some, as the author of the article

reducing the cost of re-using old

series in 1971.

called him an industrial Robin Hood.

materials, it is rather uneconomic

“We are strong enough to take what

solution.” The environmentalists

with Holden throughout the 1960s

(Australian Motor Industries) and

we want. If you don’t take it our way

would have had a fit.

and 1970s, had the opportunity

announced plans to spend $27

to visit Detroit in 1970 and noted

million on an engine and gearbox

Car industry

manufacturing at Holden was

production plant in Altona, Victoria

Following the oil crises of

keeping pace with the US.

which began the production of

you can take the consequences,” Hawke said at time.

With beaches in Sydney closed by pollution from sewage and

the 1970s, car companies

50 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Keith Moss, a worker who stayed

“We were right up to them. In

Pintara and Skyline.

In 1972 Toyota bought-out British Leyland’s interest in AMI

engines in 1978.

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1980s Boom and bust

The 1980s saw the restructuring of Australia’s manufacturing industry and the birth of the Button car plan.

Hartley Henderson writes.

T

HE 1980s in Australia

growing recognition of the need to

was a decade of

promote innovation, modernisation

contrasts: economic

and efficiency in order to compete.

boom and bust; famine

Companies increasingly saw

and consumerism; heavy metal

the need to ensure that they

and pop; and the mullet and the

performed at world’s best practice

flattop. Unfortunately, double-

following the lifting of protection.

denim still happened.

While Australians were coming to

A new approach to industry policy was based on the

terms with increasing immigration

implementation of a series of

and multiculturalism, the

industry restructuring plans for the

manufacturing industry was moving

main industries facing difficulties

off-shore to China and South East

with foreign competition, namely

Asia where it could manufacture

the Passenger Motor Vehicle

seemingly the same goods for

(PMV), Textiles Clothing and

less money. The Government

Footwear (TCF), heavy engineering,

soon realised that Australian

steel and shipbuilding industries.

manufacturing was in urgent need

The Motor Industry Development

of restructuring in order to be

Plan (also known as the Button

internationally-competitive.

car plan, after the then Minister

High unemployment in the early

for Commerce, Trade and Industry,

part of the decade was followed

John Button) was introduced in

by an economic boom. Then

the mid-1980s at a time when

came the October 1987 stock

the motor industry was heavily-

program to phase down all tariffs

market crash, followed by deep

protected by import tariffs.

(except for PMV and TFC) to 10% or

economic recession.

Key Government initiatives

The aim was to improve the

15% by 1992.

efficiency of the motor vehicle

impacting manufacturing during

industry through consolidation of

Technological advances

the period included the Hawke

resources, which in turn would

Many Australian manufacturing

Government’s 1983 decision to

enable tariffs to be reduced

companies were now recognising

float the Australian dollar and

and establish a platform for

the need to adapt to changing

introduce financial deregulation,

competitive exports. Consolidation

market conditions and to

as well as the reduction of tariff

of resources involved reducing

improve the productivity of

barriers, and a restructuring of

the existing different models by

production processes.

the industry, which included the

various manufacturers to eight,

Peter Horman, who was the

Button car plan.

and included the introduction

founding managing director of the

The reduction in tariff barriers

of badge-engineered vehicles

Sick Industrial Sensor Company

and the removal of fixed interest

whereby, for example, Holden

for Australia and New Zealand

rates meant that Australian

Commodores were also marketed

from 1982 to 2007, says sensors

businesses were placed in

as Toyota Lexen’s.

played an important role in the

direct competition with overseas businesses, and there was 56 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

In 1988, the government introduced an across-the-board

automation of manufacturing processes and the reduction in

to cover the protected area. Safety regulations were being extended

Fast Facts 1980-1989

to protect operators in machine

• Regulations were introduced to control

environments.

“Bar code readers with incandescent optics at this time were used for reading pharmacy codes for packaging verification, and the research and development of laser bar code readers gave

incandescent light optics. The output

• Button car plan to force proved unpopular with

many more application challenges to

sensors were operating with visible

the metals market

productivity solutions,”

sources were developed, allowing

“From 1980 all photoelectric

systems were introduced in

industry consolidation

1980s, modulated infrared light

manual operation methods.

• New awards and training

industry further options for Horman recalls that during the

Holden’s 1981 VH Commodore was one of the first cars to incorporate an engine from the company’s new (now closed) production facility in Fishermens Bend, Victoria.

Image: GM Holden.

industrial plant emissions

buyers • Stock market crash in 1987 caused deep recession

be solved with sensors, which had

• 120,000 manufacturing

become smaller and more robust.

workers lost their jobs.

Working conditions The February 1981 issue of Manufacturers’ Monthly carried

rise in inflation and unemployment.

The Australian Manufacturing

an editorial about how the

Workers Union’s current (AMWU)

dismantling of the wage indexation

industry and economic advisor,

system was being replaced by

Nixon Apple, who was with the

collective bargaining.

AMWU in the 1980s and 1990s said

“The early introduction of the 35-

the early 1980s and 1990s were

functions of these sensors were

hour working week now appears not

characterised by boom/bust cycles.

basically relay switching, with some

only likely, but inevitable. Disparate

“On average in each recession

analogue output logic devices. The

sections of the union movement will

some 120,000 manufacturing

industrial controllers were mainly

be able during this post-indexation

workers lost their jobs. There was

switching devices with high current

period to pressure individual

a general recognition in the early

switching relays, and the fields

employers for a shorter working

1980s of the need to rebuild the

week with far more self assurance

economic fundamentals of Australian

than they could previously muster,”

manufacturing industry. Even though

the editorial stated.

the Australian dollar was low, there

of application were mainly in the product handling, packing machines and textile machine areas.

“Safety light curtains for the protection of operators of power presses were also using incandescent optics with a rotating mirror wheel to parabolic mirror giving a parallel light beam curtain

In the 1980s, sensors played an important role in the automation of manufacturing processes.

Some concerns were raised by

was an urgent need to combine

the Confederation of Australian

the Government decision to pursue

Industry that the general

tariff reductions with positive

introduction of a 35-hour week

industry and trade development

would add $10,000 million to the

policies to develop stronger global

annual wages bill and result in a

manufacturing capability in Australia

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 57

1980s Boom and bust as the country could no longer

to GDP shrank significantly.

live off mineral resources and the

However, in terms of employment,

establishment of the Industrial

sheep’s back,” Apple said.

manufacturing was second only

Supply Network, that later became

to the retail sector,” Herbert told

the Industry Capability Network.

Era of accord Bob Herbert, who was Victorian

“The union’s drive for a shorter working week is nothing less than a disguised pay hike for those still in work,” Managing Editor, Norman B. Rydge.

Manufacturers’ Monthly.

“MTIA had made a major shift

“One positive initiative was

“Restructuring meant that industry progressively became

director of the MTIA in the 1980s

in approach to support a global

more competitive and was

when Victoria was very much

engagement, but argued that

better able to engage in the

regarded as The Manufacturing

the initiatives of the Hawke/

international marketplace, as well

State, said it was an era of

Keating government should be

as stimulate import replacement

accord that was in play and MTIA

more interventionist to support

at home. The Button plan for

supported that process.

manufacturing. It was a time when

the automotive industry was

manufacturing had much to absorb,

particularly important for Australia

of immense challenge with a

including financial deregulation,

because of its position as a

spate of factory closures, and

tariff reductions, and consequent

critical provider of technology and

manufacturing’s contribution

industry rationalisation.

skilled jobs,” Herbert said.

“The early 1980s was a time

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58 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

’ S R E R TU RDS C A F U N A A W M A R R O F OU E V L A A E S D N N E O L W A O U N N S' S N T A TURER E C A H F K U T N !

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Comment

Food industry remains healthy

Equipment innovation, shifting consumer habits and recession pressures have created a turbulent 50 years for the food manufacturing sector.

T

HE 1960s was a decade of considerable change for Australia. Fifteen

years of intensive immigration had injected some 1.5 million people into the country’s population; this growth resulted in a suddenlyflourishing workforce and meant Australia was able to progress from what had been largely a nation of primary industry – cattle, wheat, etc – to one of manufacturing. unprecedented prosperity as well

For Heat and Control, one

After the 1980s recession,

as significant and lasting social

invention followed another, with

demand for new food products

changes which brought about

the creation of production line

began to pick-up and with it, an

increasing numbers of dual-income

oven and fryer technology, which

increase in food manufacturers’

families. With less time available for

focused on the market for snacks

capital for equipment purchasing.

food preparation and cooking, a new

and prepared foods.

market for convenient, prepared and packaged foods emerged.

Throughout the 1970s and 1980s, a wide variety of processed

Frying systems were

Nevertheless, towards the end of the millennium there were

revolutionised through the invention

significantly fewer machinery

of the external heat exchanger.

manufacturers than there had been

A little later came the

at the beginning of the 1990s.

foods became available; the

multipurpose oven or MPO Cooking

marketplace became more

System, which allowed for much

mean that today’s industry

competitive and demand

more precision in preserving

largely operates within a

intensified from food companies

the original moisture content

global community, with large

for an increasing variety of food

and food flavours; by controlling

multinationals helping to

processing machinery.

the interaction between cooking

shape the food machinery

temperature and moisture, a rapid

developments from a network of

Control, MPI and Linco Food Systems

heat transfer could be achieved,

regional bases. In Australia the

rose to meet this demand, with

without the problem of dehydration.

industry continues to develop

Companies, such as Heat &

advanced and specialist machinery

David Stone EDITOR Food Magazine

Installing a heat exchanger for a potato chip line in 1976. Image: Heat & Control.

The 1960s were marked by

For the last 50 years, the

Evolving business trends

alongside changing tastes and

designed to tackle everything from

Australian processed food market

bakeries and meat processing to

has been changing and this

beverages and quality packaging.

has resulted in a need for more

automation, the reduction of water,

There was a shift from batch

eating habits.

Emphasis is increasingly put on

specialised food processing

of energy consumption and meeting

production to a continuous cooking

machinery. Smaller-scale commercial

sustainability goals, but also on

process, automation for individual

ovens and niche application

improving flavour and texture,

functions was introduced, and

products began to appear throughout

and making food that is generally

whole-line systems were created.

the 1970s and 1980s.

healthier for the consumer.

62 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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1990s

Joining the world stage

While manufacturing was becoming more specialised in the 1990s, it was also becoming more open.

Hartley Henderson reports.

W

HEN globalisation lead the way for grunge and retro-inspired

fashion, the republican debate was threatening ties with Britain, and Sydney was gearing-up for the 2000 Olympics, members of the global manufacturing industry started to get to know each other.

Using a great new thing called ‘the internet’, manufacturers could start

The export market was booming and Australian manufacturers truly became exposed to the world. Image: Ubeeco.

to see – for the first time – what competing businesses were doing in the facilities across the other side of

“Over the longer term,

the world. This transparency started

the increasing openness of

to fuel stiffer competition, as well as

manufacturing meant that, whereas

collaboration and, finally, productivity.

manufacturing exports were only

Manufacturing imports and exports

about 14% of total Australian

grew exponentially during this time,

exports in 1963-64, they stood

and businesses flourished in the

at just under a third of exports in

new global marketplace.

1997-98,” the researchers state.

Australian products became

Productivity Commission

known for their high quality –

research shows that the

especially compared to some

1990s was a stable era for

of their neighbours – and local

manufacturing, with growth rates

businesses looked outside their

less variable than past decades.

own backyards for extra coin.

According to a Productivity

“For example, for manufacturing as a whole, volatility was less

Commission research paper called

than half that prevailing in the

Trends in Australian Manufacturing

previous two decades. This

(2003), exports increased from just

probably reflects the fact that,

over 15% of manufacturing output in

other than in 1990-91, there were

1989-90, to around 24% in 1999-

no general economic downturns in

2000, with import shares also rising.

this period,” the writers say.

The paper points out that while

Australian manufacturing was

both simply- and elaborately-

becoming increasingly open. In

transformed manufacturers

1999-2000, over one-third of

(STMs and ETMs) showed

domestically-sold manufactured

substantial growth, export growth

goods was produced overseas

of ETMs was particularly strong,

and about one-quarter of

growing by over 130%.

domestically-produced goods was

64 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

The 1990s was a stable decade for manufacturing. During this time, more firms looked to automation and robotics to give them a competitive edge.

Exports increased from just over 15% of manufacturing output in 1989–90, to around 24% in 1999–2000, with import shares also rising.

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the spirit of safety

1990s

Joining the world stage

The now retired former managing

and failsafe detection requirements

director of Sick Industrial Sensor

by industry increased. Safety light

Company, Peter Horman, says

curtains became solid state with

advances in light emitting diodes

an array of beams replacing the

revolutionised the design and

need for moving parts.”

capabilities of sensors, allowing

Horman said colour sensors were

them to be used in more numerous

also established allowing many

and various locations throughout

applications in the packaging and

industry in the 1990s.

printing areas to be solved.

“The need to network the

“Scanning laser beam devices

sensors was recognised and with

also became more intelligent

the advance in PLC and electronic

allowing large safety areas

controller designs, sensor design

to be protected, and volume

and outputs were modified to meet

measurements and intelligent

the automation requirements.

barcode scanning applications to be

“Robotics in automation areas

Automation became more commonplace in the 90s and productivity increased. Towards the end of the decade, there was an increased focus on worker safety. Image: Mrs Mac’s Pies.

GM Holden, recalls the late 1980s

realised,” Horman said.

increased the need for smaller

“In the paint shop, the biggest

and early 1990s was when welding

change was going from hand

and more intelligent sensors.

Car industry changes

operations in the body shop moved

spraying to automated spraying in

Visible infra-red diodes enlarged

In the 90s, the automotive industry

from a complete manual shop to

the late 1980s and early 1990s,

the application of sensors for

rationalised from five manufacturers

the heavy use of robotics.

and then to robotic spraying.

proximity detection and control,

producing 13 models of passenger

“This continued to the point

solving background interference in

vehicles at eight plants in 1985 to

where the shop that makes the

modular approach to the vehicle.

proximity detection applications. In

four manufacturers producing five

Commodore range is now about

Things like completely developing

particular, ambient light interference

models at four plants by 1999.

98% automated. Also, through the

a cockpit module as an off-

was no longer a problem in sensor

But over the same period, industry

1990s and early 2000s, a lot more

line sub-assembly, rather than

application areas.

production increased.

automation, including robotics, was

assembling it in the vehicle, and

installed in the press shop,” Phillips

other modules included the rear

told Manufacturers’ Monthly.

suspension,” Phillips said.

Richard Phillips, director of

“Sensors became more intelligent as critical measurements

vehicle assembly operations at

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2000s We can do it all

The turn of the century brought new challenges for manufacturers who needed to become more flexible to survive.

Sarah Falson reports.

M

ANUFACTURERS

the Australian Manufacturing

have experienced

Workers’ Union, financial stimulus

their fare share

packages during the time saved

of ups and downs

an extra 50,000 manufacturing

over the past decade in Australia, but they have continued to thrive roll with the punches, and they

Technology advancements

make the best of what they’ve got.

No doubt, the 2000s have been

because they are flexible, they can

Manufacturing output has

tough for manufacturers. Fussy

grown rapidly since the inaugural

consumers, expensive raw

Manufacturers’ Monthly in

materials and rising transportation

1961, quadrupling by 2003. The

costs have made our industry a

industry’s share of total output has

harsh judge of character, where

progressively fallen however, in part

only the innovative survive.

due to the rapid rise of the resources

But survive we do. Australia now

sector. In 2001, manufacturing GDP

has one of the most technically-

was 11.6% – a figure that has been

advanced manufacturing industries

declining steadily from around 30%

in the world, developing some of

in the mid-1950s.

the most cutting-edge products on

Exports were strong in the early

the market. Cochlear, Resmed,

2000s, reaching above 25% of

Bluescope Steel, Onesteel, CSR

manufactured goods sold, however

and Boral are just some of our

this figure dropped off approximately

local success stories, proving that

innovation are most important for

5% by mid-decade due to the high

specialist products, often with high-

them, and why.

Australian dollar – a scenario we see

IP, are our strong suit.

mirrored in today’s economy.

From 2000 to the present, the

“They need to do whatever it takes – develop new products and designs,

expectation for manufacturers to

use advanced technologies, bundle

Australian manufacturers had

‘do it all’ has skyrocketed. Staying

products and services, use better

learnt the importance of playing

on top of the latest technology,

processes for market intelligence

farther afield, and multinationals

innovating to compete globally,

and assess customer responses,

were becoming more common.

reducing production costs (and

and manage international networks –

International competition – both

time), and keeping valued staff in

in a coherent, strategic manner,” the

here and overseas – forced locals

a skills crisis, are daily concerns

paper reported.

to aim higher.

for companies.

By the turn of the century,

The onslaught of the 2008 “‘Time moves on and waits for no-one’, which is why MM, even though it has technically reached what most call ‘middleage’, is in effect barely touching its prime,” Editor, Branko Miletic, MM May 2001.

workers from losing their jobs.

According to a 2005 NSW

Many of the most important manufacturing techniques used

global financial crisis hit

Business Council report, Innovation

today were developed to reel-in

Aussie manufacturers hard,

– the future of Australian

costs, maintain quality and raise

with thousands of workers

manufacturing, manufacturers

output. The majority of plants

losing their jobs as companies

must improve existing ways of

now incorporate some form of

moved offshore or closed

doing business across the board,

automation, along with more

down completely. According to

by defining clearly which kinds of

sophisticated IT systems allowing

76 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

become common over the past ten years, streamlining management,

are manufacturers entering export

simulation and workflow controls

markets, they are also embracing

into a single unit. Though a

local opportunities. Off the back

smaller number of reports and a

of the mining boom, construction,

single interface are real benefits,

technology, transport and IT

the process visibility achieved

products are required on-mass.

with systems integration shows

In building, products made from

manufacturers exactly where they

more sustainable materials are

can save money.

needed. Across the board, solar

‘If you can’t measure it, you can’t manage it,’ has been the catch-cry of the decade. Intelligent automation

‘If you can’t measure it, you can’t manage it,’ was the catch-cry of the decade. Here, operators at an O-I glass plant keep an eye on production.

Flexibility is the key. Not only

power and energy management systems are essential.

Advanced robotics, wireless

systems can now manage a plant’s

communications, broadband

energy use, safety systems, and

internet, laser welding, hydrogen

quality levels. Using this information,

fuel cells, simulation, cloud

manufacturers can react quickly

computing and mobile devices are

to change, such as new laws and

just some of the new technologies

regulations, standards, product

developed during the 2000s helping

lines and materials. Maintaining

manufacturers meet these needs.

volumes while catering for more

Heinz site manager – Wagga,

niche consumer demands is now

Phil McVeigh, says manufacturers

more realistic.

are born pioneers. It’s one thing to

greater process visibility and, in

roll with the punches when change

turn, more quality and cost control.

According to Mrs Mac’s pies

Nation of pioneers

occurs, but it’s another thing

According to Australian Made,

entirely to embrace new battles,

managing director, Iain Macgregor,

Australian Grown chief executive,

and answer them with innovation.

advanced production technology

Ian Harrison, manufacturers are

has had a huge impact on his

reacting to change in a more

huge driving force. Ten years ago, it

Western Australian plant’s

positive manner.

was safety. And now, environment is

“The need to be innovative

productivity over the past decade.

“Production levels have risen exponentially with a corresponding fall in operating costs. Engineering and staff skills have changed dramatically as manufacturing and distribution technology has evolved. IT is now a key department heading our ongoing development,” Macgregor told Manufacturers’ Monthly.

Systems integration has

“Manufacturers need to do whatever it takes, in a coherent, strategic manner.”

– NSW Business Council, Chief Executive, Australian Industry Group.

“Twenty years ago, quality was the

the driving force. If you manage your

has become pivotal for

quality right, and you manage your

manufacturers in the last 10

safety right, and you manage your

years. Manufacturers have

environment right, your costs will go

increasingly embraced the

down – it’s as simple as that,” he

continuation of a global focus and

told Manufacturers’ Monthly.

the need to succeed in export

“Every year, we re-set, and

markets. Australian manufacturing

we say, ‘What will be the big

has become very high-tech in the

challenges this year?’ We welcome

last 20 years. We are very good

that. Manufacturers have got to the

at what we do,” Harrison told

point now where change is just a

Manufacturers’ Monthly.

part of life. It’s part of the fun.”

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 77

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Future

Into the crystal ball

Why ‘smart manufacturing’ is the way of the future.

Sarah Falson writes.

F

IFTY years ago, this magazine hailed ‘methods manufacturing’ as the

way of the future. Standardising equipment and training staff to work together were the ideas of the hour. Twenty years later, ‘lean manufacturing’ was on the agenda, cutting-back materials and staff costs. Now, in 2011, a new term is being coined, encouraging us to be methodical, lean, and above all, smart. Yes, Cars of the future will run without the need for oil. Image: GM Holden.

‘smart manufacturing’ has been born, and you heard it here first.

Today, carbon pricing, waste

a global village of engineers

make important decisions as they

management, water shortages,

to collaborate on new ideas

start building a more responsive

supply chain efficiencies and

and develop new products.

and agile organisation, through

electricity costs are the biggest

Manufacturers will continue to

improvement in productivity and

stepping stones for industry.

develop ground-breaking ideas to

efficiency,” Holmes said.

Manufacturers that find ways to

manufacture ‘smarter’, and in turn

‘do more with less’ will shape

will create some of the greatest

general manager of O-I Australia

Australia’s future. In the future,

new technologies known to man.

– a Sydney-based glass bottle

rising material costs will lead to

This is not just a pipedream,

Closer to home, Brian Slingsby,

manufacturer – says smart

an even more intensified need for

according to IDC analyst,

manufacturing is already making

productivity and efficiency in the

Chris Holmes, in his report,

its way into his plant.

production line and, as a result,

IDC Manufacturing Insights. In

businesses will demand more

2011 alone, productivity and

[waste] use and safety are key

from IT as they expand globally.

efficiency will be top-of-mind for

areas of focus, and technology

manufacturers in the Asia Pacific

advancements continue in all

manufacturing’ principles will

region, and companies will spend

aspects of glass manufacturing

adopt new mobile devices and

the money to make this happen.

from melting, inspection and

Companies that heed ‘smart

embrace cloud computing. They

“While cost will definitely

“Energy use, emissions, cullet

packaging. We have a team

will look more closely at their

be one of the considerations,

dedicated to working on

supply chains both here and

the focus will shift toward

developing and implementing

abroad, and come up with new

cost efficiency rather than

emerging technologies and

ways to tap into regional growth.

cost reduction. Streamlining

each O-I region is responsible

workflows, and better visibility

for commercialising new

will be used by most

of enterprise information will

technologies and turning them

manufacturers, improving cost

also get increased attention as

into reality,” Slingsby told

and quality control, and allowing

these will help manufacturers

Product lifecycle management

82 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Continued on page 84

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Future

Pushing the boundaries

Into the crystal ball (Continued from page 82)

T

HE manufacturing

also intensifying shortages in

industry has played a

the supply of a growing range of

leading role in wealth

skilled occupations.

creation in Australia

These forces were emerging

for much of our history. In recent

before the recent global

decades it has undergone

financial crisis (GFC) and have

significant changes in the face

quickly re-emerged over the

‘smart manufacturing’ will be

of seemingly insurmountable

past year or so. The GFC itself

at the forefront of innovation.

challenges.

saw a collapse in global trade

Manufacturers’ Monthly.

Manufacturers who embrace

Those who take the leap will be

Australian manufacturing remains

that hit manufactured exports

responsible for finding new ways

a vibrant and versatile industry

particularly severely and a

to protect the planet, and all of

that has shown over its history an

retreat from spending on the

us living on it. They will find ways

ability to adapt and prosper. It plays

part of local consumers and

to tap into new energy sources,

and will continue to play a vital role

businesses. This caution and the

and develop new motors that

in the Australian economy both

resulting weak domestic demand

allow cars to run without the need

during the current mining boom and

has persisted and has been

for oil. They will further develop

beyond, when it will be required

prolonged by the swift increase

affordable, modular housing,

to sustain economic growth in the

in interest rates over the past

allowing everyone to own their

absence of the windfall from high

year or so. On top of this, recent

home. They will continue to evolve

mineral prices.

reductions in immigration have

healthy, low fat natural foods,

Despite the ongoing

reduced demand growth and are

lessening the global obesity

importance of Australian

epidemic, allowing our children to

manufacturing, the industry is at

live longer, more comfortable lives.

a key juncture. The rise of new

poses formidable challenges

centres of manufacturing around

for the industry. Challenges,

forefront of this new wave. We

the globe – most notably China

however, are not new to

were 50 years ago, and we will be

and the boom in prices in mineral

manufacturers who are intent on

in 50 years to come.

commodities and the associated

adapting, investing and looking

rush to expand output and export

for new opportunities.

And Australia will be at the

Product lifecycle management will be used by most manufacturers in the future.

facilities – is at the centre of current challenges.

On the one hand, Australian

exacerbating skill shortages.

This combination of forces

The manufacturing industry is vastly different to what it was 50 years ago. The image of low-

producers are facing increased

skilled and highly labour-intensive

competition and lower prices in

factories has been replaced

domestic and export markets. On

by modern production systems

the other hand, with the Australian

featuring high innovation and

dollar at around 40% above its

technology processes and lean

post-float average against the

manufacturing requiring skilled

US dollar, imports are becoming

labour. Manufacturers have

even cheaper and exports from

increasingly extended themselves

Australia are becoming more

into provision of services around

expensive. The mining boom is 84 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Our manufacturing industry is pivotal to the growth of our nation, explains Heather Ridout.

Continued on page 86

Heather Ridout Chief Executive, Australian Industry Group

A decision for quality

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Celebrating 50 years | Manufacturers’ Monthly May 2011 | 85

Future

Pushing the boundaries

(Continued from page 84)

industries providing construction

manufacturing of high-tech goods

their core products. They are also

and building materials.

and related services.

increasingly globally focused and

Australia also is a very

There are, therefore,

competing and investing in world

significant producer of minerals

fundamentally good reasons to

markets. From its contemporary

and agricultural goods, which

expect that manufacturing can rise

base there are considerable

provide a source of tremendous

to meet current challenges, just as

opportunities. Three broad areas

opportunity for manufacturers in

it has risen to meet challenges in

in particular stand out.

food processing, metals, plastics

the past. This is not to say that the

and paper products, for example.

challenges are not very substantial,

There are clear opportunities in linking closely with the provision

Another broad area of

but it is a vote of confidence firstly

of manufactured inputs and

opportunity relates to our

in the industry itself and secondly

associated services for the

‘know how’ – the human

in the ability of Australians and

booming mining and mining-related

capital, technology and design

Australian governments to find

construction sectors. Australia is

capabilities that Australia has and

new ways to build for the future,

a significant mining equipment

continues to invest in. Significant

to make investments and to

provider and has world-class

opportunities lie in niche

encourage success.

9 1

.2 .9 4 2

86 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

1 1 0

“Challenges are not new to manufacturers who are intent on adapting, investing and looking for new opportunities.”

– Heather Ridout, Chief Executive, Australian Industry Group.

The world of metalworking

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Integrated systems specialists

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According to Dexion Executive General Manager ANZ, Mark Barraclough, Dexion can service customers of all sizes in the region.

“We cover the entire spectrum of businesses. From supplying high-end business systems where customers are moving many thousands of parcels or products a day, through to single operators who want some shelving in their office or racking in their warehouse,” he says.

Barraclough describes Dexion

Quality is the cornerstone of the solutions and products we provide.

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“Readers will probably be familiar with Dexion’s market leading pallet handling systems, but today,

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of Kimberly Clark’s effective

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(franchises – independently

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Dexion developed, while others

in, Barraclough says.

Barraclough says Dexion is

“This mix of solutions, products

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and services ensure an unrivalled

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Dexion Real Time Distribution

control of the equipment in the

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distribution centre.

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Using just a laptop, the operator

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Celebrating 50 years | Manufacturers’ Monthly May 2011 | 87

Endeavour Awards Celebrating 50 years of innovation COMPILED BY MARGARET TRA

COLIT In 1999, COLIT – trading

Drum roll, please

ANCA

as Punch-IT Systems – was

Formed in 1974 by two founders,

developed in Victoria by two

ANCA has since expanded to

machine operators. It sold

280 employees Australia-wide.

Integra Tooling Systems’

Specialising in CNC controllers

world-first linear high-speed

and Tool and Cutter Grinders,

coil punching lines, called

BY SARAH FALSON

on the night. These are: Technology

ANCA provides solutions for

Punch-IT. In 1999 an alliance

Ninety-nine entries, six months

Application; Consumer/Trade

complex applications. ANCA

was formed with Union Steel,

of hard yakka and two weeks of

Product; Industrial Product; Steel

cultivates an innovative culture

resulting in a division called

intensive judging mean we can

Innovation; Exporter; Environmental

to engage customers. It is a

UniBlanks to sell added-value

now reveal the shortlist for the

Scheme; Enterprise Connect;

complex and robust manufacturer

products to existing customers.

final two categories in the 2011

Global Integration; Safety Scheme;

that aspires to be a global leader.

Manufacturers’ Monthly Endeavour

Young Manufacturer; Lifetime

Awards – ‘50 Years of Innovation

Achievement; and of course, Most

Austal

LyondellBasell Australia was

1961–2011’ and ‘Technology

Innovative Manufacturing Company

Formed in 1988, Austal makes

established in 2007 by a merger

Application of the Year’.

1961–2011.

customised aluminium vessels

of Basell and Lyondell, with

And not a moment too soon.

LyondellBasell Australia

A huge ‘thank you’ to our

for commercial and defence

manufacturing sites in Clyde and

Because, as you know, our

sponsors who will be there to

applications. The company

Geelong. The company employs

magazine is celebrating 50 Years of

support us: Atlas Copco, SICK,

has delivered more than 200

153 workers in Australia, with

Innovation itself this month, which

Phalanx Consulting Group,

vessels to 37 countries,

38 operators at the Clyde site.

is why we made you all wait so

Advance Metal Products, Industry

and employs 750 people in

LyondellBasell manufactures

long to reveal the finalists in this

Capability Network, Export

Australia and 2,500 worldwide.

51 homopolymer and impact

category. You can thank us later.

Finance & Insurance Corporation,

Austal wants to expand its

copolymer grades and continues

Our country develops some of

Enterprise Connect, Skilled, ifm

presence in the defence and

to develop new offerings. Future

the top manufacturing equipment

efector, Siemens PLM, NHP, and

commercial markets.

markets include coal and gas.

and uses the best production

especially BlueScope Steel, who is

techniques in the world. We

this year’s overall Awards sponsor.

Byron Group

Marand

should be proud of ourselves

See page 18 of this issue for

Byron Group began operations

Marand Precision Engineering

for innovating, when market

an interview with BlueScope

in 1963 and focused on quality

was formed in 1969. In the

conditions are against us.

Steel acting general manager –

sheet metal products, building

beginning Marand focused on

Industrial Markets, Steve Gregson.

all the masts for Australian

making tools for the Australian

and French yachts in the

automotive industry, however

The Australian manufacturing industry is a tough beast, and it

For those attending on the

will continue to thrive during the

night, we will be treated to a

America’s cup series, and

in the mid-1980s demand

next 50 years.

special address from Innovation

supporting Qantas for Aircraft

lessened so it diversified

Good luck to all the finalists;

Minister, Senator Kim Carr, and

parts. Today it operates out of

into steel, mining, rail and

we hope to see you at the

we also have a little surprise for

four manufacturing facilities

aerospace. Marand aims to be

8th Annual Endeavour Awards

our guests to get us all in the

in Sydney, with workshops

Australia’s largest supplier to

ceremony on 25 May 2011 at the

festive mood. It’s sure going to

around the country. The firm

the Joint Strike Fighter defence

RACV Club in Melbourne. All 12

be a night to remember. Long live

has expanded into emergency

program with a possible $1.5

category winners will be presented

Aussie manufacturing!

services and airline support.

billion in contracts.

88 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Finalists 2011 Robotic Automation

Victoria. The company now has

products for home and family care,

other materials. WASA uses

In 1988 Robotic Automation (RA) was

22 employees producing products

including cleaning, laundry, kitchen

CAD systems to assist design,

born, with manufacturing facilities

with paper and adhesive, including

care and body care. Tri Nature was

producing an array of fasteners

in Australia and New Zealand. It

carbon neutral paper sticky notes,

the first company to manufacture a

from just about any material.

manufactures turn-key automated

note pads and highlighted tape.

phosphate-free powder for laundry.

solutions for traditional manufacturing

Stikki designs for the Australian

companies. RA integrates robotics

market and sells to business and

with its own custom-built end-of-arms

consumer customers.

(EOAT) tools, and other automation

O-I Asia Pacific Washers and Stamped Components Australia

O-I Asia Pacific, a local glass packaging supplier, was born in

Washers and Stamped

1980. The company has 14 glass

equipment to engineer an integrated

Tri-Nature

Components Australia

plants and one mould shop across

solution that aids the process in a

In 1989 Tri-Nature was formed

(WASCA) is a family business

Australia, New Zealand, China and

production line.

to bring the marketplace natural

established in 1964 in Victoria,

Indonesia. It specialises in glass

solutions for industrial, household,

manufacturing washers and

packaging for the beer, wine,

Stikki Products

and personal care. Tri-Nature

stamped components. It has

spirit and non-alcoholic beverage

In 1976 a small Australian-owned,

manufactures on-site in Kooragang,

since increased its capabilities

markets. Innovation and design

family business was formed in

NSW. It carries in excess of 200

to parts in rubber, fibre and

are very important to O-I.

Modern solutions with a timeless service.

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.

1 1 20

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

nhp.com.au

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 89

Endeavour Awards Technology pivotal to product success COMPILED BY MARGARET TRA

a flexible solution encompassing full integration of a new robotic

Coca-Cola Amatil

system and modifications to

PET bottle self-manufacture

existing systems to enable them

Coca-Cola Amatil Supply Chain and

to remove the manual handling of

Krones Germany have designed,

timber pieces.

installed and commissioned two new production lines at Coke’s

SmartRider

production facility in Sydney.

SmartRider

These lines enable PET bottles to

SmartRider used composite

be blown and immediately filled

materials engineering firm Marco

on-line, eliminating the need to

Engineering in Brisbane to create

purchase and transport bottles

a unique horse-riding stirrups

from another facility, therefore

range called ‘Escape’ Breakaway

increasing the flexibility of the

Stirrups. The tool-making and

production lines.

plastic injection moulding facility was able to engineer the

Hawk Measurement Systems

lightweight stirrups in eight bright

Gladiator Self Cleaning Acoustic

The stirrups are designed for

Level Switch

safety, and ‘break away’ from the

A large export coal mine had

foot in the event of a fall, allowing

problems with microwave and

the rider to be freed immediately.

colours, with built-in UV protection.

Nowadays, it’s the technology that takes your concept from design to production that makes (or breaks) an idea.

admittance probes on blocked chute applications because

Govan Industries

of high dielectric magnetite

SAIPEM – ENI India, Power

manufacturing operations has

used an ‘off the shelf’ system

and coal fines build-up. Hawk

Distribution Panel

allowed the company to enter a

using ‘off the shelf’ products,

Measurement Systems used

Govan Industries supplied Saudi

new market, developing Carbon

which gave it a competitive

its automatic cleaning acoustic

Arabia a range of explosion-proof

Neutral Paper Sticky Notes for

edge since traditional military

Gladiator switch that removes

electrical power distribution panels

B2B and consumers. Though

methods are expensive. A

build-up and is not affected by

for the oil and gas industries.

most sticky notes manufacturers

new aluminium profile building

the high dielectric environment.

These were made according to

in Australia import their products

system reduced costs and Ryan

The acoustic switch is a dual

customer specifications. The

for cost reasons, Stikki can

has since signed with Boeing.

transducer system.

company used CAD, along with

manufacture various lines here

streamlined purchasing, planning,

in Australia. The Carbon Neutral

Benedict Industries

Fenning Bairnsdale

manufacturing, testing, inspection,

offering saves costs and waste.

Benedict Recycling Chipping

Robotic Timber Sorting and

packing and invoicing procedures,

Stacking

to reduce waste and labour cost.

Norton Resource Recovery

Ryan Aerospace

Facility

Helimod Helicopter Simulator

Benedict Industries’ Recycling

(MAR) designed an automated

Stikki

Ryan Aerospace (Australia)

Resource Recovery Facility is a $30

solution for Fenning Bairnsdale

Australian Carbon Neutral Paper

has manufactured the world’s

million state-of-the art building and

– a timber conservation firm – to

Sticky Notes

first low-cost, reconfigurable

construction waste recovery facility

eliminate the need for manual

Custom-made manufacturing

helicopter simulator using

in Sydney. The team invested in

stacking. The company required

equipment in Stikki’s Australian

advanced 3D CAD. The company

optical sorters, wind separation, star

Machinery Automation & Robotics

90 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Finalists 2011 screens, trommels, eddy currents

order to custom-manufacture the

solution incorporating a Major

production time and little waste

and magnet systems, saving over one

system. This removes waste and

Materials Robotic Loading System,

meant the unique vehicle has not

million tonnes of waste from landfill.

improves service.

a Minor Materials Robotic Loading

only found a market niche, but also

System and a SCADA system.

uses lean manufacturing principles.

Centor Centor Online iPad Application

Dulux Group and Robotic Automation

Brisbane-based Centor manufactures

Robotic Compositing, Handling &

hardware systems for folding

Stocking System

Fast ‘n’ Fun

Formero selective laser melting

and sliding doors. The company

Compositing the various powder

TA-37

(SLM) technology is currently being

developed its own ‘quote and order’

ingredients of a customised

Fast ‘n’ Fun, which hires radio-

used by Rex Bionics in Perth to

iPad application called Centor Online,

powder-coat product was a

controlled entertainment transport,

develop custom-made prosthesis.

which the company has rolled-out

labour-intensive process requiring

teamed with maintenance firm

The technology has already

across its business in Australia and

DuluxGroup staff to handle and

Mini Driver Grader & Earthworks to

been successfully trialed for the

overseas. It provides pricing and

decant loose, heavy bags of

develop the Trade Assistance (TA-

purpose of making a custom hip

technical illustrations, takes orders,

powders, in different sizes weighing

37) – an all-in-one grader, mower,

implant. SLM can provide custom

and prints quotes and orders on a

up to 25kg each. DuluxGroup

loader and dozer. The TA-37 was

metal parts in titanium and cobalt

mobile printer and emails them to the

worked with Robotic Automation to

manufactured of 80% roll-formed

chrome for the defence market,

customer. It then creates a production

develop and install an automated

steel from BlueScope Steel. A short

medical and dental industries.

They were able to deploy nine staff members to safer areas.

Formero Additive Manufacturing projects

The best product designers have an edge.

Solid Edge. Design better.

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will help you reach your design potential—and help your company realize greater success.

Go to siemens.com/plm/gettheedge © 2010 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. Solid Edge is a 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 used herein are the property of their respective holders.

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 91

STS - Camtek KeyCreator 2011 KeyCreator 2011 • Explicit modelling.

• Hybrid design.

• “DDE” Solid editing.

• Superior Surfaces.

• Integrated Drafting.

• Excellent Translators.

• Unbeatable PRICE that includes • 12 mths Maintenance & Support.

Austech Stand #

690

STS, CAMTEK,

VISI 19 - CAD CAM NCG CAM 10 NCG CAM 10 is the VISI 19 is a full CAD/ worlds easiest CAM system to learn and use.

And STL machining is a breeze. NCG CAM includes the full range of HSM Milling from 2, 2.5, 3, 3+2 Axis and 5 Axis machining at BEST in Show Prices.

Tel 03 5625 5200 Tel 03 9588 2390

VISI 19 Expert 2.5D VISI Expert 2.5

automates all your 2 CAM system of the high- 2.5 axis machining est quality suitable for: using your own expert Automotive, Aerospace, knowledge base. ComTool Design, General Enplete AFR/MFR with all gineering & much more. features being machined Parasolids kernel with great translators, excellent Surfaces, to your custom settings. See a VISI Solids and 2 - 5 axis Machining.

Expert 2.5D demo on Stand 690

Intelligent Drivesystems, Worldwide Services

NORD DRIVESYSTEMS THE “GERMAN“ ALTERNATIVE

Complete Drivesystems from a single source.

NORD Drivesystems (AU) Pty Ltd 18 Stoney Way, Derrimut, Victoria, 3030 Australia Phone: +61 3 9394 0500, Fax: +61 3 9394 1525, www.nord.com.au National Customer Service 1300 00 NORD (6673), au-sales@nord.com

DRIVESYSTEMS

The Most Complete Range of Planetary Gearheads Â? Stocked

in Australia - supported ported worldwide Â? Suit all servo and stepper motor brands Â? Easy selec on with online Design DesignTool Tool

Â? Online drawings and

Â? IP67

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True Helical Technology Â? Â? 100% Maintenance-free Â? Two year warranty Thinking â&#x20AC;&#x153;insideâ&#x20AC;? the Box Â? Quiet

www.apexdyna.com.au

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m nts :1 EM 0 m kla

-in eme c

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APEX DYNAMICS AUSTRALIA 36 Taunton Drv Cheltenham VIC 3192 Tel: +61 3 9585 2739 sales@apexdyna.com.au

Quality Value Delivery

Hoisting productivity without lowering safety.

ABB low voltage AC drives with direct torque control (DTC) provide smooth speed and torque control, cutting crane movement cycle times and optimizing crane capacity. Safety is enhanced via mechanical brake control with new productivity levels through quick and easy programming.

To raise your productivity expectations to new heights, visit www.abb.com/drives

ABB Australia Pty Limited Phone: 1800 222 435 E-mail: drives@au.abb.com www.abbaustralia.com.au

THIS MONTH’S PRODUCT FEATURE IS THE VACUUM LIFTER JUMBO FLEX 35

The vacuum lifter that can lift and move a huge range of products weighing up to 35kg and can handle boxes, bags, sacks, rolls of film and many other items as well.

Lifting, lowering and releasing of the load are controlled with a single trigger action on the operator control handle, this handle is also suited for both left and right handed operation

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

HANDLING SOLUTIONS

LIFT & MOVE SHEET,

STEEL OR WOOD

EASY LOADING OF YOUR CNC

JIB CRANE

WORKSTATION CRANE

FOR THE WOOD INDUSTRY

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

FREECALL 1800 99 22 11

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

maxon compact drive

Three in one. maxon compact drive Motor, sensor and controller in one.

When it concerns compact drive intelligence, maxon compact drives are called for: motor, sensor and controller are all integrated in an aluminum case. Link the drive through the CANopen network and solve even complex tasks with the programming tool included, "EPOS Studio," in no time at all. maxon motor is the worldâ&#x20AC;&#x2122;s leading supplier of high-precision drives and systems of up to 500 watts power output. Rely on the quality of the highly specialized solutions which we develop with and for you: Tel. +61 2 9476 4777, info.au@maxonmotor.com, www.maxonmotor.com.au

maxon motor driven by precision

fast track your business with Epicor ERP manufacturing & distribution software

Visit us at Stand 3507

w w w. c o g i t a . c o m 1300 COGITA

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Epicor ERP â&#x20AC;&#x201D; acclaimed software built for manufacturing, designed for individuals and ready for fast changes to your business.

Proven performance implementations in Victoria, New South Wales, Queensland, South Australia and New Zealand.

NMW 2011 Conference to focus on strategies for success An expanded National Manufacturing Week Conference will run alongside this year’s NMW 2011, on the theme of Embracing innovation for a competitive, efficient and sustainable future.

This conference, which will be in addition to the demonstrations and product shows running in NMW’s demonstration area, will bring manufacturing leaders, consultants and policymakers together to discuss industry challenges.

Its aim is to give participants the details of strategies

that have worked, as well as opportunities that are arising and actionable advice on why and how innovation can help business growth.

Speakers will include experts from Toyota Australia, Schiavello Group and Branach Ladders, as well as from Government and consultant organisations. The full conference program and costs will be published shortly on nationalmanufacturingweek.com.au.

In other news, strong bookings have meant that the combined NMW, Austech and Ausplas exhibition will take up most of the Melbourne Convention and Exhibition Centre.

The NMW exhibition space has had a substantial face lift. It now features a simplified layout, based on 10 separate, colour-coded Product Zones to make it easier for buyers and sellers to find each other.

With so much to see this year, it’s a good idea to plan your visit ahead, so that you don’t miss the highlight events and exhibitors for your industry.

Details are available at nationalmanufacturingweek. com.au.

While you’re there, don’t forget to register! Registration is quick, easy and free and it’s the only way to get into the exhibition designed to bring vital news, insights and contacts for Australian manufacturing.

Look forward to seeing you at the show.

Paul Baker Exhibition Director National Manufacturing Week

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation

Drive Electronics from SEW-EURODRIVE It’s Simple

SEW-EURODRIVE understands the need for manufacturers to have access to both simple and advanced frequency inverters. With the MOVITRAC LTE B, it’s simple - an easy to use keypad and simple installation make it the ideal solution for simple speed control. What’s more, it’s now available with IP66 protection, providing you with added defence against dust and water in harsh environments.

SEW-EURODRIVE – Driving the World

1300 SEW AUS

www.sew-eurodrive.com.au

Melbourne (HQ) I Sydney I Adelaide I Perth I Brisbane I Townsville

TUBULAR CONNECTIONS ARE SIMPLER WITH TUBE CLAMP Solid Dynamics supplies Tube Clamp range of fittings & tube which are suitable for safety and maintenance requirements. Tube Clamp fittings can be used to assemble safety handrails and guardrails for machinery and also come in many sizes and types to fit existing structures for maintenance purposes. Our fittings can be used on vehicles for portable safety rails and structures that can be foldable or fixed.

Contact Solid Dynamics today on 1800 789 098 or email: sales@soliddynamics.com.au

Show Preview devices, including the popular ALV 100 compact multifunctional laser welder, as well as the Germanmade ACI laser marker, which is used for fast, quality, permanent laser marking of metals and plastics. The ACI WorkstationPROFESSIONAL laser marker is designed for larger workpieces and batch runs for the efficient and easy inhouse marking of serial numbers, bar codes, datamatrix, text or logos. The ALV 100 laser welder is ideal for precision welding of metals in the tool and die industry, sensor production and medical device manufacturing.

1300 367 648 www.m2lasers.com.au

4. DMG/MORI SEIKI DMG/MORI SEIKI Australia will host two joint stands and one exclusive stand at Austech, featuring three new, Australia-first machines. The DMU 65 monoBLOCK is designed as an entry into the high-tech world of simul-

2

108 | May 2011 Manufacturersâ&#x20AC;&#x2122; Monthly | Celebrating 50 years

taneous machining in 5 axes; the NTX2000 is a high-precision, high-efficiency integrated mill turn

centre; and the NLX2500 is the

Tooling’s stand (584) at this

first model to be released from

year’s Austech exhibition. The

the new X-Class series of CNC

company will exhibit a line-up of

lathes. The company’s travelling

CNC machine tool accessories

column milling centre DMF 180,

to increase shops’ productivity

as well as the DMU 50 eco and

and reduce their environmental

DMU 70, will also be there.

impact. These include coolant

03 8540 4600

maintenance, clean air work-

www.dmgmoriseiki.com

shops, high-pressure coolant,

See us Austec at STAND h 635

and quick jaw change fixtures.

5. Dimac

For clean and healthy air in

IT’S ALL about productivity

workshops, Dimac is showing

and the environment on Dimac

the REVEN Recojet oil mist

3

After introducing the World-Renowned Absolute System to Digimatic Calipers, Mitutoyo now announces a further major breakthrough in electronic Caliper Design.

The New COOLANT PROOF Caliper achieves an Ultimate Dust/Water/Coolant protection level.

The COOLANT PROOF Caliper can be used in tough workshop conditions where at present only a mechanical Vernier Caliper can be used.

M.T.I. QUALOS PTY. LTD. MELBOURNE 55 Northern Road, West Heidelberg, Vic. 3081.

Phone (03) 9450 1900 Fax (03) 9458 3217

SYDNEY 5 Hallstrom Place, Wetherill Park, N.S.W. 2164.

Phone (02) 9756 5577 Fax (02) 9756 5666 Web: www.mtiqualos.com.au e-mail: sales@mtiqualos.com.au

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 109

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

Show Preview process without the effects of

designed to be mounted on

heat, which prevents hardening,

X-Y cutting tables. The ma-

warping, dripping slag or amalga-

chine uses the company’s new

mation. The waterjet machine is

APC59T Windows control. The

capable of bevel cutting and re-

touch-panel reduces the number

acts flexibly to changing contours

of keyboard and button actions

and materials.

to a minimum, allowing the

03 9799 8788

user a straightforward, intuitive

www.ultimatelaser.com.au

control of the entire production cycle. The advanced software

8. Haco Australia

‘RoboTorch’ raises the bar for

At stand 582 at Austech, Haco

other plasma software on the

will be exhibiting a CNC plasma

market due to the simple

machine, called KOMPAKT

layout of the user-interface,

3015, featuring a Hypertherm

the company claims.

HyPerformance HPR XD plasma

08 9414 8009

source, which is specifically

www.hacoaustralia.com.au

7 5 WORLD CLASS PLASMA CUTTING PCS4000HD

100%

AUSTRALIAN

MANUFACTURED

+HDY\ 'XW\ &RQVWUXFWLRQ 'XDO 6LGH $& 'LJLWDO 'ULYHV $XVWUDOLDQ 0DGH Phone: +61 (03) 9305 2555 112 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Website: www.profilecuttingsystems.com

Show Preview

9 9. Hi-Tech Metrology HI-TECH Metrology, a provider of metrology and scanning products and services, will be

aided inspection and reverse

11

engineering on stand 687 at the

and information on a complete

10. Idronic

ties for fabricators, profile cutters,

upcoming Austech exhibition.

range of laser scanning technolo-

METAL fabrication software compa-

engineering and sheet metal shops.

With a focus on using the latest

gies from Hexagon Metrology,

ny Idronic demonstrates its innova-

LaserQuote assists parts program-

scanning technology to capture

Romer, Brown & Sharpe, Shef-

tive management system software

ming, customer relations and quote

and process high-resolution 3D

field, Leica, Kreon, Perceptron

LaserQuote on stand 693. Laser-

generation, as well as production

spatial geometries for reverse

and Micro-Vu.

Quote is a business management

control of various features in metal

engineering, visitors will walk

1800 283 095

system designed to manage and

cutting and fabrication operations.

away with practical knowledge

www.hitechmetrology.com.au

streamline all daily business activi-

The softwareâ&#x20AC;&#x2122;s built-in laser cutting

displaying the latest technology for 3D scanning, computer-

114 | May 2011 Manufacturersâ&#x20AC;&#x2122; Monthly | Celebrating 50 years

Show Preview

10 wizard can generate an accurate

help advanced manufacturers

and consistent quote in seconds,

become more agile. The mini fac-

and the software facilitates the

tory will feature real examples of

automation and creation of program-

some of the tools and techniques

ming where multiple parts obtained

TXM uses to achieve: shorter lead

from clients are nested together

times and a better and more flex-

using CAD nesting software.

ible service to customers; reduced

1300 437 664

working capital to free-up cash;

www.idronic.com

changed workplace culture with all employees engaged in improving

11. TXM Lean Solutions

quality, productivity and customer

LEAN manufacturing and project

service; differentiation on service

management company, TXM Lean

and a competitive edge to com-

Solutions, will be exhibiting at

pete more effectively with imports;

stand 505 with a themed ‘mini

and reduced costs.

factory’, demonstrating how lean

03 9607 8241

manufacturing techniques can

www.txm.com.au

116 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

8

THE WORLDS MOST ENERGY EFFICIENT RELIABLE PRESS BRAKES AND GUILLOTINES. Ground breaking technology is used in the innovative servo-electric SAFAN E-BRAKE. Higher efficiency, lower production costs, better ergonomics and responsible practices.

SAFAN the specialists in the E-volution in sheetmetal working for over 70 years.

Based on the remarkable XXL-Center technology, the RAS XL Center is a new folding innovation for roofing and architectural profiles. By folding the part up and down the new model reduces material handling to a minimum. With programmable tapered gripper positions for conical parts, the XL-Center defines a new class.

HIGH-TECH MADE BY RAS since 1939.

If you want to bend precision parts, fully automatically at high speeds in high quality, regardless of batch size, with the highest levels of flexibility and total repeatability, then the full electric (no hydraulics) RAS Multibend Centre is the next level of metal fabrication for you!

E-Ventures CENTURIO the automatic sheet metal slitting and cutting machine with integrated coil warehousing systems and unlimited number of coil-storage places.

Costly and time consuming internal coil transport has been eliminated.

Sheetmetal Machinery Australia Pty Ltd Unit 45/756 Burwood Highway Ferntree Gully Victoria 3156 Ph: +61 (3) 9758 9377 Fax: +61 (3) 9752 3305 www.sheetmetalmachinery.com.au email: sales@sheetmetalmachinery.com.au

INNOVATIVE - RELIABLE - PROFESSIONAL

ls o To e in h c a M & g in rk o lw ta e M Melbourne rubber reaps rewards

BY PETER SCHOOLING

Mackay manufacturing manager, Noel Hawley.

MACKAY Consolidated Industries, an Australian supplier of engineered rubber and bonded

“They also provide significant safety improvements over the older machines.”

metal/rubber composite products, is reaping

Along with the Moorabbin plant’s equipment

the benefits of installing four new presses at

upgrade, Mackay is taking the opportunity to

its Melbourne manufacturing facility.

invest in its staff, with training designed to

The company supplies composites for

improve overall efficiency.

the automotive, transport, construction and

“We currently have twelve staff undertaking

industrial markets, and has recently received

a diploma in ‘lean manufacturing’ through

increased interest in its products from the

a course offered by Ballarat University, 50

mining, infrastructure and defence markets.

undertaking Certificate IV and a further 140

Two years ago, Mackay purchased two

staff scheduled to be put through the course

1,000-tonne presses for its Moorabbin

over the next 2 years. We expect to see

manufacturing plant to manufacture a range of

significant efficiencies as a result of this

rubber pads for armoured personnel carriers as

investment in staff training,” said Hawley.

part of a three-year defence contract with the Australian and Singaporean armed forces.

The company has now added two 500-tonne

Over the next 12 months, Mackay will also be upgrading its smaller presses with the planned installation of new 50- and 100-tonne machines.

models to the mix to produce rail suspension

“The significant investment in new equipment

components, mining equipment and other

and our commitment to staff training are

assorted industrial items.

clear evidence of the commitment we have to

All presses were supplied by Taiwanese

provide our customers with the highest quality

manufacturer, TungYu, with the 1,000-tonne

Australian manufactured products coupled with

models working around the clock. Mackay has

the shortest lead times,” Hawley said.

reportedly experienced excellent performance and reliability from these machines, and

“It will also ensure we remain competitive

external), signature reduction materials for surface warships, tank tracks, road wheels and

against overseas companies in the future.”

pads, ballistic shields and launch silo covers

Mackay’s automotive customers are the

for ESSM missiles for use on NATO warships.

expects to see the same results from the new 500-tonne models.

The operator-friendly presses have boosted productivity.

likes of Ford, General Motors and Toyota. The company is also a long-term supplier to the

• MACKAY CONSOLIDATED

presses will boost productivity, enhance product

Australian Defence Industry, providing products

03 9276 4633

quality and provide greater efficiencies,” said

such as submarine components (internal and

www.mackayrubber.com.au

“These new ‘operator friendly’ state-of-the-art

118 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

A N I W G I M C I T A M D L E n a t W e g A I S W U a L Purchase ance to WIN! PTER ONLINE . h c r EG IS R u o ! y Y r T N fo WARRA 5,000 R A E Y 1 A EXTR

lden o H t s 1 e: d u l c n i Prizes Cash 3rd $1500 Fuel 2nd $5000

x $4

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appro t a d e u l a v S Ute

WEEKLSY! PRIAZutoE-Darkening WIA Blue valued at Helmet, RP $154 R

3 +1

*

uary 2011 r b e F th 4 1 runs nder Competition th 2011. Authorised u LTPS/10/11952, o 0 2 until June 3 0/2929, NSW Permit N mit No TP 10/05243.2 1 er SA Lic No T o 10/4397 and ACT P N V IC Permit

u a . m o c . welding l details for ful

ls o To e in h c a M & g in rk o lw ta e M Robotic sin beam welding machine Electric turret punch press A SIN Beam welding machine from Austrian company Zeman

It incorporates a PLC control system with operating pane.

MAXITEC is now distributing Finn-

movement. A pull movement

Powerâ&#x20AC;&#x2122;s E5x Compact Express, a

provides strokeless wearing for

compact, high-performance servo

the mechanics.

Bauelemente which is now being

According to the Perth-based

distributed in Australia has been

distributors, Specialist Machinery

called â&#x20AC;&#x2DC;very rareâ&#x20AC;&#x2122; and a â&#x20AC;&#x2DC;game

Sales, the main advantages of the

changerâ&#x20AC;&#x2122; in the structural market.

SIN Beam are that it is one-third

eliminates the bulky, vibrating issue

monitoring centres reportedly

lighter than traditional H beam

of hydraulics by using servo-electric

provide a safe production and

corrugated web beam production

machines. It is also said to be far

punching technology together with

fast setup with optional PCS and

line, in one unit. The fully-automatic

stronger because of the corrugated

programmable punch modes,

3rd clamp with â&#x20AC;&#x2DC;moveâ&#x20AC;&#x2122;.

welding machine needs only one

web, allowing much greater spans

stepless adjustment of speed and

operator, offering welding speeds

and in many cases the removal or

position and accurate forming.

up to 1m/min.

reduction of columns.

The machine is essentially a

It offers a profile width of 333

electric turret punch press.

According to Maxitec, the unit

The unit provides a 1250mm

Users can produce various

The Pneumatic clamps with central locking and sheet security

With brush tables, the system can handle a maximum sheet weight of 200 kg and maximum

x 2500mm working area

sheet thickness of 8 mm. Optional

to 1500mm, and a profile length

widths and lengths without

that reportedly requires no

lifting brushes provide an extra

of 400-16000mm (tapered: 400-

producing scrap.

repositioning of the job piece.

safety for sensitive materials.

The unitâ&#x20AC;&#x2122;s single water-cooled

12000mm). Web thickness is 1.5â&#x20AC;&#x201C;3.0mm steel (optionally 1.5

â&#x20AC;˘ SPECIALIST MACHINERY SALES

servo motor operates on a ball

â&#x20AC;˘ MAXITEC

to 6.0mm); the unit can weld steel

0414 151 900

screw for its linear movement

02 8536 5800

coil and flange flat steel.

www.smsales.com.au

and a pneumatic RAM return

www.maxitec.com.au

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 120 | May 2011 Manufacturersâ&#x20AC;&#x2122; Monthly | Celebrating 50 years

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Automation & Robotics Lights out, machines on

BY ANNIE DANG

of this type is ever going to be

A growing number of companies

cheap,” Bentrup advises.

have gone down the path of

Thorough planning, including

becoming an automated lights out

getting as complete costs

manufacturer, shutting down their

analysis, will help manufacturers

doors at the end of the day and

monitor costs and keep it under

returning the following morning to

control. Most importantly it will

find machines have produced an

provide a clear indication of

entire shift of products, with no (or

capital outlay needed to equip

limited) human intervention.

the plant with the technology,

For these companies the addition

the costs required to operate

of an automated third shift means

and the expected return on

more orders can be accepted and

investment in full automation.

produced through present production systems, alleviating growing

Multi-stage installation

pressures and remain competitive.

Air conditioning manufacturer

Andrew Bentrup, MD of

Temperzone is in the initial

automation specialist Maxitec, said

phase of a multi-stage

the most immediate advantages

technology upgrade to become a

of automated manufacturing is

completely automated lights out

the ability to plan production more

manufacturing plant.

effectively, and further in advance.

The company is consolidating

The other, he says, is securing larger

its growth strategy on automated

and more competitive contracts,

Finn-Power technology; a move

“Automated lights out

which management expects will

manufacturing gives companies

swell its employee base and dispel

greater scope to bid for bigger

any manufacturing myths that high-

and more demanding contracts,

tech software driven fabrication

as well as the confidence to

machinery results in downsizing.

not only win these contracts

“Shop floor staff are finding that

positive results; the company is

modern technology and the power it

but also deliver well on time

with almost all the labour component

now moving into larger premises

delivers to the industry,” he said.

and on budget,” Bentrup told

taken out of the equation, they

to expand its work intake and

Manufacturers’ Monthly.

can concentrate on core activities,

maximise its investment in

company in a position where it,

return far better productivity and

machinery and personnel.

if the opportunity arises, can

He says any company that

Software-driven lights out manufacturing allows companies to have a completely unmanned third shift running overnight.

“The owner has to see the

takes steps towards becoming

enjoy much safer workspace,” said

an automated lights out

Bentrup, whose company did the

to successful lights out

market but also step into the

manufacturer, considered to be

Temperzone installation.

manufacturing is vision.

international fold,” Bentrup said.

at the top level of world’s best

The Finn-Power setup, with

Bentrup says the key

supply not only its own national

“Business owners need to be

practice, is more likely to be held

the Night Train FMS automated

innovative and forward-thinking

• MAXITEC

in high esteem among industry.

handling system soon to be at the

in their use and adoption of new

02 8536 5800

This he adds will place them in a

hub, is said to ensure Temperzone

technology.

www.maxitec.com.au

better position to qualify for major

will eventually process sheet

local and international contracts.

“Business owners have to learn

metal in more economical coiled

to let go of long-standing labour-

• TEMPERZONE

However such prestige does not

form rather than individual sheets.

intensive processes and understand

1800 21 1800

come without costs. “No investment

The adoption has so far yielded

a lot of trust has to be placed in

www.temperzone.com.au

122 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Fast Charging is Charging

Leaders in Fast Charging Technology – the smarter way to charge. affer workking enviironmentt Fast Charging Technology eliminates battery changing by safely recharging batteries quickly in the vehicle during scheduled downtimes. Removing the OH&S concerns associated with battery changing, giving you a safer working environment.

aximising running time The downtime associated with battery changing and battery watering is significantly reduced through fast charging. Fast Charging Technology gives you the power to run long or multiple shifts on just one battery. Optimising the running time of your fleet.

bolish the battery room

CenturyYuasa is leading the way in Australian Traction Batteries.

By eliminating battery changing, Fast Charging Technology abolishes battery rooms for good. Which in turn, eliminates changing equipment, the need for special ventilation and acid neutralization infrastructure. Regain your battery room real estate!

Organiise your fastt chharge suitability inspection today!

educe operational costs

Phone 1300 734 580 www.forkliftpowersolutions.com.au

By abolishing the battery room, Fast Charging Technology removes the need for extra batteries. Maximising the productivity of your fleet by removing the wasted time of battery changing. Reducing operational costs by up to 70%.

Fast Charging Technology is universal and can charge any battery, regardless of make, size, voltage or capacity. It identifies each battery as it is connected so it can automatically custom charge several trucks and batteries of various specifications simultaneously.

Maintaining optimal charging levels without exceeding safe battery temperatures.

Fast Charge Technology

LDRY CYBN694

echnologically advanced

Superior automation products offer flexibililty for any application HMI Direct sales structure: designed to meet the demand for more comprehensive technical service and support requirements for Australia’s growing factory and process automation industry. The new sales structure exemplifies TURCK’s commitment and dedication to providing locally stocked inventory and immediate service with a more aggressive

VT250 HMI touch panels combine control and application oriented visualization functions with integrated PLC functionality, providing unprecedented flexibility in communication capability. Serving as a gateway between fieldbus and real-time Ethernet, the VT250 netX controller supports multiple protocols with master or slave programmable capabilities, providing enough power for communication between virtually every fieldbus and real-time Ethernet system.

pricing arrangement for TURCK’s superior sensing, connectivity and network I/O solutions.

Managing director Cameron Dwyer is

Serving as the only authorized distributor of Bihl+Wiedemann interface products, TURCK provides customers with a single supplier capable of meeting the most diverse industrial equipment needs by offering the highest-quality automation technology and interface products for industrial networks.

elevating TURCK’s position in the industry—striving to offer customers the best products promptly, reliably and flexibly. To keep pace with TURCK’s constantly evolving customers, Dwyer plans to rapidly expand the company and change its market position to adapt to the customer’s needs.

Sensing

Connectivity

First of its kind, two-wire DC sensor with Factor 1 technology delivers extended sensing range.

Uproxx®+ sensors feature an integrated pre-damping protection to reduce metal-free mounting area in applications. Available in M12, M18, M30 and CK40 body styles with cable and quick-disconnect options— and like all TURCK sensors are weld field immune.

M12 true torque connectors ensure a secure connection— eliminating overtightening. The connectors are compatible with all M12 devices, with either a straight or right angle configuration, and available with 3,4 or 5 poles in both male and female versions.

RFID BL ident® the industry’s only modular RFID system with built-in I/O capabilities allows users to add additional I/O modules to the RFID system, plus up to 8 channels of RFID and additional discrete or analog I/O comprised on a single node on the network. Built on the ISO15693 13.56MHz HF standard, BL ident can be integrated into existing platforms while supporting multiple configurations including PROFIBUS®-DP, DeviceNet™, Modbus-TCP, PROFINET and EtherNet/IP™.

Modular I/O The best I/O available offering a complete line of products designed to save time and money.

Consisting of five product families and thousands of part numbers, I/O products can be custom designed for specific applications including, interfacing directly with motors, drives, valves, operator panels, push buttons, and analog and digital sensors—eliminating being locked into proprietary PCL I/O solutions.

Linear Measurement Q-track™ linear position sensors eliminate magnets, contact and noise using linear and rotary position sensors that provide absolute feedback with high linearity and repeatability.

The solid-state, RLC tuned inductive coil design breaks through the limitations that plague conventional technologies, and are sealed to IP67.

Q-track™ enables position without limitations.

Pressure Sensing High accuracy pressure sensors with programmable output place control in the user’s hands, allowing for output selection of either two switch points or a 4-20 mA analog output with one switch point. Providing optional rotation and varying pressure ranges, these pressure sensors provide the flexibility needed for diverse application requirements.

Direct is faster. And smarter.

Over 15,000 sensing, connectivity, interface and communications solutions are now available locally and direct from TURCK Australia.

Call us with your next application:

1300-132-566 turck.com.au

©2011 TURCK Inc.

Automation & Robotics Niche robotics hike productivity

BY HARTLEY HENDERSON AN industrial robot supplied by ABB Australia and recently installed by Applied Automation & Engineering is delivering big benefits for a manufacturing company in the Melbourne suburb of Melton.

MHG Plastic Industries, with some 140 employees, is a leading manufacturer and innovator of protective, functional and decorative automotive parts and accessories including body side mouldings, wheel covers, grilles, mudflaps and fender vents. The company’s plant at Melton is an 8,000 m² state-of-the-art facility equipped with computerised injection moulding machines and extruders.

ABB Australia’s Olivier Coquerel says the IRB 4600 robot supplied

ABB’s IRB4600 robot tending an injection moulding machine.

to MHG enables more compact manufacturing cells with increased

compact robot, with its slim swing

Andrew Shaw, says that the

“The steel tubes are conveyed

production output and higher quality.

base radius, fine elbow behind axis

IRB 4600 robot installed at

into the cell where they are over-

“Greater process speeds and

3, small lower and upper arms, and

MHG is utilised to handle blank

moulded, checked for absent

lower scrap rates mean improved

compact wrist, means that your

hydro-formed steel tubes into

runner, trimmed, and then conveyed

productivity, and the new compact

production cell can be created with

a JSW1300 injection moulding

out of the cell as an RGOR. This

and optimised design enables

reduced floor space by placing the

machine (IMM), and the over-

process commences with the

flexible floor, tilted, semi-shelf, or

robot closer to served machines.”

moulded automotive front-end

tubes being loaded onto the

bolster assembly tubes (or

infeed conveyor which transports

RGOR’s) out of the IMM.

them into the cell where they are

inverted mounting,” Coquerel said.

“The small footprint of this

Applied Automation & Engineering managing director,

126 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

singulated prior to being picked

“The robot then positions the

productivity improvements, as

by the robot. The infeed conveyor

RGOR over the attribute station

can accommodate 35 minutes of

to ensure, via stationary photo

production,” Shaw explained.

electric sensors, that all of

taken out of the cycle time, with

the runners are attached. On

the machine only operating at 25

confirming this, the robot loads

percent capacity,” he said.

“The robot is fitted with an end-of-arm tool (EOAT) that can handle both a blank hydroformed steel tube and an RGOR at the same time. During normal operation, the robot picks a tube from the infeed conveyor, moves to a holding position, and waits for the IMM tool to open.

The robot then moves into the tool and collects the completed RGOR. The EOAT then rolls over and places the blank tube into the mould before exiting the IMM with the RGOR.

The IRB 4600 robot installed at MHG Plastic Industries is utilised to handle blank hydro-formed steel tubes into a JSW1300 injection moulding machine.

the RGOR into the trim station.

“A trimming tool on the EOAT

well as other benefits.

“Some 15-20 seconds has been

“There has also been perfect consistency of product and a

proceeds to trim all runners from

significant increase in quality. In

the RGOR and trimmed waste is

addition, there are substantial

collected in a waste bin beneath

safety and ergonomic benefits. The

the trim fixture for recycling. With

structural members for the front end

trimming completed, the robot

of cars that we produce have holes

picks and places the RGOR onto

and sharp edges, but the robot takes

the outfeed conveyor, which

away the need for manual handling.”

delivers it back to the operator.”

According to Matthew Mannix,

• ABB AUSTRALIA

product engineer at MHG, the

03 8544 0000

robot has provided significant

www.abbaustralia.com.au

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 127

What’s New Desiccant air dryers

IP66 extension for inverter range

Spring scissor lift

ATLAS Copco has launched three new desiccant air-dryer ranges designed with low pressure drops and delayed dryer cycles.

The new line-up includes two ranges of heatless desiccant dryers, the CD 25+-145+ and the

OPTIMUM Handling Solutions

CD 110+-300+.

has released the Palevator spring scissor lift, said to be

The third new range is the blower purge dryer, BD 100+-

an excellent solution for safely

300+, built for energy-efficiency

stacking pallets of heavy bulk

and endurance. By using heated

products such as paper, tinned

ambient air for regeneration,

food and bottled beverages.

Requiring no power or

this dryer range keeps the energy cost minimal.

A desiccant air dryer protects

The new IP66 model provides added dust and water protection for harsh environments.

compressed air supply, the scissor lifts can be used

production, equipment and the

SEW-EURODRIVE has released

quality of the end product by using

an IP66 extension of the

to 2.2kW) and three phase (up

said to be easily-transported

desiccants to adsorb moisture

company’s Movitrac LTE version

to 7.5kW), Version B comes in

around the factory.

from the compressed air.

B frequency inverter range.

three compact frame sizes.

These three new desiccant air

Version B is said to be

Available in single phase (up

It also boasts an integrated

almost anywhere and are

The lifts are available in stainless steel, hot dipped galvanised or

dryer ranges are suitable for the

suited to low-power, variable-

DIN-rail snap-in mounting

powder-coated finishes. The weight

most demanding industries and

speed drive applications, such

capability, which simplifies

capacity of the units are said to be

applications like electronics, food

as small fans and pumps,

installation, plus it features

easily-adjusted by simply removing

and beverage, pharmaceuticals,

machine tools and conveyors.

14 standard and 26 extended

or inserting the correct springs,

and oil and gas.

Previously available in both

configuration parameters.

according to the required duty.

IP20 and IP55 housings, the • ATLAS COPCO COMPRESSORS

new IP66 model provides added

• SEW-EURODRIVE

• OPTIMUM HANDLING SOLUTIONS

02 9621 9680

dust and water protection for

03 9933 1000

1800 066 008

www.atlascopco.com

harsh environments.

www.sew-eurodrive.com.au

www.optimumgroup.com.au

128 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Innovative valve automation

Measure your process & do something about it With modern technology valves are transformed.

Seamlessly integrated positioners, feedbacks, pilots, network interfaces or integrated PID process controllers have opened limitless possibilities in process control. www.burkert.com.au | 1300 888 868

We make ideas flow

What’s New TRAJEXIA is Omron’s latest

Extended tube inserts range

motion platform, said to offer

STOCKCAP has added more

users the performance and ease

sizes to its tube insert range. It

of a dedicated motion system.

now includes round sizes from

Stand-alone modular motion system

13mm up to 100mm, square

The stand-alone modular system is said to allow maximum

sizes from 13mm to 150mm

flexibility and scalability.

and rectangular sizes starting at 30x15mm up to 150x50mm.

At the heart of Trajexia lies the

Manufactured from LDPE and

TJ2 multi-tasking machine controller,

available from stock in black,

powered by a 64-bit processor.

It can do motion tasks such

the inserts come in convenient

as ecam, e-gearbox, registration

packs of 100, 500 and 1,000.

Available for a variety of wall

control and interpolation, all via simple motion commands.

Trajexia offers control of up to

thicknesses from 0.5mm up to

The system is scalable up to 64 axes, inverters or I/O modules.

8mm, all inserts push-in easily.

64 axes over a Mechatrolink-II or EtherCAT network, or traditional analogue or pulse control with independent position, speed or

torque control for every axis.

Users can select from rotary, linear and direct drive systems.

130 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

• OMRON ELECTRONICS

• SINCLAIR & RUSH

1300 766 766

1800 003 211

www.omron.com.au

www.sinclair-rush.com

Cordless LED worklights POWERFUL cordless LED worklights that run for eight hours or more on one charge are being introduced by GO Distribution to provide optimum illumination and safety in manufacturing, fabrication, maintenance and recreational tasks.

The new HEMIPLUS LED professional worklights provide powerful beams using LUXEON REBEL LEDs to exceed the light area intensity of a 75W beam, while also eliminating hot spots, dull areas or irritating halo rings.

The HEMIPLUS LED was reportedly

Thermal imaging products FLIR Systems Australia has

revolutionise the way consumers

released two new product

think about infrared cameras due

ranges: the re-designed E-Series

to its small size and price.

handheld imagers and the i3 infrared camera.

The pocket-sized, multipurpose i3 for building and

The re-designed E-Series

electrical inspections is said to

handheld imagers are now

be the most affordable and cost-

packed with connectivity features

effective full function infrared

including Wi-Fi and Bluetooth,

camera on the market today.

along with touchscreen and • FLIR SYSTEMS AUSTRALIA

iPhone App capabilities.

The new i3 infrared camera

03 9550 2800 www.flir.com/thg

is tipped, by the company, to

built to meet the rigorous demands of the automotive repair industry, which needed a high-performance worklight that

Rotary lobe pump

would function strongly for an entire work

MATRIX Process Solutions has

pumped media with suspended

shift, illuminate an entire engine bay, and

introduced SSP Pumps’ Series ‘A’

solids, fibrous matter and sludges

recharge in fewer than a four hours.

rotary lobe pump for applications

with rag and grit included.

within general industry, mining,

The light is also useful for applications including industrial heavy vehicle maintenance, mining and

chemical and wastewater.

sizes up to 300mm dia, flow rates

Manufactured from stainless steel, the pumps can reportedly

manufacturing workshops.

The pumps feature standard port up to 680m3/Hr, and differential pressures up to 10 Bar.

handle low to high viscosity pumped • GO DISTRIBUTION

media and are said to be ideal

• MATRIX PROCESS SOLUTIONS

1300 544 369

for delicate media, froths, gels,

07 3200 3433

www.cliplight.com

emulsions and sludges, including

www.matrixps.com

www.colby.com.au

“

ColbyRACK is no problems, just solutions

“

The cordless worklights provide safety for the entire work shift.

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 131

Whatâ&#x20AC;&#x2122;s New Energy-efficient air conditioners

'EFPI )RXV] 7]WXIQW )1' 7SPYXMSRW The units use R134A earth-friendly refrigerant to reduce environmental impact.

7TEGI 7EZMRK

1ER] 3TXMSRW

)EWI 3J %WWIQFP]

9RMZIVWEP 9WEKI

SPECTRACOOL indoor and outdoor

the front of the unit and direct

2IEX *MRMWL

'YWXSQMWIH 7SPYXMSRW

air conditioners from Pentair

the air upwards in a 90-degree

Technical Products deliver cooling

angle for the most direct air path,

to sensitive electronics within

reportedly provide redundancy on

enclosures. The air conditioners

the condenser side.

'SWX IJJIGXMZI

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132 | May 2011 Manufacturersâ&#x20AC;&#x2122; Monthly | Celebrating 50 years

feature a dust-resistant treated

The units feature a modern, all-

coil, supporting filterless operation

metal exterior cover with minimal

in most environments and offer a

use of visible fasteners. The cover is

broad range of cooling capacities,

removable in one piece for repainting

power input and mounting options.

at the customerâ&#x20AC;&#x2122;s location.

The units also feature rotary compressors and use R134A

â&#x20AC;˘ BERTECH INDUSTRIAL

earth-friendly refrigerant to

ENVIRONMENTS

reduce environmental impact.

03 9898 7544

Dual impellers, which pull air into

www.bertech.com.au

Monitoring relays

Linear encoder AMO CORPORATION has released the new IP67-rated LMB-410 spar linear encoder, said to meet high-shock, high-speed and highvibration specifications.

The LMB-410 measuring scale features a stainless steel carrier and an adhesive-free mounting spar with a snap cover, and is said to perform similarly to a linear optical encoder.

The in-Case series feature configuration DIP switches.

The encoder operates on an inductive scanning principle which is suited for general purpose machines, such as machine tools, printing equipment and aerospace applications.

The IP67 rating makes The encoder eliminates the need of a test box during setup.

contaminated conditions including being submersed in fluid.

The encoder head can be equipped with wipers to

auto offset eliminates the need to use a test box during setup.

automatically clean the scale during operation, and according

• CNC DESIGN

to the company, the encoder

03 9417 2820

head’s gain compensation and

www.cncdesign.com

comes with all popular function

Group (ACE) and Hiquel’s in-Case

variants, combinations and

series provides an integrated

options selected by DIP switches.

range of industrial monitoring

Hiquel’s new offering means

and timing relays in a new,

that just three timing relays offer

compact 22.5mm DIN rail case.

all standard timing functions

The series was reportedly

and incorporate special features

designed with emphasis on

such as dual timing functions

flexibility, and incorporates a

and elapsed time indication.

new micro-controller. With just four monitoring relays, the series

• AUTOMATED CONTROL

offers single-phase current and

ENGINEERING

voltage, three-phase voltage, and

02 4954 5004

Thermistor monitoring. It also

www.aceg.com.au

www.colby.com.au

“

ColbyRACK is helpful advice on storage design

“

the scale ideal for dirty or

AUTOMATED Control Engineering

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 133

What’s New Custom cable carriers

Dust suppression system TECPRO Australia has introduced

suppressing dust that is difficult

the Elefante fog cannon to

to control using other methods.

its range of dust suppression

It uses water pressure of up

systems. Produced by Italian

to 10 bar through 156 nozzles,

company Idrotech, the Elefante

and the flow rate varies from

fog cannon is suitable for large-

14.8L per minute to 87.6L

scale dust suppression.

per minute, depending on the

Three concentric nozzle rings produce a mist of fine water

particular nozzle size fitted to the supression system.

particles which are propelled

Users can design their own cable carrier.

by a powerful fan a distance of

• TECPRO AUSTRALIA

up to 60m. The fog cannon is

02 9634 3370

said to be particularly useful for

www.tecpro.com.au

Automated quick die exchange MOTION Technologies has

and a measurable return on

TSUBAKI is now distributing cable

OnlineEngineer configuration

introduced the Serapid

investment, the company says.

and hose carrier solutions from

tool to help customers select

Quick Die Ex-Change, which

German company KabelSchlepp in

and configure the optimal

reportedly allows users to

of both standard QDX products

a variety of options, from light-

KabelSchlepp cable carrier system

handle dies and molds safely,

and custom-engineered special

weight micro-sized mono cable

for their application. There are

ergonomically and efficiently.

QDX products.

carriers up to large super-duty

also application photo and video

steel chain designs. The range

galleries on the site, along with

Technologies, the QDX program

total automation of a die

also includes carriers with 3D

2D and 3D CAD drawings.

covers the entire process of

transfer system.

movement for multi-axis robotic

According to Motion

Serapid has an extensive line

The system is said to offer

die change. Components are

applications and tube types for

• TSUBAKI AUSTRALIA

optimised for results that really

• MOTION TECHNOLOGIES

protection from chips and debris.

02 9704 2500

count to make the process of

02 9524 4782

www.tsubaki.com.au

die change quick, consistent

www.motiontech.com.au

The company offers an

134 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Industrial gloves for metal workers The gloves allow materials handling workers to effectively grip wet or oily objects.

Portable bunding system SPILL Station has released the Quickbund portable bunding system. Constructed from X-R5, a chemical-resistant material, it is said to not become brittle or crack when exposed to oils and fuels.

Featuring fold-down walls for truck and forklift easy access, the standard 1,000L model folds down to a compact 500x500x100mm size and weighs 10kg.

All of the 10 standard sizes, which range from 1,000 to

WORKERS in the metal fabrication

glove surface. Using this system,

them comfortable, healthy and

24,700L, have high-frequency

industries who have struggled to

oil penetration is eliminated,

protected.

welded seams to prevent

find an oil repellent glove with

thereby reducing the risk of

gripping properties should take a

dermatitis and eliminating the

creates a roughened surface of

look at an innovative glove option

users’ need to wear two pairs of

microscopic channels in an ultra-

The portable system can

from Ansell.

gloves in challenging applications.

thin nitrile coating on the outside

reportedly be deployed and

for grip with a barrier of nitrile.

functional in seconds.

The new HyFlex 11-920 glove

The gloves are said to allow

The Ansell Grip Technology

leaking and contamination.

They can also be custom-made.

is said to provide excellent grip in

materials handling workers

oily conditions, by using Ansell’s

to effectively grip wet or oily

• ANSELL

• SPILL STATION AUSTRALIA

own Grip Technology in the palm

objects with significantly less

1800 337 041

1300 664 266

coat to wick oil away from the

force than usual, keeping

www.ansell.com.au

www.spillstation.com.au

www.colby.com.au

ColbyRACK is improved safety, reduced damage

“

“

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 135

What’s New Solar-powered desalination system ONESTEEL, in conjunction with

manufacturing plant the system

governments and organisations

Victoria-based F CUBED, have

can separate valuable minerals

wishing to provide safe water to

developed a solar-powered

and salts for reuse.

developing countries along with

desalination system, called

OneSteel Galvatube precision

Real-time USB thermal imager

industrial and mining industries,

MICRO-EPSILON’S

Carocell, to provide industry with

tubing makes up the steel

agriculture and horticulture

thermoIMAGER TIM is a

high-quality potable water.

framework of the system, for

operations, urban usage and as a

miniature, real-time thermal

increased durability. The steel tubing

replacement for bottled water.

imager with USB. The unit can

The modular system produces

measure temperatures from -20

safe, high-quality potable water

is galvanised internally and externally

from seawater, groundwater,

and is designed for outdoor use

an $11m MOU with the South

to 900°C, and offers thermal

contaminated and polluted water.

where greater protection from

Australian town of Ceduna to supply

sensitivity of 0.1K.

corrosion is required.

13,000 Carocell panels which will

The Carocell units can be groundor roof-mounted and emit zero

The Carocell units are

F CUBED has already signed

The system has exchangeable

produce approximately 200 million

lenses with 9°FOV (field of

greenhouse gas emissions. The

manufactured in different sizes and

litres of pure drinking water annually

view), 31°FOV and 64°FOV,

system uses no chemicals, filters or

multiple panels can be connected

as a result of processing sea water.

allowing temperature to be read

electronics and also enables rainfall

together in order to produce large

to be captured and harvested.

quantities of distilled water.

both near and far away.

• ONESTEEL AUSTRALIAN TUBE MILLS

• BESTECH AUSTRALIA

disease-causing pathogens and

a high level of demand for its

02 9792 9085

03 9584 1133

heavy metals. If used outside the

Carocell systems, including from

www.onesteel.com

www.bestech.com.au

The purification process removes

F CUBED said it is experiencing

136 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

THE NEW Nilfisk CFM S2 and S3

Electrocylinders

single-phase industrial vacuums

PARKER Hannifin’s new HMIX

have been designed to meet a

cylinder is a fully-integrated

wide range of industrial cleaning

sub-system which combines

challenges.

tie-rod cylinder technology

Industrial vacuum cleaners

with a high-precision feedback

Available in a variety of configurations, the machines

transducer, manifold and

are said to feature strong, solid

pipework into a single unit.

The internally mounted

construction and cutting-edge innovations such as an electronic

magnetostrictive transducer

keypad with LED indicators that

provides continuous analogue or

monitor the performance of the

digital feedback of the actuator’s position, derived from the

main and HEPA filters.

The S2 comes with a 50L

servicing, the machines have been

99.97% of particulate, down to

collection container, while the

approved for electrical safety,

and including 0.3 microns.

S3 is available with 50 or 100L

according to Nikfisk.

collection capacities.

Featuring a modular design for easy modifications, upgrades and

interaction of two magnetic fields.

• PARKER HANNIFIN

• NILFISK

AUSTRALIA

multi-stage filtration, including

1300 556 710

02 9842 5110

an optional HEPA filter to capture

www.nilfisk.com.au

www.parker.com

They can be equipped with

Celebrating 50 years | Manufacturers’ Monthly May 2011 | 137

Materials Handling Green power in fuel cell technology

BY ANNIE DANG FOR the local materials handling and lift truck market, alternatives to traditional forklift power have provided newer and greener options for manufacturers who rely on these technologies, especially ahead of a carbon tax which could be rolled-out mid next year.

Crown Equipment general manager for markets, Craig Kenchington, told Manufacturers’ Monthly that manufacturing companies that realised their negative impact on the environment as a key issue a A fuel cell-powered Crown lift truck is refuelled at a mobile hydrogen refuelling truck.

decade or more ago will be the ones that will feel the least impact of any tax on carbon.

in materials handling to help

also Australia’s comparatively

“We don’t know yet just

mitigate future business risks

relaxed environmental laws

companies which use forklifts

how the tax will be applied or

related to the price on carbon.

and regulations compared to

the cleanest and arguably, the

administered, but the fact remains

These options include electric

its European counterparts, who

cheapest form of power in the

that those companies that are

forklifts which can be charged

favour fuel cell power as the more

history of the materials handling

already embracing cleaner energy

using renewable energy and

carbon-efficient solution.

industry,” he says.

options will be in a position of

alternative fuel sources, such as

competitive advantage regardless

hydrogen fuel cell technology.

However, fuel cell power’s

“Fuel cell power offers

“This is because the process

limited take-up in Australia

involves basically little more than

of what the final carbon tax

Electric forklift models are

reportedly has more to do with

hydrogen and water, both of which

outcome may be,” he says.

the most popular alternative

lack of awareness rather than

are naturally occurring.”

According to Kenchington,

source of clean power for the

price. It’s a new type of power

there are a number of options

local market. This is largely

which the market knows little

available to companies engaged

due to their cost efficiency and

about, explains Kenchington.

138 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

In fact, Kenchington says many companies in food manufacturing, Continued on page 140

Materials Handling Forklift safety barriers

Green power in fuel cell technology (Continued from page 138)

A NEW range of forklift barriers from Barrier Group – consisting of the

The barriers are designed to keep people and forklifts separated.

Post-Q, Menni-Q and Dock Safe Q – is designed to keep forklifts and people separate to avoid accidents.

Post-Q provides impact protection

for example, are already using

which was established in 2008.

hydrogen onsite for production,

Locally, the next step in

but are unaware that that same

Crown’s fuel cell power R&D

source of hydrogen can power

is working with relevant

their forklift fleet.

Government authorities and

against low-speed manoeuvring

Menni also acts as a delineator

In the US market, Crown is

vehicles. It is a Modular Safety

against forklift tines or straying

already supplying companies,

the technology. The company

Fence which is non-conductive,

pallets entering walkways under

such as Wal-Mart, with vehicles

is currently in contact with a

corrosion- and abrasion-resistant,

the fence system.

designed and manufactured

number of applicable Government

and can be used indoors or

suitable customers to trial

for fuel cell power packs. The

departments and is in the

outdoors. The Impact Protection

deployment loading barrier dock

adoption of the technology

process of shortlisting suitable

Fence, Menni-Q, is designed

designed to prevent people falling

followed a 24-month trial of 20

customers for Australian Fuel

specifically for warehouses,

from loading docks.

Crown Fuel Cell Qualified Trucks

Cell technology trials.

Dock Safe Q is a rapid

factories and road work.

at the Warner Robins Air Force • BARRIER GROUP

Base in Georgia, USA by Crown

• CROWN EQUIPMENT

Barriers’ Menni System enables

1300 553 320

Research & Development division

1300 131 604

it to be fixed to the ground. The

www.barriergroup.com.au

dedicated Fuel Cell Project Centre,

www.crown.com/au

Used in conjunction with

THE CROWN

REVOLUTION IS ABOUT TO BEGIN Contact Crown now to be one of the first to see the new Crown C-5 internal combustion forklift, designed and manufactured by Crown.

131 604 crowninfo@crown.com or visit crown.com/au to learn more.

There is nothing like a Crown, for picking it up and putting it down.

140 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

Powered by

Materials Handling Heavy-duty conveyor’s no rubbish

BY TONY SCULPHER

The horizontal conveyor is 12

BRUNTON Engineering &

meters long, and the incline

Construction has recently

conveyor is 13.25 meters long and

commissioned two new, heavy-duty

then elevates 6.5 meters at 35

slatted belt conveyors for SKM

degrees. Both conveyors feature

Recycling’s new Waste Recovery

a 1,800mm-wide rubber belt, and

Facility in South Geelong, Victoria,

have the capacity to move up to 20

capable of handling 500 tonnes of

tonnes of waste products per hour.

waste per day.

SKM Recycling, founded in 1999,

The waste recovery trucks deliver to the SKM Recycling site

now has four recycling sites across

all waste products as collected

Melbourne and Geelong, recycling

from household domestic recycling

household waste and distributing it

waste bins. The contents can

to 12 councils across the state.

contain all manner of household

With daily recycling exceeding

waste products from cardboard,

500 tonnes, SKM also provides

cans and glass, to non-compliant

recyclable collection services to

items such as automotive

schools, hospitals, government

batteries, and automotive engine

departments, and from commercial

components. The calculated

multi-stage assembly comprises

Unicase construction, offering a

and industrial businesses. Sorted

density of the waste product is

of a combination of one NORD

rigid, single-cast housing with high

recycled products are then on-sold

0.4 tonnes per cubic metre.

The NORD motors allow the 12-metre conveyor to move 20 tonnes of waste per hour.

Helical bevel gearbox and one

overhung load capacity. Featuring

The complete design and

NORD Helical inline gearbox, close

double output shaft seals fitted

furniture, and paper and cardboard

construction of the two heavy-

coupled together to provide a large

as standard equipment, the NORD

manufacturers.

duty slatted belt conveyors

range of slow output speeds and

assemblies proved to be ideal for

was completed at Brunton

very high torque capacities.

the dirty and arduous conditions.

to packaging, clothing, plastic

The SKM Recycling project consisted of one horizontal conveyor

Engineering’s Somerton, Victoria,

for loading of waste products from

engineering workshops.

the recovery trucks, and one incline

The company selected and

The NORD multi-stage assemblies are identified by

[Tony Sculpher is regional sales manager for NORD Drivesystems AU.]

the NORD type designation

conveyor for delivery of the waste

installed two 3kW NORD multi-

‘SK9072.1/32AZK-112LH/4TF’. All

• NORD

products to the existing sorting

stage geared motor assemblies for

of NORD’s Helical bevel and Helical

1300 006 673

systems conveyor.

this unusual application. The NORD

inline gearboxs feature NORD’s

www.nord.com.au

142 | May 2011 Manufacturers’ Monthly | Celebrating 50 years

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