Manufacturers' Monthly September 2012

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September 2012

INSIDE Industry News & Comment >> New Products >> Made in Australia >> Materials Handling >> Automation & Robotics >> Metalworking >> Body Protection

You can buy one of our Aussie products, or you can buy imported ones and put us out of work.

When you buy an Australian made product, you know it’s been made to a high standard by Australian workers.

But when you choose an imported product, you’re actually taking work away from Australians. So keep our workers working and buy Australian. It’s your choice. australianmade.com.au

Publisher Martin Sinclair martin.sinclair@reedbusiness.com.au Managing Editor Cole Latimer Ph: (02) 9422 2352 Fax (02) 9422 2722 cole.latimer@reedbusiness.com.au Deputy Editor Annie Dang Ph: (02) 9422 2964 Fax (02) 9422 2722 annie.dang@reedbusiness.com.au Journalist Angela Welsh Ph: (02) 9422 2898 Fax (02) 9422 2722 angela.welsh@reedbusiness.com.au Graphic Designer Ronnie Lawrence ronald.lawrence@reedbusiness.com.au Creative Director Julie Coughlan Production Co-ordinator Mary Copland Ph: (02) 9422 2738 mary.copland@reedbusiness.com.au VIC/Overseas Sales Michael Northcott PO Box 3069 Eltham VIC 3095 Ph: 0448 077 247 michael.northcott@reedbusiness.com.au NSW Sales Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067.

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

Inside SEPTEMBER 2012

4 Editorial Q A nation of quality

For daily news visit manmonthly.com.au

12

6 Comment Q Lost opportunities for change

8 Analysis News

30

Q A path for our manufacturing

future Q Are local content laws going far enough?

12 Heavy industry Q A vision in charcoal

14 Training

42

Q Up-skilling for tomorrow

16 Made in Australia Q Keeping industry viable Q Bucking the trend Q Railroading the industry

36 Metalworking

44 IT@MM

Q When sparks fly Q Local welding technology exported

Q Hard maintenance for software Q Speeding ahead

to UK, Middle East

26 Materials Handling Q Upsides of a downturn Q ‘Palletable’ developments

30 Automation & Robotics Q Robots are go Q Ready, set, weld

ABN 80 132 719 861 Average Net Distribution Period ending March 12 15,300 ISSN 0025-2530

Q Heavy duty metal cutting Q Welding safety

50 What’s New

42 Body Protection

Q Safety footwear Q Welding helmets

Q Latest products for Australian

manufacturers Q Reducing serious muscle injuries Q Hand protection

Q Motors and drives Q Compressors

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Editorial

COLE LATIMER – Managing Editor

editor@manmonthly.com.au

A nation of quality Australian manufacturers should compete on their own terms, not those set by other nations.

A

ustralia is not a nation of cheap and nasty.

The simple fact is that we can not compete with the scale and mass production ability of China or the U.S. But the point is should we be trying to compete with them in this way?

Both these countries have the manpower and cheaper labour to allow them to manufacture goods in massive numbers Australia just can’t match.

But despite having these giants of manufacturing as our nearest, largest Pacific neighbours, our manufacturing industry has not gone under like other nations that have attempted to compete with them on their terms of scale and bulk.

And the reason Australia has not is because we are not the country of cheap goods, mass produced for the lowest price.

Our nation is one of quality of sheer quantity.

Australia is known for the quality of its goods, whether they be metal fabricated pieces, heavy machinery, high end technology, intricate electronics, clothes, or food and beverages, you know what you get with Australian products.

Quality, not quantity is what we should aim for.

A great example of this was when I was in Hong Kong.

I was amazed by the actual number of Australian made products on the shelves.

Food products, beverages, even clothes and Australian made high end goods were found in many stores around the island.

Speaking to some of the people I was working with, they explained that Australian goods did well in Hong Kong for the simple fact that while Chinese made goods from

across the border were cheaper and more plentiful, the quality was at best spotty and at other times downright dangerous.

And while the Australian goods were more expensive, you got what you paid for, and that was assurance of quality; assurance that what ever you were drinking, eating, wearing, or using, did not have high levels of lead, or melamine, or cadmium; was not going to explode, burn, or simply break after only a few weeks of using it.

The Australian made product was going to work.

And this is what our reputation is built on.

You may pay more for Australian made goods, but you get the quality and assurance that it will do what it says it will.

We have a manufacturing industry that operates to the high levels of quality assurance we’ve come to expect, rather pushing out the goods regardless of whether it is actually safe enough for human consumption.

Our manufacturing industry is going through a slump right now, and it is unlikely to rise to the dizzying heights of scale that it did last century, but it will remain strong and as always it will bounce back.

Because Australia is not the country of cheap and nasty, and it shouldn’t aim to compete with those nations that are; instead it should grow through its strengths of quality, invention and innovation These were the aspects pointed to as our saving grace, and future, in the Manufacturing Taskforce’s recent report on how to save the industry. Because at the end of the day, you get will always get what you pay for, and sheer quantity can’t always beat quality.

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Comment

INNES WILLOX – CEO Australian Industry Group

editor@manmonthly.com.au

Lost opportunities for change A review of the Fair Work Act has fallen short.

T

he recent review of the Fair Work Act represents a lost opportunity to make changes to deliver sustained, higher rates of productivity growth.

While we support some recommendations, some we only support if modified.

Among those select ones we approve of, and indeed were part of our submission to the Review, include the proposal to address the problem of State and Territory Government’s proclaiming additional public holidays beyond the 11 which have traditionally applied.

Additional public holidays impose major cost increases on business.

We also support remedying the problems caused by the ‘JJ Richards’ bargaining decision and the ‘Barclay v Bendigo TAFE’ general protections decision. These decisions have

6 SEPTEMBER 2012 Manufacturers’ Monthly

imposed unworkable outcomes on employers. It is especially disappointing that the Fair Work Act Review Panel did not take a more proactive view of the role that changes to the Fair Work Act (FW Act) could make to sustaining higher rates of productivity growth over coming years.

This flies in the face of the views of employers with coal-face experience of working under the Act. The Panel’s argument that the Act has not damaged productivity suggests a lack of ambition. We need to have workplace laws which are a positive force in raising productivity.

Workplace relations is not the only factor which contributes to productivity performance but it is a very important factor. The full potential of other drivers of productivity, including product and process

innovation, technological change, management skills, workplace training and active supply chain management for instance, depend upon flexible workplaces and good workplace relations.

There are a number of recommendations strongly opposed by Ai Group. One of these is the proposal to give FWA the power to arbitrate, at the request of unions or employers, on greenfields agreements.

Employers incur the cost risks on a project and it would be a step backwards to allow FWA to determine labour costs on application by unions. Similarly, requiring an employer to notify and potentially bargain with a very large number of unions whenever a greenfields agreement is proposed, would lead to demarcation problems and delay the commencement of projects.

The proposal to allow unions to apply for bargaining orders long before an enterprise agreement expires does not take into account that employers are entitled to have a reasonable period of industrial peace and relief from bargaining once they enter into an enterprise agreement.

In the current environment, a company cannot afford to give up flexibility. We also cannot afford to add to the barriers against Australia being chosen as an investment destination if we fail to take positive steps to improve our workplace productivity and flexibility.

The ball is now in the Government’s court.

It is vital that in its response, the Government does not waste another opportunity to implement the necessary changes to promote productivity and flexible workplaces.

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AnalysisNEWS A path for our manufacturing future The CSIRO’s Swee Mak discusses the future of the industry in Australia.

B

y virtue of my role as the Director of the Future Manufacturing National Research Flagship at CSIRO, I am often confronted by this question.

Many commentators and peers expect a simple answer, but that would be underestimating the complexity of manufacturing, both in terms of challenges and opportunities. The recent work undertaken by the Prime Minister’s Manufacturing Task Force and other commentary is beginning to create a picture of what the future could (or ought) to look like for manufacturing in this country. Irrespective of the wide-ranging views on what alternate futures for manufacturing might look like, Australian manufacturers need to be competitive in global markets and be highly productive and sustainable in their business operations.

8 SEPTEMBER 2012 Manufacturers’ Monthly

Manufacturing firms also need to capture the opportunities offered by Australia’s comparative advantage in natural resources in minerals and

agriculture, as well as emerging markets for products and services that support sustainable living in transport, construction, and energy.

As part of its contribution to the Task Force, CSIRO has done an analysis of global mega-trends and identified a number of drivers that are already shaping the future of manufacturing in Australia. They include the rise of a new digitallydriven infrastructure, a move towards mass customisation, an emphasis on sustainability and the need to produce more from less.

Over the next decade, success factors that will influence the competitiveness of Australian manufacturing firms will include the need for faster discovery and development to respond more quickly to dynamic markets, advanced design to create much more competitive and sustainable products, improved collaboration across our innovation system to maximise the exchange and transfer of knowledge, an increase in our

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ability to leverage our national broadband infrastructure, and encouraging a better understanding of supply chains.

Another key success factor will be our ability to develop, adapt, adopt and integrate the right enabling technologies that provide a competitive advantage for Australian manufacturing firms. There are number of potential game changers in terms of enabling technologies and advanced capabilities. This includes additive manufacturing, assistive automation, advanced design and smart information systems. Globally we have seen a major shift towards technology-led manufacturing focused on large scale industrial automation. In countries such as Germany, production lines are increasingly dominated by automated processes and robotics. More recently, China has embarked on a large-scale industrial automation program. However, we need to think

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about how such technological leaps work for Australia. We have our own unique manufacturing DNA, made up of tens of thousands of SMEs. This is very different to some other industrialised countries, where there are many more large scale manufacturing enterprises. Australian SMEs often find it difficult to embrace industrial automation because of cost and the risk of disruption to their production. However, there may be other paths to large scale industrial automation. Simple repetitive tasks have largely been addressed by automation (robotics) in manufacturing environments. However, there are many complex tasks that still require human involvement; it may be these technologies that “assist� (rather than replace) human processes that may become more prominent in Australia. The emerging field of assistive automation may play an important role in the future of

Australian manufacturing. Additive manufacturing is a method of fabrication by layers that translates digital design information into prototype or production parts. Currently used mainly in prototyping, additive techniques are increasingly seen as effective for manufacturing highly complex parts and devices that are costly to make by conventional means. Manufacturers can potentially deliver more niche, high value, customised products and be competitive even by producing low volumes.

This is important as Australian manufacturers operate in a relatively high-cost environment, and generally cannot compete by generating economies of scale. In the Australian context, the availability of highspeed broadband will also greatly assist the adoption of this digitallyenabled technology. However, much still needs to be done to adapt these relatively new additive processes to

make them robust and cost-effective for mainstream manufacturing.

Design will become increasingly important part of the manufacturing value chain. For manufacturing firms, making the transition from pure production to being more service based, design thinking could also play an increasingly important role in innovation. There is emerging evidence, particularly in northern European countries, that the adoption of design-led innovation is directly linked to increasing firm competitiveness.

The application of Smart Information Systems has the potential to lift productivity, competitiveness and safety.

There is no doubt that Australian manufacturing will need to take its own path to innovation and maintaining its competitiveness.

This piece originally appeared in full on The Conversation.

Manufacturers’ Monthly SEPTEMBER 2012 9

AnalysisNEWS

Are local content laws going far enough?

In July the government introduced new local content plans to increase Australian representation. Vicky Validakis looks at the effectiveness of these measures so far.

U

nder the Australian Industry Participation plan companies with projects worth more than $2 billion in the private sector and $20 million in the public sector, must put plans in place which ensure components for the projects are being sourced from local firms.

The new measures mean companies undertaking large-scale projects must make their plans public and include more Australian-made components.

The Department of Innovation, Industry, Science and Research says these measures will ensure “Australian industry has the same opportunity afforded to other global supply chain partners [and] Australian industry is provided the same opportunity as global suppliers to compete on investment projects on an equal and transparent basis�.

However the initiative’s effectiveness in forcing major companies to buy local has come under fire in recent weeks for what many claim is a poor approach to the plight of the manufacturing industry.

With no legislation surrounding the plans, and little policing of the findings or actual usage levels, many industries have ignored the rules.

Mining companies in particular are under the spotlight, with many asking questions about how much mining is doing to support local industry.

The most recent adversary, Illawarra MP Stephen Throsby,

has gone after miners, saying they should not be allowed to employ foreign workers until they can show they are taking the AIP initiative seriously. He stated that “they’re not policed and I think we need to lift the bar�.

With the sacking of almost 1000 workers last year from BlueScope Steel in Wollongong, Throsby’s electorate, it is little wonder he is asking questions of the AIP and how major companies are participating in the initiative. “Local firms are currently getting around 10 to 12 per cent of the work.

We think that doubling that would have every manufacturing and fabricating shop in the country more than full so there’s a fair bit of leeway there,� he said.

Throsby’s figures have annoyed the mining community with Minerals Council public affairs director Ben Mitchell stating that the mining industry is supporting local content. “A report produced for the steel industry shows that mining is buying about 88 per cent of goods and services locally,� Throsby said.

However with plans to ‘name and shame’ companies not using local content scrapped and no firm legislation in place to regulate polices, the manufacturing industry still languishes from low-cost imports being used not only by mining companies but in other major projects also. The NSW Government’s decision to use a

The Australian Industry Participation Plans were designed to hold civil and mining projects accountable for local content.

Spanish company for the Sydney Light Rail extension, a project worth around $103 million, only highlights the issue; with the money set to go offshore and little to no local content to be used.

With sales and new orders in the services sector contracting by 2.3 points in July, Australian Industry Group Chief Executive, Innes Willox, said “the fall....highlights the fragility of business conditions in the services sector, which is struggling to build momentum�.

The group also reports significant declines in production in the textiles; wood products & furniture; paper, printing & publishing; construction materials; basic metals; fabricated metals; and miscellaneous manufactures sub-sectors during July.

However Willox did point to the ways in which the Smarter Manufacturing for A Smart Australia report highlighted a new positive agenda for the industry, with “go to policies around innovation; making research organisations more business facing; skilling and education of new workers; energy and climate policy; procurement, including for the defence sector; listing management capabilities; and trade�.

He added that we need to focus on a “stronger manufacturing sector�. “Without such an agenda we risk travelling further down a path that would leave us more vulnerable to commodity price fluctuations and more exposed to a reliance on the export of a handful of commodities to a handful of countries.�

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AnalysisNEWS

A vision in charcoal New developments by the CSIRO may be an injection into the arm of Australia’s steel making industry, writes Tony Heselev.

T

he Australian steel industry has been hit hard by the high dollar, rising raw material prices and low cost imports, but technologies developed by CSIRO and its industry partners could set the industry on a new, low emissions path.

An integrated and visionary process that would reduce greenhouse gas emissions in steelmaking could help revive the industry in Australia while providing significant opportunities for other businesses.

The process, developed by CSIRO and industry partners, could more than halve the steel industry’s greenhouse gas emissions without increasing production costs. It would also produce valuable by-products and enable the industry to make ‘carbon lite’ steel, differentiating it from other producers including low cost importers.

Emissions may be cut.

The process is driven by two technologies: partial replacement of coal and coke in steelmaking with greenhouse gas neutral, renewable charcoal, and recovering waste heat

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12 SEPTEMBER 2012 Manufacturers’ Monthly

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Page 1

through dry granulation of slag.

CSIRO and its industry partners, BlueScope Steel and OneSteel, began working on the technologies in 2006 in a project that has cost $12 million so far.

Assuming 10–13 per cent market penetration by 2030, a leading project management and engineering consultancy has estimated that these technologies have a potential risk- adjusted net present value of $42 billion.

The Australian iron and steel industry produces about six million tonnes of steel and 14 million tonnes of greenhouse gases (mostly carbon dioxide) a year. This is about 2.5 per cent of Australia’s total annual emissions.

Most of the iron and steel industry’s emissions occur during production of iron in the blast furnace, where coal and coke are used as fuel and reductant.

CSIRO and its partners found that between 32 and 58 per cent of coal and coke used for integrated iron and steelmaking could be replaced by charcoal without substantially modifying the steelworks. This would lead to a significant reduction in net greenhouse gas emissions produced by the industry.

As part of the integrated steelmaking process, charcoal would be produced by using pyrolysis to dry and heat biomass sourced from tree

plantations and residues from forestry, agriculture and wood processing.

Pyrolysis is an oxygen-free system that works (at temperatures above 300oC) in a similar way to a home oven. Different products are generated depending on the type of biomass feed material, how fast the biomass is heated and to what temperature it is heated. This technique creates ‘designer biochar’, so called because different types of charcoal can be made to meet the demands of the eight potential applications involved in steelmaking.

Charcoal can have similar properties to coal in that it contains carbon, ash and volatile matter, can be very reactive and when required, can be made dense and strong.

Dr Sharif Jahanshahi, who leads the CO2 program for CSIRO, says, “just as oils ain’t oils, charcoals ain’t charcoals. Depending on the application required, the charcoal properties can vary. “In some cases, you may want to grind the charcoal into very fine powder because you want to inject it with air/ oxygen through a little nozzle and burn it. So you want it to be very reactive, easy to grind and contain 10–20 per cent volatile matter. “In another case, you may want it to be the complete opposite – very low in volatility and dense so that it doesn’t introduce hydrocarbon and moisture, because this is detrimental to steel.�

Work on each of the applications is being progressed, from laboratory to pilot scale and then to full demonstration (industrial) scale. Three have been successfully piloted, of which one has gone to full-scale.

Dr Jahanshahi expects many of the applications to reach the demonstration stage by 2015.

The biggest application with the largest greenhouse ‘gain’ is the injection of pulverised charcoal into the blast furnace. This was successfully laboratory tested by BlueScope Steel in Newcastle about two years ago.

Dr Jahanshahi says it showed superior results to coal and he is manmonthly.com.au

confident that with support from industry, it will lead to a successful demonstration project.

A novel pyrolysis process to convert biomass into charcoal, which CSIRO is developing at its onsite pilot plant in Clayton (Melbourne), also produces some valuable and carbon neutral by-products. These include bio-oil and hydrocarbons that could be used to produce green electricity, plastics and liquid fuels.

Capturing and maximising the value of these by-products will be essential in making charcoal an economically viable alternative to coke and coal in Australia.

Pyrolysis of wood is an ancient technique but no technology exists to make very large quantities at a low enough cost. The pilot plant needs to demonstrate low capital costs, be able to process inexpensive woody materials efficiently and operate continuously with low emissions and high yield.

The pilot plant operates at 100 kilograms of biomass per hour and is

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Charcoal may be a subsitute for coal, BlueScope says.

designed to recover bio-oil and other by-products using its own energy (autogenously). Proof of concept is expected in the second half of 2012, with scale-up and demonstration to follow. The aim is for the plant to be scaled “The pyrolysis process needs to be versatile enough to be a modular

plant next to the biomass resource or a giant plant providing charcoal next to the blast furnace,”Jahanshahi says.

Biomass materials used to create charcoal will come from sustainable sources rather than native forests, and are considered to be carbon neutral. Substituting these materials

for coal-based fuels and reductants used in iron and steelmaking reduces the industry’s net CO2 emissions without the need for major capital expenditure. In a carbon-constrained environment this is good news for the industry and it could minimise its liability for the carbon tax.

Andy Purvis, BlueScope Steel’s environment manager says, “we see this project as one opportunity to make a breakthrough improvement in our direct emissions, by replacing coal with greenhouse neutral and renewable charcoal.

“It could be the right solution for the Australian steel industry without us having to spend hundreds of millions developing entirely new processes or building a new plant.

“If we can overcome these challenges, the early signs are that charcoal could be an excellent substitute material for coal and coke, especially if and when the carbon price goes higher,” Purvis says.

This article appeared in full in the CSIRO’s Resourceful magazine.

Manufacturers’ Monthly SEPTEMBER 2012 13

InsiderSERIES

MANUFACTURING TRAINING & SKILLS

Up-skilling for tomorrow A general skills shortage has made it hard for local industry to recruit and retain a new generation of manufacturing workers. Angela Welsh writes.

I

N THE wake of the Global Financial Crisis, it is hard to imagine that some employers are struggling to fill vacant positions.

Yet the manufacturing industry is one of several sectors suffering from a skills shortage.

While the Department of Education, Employment and Workplace Relations (DEEWR) has reported an easing of the skills shortage from 2010 to 2011, conditions remain far from ideal for many companies.

Engineers and automotive trade workers were in high demand throughout 2011, according to Government statistics from the Department of Education, Employment and Workplace Relations (DEEWR). However, there was a serious shortfall in the number of suitable applicants able to fill these positions.

Only 43% of positions requiring a skilled automotive tradesperson were filled last year. Employers seeking professional engineers had it even worse, with a vacancy fill rate of 40%. By contrast, 88% of vacancies for accountants and 72% of vacancies in construction trades

14 SEPTEMBER 2012 Manufacturers’ Monthly

The skills crisis has eased, but training is still down.

were filled, according to the government’s skill shortage report.

Skills shortages in key trades The severity of the national skills shortage may be surprising to some, but it is not news to Bob Paton, CEO

of Manufacturing Skills Australia (MSA). He says there are several key trades within the manufacturing industry alone that desperately need skilled workers.

“The skills shortages are in occupations often associated with manufacturing, or that come from manufacturing,” Paton told

Manufacturers’ Monthly.

However, with the resources and energy boom and the projects coming out of those sectors, there is high demand for the traditional metal trades, such as fitters, welders, boiler-makers, fabricators and so on, he says.

“And that’s generating some fairly

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strong draw-cards for people to take up work in those high-paid occupations, which is actually pulling them out of other companies within the manufacturing sector.”

Paton points out that even at the height of the GST in 2009-10, there were still significant shortages of skilled workers in those areas.

Industry action In Australia, formal training for these sort of jobs is commonly done via an apprenticeship. Outside of this channel, there are programs that seek to identify people with existing skills in a related field, which sees them receive further training so they can fill trade-level jobs.

One example is a program run by group training company East Coast Apprenticeships. The program has gained support from the Federal Government, and has the cooperation of a handful of companies in the industry.

“The concept is to target the companies in Queensland and eastern Australia that have a need around some of these trades; identify job opportunities there might be, and find existing workers who have some of the basic skills and experience that might make them into tradespeople,” Paton says.

“These targeted workers can undertake a shorter training period than would normally run for, say, a school leaver entering the industry.”

The program run by East Coast identifies and recruits suitable

High demand from other industries has poached workers away from manufacturing. participants, provides basic wage costs for students for a short period, and then helps them find employment when they complete their training and up-skilling.

Recruitment for skills training programs is generally done through advertising and other publicity channels, such as company websites, major job seeker websites, niche recruiters, universities, job expos, local papers and even local notice boards.

Getting competitive The organisation that Paton directs,

Manufacturing Skills Australia (MSA) previously offered a series of qualifications and training called Competitive Manufacturing.

The program has been overhauled in the last year and re-released recently. Now called Competitive Systems and Practice, the program is aimed not just at manufacturers but the broader community.

Paton says the curriculum centres on Lean Manufacturing, “a process that strips out the excess and the superfluous about the actual product or service you’re delivering and focus on delivering

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that outcome”.

“To be really successful, one of the keys is about a buy-in from the boardroom to factory floor,” Paton says.

“The whole company needs to be engaged in this notion about improvement. But there have been some excellent examples of that, and productivity gains almost immediately and benefits keep on going.

“But it’s a forever journey.

Toyota motor company is probably the world’s best known example of a company that embraces this approach, Paton points out.

“But the tighter you squeeze that last ounce of improvement – or last gram of improvement – the cost and the effort required goes up exponentially. And the quest for that leanness in what you’re just doing goes on and on,” he says.

But for companies yet to adopt this approach, there could be some pretty rapid improvement almost straight away, he adds.

While Australian industries are being pro-active about developing, enhancing and expanding it skills training base, the challenge still remains as to how best to apply those skills from the program to the workplace.

“The real benefit is around the question, ‘How do you best use those skills to the benefit of the enterprise?’” he says. And by enterprise, Paton is shareholders, owners and also the workers.

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Manufacturers’ Monthly SEPTEMBER 2012 15

MadeIN OZ Keeping industry viable While government and business leaders are finally realising Australia’s manufacturing industry is struggling to survive, numerous solutions are being proposed, but are they too little, too late? Alan Johnson reports.

W

ITH the manufacturing industry down over 100,000 jobs since the GFS started, with a further 85,000 plus expected to go before 2017, it is clear the sector is going through its worst period on record and struggling to remain competitive.

While the resources-driven high Australian dollar is probably the main reason for manufacturing’s demise, rising labour costs, ever increasing taxes and regulations, higher energy costs and slow productivity growth all play their part in making Australia increasingly difficult place to manufacture.

Dick Warburton, executive chairman of the Manufacturing Australia group, and keynote speaker at this year’s Endeavour Awards ceremony, is highly critical of the Gillard government and is calling for courageous leadership to ward off the continued decline of Australia’s manufacturing base.

“As a community we rightly question the wisdom of taxpayer funded bailouts for struggling manufacturers, but then wonder why there is not more vigorous and earnest debate about the policy reforms that might break this unsustainable cycle.

“The problems impacting Australia’s non-mining industry sectors are increasingly put in the too hard basket. Australia’s progress on industrial relations reform is

“Australian businesses need real industrial relations reforms in order to remain competitive internationally,” Warburton said.

Report released

Closing a factory in Australia is industrially easier to achieve than shedding 10% of the workforce - Warburton. disappointing, and is being stymied by slogans and tokenism taking the place of earnest debate.

“It is a sad indictment of our industrial relations system that closing a factory in Australia is easier to achieve than shedding 10 per cent of the workforce or outsourcing noncore activities so the factory can be kept open,” Warburton said.

“Presently direct relationships between employees and employers are undermined by third parties having the legislated right to become default bargaining representatives for employees, even when not appointed by employees.

In response to the many issues facing the industry, the Gillard government’s manufacturing taskforce, which first met in November last year and includes a number of union and manufacturing heavyweights, released its much anticipated report in August with more than 40 recommendations ranging from industry assistance to more spending on infrastructure.

The authors of the 117 page report, Smarter Manufacturing for a Smarter Australia, have developed a five point policy agenda which looks to shape a more dynamic contribution from manufacturing.

The agenda proposes “specific measures to boost the public and private investment pipeline, strengthen value capture from large projects in the existing pipeline, and help businesses, workers and communities manage change as well improving productivity growth, encourage investment and reduce the costs of doing business”.

The agenda also calls for “fundamental changes in behaviour on the part of researchers, research organisations and businesses with a new Smarter Australia Network linking

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businesses, research organisations and others”.

To address the multiple barriers facing SMEs, the taskforce proposes Enterprise Connect be upgraded and its funding to support manufacturers be increased, plus a new national partnership for Smarter Workplaces is proposed.

The taskforce’s agenda also includes transforming a larger portion of the $9.4bn that is invested each year by the Commonwealth Government in science and research into applied knowledge in manufacturing.

Other proposals include building better supply chains, a more efficient manufacturing industry, a world class food industry and winning the lion’s share of the $25bn plus to be spent on the next generation submarines.

Ai Group’s chief executive Innes Willox, a member of the taskforce, described the report as a vote of confidence in the role that manufacturing can play in building a stronger, balanced and more Australian resilient economy.

“While the sector faces a unique coincidence of global, structural and cyclical pressures the Report proposes that Australia capitalises on its considerable strengths and builds new sources of strength to position the sector to take advantage of emerging opportunities.

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Politicians are being encouraged to increase their knowledge of the manufacturing sector.

“Its recommendations go to policies around innovation; making research organisations more business facing; skilling and education; energy and climate policy; procurement, including for the defence sector; lifting management capabilities; and trade,”Willox said.

Industry Capability Network‘s executive director, Derek Lark, also welcomed the report saying it maps out a shared vision for the future of Australia’s manufacturing sector.

“We are excited by the recommendations and look forward to working with government and industry bodies to continue to support, develop and enhance relationships for Australian manufacturing and services companies,” he said.

“In particular, we welcome the recommendation to expand the Australian Government’s Buy Australian at Home and Abroad Scheme.

However many in the industry are questioning the report’s substance describing it as “disappointing and limp”. They point to the report’s failure to say anything of substance about the main issues affecting the manufacturing industry such as the high Australian dollar, the unpopular carbon tax and industrial relations.

Many are also pushing for a cut in inefficient subsidies and the creation of a new high-value manufacturing model for the sector. manmonthly.com.au

Former Foster’s Group CEO, John Pollaers, believes a successful manufacturing industry should look beyond production and incorporate R&D, design, supply management as well as sales and marketing.

For the full manufacturing taskforce report, go to www. innovation.gov.au/Industry/ Manufacturing/Taskforce/Documents/ SmarterManufacturing.pdf

Lobby group formed The same day as the Federal Government’s manufacturing report was announced, the Australian Manufacturing and Farming Program (AMFP) initiative, which encourages politicians from both sides of the fence to directly engage with Australian manufacturing and agricultural companies, was being launched on the lawns of Parliament House.

The program sees a wide range of businesses and industry associations from these sectors meeting directly with politicians to discuss their business, its history, and its people.

Participating politicians are being encouraged by the founders of the AMFP - Victorian senator John Madigan, senator Nick Xenophon from South Australia and Bob Katter from Queensland - to increase their overall knowledge of either the manufacturing or farming sector.

David Keech, director of sales and

marketing of Keech Australia, joined the event in the hope of initiating critical change.

“Australia’s manufacturing sector plays a critical role in our economic future, yet many politicians don’t fully realise the important contribution that businesses like ours make to the regional job market and the Australian economy,” he said.

Herbert Hermens, Keech’s CEO, said workforce flexibility was one of the key issues hampering the future of the manufacturing sector.

“We’re competing against countries with very different cost structures and the manufacturing sector needs more freedom to work at a local level, directly with its employees, to encourage more flexibility.

“Skilled migration is another issue, given the fact that many graduate engineers are heading off to work in mining. We need the ability to quickly fill our professional skills gaps with overseas workers if locally

trained professionals are unavailable or unwilling to work in the manufacturing sector.

“Today we also plan to share insights into our workforce, where we’re seeing an increase in the number of young people lacking basic skills. Last year we invested $200,000 to put 60 of our foundry labourers through a Certificate 3 in Production.

“Government needs to support manufacturing businesses investing in research and development by making it easier to foster closer working collaborations between government departments and private businesses such as ours.

“The current process of collaboration is difficult and time consuming, and to support innovation, this needs to change. Being able to meet with politicians and have these discussions face-to-face is an important first step in reversing the decline in Australia’s manufacturing sector.”

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TM TM Austral ustraallilian iia ian an Madde e! de!

In 1992 Nitto Kohki Co., Ltd Japan bought a stake in its existing Australian Exclusive Distributor, Westair Pneumatics. Soon after this the company decided to produce an Australian Made Broach Cutter to supply along side Nitto Kohkiâ&#x20AC;&#x2122;s Atra Ace Magnetic Based Drills.

The company leased a premises on the Southside of Brisbane and the Manufacturing Division was created on an initial budget of $400,000 and commenced with 3 employees.

Four machines were purchased consisting of a Lathe, two Vertical Machining Centers and a Cylindrical Grinder. In these early days the two machining centers were used for four operations which meant many set ups and angle plates were used to produce the cutting teeth.

Australia Made cutter was In 1992 the first proudly manufactured by Westair Pneumatics.

Over the next couple of years two more vertical machining centers were added and another lathe to streamline the process. In 1998 another shift was added to keep up with the growing sales and demand.

The Quality Control was then further enhanced with the addition of in-process gauging for the grinding procedure.

In 2000 the company was fully acquired by Nitto Kohki Co., LTD Japan and our Company names changed to Nitto Kohki Australia Pty Ltd (Sales Division) and Nitto Kohki Australia Manufacturing Pty Ltd. In 2004 the Company moved to new premises so the Sales and Manufacturing Teams could operate from the same premises, now still situated at Eight Mile Plains, in Brisbane Technology Park.

DEMAND

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In 2005 the purchase of a new 5 Axis CNC Grinding Machine from a local Australian company, ANCA in Melbourne, enabled the manufacturing process to be streamlined further so that the Gash and Tooth Geometry could be machined in one set up and this also enabled automation to commence.

In 2007 the company purchased a new Twin Spindle, Twin Turret Nakamura Lathe in order to replace our old Victor Lathe. In 2008 we then purchased a second new ANCA 5 Axis CNC Grinding Machine, to enable us to keep up with the continual increase in demand from the market.

In 2010 we decided to give our Brand a rebirth and after much thought we registered , our new trademark, incorporating the well respected Nitto Logo.

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It is with great pride that today we continue to grow and strengthen our sales of the HSS cutters, providing Steel Fabricators a high quality Australian Made product which is now requested by name.

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Bucking the trend

With manufacturing slowing down in Australia, Manufacturers’ Monthly talk to one company that is growing, and finds out how they did it, and what can be done to reverse the slump.

W

hat makes a successful manufacturing company?

Is it profit margins, company size, number of employees, culture, or simply not shutting down?

With manufacturing slowing down in Australia and many companies laying off workers or shutting factories, it’s unusual to hear of an Australian company expanding.

Many in the media focus solely on the parts of the industry that are struggling, particularly the automotive sector.

However it isn’t like that right across the board, one such company, SMC Pneumatics Australia, is not only weathering this apparent downturn in the industry, but is actually thriving.

Speaking to its managing director, Wayne Driver, he told Manufacturers’ Monthly that he “sees a future for manufacturing in Australia, and the imperative for the country is that we’re not just a supplier [through primary industries such as mining] to other nations’ manufacturing industry, but that we ensure we are a manufacturer ourselves.

“The industry in Australia is being moved from manufacturing to more services based industries, and it will be a shame if Australia loses this manufacturing sector, because manmonthly.com.au

if we ever lose that we will become very reliant on overseas,” Driver explained.

“But we can build our future on innovation.”

Being an innovative Australian company is a notion that SMC has tried to operate to, since its early incarnations in Australia back in the 1960s.

Since this time is has exponentially and spread across the Tasman into New Zealand.

Driver said what has kept the pneumatic and automation equipment company not just surviving but expanding is “continually asking how can we do this better, which is a question that should be asked right across the industry.

“There is a lot of innovation going on in Australia in term of research and development going here…. research and development is paramount, as Australia is such a small [manufacturing] market for producers so by having our own R&D and engineering (rather than outsourcing it to other countries) as it allows us to focus on niche sectors or operating conditions that other countries simply don’t have, conditions unique to Australia,” Driver said.

People on the ground Driver also identified the ongoing

The company builds all of Australia’s bus doors. skills issue as one of the major problems affecting manufacturing.

“One of the main issues is just where do you source your skilled people from,” Driver asked.

Developing the workers with the appropriate skills set in Australia has always been an issue, however this to date has seen a lack of support from those in

the government.

“We really need more government initiatives to help drive training in the industry and to create these skills sets.”

Illawarra Mp Stephen Throsby recently stated even the current government’s backbenchers are concerned that the government isn’t

Continued on page 21 Manufacturers’ Monthly SEPTEMBER 2012 19

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Made IN OZ Continued from page 19 doing enough. â&#x20AC;&#x153;The government needs to support manufacturingâ&#x20AC;Ś..they need to look at the bigger picture,â&#x20AC;? Driver stated. â&#x20AC;&#x153;This high Australian dollar is really a double edged sword; some companies are even buying out of New Zealand as itâ&#x20AC;&#x2122;s cheaper to manufacture there and then transport it across,â&#x20AC;? he explained. â&#x20AC;&#x153;There are a lot of challenges we face right now, and manufacturing needs to look at how to do things better to grow again, but the government have a major part to play in this.â&#x20AC;?

The Australian story So how has SMC bucked the trend?

At the time of publication it had recently bought additional land on its already large seven hectare site, with plans to build new facilities in addition to its warehouses in every single state.

Regarding the new site, the company may take a larger role in the mining industry, Driver explain-

Access to supplies is crucial. ing that â&#x20AC;&#x153;we could do more manufacturing for the mining industry, in the future they may be running the global mining projects for the company (which is Japanese) out of Australia, as we have the knowledge for it here, so we may manufacture locally for the mining industryâ&#x20AC;?.

In addition to pneumatic actuators it also produces electrical actuators, with plans to â&#x20AC;&#x153;grow the electrical side, as we see it will be a big part of

business in the futureâ&#x20AC;?.

In doing so it allowed SMC â&#x20AC;&#x153;a point of difference, as we have high precision components and actuator through to the mechanical parts. â&#x20AC;&#x153;From a single plant weâ&#x20AC;&#x2122;ve produced around 20 000 actuators a year.â&#x20AC;?

However, it also manufacturers a high number of bespoke actuators and equipment. â&#x20AC;&#x153;We are the only company in

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Australia that produces the doors for buses.â&#x20AC;?

Yet, Australian companies canâ&#x20AC;&#x2122;t do it all by themselves, which is why SMC has teamed up with RS Components. The company explained it is about widening its distribution and being able to reach more end users through RS. Speaking to RS Components Simon Pullinger, he told Manufacturersâ&#x20AC;&#x2122; Monthly that they are â&#x20AC;&#x153;able to reach 92 per cent of Australia within 24 hours now.â&#x20AC;?

While it has concentrated on mining and processing in the last few years, Driver said will develop further into the food and packaging, and life sciences area, explaining that SMC will look at broadening its range and is â&#x20AC;&#x153;trying to identify new markets that we donâ&#x20AC;&#x2122;t play in yetâ&#x20AC;?.

Driver stated that they were hoping to do something similar to the companyâ&#x20AC;&#x2122;s growth in wastewater.

In addition to its pneumatics manufacturing, the business also operates a precision sheet metal manufacturing plant on a 4500m2 site on its grounds.

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manmonthly.com.au

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

Made IN OZ

Railroading the industry

Has the rail roadmap been derailed?

The announcement of Downer EDI’s locomotive manufacturing business is dire news for the rail industry.

W

ith Australia’s massive expanse it is crucial that we have the infrastructure to support our burgeoning minerals industry and nation’s development.

And considering our distance from other nations of heavy manufacturing it only makes sense that we manufacture our own trains and locomotives to keep the mining industry moving, as well as keep our cities running.

In June the minister for industry and innovation, Greg Combet, announced a new focus on rail manufacturing, with the release of the Rail Manufacturing Roadmap - On Track to 2004.

“This project is an example of how the rail industry can successfully collaborate to identify opportunities and challenges facing the sector,” Combet said at the time.

“More than 210 representatives from 110 organisations contributed to the development of the Roadmap, to deliver a vision for the Australian rail manufacturing sector’s future.”

However this vision would soon be 22 SEPTEMBER 2012 Manufacturers’ Monthly

distorted as within the space of two weeks both UGL and Downer EDI made announcements that would have major repercussions for the industry.

In late June Downer announced that it had signed a new five year agreement with Electro-Motive Diesel, however within this agreement Downer stated that it would move its entire locomotive manufacturing offshore, closing down its operations in Australia.

The company stated that it will “manufacture all the locomotives at one its low cost overseas facilities”.

However “during the transition period, which is expected to take between 12 months and two years, Downer will continue to manufacture locomotives in Australia,” the company said. While “the demand for locomotives in Australia remains strong ...this new agreement with EMD means Downer will be better positioned to meet our customers’ demands for better value and shorter lead times,” Downer EDI chief executive Grant Fenn said.

“We will have a sustainable locomotive business as we exit high cost manufacturing and concentrate on sales, repairs, and maintenance and whole of life asset management.”

Soon after this announcement UGL began to shrink operations, announcing that it would be laying off 25 workers at its Broadmeadow factory as its contract to build the OSCAR locomotives came to an end.

Within the space of a week the locomotive manufacturing industry in Australia had been seriously shaken, but what did it mean for the workers? Australian Manufacturing Workers’ Union representative Jim O’Neill held a round of talks with Downer to try and convince them not to leave the country.

“We certainly, as the AMWU, want to strive to ensure that we have local manufacturing of all products within the rail industry,” O’Neill said. When contacted he was unavailable for further comment, however he did state that companies such as Downer should not abandon these local skills bases for cheaper

foreign labour. The Federal minister for industry and innovation, Greg Combet, was quickly on the scene to reassure workers at Downer EDI’s Cardiff plant that dozens of job were not going to be cut; instead these workers would be transferred to the problematic Waratah trains.

But the issue of retaining a strong skills base remains as both major companies wind up their local locomotive heavy manufacturing. As manufacturers move production offshore the issue of quality will no doubt again rise its head, with the ghost of the Waratah train problems seemingly forgotten for now.

The significant problems associated with Sydney’s $3.6 billion Waratah train project, which saw the manufacturing moved to China, only further highlighted the need for greater involvement of Australian manufacturing companies in major rail projects. Jill Walsh from the Australian Rail Manufacturers Group has previously told Manufacturers’ Monthly “Australia has the capacity to build high quality trains at competitive prices, but this would be significantly enhanced if procurement planning was streamlined so orders were not required to be built in bits and pieces”.

The question remains, if the mining industry and the government are more willing to invest in Australia’s locomotive and rolling stock manufacturing industries, can this country have a strong, vibrant industry?

Or will all future trains simply be brought in, whole, from overseas? manmonthly.com.au

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MaterialsHANDLING bringing together more than 1000 dealers, bankers, suppliers, analysts, and journalists from around the world for a few days for “The Festival”.

Held in Spain, the multi-national event was designed to discuss the company’s outlook and its future growth, particularly in the mining, agricultural, and industrial space.

Heavy machinery lined the pavement for half a kilometre in front of the event’s premises, while conferences and roundtables were held almost continually inside, on the main day.

Hosting such an event was an interesting move by the company considering the huge debt spiral that has engulfed Europe, especially the choice to hold it in Spain, a nation that only last month received a massive Euro Zone bailout of more than (US, AUD or EURO) $126 billion.

It could be argued that the company was aiming to buck the Euro trend and highlight its growth amidst the downturn, with CEO Jean-Christophe Giroux stating “after three very difficult years, it’s time to share our convictions and our view of the future – this ‘Festival’ aims to give us a real platform where we can exchange ideas and subscribe to a shared goal”.

Face-to-face One of the most interesting aspects of The Festival were the 21 roundtables, which were designed as way to pick the dealers, suppliers, and operators’ brains, find out what was working, and what wasn’t.

The upsides of a downturn Instead of going to the market to announce its recent restructure and new growth plans, Manitou brought the market to Spain. Cole Latimer writes.

M

INING equipment and machinery companies have always been fairly quiet about what they do. They design the equipment, watch it at work, and see that it gets the job done.

Whether it’s moving and shifting or heavy lifting, if their machines and equipment does what it’s supposed to then, end of story. We

26 SEPTEMBER 2012 Manufacturers’ Monthly

rarely hear about what else the company is doing, especially in the case of crane and lifting companies.

Manitou is fairly typical of this standard. It’s a quiet company, and even the company itself agrees.

However, the company took a break from its usual form in late May when it held a massive showcase of all its latest equipment,

While the roundtables did focus on brands and environmental issues, attendees were predominantly interested in the products on show and finding out what the operators liked and disliked.

A good example of this was the roundtable on ‘New product range for industry: Any suggestions?’

It also gave the machinery deal-

ers a chance to air their customers’ complaints or concerns to the people who design the machines themselves.

One roundtable session became a barrage of statements for the Manitou personnel as to how their machines were used, what would work better and what should be dropped.

Dan Miller, head of the American operations explained that “all of the input that we get [from the roundtables] will be put back into the business and be utilised to improve applications, maybe develop new products”.

It was a different approach to the usual design process of assuming what the customer’s needs are and creating a machine, giving way to more customer influenced machinery and equipment, particularly attachments.

The conferences also provided a more precise view from the company and just how it was changing its structure. These mostly dealt with the new divisions; the various markets such as agriculture and materials handling, servicing, attachments, new product lines and the rental market.

Moving into mining Mining is set to become a major component of Manitou’s new structure.

Speaking to Eric Lambert, the president of the Rough Terrain Handling Division (under which mining falls), he told Manufacturers’ Monthly the focus for the division will be on “developing machines and developing attachments.

“For example, our tyre handler for the mining industry, if that is a custom machine it is being used for one task only, but with a number of attachments you can keep the machine in constant use, so it is not just sitting idle between tyre handling applications. It’s the same machine, just changing the attachments.

“Our ambition is to have multitask machines with special attachments.”

Part of The Festival was also announcing Manitou’s greater focus on mining.

“With this new business we can find out what the customer wants, and learn from their very specific manmonthly.com.au

requirements in mining worldwide, so we can continue to improve our presence in mining and safety,” Lambert said.

The release of its flameproof, underground coal mine specific telehandler – the MT732 - last year at AIMEX has demonstrated the company’s early steps.

At the time, Manitou’s export sales manager Francois Piffard told Manufacturers’ Monthly: “The development of this explosion proof telehandler is an Australian first and may even be a world first”.

Managing director for Manitou South Africa, Lindsay Shankland, told Manufacturers’ Monthly at The Festival that the new focus on mining attachments is seeing new drilling products trialled at mines in South Africa.

However Shankland was reticent in describing how the drill attachment works and its applications on site.

Australian focus Despite the ongoing European financial crisis, Manitou remains

Manitou is looking towards more regional manufacturing.

focused on the region and its development. But as is the case with many companies, it has seen a “huge potential” for its existing operations in Australia, and its mining industry.

The company heads stated that they would “use niche markets [such as Australia, Brazil, and Russia] and try and capitalise on their markets”.

However, geographically around

75 per cent of its business is still focused on Europe. Speaking to Stuart Walker, Manitou Australia’s managing director, he explained that the handling company is “looking at attachments, skid steers, and really adapting our products to the problems”.

Walker went on to give an example of its current work in Australia, developing solutions to eliminate some of the swinging load problems faced

by BHP Billiton and Rio Tinto, and the increased risk factor they cause on site whenever cranes are used.

Eric Lambert, Manitou’s president of Rough Terrain Handling Division, told Manufacturers’ Monthly that through the event “we feel what we wanted to show and say has been done, as we wanted to create an event to involve everyone in the growth of the company, and make them aware of what we’ve done.”

It will be an interesting few years ahead of this company, but with its restructure it has definitely prepared itself to weather the storm. *Manufacturers’ Monthly travelled to Spain courtesy of Manitou.

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Manufacturers’ Monthly SEPTEMBER 2012 27

MaterialsHANDLING

â&#x20AC;&#x2DC;Palletableâ&#x20AC;&#x2122; developments An environmental initiative has seen an Australian manufacturer recognised by the UN

A

n Australian conveyor manufacturer was a finalists in UN environemntal awards for its innovative conveyor belt recycling technology.

In the Melbourne suburb of Braeside the company is converting their customersâ&#x20AC;&#x2122; rollers into recycled shipping pallets.

The initiative means that after years of bulk handling the worn rollers are reborn to serve a second purpose.

Kinder says after reaching the end of their useful life, the conveyor rollers are shredded, granulated, and mixed with a special formula.

The material is then recycled into new lengths, cut to size, and rebuilt into pallets.

The born again pallets are then used by the company to transport new loads of rollers back to clients, completing the cycle.

Kinder said the entire process had reduced costs and saved â&#x20AC;&#x153;thousands of tonnes of timberâ&#x20AC;? that would otherwise be needed to build pallets.

In a statement the company said the recycling process had been made possible through a commercial arrangement with Victoria-based Australian Composite Technology.

ACT director Roger Sweeney said the process involved specialised technology that had taken nearly 15 years to perfect.

He said the pallets had a longer life cycle due to immunity from marine, insect, and fungal attacks.

Sweeny went on to say that they could be â&#x20AC;&#x153;recycled indefinitely,â&#x20AC;? and be manufactured to produce non-slip

The pallets can be recycled indefinitely.

The move cuts a companyâ&#x20AC;&#x2122;s environmental footprint, Kinder says.

features for grip and safety. The pallets can be totally fireproofed without the use of chemicals, and donâ&#x20AC;&#x2122;t need to be fumigated in an export environment.

Kinder said the pallets had sparked interest not only from clients, but also from businesses and companies that have traditionally relied on wooden pallets.

It listed local energy provider TRUenergy as one prominent business that had taken them on. â&#x20AC;&#x153;TRUenergy runs numerous conveyor belts in its operations, and Kinder educated and supplied to TRUenergy a less resource dependant Polymer (HDPE) conveyor roller to suit their needs,â&#x20AC;? Kinder said. â&#x20AC;&#x153;As one of Kinder & Coâ&#x20AC;&#x2122;s longest serving and environmentally conscious clients, TRUenergy has recently started utilising these recycled pallets and is finding them a very good fit with their environmental policy,â&#x20AC;? it said.

Kinder CEO Neil Kinder said in a statement the recycled pallets were only one move in a series of environmentally conscious steps for the company. â&#x20AC;&#x153;Recycling is not a new phenomenon at Kinder,â&#x20AC;? he said. â&#x20AC;&#x153;In this day and age with the global environmental sustainability imperatives, no company can afford to accept the status quo.â&#x20AC;?

And now the Australian company has been recognised by the UN for this technology, and was a finalist in the â&#x20AC;&#x2DC;Best Specific Environmental Initiative Categoryâ&#x20AC;&#x2122;.

Kinder, 03 9587 9244, www.kinder.com.au

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manmonthly.com.au

Automation& ROBOTI Robots are go New inroads in robotics technology have reduced return on investment times, making a compelling argument for investors.

Sarah Falson writes.

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30 SEPTEMBER 2012 Manufacturersâ&#x20AC;&#x2122; Monthly

ACED with the rising cost of labour, a shortage of skilled workers and cheap competition from overseas, manufacturers today are without doubt doing it tough. But many manufacturers have been able to tackle these setbacks by investing in new technology which has improved their overall production line performance and end of line results.

Innovation and forward thing is the key, according to Greg Sale, Headland general manager, Robotics and Automation, who says manufacturers need to be aware that remaining â&#x20AC;&#x2DC;traditionalâ&#x20AC;&#x2122; in the manufacturing realm can be detrimental to oneâ&#x20AC;&#x2122;s business; investing in new technology such as robotics and automation can be fruitful in the long-term. â&#x20AC;&#x153;Many small manufacturers donâ&#x20AC;&#x2122;t think they are big enough to automate, and this can be the beginning of the end for them.

We have a responsibility to these smaller companies to help them understand how cost-effective, safe, reliable and easy-touse good automation is,â&#x20AC;? Sale told Manufacturersâ&#x20AC;&#x2122; Monthly.

With suppliers constantly improving their robotics and automation offerings â&#x20AC;&#x201C; especially in the areas of speed and power consumption â&#x20AC;&#x201C; â&#x20AC;&#x2DC;investing to saveâ&#x20AC;&#x2122; is the mantra many smart manufacturers are adopting. â&#x20AC;&#x153;Presently the Federal Government will even assist with the cost of replacing old, energy-hungry robots with robots that have a proven power reduction feature like Kukaâ&#x20AC;&#x2122;s PROFIenergy profile [distributed by Headland], which reduces the robotâ&#x20AC;&#x2122;s energy consumption by as much as Scale is no arguement against automa- 90%,â&#x20AC;? Sale said. tion of your workplace. â&#x20AC;&#x153;Is it a good time to invest in robotics... and specifically to the manufacturers who donâ&#x20AC;&#x2122;t have robotics at present, those who make a lot of repeat product, or those with sound vision and business plans itâ&#x20AC;&#x2122;s a great time to invest in robot based automation, probably the best I have seen in over 20 years,â&#x20AC;? Sale explained to Manufacturersâ&#x20AC;&#x2122; Monthly. â&#x20AC;&#x153;Donâ&#x20AC;&#x2122;t dismiss automation as too expensive or not right for your manufacturing. In the end you are experts in your field, and likewise so are we. Just ask. I consider that giving the right initial advice is imperative, from the benefits to the downsides, and whether automation is the right direction, or whether that skilled person is actually making you a lot of money and shouldnâ&#x20AC;&#x2122;t be replaced,â&#x20AC;? he said.

Donâ&#x20AC;&#x2122;t get left behind Peter Davis, Robotic Automation marketing officer, agrees that the marketâ&#x20AC;&#x2122;s need to reduce day-to-day manufacturing costs is a compelling reason to take the plunge. â&#x20AC;&#x153;You canâ&#x20AC;&#x2122;t better your production without investing in it. Sitting still will allow the competition to get further ahead and â&#x20AC;&#x2DC;band-aid solutionsâ&#x20AC;&#x2122; will often cost more in the long run,â&#x20AC;? Davis told Manufacturersâ&#x20AC;&#x2122; Monthly. â&#x20AC;&#x153;Robots are becoming increasingly more efficient, and manufacturers can now utilise robots for an manmonthly.com.au

TICS This Headland Kuka robot incorporates the PROFIenergy profile which can reportedly reduce the robot’s energy consumption by as much as 90%.

ever-increasing range of applications – not just in the production line, but further afield such as in warehousing and distribution.

“A lot of improvement has been made in minimising the foot-print of robots while increasing the dexterity with added axes of movement.”

Davis cites a project performed

by Robotic Automation, in which the company’s SIA20 robot allowed a CNC machine to be automatically tended without increased floorspace and without blocking operator access.

“This example shows how the latest robotics can adapt to the plant without the plant having to adapt for automation,” he said.

Are robots enough?

According to Olivier Coquerel, ABB Australia general manager – robotics, manufacturers would do well to consider robots in context of the bigger picture, rather than as a single solution.

“I don’t think you should invest in robotics because robots are now a little bit cheaper or because you can

manmonthly.com.au

get them funded by a government grant. It has to be planned and be an integral part of your manufacturing strategy,” he told Manufacturers’ Monthly.

“Most of our customers have different needs. Some of them in food and beverage are facing

increasing demands for their products and need robots and automation to cope with the additional volume.

“Others just won contracts with a mining industry and use this opportunity to upgrade their production processes with innovative solutions which will improve their bottom line

and put them in a better position to win further businesses.”

Coquerel says that if manufacturers run two to three shifts, there are probably some good potential robot projects which will offer short return on investment. “[If] you are looking to improve productivity and reduce the material waste then you should look at robots to automate some tasks,” he said.

Coquerel gives the following advice: “Firstly, work out in dollars what you are trying to achieve, for example, increase my production by 20% which will give an additional revenue of how much; reduce my waste by 30% which will give me a saving of how much; and secondly, talk to one of our experienced Australian Authorised Value Providers to see what solutions can be implemented to achieve your targets.”

ABB Australia 1300 782 527, www.abb.com/robotics Headland 1300 592 061, www.headland.com.au Robotic Automation 1300 552 333, www.ragroup.com.au

Manufacturers’ Monthly SEPTEMBER 2012 31

Automation&ROBOTICS

Ready, set, weld Automated arc welding is removing some of the job’s daily dangers.

A

utomation is not only about making the workplace more efficient, it is also about making the workplace safer.

Generally arc welding can be a dangerous process for welders, putting them at risk of burns and over exposure to ultraviolet light that can cause serious eye injuries.

With this in mind, ABB have developed a new welding robot designed to remove some of the danger from this situation.

Dubbed the IRB 1520ID, the robot is designed specifically for use in metal fabrication and has all the necessary gas and pressurised air hoses used for arc welding integrated into the arm of the robot, providing a shielded dressing or covering.

This protection provides greater safety for operators plus more simplified robotic programming with more predictable welding results without having to estimate for swinging cables.

The machine can be mounted on the floor or inverted.

According to ABB “the IRB 1520ID provides increased safety for operators plus delivers ‘bulls-eye’ motion control and welding reliability”.

Further risk is removed as the cables are contained within the

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robot’s arm, which means that the danger of sharp metals damaging the cables - which can cause serious hazards for operators, is significantly reduced. “With the cabling tucked away, the lifespan of the cabling and

the robot itself is also extended.”

All safety aspects aside, the integrated dressing design also increases accuracy and allows for more flexible movements.

“More uninhibited movement is needed, for example, for single motion welds around cylindrical objects or hard to reach weld seams,” ABB explained.

The new welding robot has been designed with a slim upper arm for access to narrow spaces, has a reach of 1.5 metres, and a payload capacity of four kilograms. It can be mounted on the floor or inverted for different welding needs. The IRB 1520ID is operated with the FlexPendant human machine interface.

A power interface is also fully integrated so operators can have full control over voltage, current, speed, gas flows, and other welding parameters.

ABB www.abb.com.au

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32 SEPTEMBER 2012 Manufacturers’ Monthly

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Automation&ROBOTICS Compact relays

New contact materials allow increased switching capacity.

ELEMENT14 has introduced TE Connectivity’s Schrack series of force-guided relays to the Asia-Pacific market.

The relays are suitable for use in robotics and industrial automation applications throughout the manufacturing industry.

Their compact size is designed to help engineers overcome space restriction challenges that are often found in factories.

Force-guided relays are commonly used in applications such as emergency shut-off, process control, machine control, and safety relays in computing, automotive, telecommunication, military and aerospace, medical, and industrial/ instrumentation.

The distributors say the key benefits of the relay include: a high level of relay sensitivity; increased switching capacity and insulation properties, thanks to new plastic contact materials; and the relay’s four poles with force-guided contacts in accordance with EN 50205 standards.

Element14 1300 590 443, www.element14.com

Input/Output modules ROCKWELL Automation has introduced new high-speed Input/Output (I/O) modules for its ControlLogix programmable automation controller (PAC) platform to enable faster machine speeds in a range of discrete applications.

The Allen-Bradley ControlLogix 24vdc I/O modules, used with the 5570 family of PACs in the same range, are engineered to improve total System Response Time (SRT) through new hardware technology and peer-to-peer communication capabilities that reduce the time it takes for modules to communicate with the controller.

The system response time equates to the time required for input module response, controller processing and output module response.

Therefore, reducing input/output latency results in higher machine speeds for increased parts production.

The I/O modules are designed to improve system response time for sequential control applications.

For even faster performance, the new modules also function in peer-to-peer mode, bypassing the controller by establishing in-chassis connections that allow I/O modules to communicate directly with each other. Shifting task management

to the I/O modules can relieve a controller of the overhead required to process and direct I/O modules, helping improve reliability in program execution and throughput.

Rockwell Automation 03 9757 1111, www.rockwellautomation.com.au

Toolpathing and nesting ADVANCED Robotic Technology has released version 2.0 of its toolpathing and nesting software ToolShop for the manufacturing and machining industries..

The software enables manufacturers to schedule parts in the office and have them automatically cut in the factory.

It is a Windows-based software package that allows users to draw and import components using standard CAD tools.

The software can be fully integrated in existing processes and manages

The software can schedule parts for automatic cutting. all necessary data such as CAD drawings, parts libraries and even customer data. The product features a fully remote material library

on the users’ individual company network and allows for the entry of sheet and plate stock levels, which are then automatically subtracted whenever a nest is created on that sheet.

Improved features include fully automatic toolpathing, auto-nesting function, automatic cut order, auto lead in sizing and position, nest reports, cut time projections, remnant cut-off and material management Advanced Robotic Technology 1300 565 528, www.advancedrobotic.com

sales

34 SEPTEMBER 2012 Manufacturers’ Monthly

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Pilz offers expert training solutions for machinery and equipment safety.

Machinery Safety Training

Our training is based on AS4024.1-2006 Safety of Machinery and the new harmonised Work Health and Safety legislation.

Our updated course offerings include: MachineSAFE Introduction (1 Day) This popular course has been designed to provide a basic knowledge on how to make machinery safe. It has been updated to include the key points of machinery safety with reference to the new WHS legislation, and Australian Standard AS4024.1-2006 Safety of machinery.

MachineSAFE Advanced (2 Day) This newly developed course is a follow on from the Introduction Course and has been specially put together for technical staff who are given the very important task of building safety features into new machinery or upgrading the safety features on existing machinery. It delves into much more detail on the key aspects of mechanical and electrical safety design for machinery.

Customised Machinery Safety Courses.

We can create customised courses that cater for the speciďŹ c needs of your organisation such as conveyor safety, Lock out Tag out/energy isolation, risk assessment, machine guarding, safety control system design, etc.

For more details on our courses see our website www.machinesafe.com.au or phone us on 03 9544 6300 or email us at training@machinesafe.com.au -ELBOURNE s 3YDNEY s "RISBANE s !UCKLAND

Ph: 03 9544 6300 Fax: 03 9544 6311 www.pilz.com.au safety@pilz.com.au

the spirit of safety

Metalworking& MACHINE TOOLS Training and awareness

Managers should provide their workers with appropriate training about welding risks, safety practices and PPE use.

When sparks fly Welding safety is often overlooked by both plant-owners and operators.

Sarah Falson shares some tips to keep injuries at bay.

U

NDERSTANDING welding safety is of the utmost importance to avoid both short- and long-term injuries and serious legal ramifications.

AWS marketing manager, David Chippendale says short-term physical impairments resulting from unsafe welding can include eye and skin irritation; nausea and other gastrointestinal effects; headache and muscle ache; dizziness; metal fume fever; chills; and pulmonary oedema (fluid in the lungs).

More serious, long-term ailments comprises of increased risk of cancer in lung, larynx and urinary tract; bronchitis, asthma, and pneumonia; both emphysema and siderosis; ulcers and kidney damage; heart and skin disease; and damage to the central nervous system and brain (including Parkinson’s disease), Chippendale says.

Maintaining standards According to Chippendale, avoiding these risks is not only about employing the right personal protective equipment (PPE), but also about 36 SEPTEMBER 2012 Manufacturers’ Monthly

educating managers and employees about safe operating practices.

“Operator training is imperative.

“It’s no good having the correct safety measures and products in place if they are being used incorrectly or not at all,” Chippendale told Manufacturers’ Monthly.

He advises that managers should provide training, for both welding operators and staff working in areas where welding is performed, about the correct way to use and maintain welding equipment. Training should be based on the appropriate welding safety standards.

“The relevant Australian Standards for PPE that employers and employees alike should take note of are as follows: AS/ NZS1337 & AS/NZS1337.1 – Eye and Face Protection; AS/NZS1338.1 - Eye Protection for Welding; AS/ NZS1716 - Respiratory Protection; AS/NZS1801 - Head Protection; and AS/NZS1270 - Hearing Protection,” Chippendale said. He warns that ANSI (US) and EN (European) standards are not interchangeable with Australian Standards.

Protective gear Chippendale suggests a variety of PPE should be used in any manufacturing facility performing welding.

“Australian Standards-compliant, high impact auto-darkening welding helmets, if used correctly, will ensure that eye injuries are a thing of the past in the workplace when welding,” he said.

“Respiratory protection is always recommended – whether it be a disposable, reusable, powered or supplied air respirator. However, when deciding on suitable respiratory protection you should always take into account your individual circumstances and any relevant local standards.

“Respiratory protective equipment should be selected using accurate information on the toxicity of the various airborne hazards and the amount present in the working environment. Therefore, it is essential that air monitoring is regularly carried out, even when respiratory protective equipment is used,” Chippendale added.

According to SkillsTech Australia welding teacher, Paul Galna, traditional media, social media and signage all play a part in conveying the correct message about welding safety.

“There are too many television programs at the moment which show people welding with no protective gear or just wearing t-shirts and tacking metals together without using helmets,” he told Manufacturers’ Monthly.

“It is really frustrating to watch because it portrays the wrong message that people with no welding experience can think that what’s been shown on TV is ok - it’s not ok.

This is a really important point that we always talk about at TAFE.” Galna says the basic PPE requirements for safe welding include safety glasses; a welding helmet; welding cap; cotton drill long sleeve shirts and pants; steel-capped boots; goodquality gloves; and welding tongs.

According to Galna, training is imperative – not only for managers but also (perhaps more importantly) for workers.

“More and more today we see employers taking a lead role in providing training on-site and more importantly through training organisations such as SkillsTech Australia.

“Our training organisation provides trainers who are industry trained tradespeople so they know all the challenges and will make sure you are aware of them.”

Galna suggests the following guidelines to ensure the welding site is safe: find what is unsafe or unhealthy in the workplace; decide what is the highest risk and needs to be fixed first, and how to go about fixing it; take action to fix the unsafe or unhealthy workplace problems; check the problems are fixed; complete a job-site safety analysis; provide specific training to do work safely; provide appropriate safety gear; and provide work procedure sheets.

“At the end of the day it’s everybody’s responsibility to know the dangers, take precautions, and look after each other – be it on the workshop floor or in someone’s shed. A simple warning can save somebody’s life or even your own.”. manmonthly.com.au

Metalworking & MACHINE TOOLS Integrated welding protection

Local welding technology exported to UK, Middle East

A

The helmet provides protection for the welder’s head, eyes, face, hearing and respiratory system.

3M has released the Speedglas 9100 MP Air Welding and Safety Helmet, developed for integrated welding protection in demanding environments.

The helmet provides integrated head, eye, face, hearing and respiratory protection for welders. The welding gear consists of a comfortable AS/NZS compliant industrial safety helmet that offers high impact head protection.

A flip-up mechanism reveals a high impact protective visor that is suitable for grinding and low light conditions.

The large visor (100x170mm) gives the welder a vertical and lateral field of view with continuous respiratory protection when not welding, something that is not possible with non flip-up welding helmets with respiratory protection. According to the distributors, the Adflo Powered Air Purifying Respirator (PAPR) or the new V-500E Supplied Air Regulator (SAR) integrates with the new welding helmet to provide respiratory protection.

Australian Welding Supplies, 02 9439 0111, www.awsupplies.com.au

USTRALIAN welding company Keyhole TIG (K-TIG) has secured its first two international sales of its welding solution, which can weld thick gauge materials in minutes instead of hours.

Worth more than $250,000, these first export sales are to the UK and the Middle East where K-TIG’s recently appointed distributors, WB Alloys in England, and Dubai-based PCT, will demonstrate the time, cost and energy saving benefits of Keyhole TIG welding. WB Alloys will also market K-TIG in Germany.

The Adelaide-based company holds patent-protected welding technology that enables thick gauge materials, including traditionally difficult metals such as stainless steel and titanium, to be welded in one-tenth of the time possible with standard welding processes.

Originally developed by CSIRO, and now wholly owned by Keyhole TIG, the K-TIG welding process is already used by major organisations including the shipbuilding division of Samsung Heavy Industries.

Neil Le Quesne, K-TIG general manager, international development, sees these first international sales as just the company dipping it’s “toe in the water”.

“K-TIG’s technology is transformational,” Le Quesne said. “The lightning speed of the welding process and, in many cases, a 95% reduction in power and gas consumption, dramatically reduces both the cost and carbon footprint of industrial welding.”

Federal Minister for Small Business, Brendan O’Connor, recently visited the company’s Salisbury head office to see K-TIG’s breakthrough welding technology.

In attendance was Salisbury Mayor Gillian Aldridge, City of Salisbury CEO John Harry, MP for Makin Tony Zappia, and Salisbury Business & Export Centre business advisor, Rob Chisholm.

The Minister was shown how the welding technology could complete the entire weld in about three

minutes, whereas traditional TIG welding would have taken six hours to do it.

“For industries that need to weld thick gauge materials such as carbon steel, stainless steel and titanium, K-TIG welding offers enormous savings by eliminating the cost of that six hours’ worth of materials, energy and labour,” Laurie Jarvis, K-TIG founder and R&D manager, said following the demonstration.

K-TIG 08 7324 6800 www.k-tig.com

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CASTROL LONGTIME HS 1.5 LOWER FRICTION AT HIGH SPEEDS.* THATS THE POWER OF… Spindle technology is constantly advancing and Castrol Longtime HS 1.5 has been developed to keep up.

Using revolutionary, cutting edge technology, Castrol Longtime HS 1.5 can help to reduce costly downtime and add savings to your operations by potentially reducing grease usage.

THE TECHNOLOGY INSIDE

Technology Platform Castrol Longtime HS 1.5 uses a unique, revolutionary technology platform which performs more like an oil than a grease, delivering lower friction to critical spindle bearings.* Better washout prevention Castrol Longtime HS 1.5 non-ionic thickener resists water washout more effectively at low speeds.* Superior water and emulsion stability Minimal interaction with water enables the grease to retain its protective properties to the spindle bearing for longer than previously experienced with any other products.

Novel additive response and compatibility Non-polar thickening additive acts as a superior carrier for lubricant additives to reach the metal surfaces, helping to increase the protective properties of the grease in the contact area.* Lower base oil viscosity Unique Polymer-based thickening system can help improve lubrication performance when compared to lower viscosity oils, which can help deliver lower wear and improved surface finish.* Environmental / Health and Safety Castrol Longtime HS 1.5 does not contain heavy metals such as barium, which can have an impact on the environment and people’s health.

For more information contact: Castrol Industrial Sales on 1800 722 088 Castrolindustrial@castrol.com.au

www.castrol.com *Under testing conditions. Independent study conducted by Powertrib on 17th November 2010. Tests conducted at High Speed / Low Load (FE8 500h angular ball bearings - 6000 rpm - 5 kN - 90°C) & Low Speed / High Load (FE8 500h angular ball bearings - 7,7 rpm - 80 kN - RT)

Metalworking & MACHINE TOOLS The rebar cutter produces 14 tonnes of force with a cutting speed of 3 seconds.

High-tensile rebar cutters STAINELEC Hydraulic Equipment has introduced the Edilgrappa Silvercut 20 high-tensile rebar cutters with a maximum cutting capacity of 20mm.

The newly designed cutting head allows the operator easier access in awkward locations were rebars need to be cut on site.

The company claims the new cutting head is the smallest in size compared to competitors, due to the Drop Forged head assembly, designed and engineered by Edilgrappa. Featuring a powerful double insulated 230V 1100W motor

to drive the precision designed radial hydraulic pump, the rebar cutter’s weight is 10kg.

It produces 14 tonnes of force with a cutting speed of 3 seconds.

The rebar cutters are suitable for use on building sites and factory operations.

A special grip on the cutter allows it to be carried easily between jobs or worksites. The rebar cutters are fitted with cutter guards for user safety.

Stainelec Hydraulic Equipment 02 9824 2499, www.stainelec.com.au

Replaceable-head drills DORMER has expanded its solid carbide replaceable-head drilling range. Designed to offer high productivity across a range of materials, the Hydra series is an alternative to solid carbide drills.

Two head types are available. The R950 – now available in diameters up to 42.0mm – has been developed specifically for drilling operations in carbon and alloy steels.

The second model, the R960, is suitable for stainless steel and cast iron, but is also recommended for use in titanium and nickel. Both head types incorporate a self-centering 140˚ four-facet split point. This feature is designed to ensure low thrust forces throughout the drilling cycle. Each head is available with a 40 SEPTEMBER 2012 Manufacturers’ Monthly

The drills have a self-centering 140˚ four-facet split point. range of drill bodies to support drilling depths to 3 x diameter (H853), 5 x diameter (H855) and 8 x diameter (H858). One body can accommodate multiple head sizes.

Dormer 1300 131 274, www.dormertools.com manmonthly.com.au

Hypertherm Powermax105® the new 105 amp air plasma system for hand, automated cutting and gouging designed to comfortably cut 32mm thick metal, and sever metal up to 50mm thick.

Based on the same technology platform of the highly successful Powermax65 and Powermax85, the Powermax105 is the culmination of four years of research, engineering and testing to design the toughest, most versatile system in its class.

The new system delivers: • Faster cut speed, improved cut quality, and industry leading consumable life for better performance and a lower operating cost with less weight and more cutting power.

• Seven different torch options – the most in the industry – for unparalleled cutting and gouging versatility, whether by hand, machine, or robot.

• Ease of use with simple controls and patented SmartSense™ technology that automatically adjusts gas pressure for better, more efficient cutting.

• Bulletproof reliability thanks to relentless standards, smart design, and intense testing.

• New feature – detects when consumables have reached end of life.

www.hypertherm.com

www.westgatehitech.com.au Ph: 03 9391 1133 Fax: 03 9391 1244 Note: Wheel kit is an optional accessory.

BodyPROTECTION Musculoskeletal injuries is a $1 billion a year cost.

Reducing serious muscle injuries The rising cost of injuries is highlighting just how seriously minor incidents affect the workplace.

M

ANUAL handling is the biggest cause of workplace injury in Victoria. Last year, more than 10,000 people were injured as a result of unsafe manual handling.

In June this year, WorkSafe Victoria launched a year-long campaign targeting musculoskeletal injuries ,which are estimated to cause $1 billion in problems “Musculoskeletal injuries are the most common workplace injury, costing nearly $1 billion a year in medical costs, wages and other expenses,” said Victorian Assistant Treasurer, Gordon Rich-Phillips at the time of the launch.

“They affect the body’s muscles, joints, tendons, ligaments and nerves, are easily prevented, often difficult to treat and can be longlasting and a source of great pain.

Rich-Phillips stated that every day 43 Victorians are seriously hurt with these sorts of injuries, with an average workers’ compensation claim costing $55,000 in medical costs, wages and other expenses.

He also noted that Victoria had the lowest workplace injury insurance premiums in Australia stating that the State Government had

slashed WorkCover premiums by 3 per cent to 1.298 per cent in this year’s Budget, which he is said is saving employers $57 million a year.

“Dangerous manual handling particularly lifting, lowering and moving things account for about 68 per cent of all musculoskeletal injury claims, while about 20 per cent are the result of slips, trips and falls,” Rich-Phillips said.

“These injuries are largely hidden because they do not make the nightly news, but the impact on workers, their families and their employer’s business can be enormous and longlasting.

“Ensuring people are properly trained and supervised, use the right equipment, and clean up spills to prevent falls are no-cost or low-cost measures that will reduce workplace accidents,” he said.

Legal duties Employers have a general duty to make the workplace safe, as well as specific duties in relation to hazards such as manual handling. They must identify any tasks that involve hazardous manual handling.

If these tasks pose a risk of musculoskeletal disorder, you must

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42 SEPTEMBER 2012 Manufacturers’ Monthly

manmonthly.com.au

The number of crush and cut injuries are higher than they need to be on site, and if a manufacturer’s hands are out of order, then they aren’t much use on site.

With hand protection at the fore of their developments, Ansell have a new glove designed to protect users while still providing comfort and flexibility.

The company has launched its HyFlex 11-820 glove for multipurpose light duty mechanical appli-

cations.

According to Ansell head of marketing, Mitchell Mackey, the HyFlex is a “genuine next generation glove which delivers high performance for general purpose industrial hand protection”.

It features “a breathable, highabrasion resistant palm coating formulation gives superior mechanical wear and tear performance and a new generation liner provides the wearer with a ‘second-skin’ level of

comfort.“The HyFlex 11-820 addresses the problems of worn coatings and dirty liners workers often experience with their conventional gloves. The dark blue ‘second skin’ Spandex liner hides dirt and offers a snug, comfortable all-shift fit.

“Ansell’s Nitrile long-life coating formulation is designed to excel when the glove is used in applications where abrasion resistance is a priority,” he added.

The company has also focused on increasing comfort.These gloves have been enhanced by an additional knitting process that drops down the little finger. Additionally the upper palm portion below the middle three fingers is knitted separately from the rest of the palm, as well as the little finger joint mounted lower, means that independent movement have been increased, resulting in a better fitting glove. On top of this, wearers will also find an “extra comfort” cuff that features an over edge that means the glove can be more easily pulled on or off. Independent testing has confirmed the HyFlex 11-820 glove meets level 4 abrasion rating.

Ansell,1800 337 041, www.ansell.com

eliminate the risk.

If it’s not reasonably practicable to eliminate the risk, employers must reduce the risk, as far as reasonably practicable, by: changing the workplace layout, the workplace environment or the systems of work changing the objects used in the task; or using mechanical aids. If there is still a risk after using these methods, you should control it by providing information, training or instruction.

Employers must review (and,

where necessary, revise) workers risk controls if things change, if there is a report of a MSD in the workplace, or at the request of a health and safety representative.

While employers are required to protect employees from manual handling injuries, employees also have a general duty to take reasonable care for their own health and safety, and that of others who may be affected by their work, and to cooperate with the employer’s

efforts to make the workplace safe.

This may include: using manual handling equipment properly following workplace policies and procedures (e.g. using trolleys, team lifting) attending health and safety training; and not taking any shortcuts that could increase manual handling risks.

Employees can also help their employer make the workplace safer by notifying them of any hazardous manual handling tasks that you

Hand protection is a major issue in manufacturing.

Hand protection

manmonthly.com.au

Disposable coveralls 3M has launched a comprehensive range of disposable coveralls.

The coveralls have been designed to provide protection for a variety of applications ranging including food processing, light-duty industrial cleaning, asbestos removal, painting and coating, pesticide spraying and chemical spills, as well as decontamination and tank cleaning.

According to 3M, its Coveralls contain no components made from natural rubber latex or silicone and are designed with extra material in the arms and legs for enhanced mobility.

Built with two-way zippers provide added on/off convenience, it has storm flaps that help to provide additional protection and seamless shoulders and sleeve tops which translate to fewer entry points for contaminants and increased comfort.

3M 136 136 www.3m.com/au/ppesafety

become aware of.

A manual handling code of practice is available for employers through the WorkSafe Victoria website (www.worksafe.vic.gov. au). The document covers the steps of risk assessment and control and includes information on the responsibilities of designers, manufacturers, importers and suppliers of machinery and equipment.

WorkSafe Victoria 1800 136 089 www.worksafe.vic.gov.au

Manufacturers’ Monthly SEPTEMBER 2012 43

TechnologyIT@MM

Maintenance is continuous.

Hard maintenance for software Software maintenance is an ignored, but essential part of business improvement, writes Paul Owen & Glen Clarke*

M

OST manufacturing businesses will have the words “continuous improvement” written into their business strategies. Some specific processes and operational equipment will never require modification, but some most

definitely will.

So why maintain software?

Software maintenance is driven by a businesses need for continuous improvement.

IEEE standard 1219 defines software maintenance, as the modifi-

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44 SEPTEMBER 2012 Manufacturers’ Monthly

protecting the

cation of a software product after delivery to correct faults, to improve performance or other attributes, or to adapt the product to a modified environment.

Software maintenance actually covers a range of solutions and is used for different reasons.

Corrective maintenance is a reactive modification of a software product performed after delivery to correct discovered problems; while adaptive maintenance is the modification of a software product performed after delivery to keep a software product usable in a changed or changing environment.

Most businesses carry out what is known as perfective maintenance or the modification of a software product after delivery to improve performance or maintainability.

They also consistently carry out preventive maintenance:

Modification of a software product after delivery to detect and correct latent faults in the software product before they become effective faults.

Below are typical software maintenance functions and why you may need to carry them out: Improvement in monitoring and reporting functions of the process.

The first stage in process control improvement is the measurement of all the input variables and the resultant outputs from the process. This is usually achieved via data logging and then displayed with trending packages. It allows managers, designers and analysts the ability to view relationships between the influences on a process, the processes response and the resultant output.

Improvements in measurement and an increase in the number of variables being measured can show

continued on page 49 manmonthly.com.au

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TechnologyIT@MM

Speeding ahead Advances in PLM are delivering multiple benefits from design through to product engineering.

Hartley Henderson Writes.

T

HE latest developments in Product Lifecycle Management (PLM) software can deliver significant benefits across a wide spectrum of industry through smarter decisions and better products.

Vice president and general manger for ASEAN/Australia of Siemens PLM Software, Rajiv Ghatikar, explains that there are three broad pillars in the company’s PLM offering. These are computer aided functions (design, manufacturing and engineering), plus collaborated product data management (CPDM), and digital manufacturing.

“CAD drives the entire product lifecycle – from simulation and analysis through tooling design, manufacturing, assembly, service and support. The next generation NX design tools from Siemens offer greater power, flexibility and

46 SEPTEMBER 2012 Manufacturers’ Monthly

Users are able to perform tasks 100 times faster.

PLM is resulting in reduced manufacturing costs at FPR. productivity,” he told Manufacturers’ Monthly.

“Synchronous Technology in NX is seamlessly integrated into a history-based design environment,

and provides customers with the power of history-based modelling combined with the speed and flexibility of Synchronous Technology.

Such combination enables customers to perform many design tasks up to 100 times faster than with purely a traditional modelling approach.

“The aim is to help companies to better manage development processes and achieve best practice, with a strong focus on providing a clearer view of the information needed to make smarter and faster decisions.”

Recent releases by Siemens include NX CAD, NX CAM, NX CAE, and Teamcentre 9.

Chris Gielens, PLM solutions architect at Siemens Australian distributor, PhoenxPLM, says that Teamcentre is an open-ended scalable system that can be integrated with a range of other applications, including Microsoft Office and leading CAD/CAM tools.

“Teamcentre can connect team members anywhere in the world at any time and drive productivity with a single source of product and process knowledge,” he said.

“This is a product management system with layer-upon-layer of data that can be turned into information that is secure and provides traceability throughout a products entire life cycle. It is a means of providing intelligently integrated information to deliver higher quality products.

“Globally distributed design chains can collaborate more easily, communicate visually across an entire product life cycle, and identify opportunities to automate common functional processes throughout the lifecycle.”

Fast forward Last year PhoenxPLM implemented Unigraphics NX7.5 CAD and CAM software at leading V8 Supercars team Ford Performance Racing (FPR) and is currently introducing Teamcentre to the company’s operations.

With eleven production departments, including a machine shop, fabrication shop, and composite shop, FPR is a vertically integrated company that builds 90 percent of its Ford Falcon race cars in-house.

According to FPR engineering manager, Mathew Nilsson, the introduction of PLM is resulting in major benefits and assisting the company to develop the Car of the Future.

“The time required to manufacture vehicle front rails has been reduced by 1.5 weeks, cross members by 2 weeks, and engine sumps by 2 days. Reductions in the cost of car build and maintenance are being achieved, and we can more easily comply with new regulations, such as a common roll cage and chassis,” he explained.

“Our approach to manufacturing manmonthly.com.au

5-port unmanaged fullgigabit Ethernet switches MADISON Technologies has released Moxa EDS-G205A-4PoE switches, smart, 5-port, unmanaged full-gigabit Ethernet switches that support Power-over-Ethernet on ports 2 to 5. The switches are classified as power source equipment (PSE), and when used in this way, they enable centralisation of the power supply, providing up to 30W of power per port and reducing the effort needed for installing power.

Embedded PCs for PLC motion control

The Ethernet switches can be used to power IEEE 802.3af/at standard devices (PD), eliminating the need for additional wiring.

These smart 5-port switches support IEEE 802.3/802.3u/802.3x with 10/100/1000M, full/half-duplex, MDI/ MDI-X auto-sensing to provide a high bandwidth solution for industrial Ethernet networks.

Madison Technologies 1300 606 359, www.madisontech.com.au

includes a big emphasis on jigging quality and accuracy, which is assisted by the latest CAD/CAM applications as part of the PLM umbrella.

More controlled and common parts are being produced, which is also contributing to an increase in the speed that we produce cars.

“The implementation of Teamcentre will enable the integration of departments and result in better workflow management, decision-making transparency, improved communications and efficiency, and rapid response times in design and manufacturing.”

and future-proofed architecture.

He believes future PLM developments will include an emphasis on quicker usability, increased levels of data reuse throughout the design process, enhanced Teamcentre integration to manage the data of massive products, and the ability to answer questions quickly and track issues with geometry.

“Product design solutions will be increasingly efficient, providing iterations in reduced time, and there will be increased flexibility in part creation and editing including ‘what if’ design studies,” he said.

“There will be increased levels of multi-CAD collaboration, flexible tools for collaborative design, and creation of design modules to help make changes. Simulation will include earlier evaluation of crossdiscipline trade-offs, and optimised shape will reduce waste.”

PLM future directions Siemens PLM Software director of product management, Mike Rebrukh, advises that the company will release NX 8.5 in October with a continued focus on productivity, intelligently integrated information,

The Ethernet switches support Power-over-Ethernet on ports 2 to 5.

Siemens PLM Connection 2012 In July this year, SIEMENS PLM hosted its first Connection Event in Australia. The event is part of a set of annual unified user conferences that connects leading industry analysts, peers, partners and Siemens executives from around the globe. Over two days Siemens PLM Software discussed how its HD-PLM vision is helping manufacturing and engineering users make smarter decisions and better products, as well as effectively managing big data and systems integration, customer success stories and the latest Siemens PLM product launches, such as NX 8 Teamcenter 9, Solid Edge ST 5, and the new Insight XT. Siemens PLM Software 1300 519 144 www.siemens.com/plm

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The PC can be integrated with all common Fieldbuses and industrial Ethernet systems.

BECKHOFF Automation has introduced the new CX9020 series of embedded PCs, which offer compact PC control for a wider range of applications. Equipped with a powerful 1 GHz ARM Cortex A8 processor, the fanless CX9020 embedded PCs are suitable for PLC and motion control applications in small- and mediumsized machines, systems or buildings.

The multi-interface can be configured ex-factory, if required, offering scope for numerous optional extensions from an audio interface up to the connection of Fieldbus masters or slaves. The multi-optional interface of the embedded PC enables integration with all common Fieldbuses and industrial Ethernet systems. These include EtherCAT (slave only), PROFINET, Ethernet/IP, PROFIBUS, CANopen and DeviceNet serial interface (RS232/RS422/RS485) or audio.

Beckhoff Automation 1300 321 058, www.beckhoff.com.au

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Manufacturers’ Monthly SEPTEMBER 2012 47

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TechnologyIT@MM continued from page 44 surprising results, that offer pathways to improvement.

Improvement in control algorithms: As more variables in the process are better understood, modification to control algorithms can “fine tune” performance.

Experimental testing of new ideas: Lateral thinking will often produce a whole different concept in how a process might be controlled. With careful coding, it is possible to build an alternate method that can be switched in to replace the old method with a single bit. This method allows development of new ideas during maintenance or slow periods with the ability to switch back to the old system quickly and continue normal production.

Expansion to include additional or different equipment and materials: Equipment upgrades nearly always involve the expansion of the control system to include new measurements, additional outputs or different control sequences and algorithms for different materials.

Improved fault and failure diagnostics: Diagnostic software incorporated into the controller can improve

mean time to repair, by quickly identifying problems for maintainers. As more is learnt about a process and its failure modes, more diagnostic software can be developed.

Improved reliability: Reliability or robustness in process control software, refers to its ability to detect and act appropriately to equipment or other failures. Development in this area is associated with orderly process shutdowns or bypasses, without the system going haywire. It may also include automatic switch over to back up systems.

Improvements in predictive alarming: Predictive alarming has the potential to greatly reduce down time and rate losses. This normally incorporates increased monitoring by the process control system, with an associated rate change or variable value software warning system.

It may also monitor for a particular sequence of events which have the potential to cause problems. These flags may be acted on immediately to avert a shutdown, or may be an indicator that programmed maintenance is required.

Improvements in safety monitoring: Human protection from injury is

paramount in any business. As technology advances, safety systems are also advancing. Process controller systems are generally not part of a safety circuit, however they are used to monitor and report on the safety systems and therefore are required to be updated.

Improvements in statistical data for business analysis: Process control systems are usually involved in the collection and collation of raw data for business analysis and other high level tools. Given the amount of raw data in a PCS, more of this data is being filtered or manipulated to better suit business requirements, rather than just the PCS requirements.

Improvements in the Human Machine Interface: Even without process improvements, significant productivity gains can be made by better connecting equipment to operators. A thought out interface providing operators with what “they want” to optimise their performance, will be an improvement to any business. Temporary work-arounds and bypasses: Often small equipment failures can be tolerated by a process with only a minor loss in time or

rate. Temporary software modifications may be needed while repairs or replacements are completed.

Adverse effects The largest problem with any software change is that it has the potential to affect some other previously working function. This comes about because the software modifier has not completely understood the functions being modified. This problem is exacerbated if the software is not easily maintainable. There are obvious business advantages in insisting on maintainable software.

Historically, clients have been naïve when it comes to negotiating with suppliers for the quality of the software they receive. As long as it functions as specified at handover, they are satisfied.

In the industry, there exists a black box mentality towards the “propeller heads” that sit in a room and produce control software. This should not be the case. The principles of good software development fall in line with any other principle for good business management. *Paul Owen is with Jasdip and Glen Clarke works at Infoscada.

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Manufacturers’ Monthly SEPTEMBER 2012 49

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

Foot protection OLIVER Foot wear has introduced two new styles of safety footwear.

Its latest offerings are the King’s Style 15-411 - a low cut sports shoe with a lightweight upper constructed of suede leather and fabric.

The other shoe - the Kings Style 15-421 - is an ankle high sports boot that employs the same upper materials which deliver lightweight, breathable construction.

Both styles include a Dual Density Polyurethane sole which delivers superior adherence requirements in slippery or damp job site conditions.

This is achieved by a distinctive tread pattern which effectively sweeps away liquids, so that there is a dry surface

contact under the cleat pattern of the sole.

The anti static sole features temperature resistance up to 130 degrees C as well as resistance to most oils, acids and alkalis.

The King’s Dual Density Polyurethane construction also combines a shock absorbing low density midsole for comfort with a hardwearing outer sole to withstand tough job or work site conditions.

Both Styles also have a Type 1 protective high carbon steel toecap made in a scientifically shaped wider profile for greater comfort and ensures there is no contact between toes and the toecap.

The Type 1 toecap also affords

Has anti -static soles.

maximum impact protection.

Both Styles also have a distinctive grey reflective high visibility strip along the side of each shoe which provides improved safety in work site condition such as warehousing and distribution.

The King’s 15-411 and 15-421 sports style shoes comply with the relevant

Personal photo-ionization detector (PID) ION Science has launched the Cub TAC personal Photo-Ionization Detector (PID).

It is designed to continuously check the breathing space of an individual employee to measure air quality.

The new device has a high output 10.0eV lamp provides continuous monitoring and alarms for Total Aromatic Compounds (TACs), with a finely-tuned parts-per-billion sensitivity.

Providing accurate monitoring of the full range of aromatic compounds, the new The detector provides readings in ppb and mg/m3 on a backlit LCD display.

50 SEPTEMBER 2012 Manufacturers’ Monthly

Australian Standard AS/NZS 2210.3 as well as the relevant International Standards.

The size choices available are from size 5 to 13 with half size increments from 6½ to 10½.

Oliver 1300 126687 www.kingsafety.com.au

Temp screen recorder device is engineered to ensure effective protection for plant personnel, giving them an early warning of any harmful levels of exposure to hazardous aromatic compounds, including benzene.

The new PID is sensitive to over 480 gaseous compounds, with a range from 1ppb - 5,000ppm.

With a response time of less than 13 seconds, the detector provides readings in parts-per-billion (ppb) as well as mg/ m3.

Air-Met Scientific 1800 000 744, www.airmet.com.au

PACIFIC Sensor Technologies has developed the new FT530 Touch Screen Temperature display recorder features full graphing capabilities.

This means the user’s complete recorded temperature history is available on-screen, with scrolling and zoom.

The temperature display recorder is equipped with two K-Thermocouple probes for functionality and flexibility and is designed to work without software, which is only needed if the user wants to download the data to a PC. Pacific Sensor Technologies 1300 662 720, www.pacificsensortech.com.au

manmonthly.com.au

Embedded PCs for PLC motion control

Has a passive flip front.

The PC can be integrated with all common Fieldbuses and industrial Ethernet systems.

High impact welding helmets HONEYWELL has unveiled its latest development, the Galaxy high impact welding helmet with a hard hat adaptor.

Designed with a passive flip front, the high impact welding helmet has been rigorously tested to Australian Standards and approved by SAI Global, which providing workers peace of mind when using the product, as not only does it conform to Australian standards, it is certified.

Offering welders both face and head protection, the Optrel Galaxy High Impact Welding Helmet is also available with a hard hat adaptor to suit PA620V and MSA V-Guard Elite hard hats.

Available as a spare part, users can quickly and easily convert their standard Optrel Galaxy High Impact Welding Helmets to be used with a hard hat.

Providing maximum protection for the head without the need to switch helmets and hardhats, plus maximum wearer comfort, the welding helmet with a hard hat adaptor is ideal for use at construction sites.

Featuring a passive shade 10 welding filter and replaceable high impact lens cover, these protective personal welding equipment pieces also offer welders even greater protection when electric arc welding, electrode welding and even grinding, according to manufacturer Honeywell.

The Optrel Galaxy High Impact Welding Helmet with hard hat adaptor is certified to ASNZS 1337 and 1338, and approved by SAI Global.

Honeywell 1300 139 166 www.honeywellsafety.com

Lifting magnets for heavy-duty applications ALL Purpose Abrasives has released its new heavy-duty lifting magnets, which are strong enough for use in the sheet and heavy metal, roll forming, mining and construction industries.

The magnets, manufactured entirely from metal, are available in lifting strengths from 100kg through to 6000kg.

According to the manufacturers, the optimal strength to weight ratio of the lifting magnets make them a safe and efficient way of handling heavy metal loads. manmonthly.com.au

The magnets may also reduce occupational health and safety incidents by bearing heavy loads.

Designed for safety and ease of use, the magnets also eliminate the need for manual handling, says All Purpose Abrasives They can be used to lift heavy steel loads, including lift plates, profiles, beams and round sections.

All Purpose Abrasives 1300 216 456 www.allpurposeabrasives.com.au

BECKHOFF Automation has introduced the new CX9020 series of embedded PCs, which offer compact PC control for a wider range of applications.

Equipped with a powerful 1 GHz ARM Cortex A8 processor, the fanless CX9020 embedded PCs are suitable for PLC and motion control applications in small- and medium-sized machines, systems or buildings.

The multi-interface can be configured ex-factory, if required, offering scope for numerous optional extensions from an audio interface up to the connection of Fieldbus masters or slaves.

The multi-optional interface of the

embedded PC enables integration with all common Fieldbuses and industrial Ethernet systems. These include EtherCAT (slave only), PROFINET, Ethernet/IP, PROFIBUS, CANopen and DeviceNet serial interface (RS232/RS422/ RS485) or audio.

The extended operating temperature range of -25ºC to +60ºC enables the embedded PCs to be used in demanding environments including a wide range of manufacturing facilities as well as outdoor applications such as wind turbines and solar power plants.

Beckhoff Automation 1300 321 058 www.beckhoff.com.au

Slip-ring style torque transducer BESTECH has introduced the Lorenz DR20 slip-ring type Torque Transducer, which measures rotating torque in full scale ranges from 1 to 500N/m.

The maximum shaft speeds are 2000rpm for the lower torque ranges, 1500rpm for intermediate ranges, and 1000rpm for the higher torque ranges.

The output signal is unamplifed from 0.5 to 2 mV/V FS, the actual signal being dependant on the torque range.

The DR20 torque sensor also includes as standard a dual channel TTL quadrature output signal for both speed measurement and direction of rotation sensing. Both ends of the shaft are plain keyed, and electrical connection is made via the 12pin mating connector supplied.

Applications include monitoring of torque applied during automatic

The sensor measures torque in ranges from 1 to 500 N/m. assembly of automotive components such as windscreen wipers, window winders, and rear vision mirror drives.

Bestech 03 9540 5100 www.bestech.com.au

Manufacturers’ Monthly SEPTEMBER 2012 51

What’sNEW New loop calibrator with HART technology

The loop calibrator supports Universal and Common Practice commands.

ZEDFLO has released a new calibration product designed to bring flexibility to end-users.

The Beta-Martel model LC-110H is a loop calibrator that includes true HART (Highway Addressable Remote Transducer) communications technology. It supports Universal and Common Practice commands that let the user read, display and store the full configuration data of any HART device.

The commands also allow the users to adjust the Upper Range Value (URV) and Lower Range Value (LRV) of any HART device.

In addition, the operator can perform full analogue output trim and ‘instrument zero’ functions.

By using the optional BetaLOG HART software, the previously stored configuration data can be uploaded as well as up to 9800 data points from any device equipped with the communications technology, including the 4PV valves.

Alternatively, the LC-110 model is available without HART technology for those who just need a competent loop calibrator.

Zedflo Australia 08 9302 1266 www.zedflo.com.au

52 SEPTEMBER 2012 Manufacturers’ Monthly

Stop contamination at the door FMCG Industry Solutions has released Profilgate, a new foreign matter capturing system which actively captures metal, glass, sand, soil and dust fragments from tyres and boots, every time they travel over the system.

The system has been designed to stop the transportation of contaminants into the factory and warehouse space by forklift tyres, trolleys and boots, such as dirt and potential pathogens.

Areas protected include entrances into and out of warehouses, production areas, processing area, maintenance department and other high risk areas reducing the risk of product contamination and potential recalls.

Using the latest cleaning technology, the unique brush system is activated by the weight of a fork lift as it travels across metal grid and removes contaminants from the tyres and traps them in a stainless steel capture tray.

The brushes have specifically been developed with the optimal hardness, angle and height to actively capture metal, glass, sand and soil from staff safety shoes, boots, trolley wheels and even forklift tyres, every minute of the

A wet version is available to not only clean tyres and shoes, but to sanitise them as well. day. It requires no power and very little maintenance and is certified for up to 10 tonnes.

Once installed, the system only requires foreign matter collected in the tray to be removed monthly which dramatically reduces on-going cleaning costs.

Unlike most places where cleaners inefficiently move around the site

The flow meters have a low pressure drop of less than 3mbar through the sensor element.

Digital flow meters SENSIRION has launched new digital SFM3000 mass flow meters for high volume applications in medical devices, process automation and burner control.

The flow meters bi-directionally measure the flow of air and other nonaggressive gases at rates up to 200slm with what the company states is high accuracy and high speed. The meters output a 14-bit digital signal at a 2kHz update rate. The signal is internally

linearised and temperature compensated.

The flow channel is designed to achieve a very low pressure drop of less than 3mbar through the sensor element.

These new mass flow meters operate from a 5V DC supply voltage and feature a digital 2-wire interface, allowing for connection directly to a microcontroller.

Gas flow is measured by a thermal sensor element.

Soanar 02 8832 3018, www.soanar.com

sweeping and vacuuming foreign contaminants using brushes, brooms or floor sweepers after they entered the factory.

The Profiligate system operates 24/7 collecting glass, metal and other foreign objects before they enter the production area.

FMCG Industry Solutions 02 8005 6882 www.fmcgis.com.au

Digital positioning systems AIR & Hydraulic Systems has unvieled the new J+J digital positioning system (DPS), which features a modulating function whereby the movement of the actuator is controlled by either a 4-20mA or a 0-10VDC control signal.

The system is entirely self calibrating, Air & Hydraulic says.

Any change in the control input signal results in a corresponding and proportional change in the position of the actuator, which is achieved with the use of an internal digital positioning system.

The DPS can be supplied as a retrofit kit containing all the parts required to convert a standard on-off actuator to a modulating unit.

An internal microprocessor on the DPS circuit board monitors the analogue input and output signals digitally and compares them to the physical position.

Digital control ensures high sensitivity, with all the usual positioning characteristics coming in at under 1% (hysteresis, linearity and precision).

Air & Hydraulic Systems 1300 673 226 www.ahs.com.au

manmonthly.com.au

EFIC DID MORE THAN FINANCE OUR CONTRACT

THEY ENABLED IT. Cory Stevens, Managing Director, Lean Field Developments

When we won the contract to be part of the supply chain to the massive Queensland Curtis LNG project, we were delighted. This was an opportunity to further establish our track record and reputation within the oil and gas industry in Australia.

However, like other suppliers, we were required to provide performance bonds in support of our contractual obligations. We also needed to ensure that we had access to additional working capital for other contracts. Yet, as a company without a long

trading history in Australia, we couldn’t get sufficient bonding or bank finance for our needs.

Luckily we knew in which direction to turn. With the support of EFIC’s export working capital guarantee and bonds, we were able to meet the financial requirements and demonstrate our company’s ability to take on such challenging projects.

Overcoming financial barriers for exporters Visit efic.gov.au/mm

What’sNEW High-pressure magnetic filters

The magnetic filters have a maximum pressure 50Bar-g.

ECLIPSE Magnetics has developed the Micromag HP50 and HP80 magnetic filters, which share the features of the standard Micromag magnetic filter but have been developed to suit high pressure through to spindle-coolant applications.

In these applications the smallest of particles can damage seals, spindles and even reduce the efficiency of the cutting tool.

The filter consists of an aluminium lid and housing, stainless steel magnet tube. The HP50 can be installed anywhere in the fluid delivery system and will ensure that even sub-micron magnetic and para-magnetic particles are removed before they can cause any expensive damage.

According to the company, when staff use the supplied cleaning tool, a fully contaminated core can be cleaned in under 30 seconds. Only metallic particles are removed from the filter and these can be easily disposed of.

No dirty cartridges are involved.

The filters are intended for use on neat and soluble oils. They can be installed pre- or post-pump, delivery line, spindle feed or pre-membrane cartridge.

Spear & Jackson (Australia) 03 8792 9999, www.spear-and-jackson.com

54 SEPTEMBER 2012 Manufacturers’ Monthly

Measuring transport, storage damage THE Lamerholm 298 ShockLog range is a complete motion-monitoring instrumentation solution that combines advanced tri-axel piezo electric accelerometer technology with the latest in MEMS electronic accelerometers in a single unit.

Available from Warsash Scientific, the range has been designed to monitor shock and vibrations based on acceleration or velocity measurements.

Tilt or roll is measured in degrees of angle (+/- 180 degrees). It can also monitor temperature, humidity and changes in atmospheric pressure.

Tilt and roll sensors extend the monitoring capabilities to include the tilt (front-to-back) and roll (‘Sway’, leftto-right) movement of an object being monitored.

The ShockLog records the data within the timeslot memory as the highest angle of movement both + and - during any given time period as well as being able to identify full 180 degree turnovers of a product.

Optimal modes of transportation, route, storage options is indentified through full-journey and motion profiling.

GPS coordinates are recorded within the ShockLog memory. The units will record the GPS coordinates at the end of each summary interval as well as at the point of every event. Upon downloading the data, users can access all of the usual ShockLog data with the GPS coordinates being added to both the

summary and event information.

From within the Windows-based software programme, users are able to view the angle of motion in the timeslot graphs, zooming into specific problem areas to identify problematic periods.

Warsash Scientific 02 9319 0122 www.warsash.com.au

The inverters have a brake controller and two integrated potentiometers.

Distributed inverter The vertically-split design provides fast access to major components of the compressor.

High-volume output centrifugal compressors COMPRESSED Air and Power Solutions (CAPS) Australia has developed its latest model of Centac centrifugal compressors, the C1000.

These compressors are oil-free, single to multi-stage compressors, which provide high-quality, clean compressed air to Class 0 certification. The latest design comprises the main compressor unit and at least three coolers, all mounted on a cast-iron frame.

The three coolers – two inter-stage and one after-cooler – have been oversized to provide greater resistance to fouling.

They also provide low CTD and pressure drop to increase efficiency and reliability.

The water-in-tube coolers are accessible and serviceable from both ends of the package.

CAPS Australia (08) 6250 9800 www.capsaust.com.au

NORD Drivesystems has introduced the SK 200E series frequency inverters for drives with a performance between 0.25 and 22 kW. Available for installation near the motor or as motor-integrated models, the series has been designed to cover all typical distributed applications.

Frequency inverters from the SK 2x0E line, for instance, are equipped with a process and PI controller, and qualify for use with fans and pumps through their internal 24V power supply and two analog inputs.

The SK 2X5E line is tailored for the needs of conveyor technology.

NORD Drivesystems,1300 006 673 www.nord.com

manmonthly.com.au

Your partner in pneumatics and automation

Accurate speed, force and position control is now child’s play At SMC, we are best known for our expert knowledge, design capabilities and superior quality when it comes to pneumatic actuators and controls. We have now combined this know-how with experience gained through years of work with industrial automation to bring you one of the most comprehensive ranges of electric actuators available in the market.

Whether you are looking for linear, rotary or gripper styles, we’ve got the solution for you. The great news is that our new range is so easy to select and program, that solving your electric actuator application is now child’s play.

Contact us now to see just how easy it can be.

1800 763 862 Australia wide enquiries@smcaus.com.au www.smcaus.com.au

A Member of The Linde Group

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