Manufacturers' Monthly May 2013

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961 MAY 2013

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Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au Managing Editor: Cole Latimer Ph: (02) 8484 0652 Fax: (02) 8484 0722 cole.latimer@cirrusmedia.com.au Journalists: Brent Balinski Ph: (02) 8484 0680 Fax: (02) 8484 0722 brent.balinski@cirrusmedia.com.au Alex Heber Ph: (02) 8484 0884 Fax: (02) 8484 0722 alex.heber@cirrusmedia.com.au Vicky Validakis Ph: (02) 8484 0964 Fax: (02) 8484 0722 vicky.validakis@cirrusmedia.com.au Editor-at-Large: Alan Johnson Ph: (02) 8484 0325 alan.johnson@cirrusmedia.com.au Graphic Designer: Dave Ashley david.ashley@cirrusmedia.com.au Creative Director: Julie Coughlan Production Co-ordinator: Mary Copland Ph: (02) 8484 0737 mary.copland@cirrusmedia.com.au VIC/Overseas Sales: Michael Northcott PO Box 3069, Eltham, VIC 3095 Ph: 0448 077 247 michael.northcott@cirrusmedia.com.au NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8484 0868 Fax: (02) 8484 0722 Mobile: 0414 644 664 anthony.head@cirrusmedia.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@cirrusmedia.com.au NSW, SA/NT & WA Sales: Cirrus Media Ph: (02) 8484 0868 anthony.head@cirrusmedia.com.au Published 11 times a year Subscriptions $140.00 per annum (inc GST) Overseas prices apply Ph: 1300 360 126 ISSN 0025-2530

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For daily news visit manmonthly.com.au

MAY 2013

18

4 Editorial ■ Manufacturing’s evolution

6 Comment ■ Don’t put the cart before the horse

8 Analysis News ■ What’s happening

16

14 IT@MM54 ■ The maker movement ■ Manufacturing 2.0: The additive era

18 Automation & Robotics ■ Steeling itself for the future ■ Using wireless to boost automation

22 Management ■ Time to invest

24 The Endeavour Awards Finalists ■ Manufacturers ready for a gala

night

32 National Manufacturing Week Preview ■ The industry on show

■ Metalworking and machining

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manmonthly.com.au

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961 MAY 2013

46 What’s New ■ ■ ■ ■

52 Pumps & Valves

Profile grinders Hazard cordoning Pallet trucks Knife edge rolls

■ Corrosive industry pumps ■ Seals

54 Rules & Regulations ■ Trading on reputation

56 Automotive’s Future

■ Automated handling ■ Floating blade ploughs

■ Is subsiding the car industry that

expensive?

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MA0513_003.pdf

ENDEAVOUR AWARDS FINALISTS >> Shortlisted nominations for our 2013 manufacturing awards announced!

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Manufacturers’ Monthly MAY 2013 3

MA0513_004.pdf

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Editorial

COLE LATIMER – Managing Editor

editor@manmonthly.com.au

Manufacturing’s evolution Manufacturing will have its day in May, with a number of events highlighting the industry.

I

t’s all about manufacturing in the month of May. And why not, because it is about time.

The Endeavour Awards, National Manufacturing Week, Austech, and AUSPACK PLUS all kick off the start of the month.

All these events are highlighting what an innovative and high achieving industry it really is, despite the constant reports of its early demise.

And all coming within the space of two weeks, as they do, only reinforces that this is hardly an industry that is on its last legs.

I for one am excited, as this will be both my first National Manufacturing Week and first Endeavour Awards since I took the helm of this magazine.

In the six months that I’ve worked on this magazine I’ve seen that the apparent doom and gloom, as well as the constant forecasts of the end of Australian manufacturing, simply isn’t the case.

While exponential growth isn’t being seen month on month, the contraction of the industry is not at the seemingly rapid pace that many outside of the industry appear to D _ MA N MA B B A P R _ 1 3 crowAabout.

There is such a wealth of

4 MAY 2013 Manufacturers’ Monthly

May is manufacturing’s month. innovation and development in this manufacturing’s end can. industry that is simply not being This lack of recognition is reported on because we’re only one disappointing. magazine; and it doesn’t pull in much The industry, although not exactly -of the 1 mainstream 2 0 1 3 - 0media 3 - 1 the 1 Tway 1 8 : 4 1 expanding : 3 8 + 1 in 1 :leaps 0 0 and bounds, is that quick and easy predictions of still a thriving one, and integral to

Australia’s future and our economy.

And events such as National Manufacturing Week, Austech, AUSPACK, and the Endeavour Awards all seek to highlight this.

Manufacturing has been a part of the Australian landscape since we first became a nation, and will continue to do so into our future.

We have a globally unique position as a nation with a high quality and high tech manufacturing base smack bang in the middle of one of the fastest growing consumer bases in the world – Asia.

Traditional manufacturing in Australia – automotive, industrial, may be coming to a slow end, but we are seeing the rise of new manufacturing streams that will give a new life to the industry.

Manufacturing is evolving and we are all a part of this new development.

The Endeavour Awards, National Manufacturing Week, Austech, and AUSPACK PLUS are all highlighting this manufacturing evolution.

And this is why I am so excited for May. We’ll be at NMW on stand 2002 during the event, so drop in and say hello to the team. We’re looking forward to meeting you.

manmonthly.com.au

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Industrial COMMENT Don’t put the cart before the horse Manufacturing Australia’s new chair, Sue Morphet, discusses manufacturing’s importance.

M

anufacturing is the manifesto, Australia’s Manufacturing with Asia, our capacity for innovation silent workhorse of the Advantage, which advocates and research and our stable Australian economy. for three key areas of reform governance. Through smart policy Through job creation, import that we believe help Australian and strategic investments, our sector replacement and maximising the manufacturers to compete in this can in the next decade directly and value of our natural resources, global sector. Certainly we face indirectly create new jobs and drive a manufacturing delivers tremendous formidable challenges: among resurgence throughout rural, regional benefits to the nation them the high Aussie dollar, high and outer-suburban Australia.

Our sector employs almost 1 million input costs, increased imports, So to our three priority areas Australians, contributes more than which are sometimes “dumped” of reform: First, we must better $160 billion into other sectors of the in Australia, the cost of running capitalise on Australia’s energy economy. I strongly believe that there and constructing manufacturing advantage. Australia is an energy is a positive future for this sector plants in Australia and excessive or and resources superpower, but and I want to help ensure that we inconsistent regulation. But we also currently our domestic energy have the right type of manufacturing have significant advantages, and policies largely fail to capitalise on in Australia: manufacturing that manufacturing flourishes in those our energy advantage. The most takes advantage of our natural countries that identify and exploit important way we can do that is by competitive advantages to create their natural advantages. creating a domestic gas market that stable, rewarding employment For some nations that advantage enables value-adding manufacturing not just in our cities, but also is cheap labour. For others, like alongside gas exports. Secondly, we throughout rural, regional and outerAustralia, those advantages include must restore fair trading conditions. suburban have been made M A 0 Australia.

5 1 3 _ 0Manufacturing 0 0 _ AT L 1our 2abundant 0 1 3 - energy 0 4 - 1resources, 1 T 1 4 : our 4 8 : 2 Great 1 + 1 improvements 0 : 0 0 0513 HPAtlas Copco.pdf 1 9/04/2013 1:13:14 PM skilled workforce, our ties Australia has released its policy highly to Australia’s anti-dumping regime in

the past 18 months, but more needs to be done. Mismanagement of open trade can easily lead to unintended consequences such as dumping and exclusion of domestic manufacturers from domestic markets. Through changes to shipping regulations, further anti-dumping reforms and stronger industry participation schemes, we can ensure we are competing on a level playing field with our competitors. Finally, we need to invest for manufacturing growth.

It’s time for governments and communities alike to get over the perception that manufacturing in Australia is a “sunset” industry, because it’s not. With the right policies, and the right investments, manufacturing can and will continue to flourish throughout the boom and bust cycles of other industries.

Atlas Copco Compressors introduces the new GA VSD+ with up to 50% energy savings

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MA0513_008.pdf

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Analysis NEWS More help needed from Government: Orica boss

E

xplosives maker Orica has called on the Government to do more to help manufacturers struggling with rising costs and the high exchange rate.

Orica CEO Ian Smith told the Melbourne Mining Club the Federal Government needed to work on making Australia’s industry “the most cost competitive and open market we can”.

In particular Smith said the dollar might stay above parity for the next five to ten years, and new policy was needed to help businesses cope with the challenge.

“We haven’t got any actual policies in place that reduce the Aussie dollar,” he said.

But while manufacturers faced difficult conditions Smith said the longer-term outlook was positive.

“At the moment we might be going through some hiccups, and gas may be thrust into the equation. But the general trend point is there,” he said.

Smith’s criticism follows the Central Highlands Regional Council’s move to approve Orica’s new explosives manufacturing plant east of Dingo in Queensland.

The plant was approved in a vote five in favour to four against, M M with 0 5 1some 3 _ 0members 0 0 _ Aexpressing 2 K 1concern 2 0 1over 3 - the 0 4site’s - 0 9 T 0 9 : 3 7 : 4 0 + 1 0 Dollar : 0 0parity is safety, security, and impact on local roads. harming business.

8 MAY 2013 Manufacturers’ Monthly

Unions to rally in support of manufacturing in Adelaide THE Construction, Forestry, Mining and Energy Union, Australian Manufacturing Workers Union and Maritime Workers Union rallied at North Terrace in Adelaide to demand more support for what they call a “jobs crisis” in manufacturing and construction.

The campaign pushed for more federal government support for the sector, following examples in the United States.

“There is plenty of evidence of how government support and company-led innovation can maintain a high-wage, strong manufacturing industry,” explains the campaign’s material.

“In the US, the Obama administration has strengthened Buy Local policies, and provided support to the automotive sector which has driven Ohio’s unemployment rate from 11 per cent in 2008 to 7 per cent in 2012.”

The SAHMRI is emblematic of what the unions claim is a problem.

“The façade was built in China and then it was too big to get into shipping containers so they’ve had to take it apart to ship it,” Aaron Cartledge from the CFMEU explained.

“This has delayed the project and ultimately, cost taxpayer dollars. And this is just one example.

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Analysis NEWS Auto manufacturing demise could be inevitable JAc Nasser, current chairman of mining giant BHP Billiton and former global head of Ford, has said Australia lacks the patriotic support of its car makers that other countries display and expressed pessimism about the industry’s future.

During a speech to the Australian British chamber of commerce, Nasser, who worked at Ford for 33 years and was its global cEO from 1998-2001, told an audience that other countries were more sentimental when it came to their auto industry.

“Here, we’ve had it with some products but we haven’t seemed, as Australians, to be emotionally connected to the industry,” he said.

“I’m disappointed in some of the rhetoric that I hear, where it’s clear that the general feeling in Australia is that they’re not patriotic around their automotive industry. In most countries around the world they are emotional about their automotive industry.’’

He suggested that other countries were also offering more in the way of taxpayer support.

“I would say we haven’t spent a lot on it, when you compare the incentives that the automotive industry has received, to others,” he said.

Nasser grown A Dsaid _ Mthat A N he’d MB O G M Aless Y _ hopeful 1 3 . pabout df P automotive manufacturing’s future in Australia,

THE CSIRO has allegedly duped the Swissbased multinational pharmaceutical company Novartis into buying anticounterfeit technology that can be easily compromised.

Novartis signed up to use technology that was designed to prevent vials of injectible Voltaren from being copied, filled with a placebo and sold by crime syndicates.

CSIRO and its joint venture partner, DataDot Australia lacks patriotic support.

Technology claimed to be selling Norvatis a customand if one of the remaining three companies designed tracer, but in fact sold the company a widely making cars in Australia, it could have disastrous available Chinese-made tracer material that is not flow-on effects for the industry as a whole. suitable for pharmaceutical applications.

“Let’s assume one of the three decide to exit The counterfeiting of drugs is a serious problem Australia in terms of manufacturing, then you which has lead to deaths worldwide. end up potentially with a sub-scale supplier Following investigations by Interpol last year, 3.75 infrastructure, and once that happens I think it’s a million units of fake drugs were seized and 80 people domino effect,” he said. were arrested.

“It would be a very sad day for Australia but CSIRO officials and Datadot executives misled unfortunately it looks like it could be inevitable.”

Novartis even though they had received explicit internal Holden announced that it was cutting 500 warnings that the Novartis code could be duplicated. revealed has confirmed that it will undertake an a positions g e 1 only 9 / a0week 4 / 1after 3 , it 4 : 5 5 : it0had 2 P M A E Novartis ST received over $2 billion in government support. internal investigation into the matter.

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CSIRO accused of corruption

A fire which broke out in at the Alcoa Kwinana refinery fire is thought to have caused up to one million dollars worth of damage.

The fire was situated in the plant’s cooling tower and was accompanied by an explosion and a plume of black smoke.

“There was a fire in the cooling tower, which they were able to extinguish very quickly themselves and did not need assistance,” Department of Fire and Emergency Services spokesman Allen Gale said.

“There were no other associated hazards.”

According to an Alcoa spokeswoman, the cooling tower was

No one was injured in the blaze. undergoing planned maintenance when the fire started.

“An investigation is now underway and the necessary authorities have been informed,” she told the West Australian.

She said no one was injured and it did not appear the incident would impact production. manmonthly.com.au

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MA0513_012.pdf

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Analysis NEWS Canberra could intervene in exchange rate

Mirabella backs future of manufacturing

Independent Senator nick Xenophon is pushing for a Senate inquiry into the impact of the high Australian dollar after declaring it was “situation critical� for the manufacturing sector. the inquiry would consider whether the Federal Government could intervene in order to bring down the value of the currency.

Xenophon said while manufacturers were hurting other parts of the economy were also doing it tough because of the exchange rate.

Is governmental control needed? “the major parties need to get their heads out of the sand and grapple with the impact from changes in the exchange rate. of the high dollar as a key and urgent policy despite the new pressure from Xenophon, issue,� he said. both the Opposition and the Gillard “the problem with doing nothing is large Government have not put their weight behind portions of manufacturing will turn into an any measure to intervene in the exchange rate. industrial wasteland.� the debate follows comments by the Reserve “Once they shut their doors it’s likely they’ll Bank claiming the wider economy was coping be lost forever.� well with the high dollar.

Xenophon said Canberra could consider “I would prefer a lower currency and it approaches used by Swiss and Japanese policy does pose some problems for us,� RBA board makers, which saw the Government push down member John edwards said. the value of the dollar. “But I don’t think they’re at all, at this point, HeAalso the aM D _ said MA N M Government E C I F E B _could 1 3 .consider pdf P athe g ekinds 1 of1issues 0 / 0that 1 / require 1 3 , us 9 to : 5make 9 A introducing strategies to cushion businesses response.�

OppOSItIOn minister for Innovation, Industry, and Science Sophie Mirabella says she still has faith in the future of the manufacturing sector, despite its current challenges.

In a visit to Wagga Wagga in nSW yesterday Mirabella said the industry still had a future, and new measures were needed to lower costs and improve the Mirabella calls for efficiency of government better support. support.

Mirabella said in particular Holden’s decision to axe 500 workers showed support for the automotive industry needed to be reworked. “there are policy failures regarding car industry policy. the current funding arrangements aren’t working; the carbon tax has imposed a cost on the industry,� she stated. “We think there’s a better way and this is for the productivity commission to have a review to come up with a funding model that is transparent and provides long-term viability for the industry.�

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12 MAY 2013 Manufacturers’ Monthly

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MA0513_014.pdf

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TechnologyIT@MM The makers movement Technological advances in manufacturing is putting the industry back in the hands of the people. Brent Balinski writes.

“I

t’s everything from of the sub-culture’s bible, Make engineers to artists and magazine. Its evangelical fans, such designers, craft people, as former Wired editor and author people with a general interest in of Makers (published in October last electronics – all kinds of people,” year) Chris Anderson claim it as a explained Karen Marsh, manager of new industrial revolution. Others Fab Lab Adelaide, when asked who say it’s simply a group of people used the facility, open to the public who’ve fallen in love with tinkering. on Thursdays and Fridays.

Whatever the case, it’s starting to The lab was opened last year in interest more and more people here.

November, the first of its kind in “We had between three and four Australia, though one of over 100 thousand people show up, which over the world. It gives visitors was way, way more than we ever access to a laser cutter, milling, expected,” Marsh told Manufacturers’ machine, vinyl cutter and a number Monthly of the Adelaide event. of 3D printers.

“We were anticipating 1,000 Last month the Fab Lab hosted people but we got about four times only the second-ever Mini Maker that. So it was fantastic.”

Faire in Australia. The Maker It’s not quite the 100,000-plus Movement got itsMtitle 2005 Area AD_ M AN P I in EM A Y _ 1 3 . pthat d f attended P a g ethe Bay 1 3 / 0 Maker 4 / 1 3 , from O’Reilly Media, publishers Faire in May last year, but it far

outstripped the first Australian Mini Maker Faire, held at Swinburne University’s Hawthorn campus in January last year.

The Maker culture puts emphases on sharing knowledge and one’s creative efforts, with what’s made both super-modern and occasionally the opposite.

“We had lots of digital, high-tech stuff, we had loads of 3D printing, we had a whole 3D printing atrium, we had about 30 3D printers going throughout the day,” said Marsh.

“Some really cool high-tech stuff, some traditional stuff, some spinners and weavers, the traditional blacksmiths, we had a tinsmith outside, just making traditional stuff, we silk,Awe had 2 :had 4 1painting : 3 2 on PM ED T Daleks!”

Is this democratisation of manufacturing?

Marsh believes that, although we’ve been slow to officially celebrate the Maker subculture, Australians are natural born Makers.

“I think there’s a real tradition

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of fixing things and making things and doing stuff in our shed. I think Australia naturally is a nation of Makers.

“I don’t think we’ve termed ourselves that before: it’s been words like tinkerers or that kind of thing, but the term Maker is fairly new. I think we’re Makers anyway. We have a culture of – particularly people in country or remote areas, they have to fix things... They need to fix stuff and mend stuff and naturally we have a tendency towards being fixers and menders and tinkerers.”

3D Printing Systems sponsored Australia’s first faire, and its CEO Bruce Jackson believes that the Maker movement has been slow to emerge in Australia, but is now growing strongly, with hackerspaces (or makerspaces – open community labs with equipment for users to realise their projects) starting to crop up. 3D printing is becoming more affordable and user friendly, meaning its use by hobbyists is becoming A D _ more M A Nappealing.

MB A C A P R _ 1 1 .

“We try to aim for the user

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experience that you’d expect with an HP or an Epson or Brother printer,” he told Manufacturers’ Monthly.

“Now there’s two types of users.

There’s the type of user just downloads, and there’s so much out there that downloading is good enough for a lot of people.

And you’ve got your people who download and design. I’m probably one of those people.

“And then you get your designers who are really hardcore into their 3D design. They can virtually design and physically make.”

Websites like www.thingiverse. com provide a smorgasboard of design files to be punched into a 3D printer and made into a real product (generally fabricated out of ABS plastic – the same material used to make Lego).

For design whizzes, like Jackson pointed out, you can dream up your own 3D creations with CAD software. Or you can just get an app like Autodesk’s 123D Catch, use pyour d f phone P a as g ea 3D1 scanner, 9 / 0 3and / 1 1 , then do what you want with the file.

Don’t have a printer of your own?

Visit a makerspace or outsource the task to a site like Shapeways, have them do the task for you, and get the result sent out in the mail.

Some of the momentum around the Maker movement and the technology associated with it has people excited.

When SA industry minister Tom Kenyon opened the Adelaide Fab Lab, he mentioned the facility’s role in “promoting and demonstrating the potential benefits of 3D printing for local manufacturers”, and Marsh said it’s allowed a number of potential commercial users to try before investing in the technology.

Anderson’s thesis is that the democratisation of digital manufacturing technologies and the collaborative model of the Maker movement will lead to things such increasingly brisk innovation, the onshoring of industry, and an overall “bottom-up transformation of manufacturing”.

Not everybody believes the Maker will do anything 2 : 3 3movement PM so revolutionary. Many argue that,

though it’s interesting, it’s not, strictly speaking, “manufacturing”.

“Is manufacturing making one-offs, or is manufacturing making multiple copies?” asked Jackson.

He went on to add that the trend towards greater customisability, however, would change what manufacturers would have to do to keep their markets happy.

“I probably see the future of products – your iPhone or whatever – as customised, really customised products,” he said.

“So moving into the future you’re going to buy your own Nike shoe with your name on it, with whatever colour design you want – and this is happening now, this has started to be available from Nike, for example.

“So the whole mass manufacturing is going to change for the consumer world,” Jackson explained.

“Now if you want to buy something it’s going to be made personally for you, manufactured on the spot and delivered to you from a local centre.”

Manufacturers’ Monthly MAY 2013 15

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Technology IT@MM Manufacturing 2.0: The additive era

S

ince the industrial revolution manufacturing has meant cumbersome factories, production lines, machinery, labour and striving for the creation of economies of scale.

For a manufacturer to scale up, down or change a product line it has required a fair amount of effort, time and money. But now revolution is in the air, driven by the development of 3D printing technology which is set to change manufacturing as we know it.

Downloading a product’s data specifications and manufacturing it without even getting up to make a cup of tea is now a reality.

Additive manufacturing has arrived in a very big way and it is going to transform tradition manufacturing notions one thin layer at a time. Labelled an ‘emerging technology’, 3D printing has actually been around for more than 30 years.

But with heightened accuracy, increased efficiency, affordability and growing demand 3D printing is now entering into the consumer market.

Additive printing is breaking through the traditional barriers of large scale manufacturing and has been tipped to disrupt the industry’s current norms.

Forget the woes cheap offshore labour and mass production has inflicted on Australian manufacturers, the evolution of 3D printing is set to be even more disruptive. The process of 3D printing uses CAD data to simplify product specifications into 2D slices and in an additive process builds a product from the ground up, layer by layer.

3D printing breathes life into incredibly intricate and detailed designs in a matter of hours.

It can produce parts within parts; create micro products and medical grade, life giving devices and can do all of this with very little economies of scale, meaning bespoke and personalised products can be fashioned relatively cheaply.

The technology will result in a manufacturing renaissance, intellectual property litigator at US law firm Finnegan John Hornick proudly told Manufacturers’ Monthly.

“You can make anything and everything will change,” he said.

16 MAY 2013 Manufacturers’ Monthly

A new industrial revolution.

But for manufacturers to take advantage of the advancements, swift and purposeful change is required from traditional companies.

Hornick warns that if segments of the manufacturing industry don’t adapt quickly they will go down in much the same way the music industry did when sites like Napster and Limewire were launched and music downloading went mainstream.

As additive printing advances, it will disrupt traditional manufacturing and will initially result in job losses, however entirely new industries will grow up around it.

“3D printing will cause business to either change, adapt, or vanish,” he said.

Just like the ‘App revolution’, companies that may not have previously had a reason to exist will now open their doors, Hornick explained.

Traditional manufacturers also have an opportunity to diversify and instead of relying on a primary product they will be able to best position themselves to meet market demands as they develop.

Hornick predicts that as 3D printing technology becomes cheaper and more refined the process will to become increasingly common and will enter the home.

Already you can buy a 3D printer for your home for under $500. The revolution is here and Hornick recommends not “fighting it, but embracing it”.

Additive manufacturing also brings with it wealth of opportunity

for high labour countries like Australia to benefit.

In some cases 3D printing products can abolish the need for extensive manual labour and it has the power to bring manufacturing operations back on shore.

“3D printing will take away the advantage of off shoring manufacturing and will stimulate a manufacturing renaissance,” he said.

Hornick explains that high employee numbers will not be required and fewer types of machines will be needed on production lines.

“Fewer people will be needed; companies won’t be forced to make products in China or overseas,” Hornick explained.

3D printing will flip manufacturing as we know it, and traditional manufacturing processes and models will need change with it.

“3D printing will disrupt traditional manufacturing, you will sell designs not products,” he said.

Companies like Ford who have come under fire for off shoring operations in favour of cheaper labour markets have already jumped on board because 3D printing allows for rapid and refined prototyping.

The flexibility 3D printing affords manufacturers is another distinct benefit, it eliminates the constraints of large runs and is a step up from mass injection moulding processes.

“The technology is there, use it to benefit,” Hornick said.

“Any company that can afford to make something with 3D printing should,” he added. manmonthly.com.au

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Automation & ROBOTICS Steeling itself for the future Steel manufacturer OneSteel needed to upgrade and automate its Whyalla plant, but with one of the few short furnace shutdowns in more than a decade coming up soon, time was limited.

I

n a steel production plant, In 2008, the existing skip hoist time is money. Any unplanned process control system was nearing shutdown of essential equipment the end of its operational life, but leads to major losses for operators opportunities to upgrade it were few such as OneSteel Whyalla, and and far between. According to Craig the customers who rely on their Foulkes, an engineer with OneSteel products.

Whyalla, the plant’s operations OneSteel Whyalla is a largeallowed for two 24 hour shutdowns scale operation built around a key per year.

South Australian port. Its diverse “That doesn’t mean that the skip operations encompass mining system needs to shut down for this and export of iron ore, as well as amount of time, but rather that these manufacture and structural milling are the only available windows for of steel for the Australian and scheduled maintenance,” he said. overseas markets.

A rare chance to overcome this The plant’s blast furnace is hurdle was to timetable installation the power house of its steel and commissioning of a new manufacturing operations. The skip hoist control system during furnace operates around the a planned blast furnace repair clock, producing molten iron for scheduled in 2011, which would conversion to steel. Two massive involve approximately 60 days break skips alternately provide the raw in furnace operations. materials required by the furnace: On average, major furnace pellets, coke, lump ore, limestone shutdowns occur every 15 to 20 and dolomite. years.

If the skip hoist shuts down, OneSteel Whyalla contracted furnace operations are disrupted, Rockwell Automation to locally History and customer which could potentially cost tens of design, manufacture and commission thousands dollars A D of _ M A N Mper D Ahour T M AofRlost _ 1 3 .anp upgrade df P solution a g e 1within 1 2this / 0tight 2 / 1 3 requirements , 5 : 3 5 PM The original skip hoist system was production. time frame. installed in 1965 and an updated power module was added in 1990.

Low Voltage 3 Phase Motor Tester In 1998, Rockwell Automation … GET TESTED NOW commissioned an upgraded process If you have a low voltage 3 Phase motor: 24V, 36V or 40V. control system, which consisted Our unique test unit rotates the motor using a PWM (Pulse Width a pair of Automax controllers Modulated) drive system and tests for a shorted phase winding, it interfaced to the third party power also measures current in each phase. Plus there are numerous module. safety features to ensure the system stays intact even if the motor The Automax units provided under test is faulty. control and monitoring of a pair * Produced to order. of drive motors, either of which * Pricing and details available upon request. could be switched in to operate the * Extensive engineering expertise. skip hoist drum. “Effectively there were two independent switched systems,” said Andrew Simpson, a senior design engineer at Rockwell www.datafactory.com.au Automation.

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The opportunity to upgrade the blast furnace was a rare one for OneSteel.

“If a motor failed, it could be switched out and the system would run at a reduced rate.”

However the scarcity of spare parts and limited maintenance availability were both issues affecting the viability of the system, while on-site technicians and engineers did not have the knowledge to work with the skip hoist controller, as it was a specialised system and not in use in other parts of the plant. Due to this OneSteel Whyalla decided to upgrade the whole control system while retaining existing system functionality.

Additional complications were that the power module interface hardware was also obsolete; manmonthly.com.au

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maintenance and diagnostics were limited to a stand-alone ‘black box’ system, and the control system did not comply with current safety standards in South Australia.

to retain this part of the system reduced project costs significantly”.

The Automax controllers were replaced with Allen-Bradley GuardLogix systems, and the outdated power module interface hardware was also upgraded, with SD3000+ interface hardware bringing it up to current technological standards.

Combining safety and availability The high operational cost of skip hoist shutdowns made availability of equipment a design priority for the upgraded system.

There are also many operational hazards when working with large machinery, so safety features were paramount. Achieving a system design with an acceptable balance between safety and availability was a challenge.

Simpson was responsible for preliminary design and risk assessment of the new skip hoist control system.

“The main thing is to make sure that the hoist doesn’t go too fast, or too far. So you need to test for overspeed and overwind to keep the system said.

M Asafe,” 0 5 1he 3 _ 0 0 0 _ SCH “Having two individual controllers,

Upgrading safety

The existing skip hoist system was due for an overhaul.

Cost effective solution one system online and one as backup, each with its own overspeed Rockwell Automation designed a and overwind detection devices, control solution that interfaced means that if one fails the other to the existing third party power |can take over to maintain module. According to Foulkes “the availability. Having the built-in current power module was reliable, 1redundancy 2 0 1 3 -minimises 0 4 - 1 1disruption T 2 0 : 1 to 1 : 1 and 3 + we 1 0had : 0both 0 an online system operations.” and spare to back it up. Being able

The first step in improving the safety of the new skip hoist control system was selecting an appropriate standard for compliance. According to Simpson, there was no definitive standard because the skip hoist incorporated aspects of mine winders, cranes and conveyors.

Simpson chose the New South Wales Government guideline for mine winders, MDG 2005 Electrical Technical Reference for the Approval of Power Winding Systems.

Mine winders are subject to more rigorous safety regulations because they may be required to carry people as well as equipment. Although

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manmonthly.com.au

Manufacturers’ Monthly MAY 2013 19

>>

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Automation & ROBOTICS

The original skip hoist was installed in 1965, and updated in 1998.

>>

The new system allowed the hoists to operate with new failsafes.

the skip hoist does not take human devices were included in the new The new system also provided test cargo, the importance of the system system, one attached to each of modes for each of the brakes on the demanded a high level of reliability. the GuardLogix controllers by an skip hoist’s dual motors. “Operators To determine the appropriate absolute encoder module. can lift one brake, and try and drive level of safety for the new system, The existing system had only one through that brake to a certain OneSteel Whyalla and Rockwell device, which was decommissioned level. If it doesn’t move it passes, if Automation undertook a system risk during the upgrade. it moves they know they need to do assessment. This stage of the project These features meant that if maintenance,” he explained. was facilitated by an accredited the new online system detected Limited availability third party company. an overspeed or overwind, it The outcome of the risk would trigger a system shutdown.

The main focus was ensuring that the assessment was that critical The machine operators could new skip hoist control system was functions including the overspeed, then investigate the problem and installed and commissioned within overwind and emergency stops manually switch to the backup the 60 day shutdown period allocated needed to meet Safety Integrity system if required. for the blast furnace repair.

Level (SIL) 2.

During maintenance periods, To achieve this, work had to be To achieve this, Rockwell operators would be able run test scheduled around other demolition Automation incorporated extra modes to safely determine whether and construction tasks that took MA _ 0 5 1 into 3 _ 0 0 design.

0 _ S P R - the 1 overspeed 2 0 1 3 -and 0 4overwind - 0 9 T 0devices 9 : 5 4 : place 2 8 +during 1 0 : that 0 0 time. safety functions the Spray ad 80x210 4/4/13 10:37 AM Page 1 Two overspeed and overwind were functioning correctly.

Foulkes explained that access to

Do you overlook one of the most critical parts of your process?

the skip hoist system was therefore limited to only 10 days, spread over the 60 day shutdown period.

To ensure that the project did not run over time, Rockwell Automation undertook pre-installation work and testing.

A new control desk was also supplied as part of the solution, so that the new system could be pre-wired and factory tested before it was delivered.

Since commissioning, the upgraded skip hoist system has been operating well, with only minor teething problems. Many of these issues can be rectified by on-site maintainers, with the knowledge that Rockwell Automation field engineers are available if needed.

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Using wireless to boost automation Wireless systems are allowing sites to rapidly expand.

I

ntelligent devices, whether they are valve positioners, temperature devices, flow meters, or level meters, supply additional data such as secondary process variables or device diagnostics that can be used to obtain a better insight into the process. This data can be made accessible using a HART data transfer protocol. Although new control systems are HART enabled, the many legacy control systems in the field frequently lack the ability to collect HART data. The WirelessHART standard can be used in both retrofit and greenfield installations, providing distinct advantages for each.

The time to engineer and develop the expansion or construction of a process unit can be drastically reduced by installing wireless systems to replace both infrastructure and signal cabling.

Moreover, investment asOwell AD_ M A N M S Ccosts H1 N V_ 1 2 as the costs associated with obtaining

Signals that took days now takes hours. the necessary approvals are reduced. allows maintenance crews to deploy A signal that previously took days to wireless nodes for temporary bring online using traditional wiring troubleshooting or adding “stranded� can now be commissioned within just measurement points to increase efficiency. By .a pfew d fhours P ausing g e WirelessHART. 1 8 / 1 0 / 1 2 , safety 1 0 or : 3improve 2 AM Less time and higher flexibility utilising previously unused HART

diagnostic data, a maintenance department can detect issues, for example plugged lines or worn valve seals. Leaks and contamination may also be detected before they ever cause a problem to other instruments or the complete process.

What’s more, plant personnel are protected against safety risks.

A logistics department can better plan when to turn assets on and off.

What also should not be forgotten is that the efficiency of critical parts of plants and systems can be monitored from remote locations using WirelessHART. A manufacturing plant’s network is fairly complex, as different applications, such as visualisation, asset management, and data historians require access to measurement and control data from the field. Directly connecting the WirelessHART gateway with the plant network has proven to be advantageous.

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Management FINANCE Time to invest The stubbornly high Australian dollar continues to challenge Australian exporters, however the good news is imported machinery prices are now at record lows. Alan Johnson reports.

W

ith the cost of imported equipment now at bargain basement prices, compared to five years ago, banks and non-banks are now keen to lend manufacturers the capital needed for that new machining centre or for that new production line companies may have been planning to install.

While Australian manufacturers are facing some real challenges, Grant Cairns, General Manager Banking Specialist with CBA, says most companies are adapting to changing market conditions.

“The high Australian dollar is a major challenge for Australian manufacturers, but equally we are seeing a number of Australian manufacturers reorientating their business to take advantage of the strong dollar to reinvest in equipment and gear up,” he told Manufacturers’ Monthly.

However Cairns explains that which sector of the manufacturing industry a company operates in is important when attempting to raise funds. “Obviously there are manufacturers in sectors that are geared to growth, but unfortunately there are others in sectors facing structural decline.

“Australian manufacturing has many unique niches, with many enjoying M A 0the 5 1opportunity 3 _ 0 0 0 _toEget NW access to finance.

Squeeze on raising capital eases.

“In fact, we have seen growth in to have a good open dialogue with the amount of money we are lending their banks, and to explore all to the manufacturing sector over the finance alternatives. past year,” Cairns said.

“We try to work closely with our “However,whether it’s a $1m or clients to really understand their $100m loan, it’s critical for us to business better so we can make understand our clients business, informative decisions based on a therefore it’s important for business by business proposition not manufacturers to have a robust at an industry level. and strong dialogue with their “For example, we need to know banks around how their business the type of equipment they are is travelling; what the business buying, whether they are sourcing is looking to do to capitalise on it from overseas or locally, what it opportunities or to manage risk, and will be used for, and the average life what productivity improvements for that plant. We go through that 1they2 are 0 1putting 3 - 0 4in- place 0 9 Tetc.

1 0 : 0 4 : 2 diagnostic 5 + 1 0 : first 0 0 before we jump to “My advice is for manufacturers what type of solution,” Cairns said.

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“In many respects, the type of solution will be different, depending on the security of the asset. We would need to know for example, if it’s an asset that we can easily sell on the market or if it is a specialised and bespoke piece of equipment to that particular business. That would influence whether it would be an asset finance solution or a commercial loan for example.

“Obviously there is more due diligence on a loan of $100m than $1m, but it depends on the size of the business as well.

“A $100m loan to a very large manufacturer maybe not that significant, but $1m to a smaller manufacturer maybe. Loans are very specific to the clients needs.”

He also said interest rates can vary considerably between clients.

“It all depends on the business itself and on the level of security that we are offered. It also depends on the type of utility; overdrafts for example are very different to a loan that is secured by a commercial property,” he said.

When it comes to types of loans, Cairns says the CBA is seeing strong growth in equipment loans using chattel mortgages.

“It’s mainly for tax reasons, for GST claiming, but it all depends on the particular circumstances of the business, and their tax circumstances

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what type of solution,” Cairns said.

“In many respects, the type of solution will be different, depending on the security of the asset. We would need to know for example, if it’s an asset that we can easily sell on the market or if it is a specialised and bespoke piece of equipment to that particular business. That would influence whether it would be an asset finance solution or a commercial loan for example.

“Obviously there is more due diligence on a loan of $100m than $1m, but it depends on the size of the business as well.

“A $100m loan to a very large manufacturer maybe not that significant, but $1m to a smaller manufacturer maybe. Loans are very specific to the clients needs.”

He also said interest rates can vary considerably between clients.

“It all depends on the business itself and on the level of security that we are offered. It also depends on the type of utility; overdrafts for example are very different to a loan that is secured by a commercial property,” he said.

When it comes to types of loans, Cairns says the CBA is seeing strong growth in equipment loans using chattel mortgages.

“It’s mainly for tax reasons, for GST claiming, but it all depends on the particular circumstances of the business, and their tax circumstances in particular. The landscape changed last year with the introduction of the GST on hire purchase, so it’s important companies look at the most important instrument to use when structuring the financing,” he said.

Last year also saw the introduction of the PPSR (Personal Property Securities Register), which according to Cairns has been a fantastic thing for the assets finance industry.

“Now we have one national register, rather than multiple state registers, plus it is broader with users able to register intangible and tangible assets

that they have incumbrance over.

“However manufacturers should be aware of changes, especially the invoicing of the goods they ship to their customers.

“Previously they were protected by the retention of title on the invoices with payment terms, but that has been replaced by the PPSR. “It’s important for manufacturers to understand how the PPSR legislation impacts them in terms of adding protection for them to make sure that when their customers default what rights they have to those goods,” Cairns said.

Finance options for SMEs One recent new tool aimed at SMEs looking for finance is Finnovate’s equipment finance comparison website. Launched in 2012, it is a free service to business with direct access to nine different lenders.

It is an online Business Finance tool which allows businesses to compare rates and costs and apply directly to the selected institution for finance.

According to Chris Beath CEO of Finnovate, the site is impartial as it does not advise or recommend to business which lender to select.

“It simply presents all the relevant information allowing an informed decision to be made and covers most variables,” Beath says.

“At it’s core is plant and equipment leasing and chattle mortgage, with chattle mortgage option overwhelmingly the most popular product in Australia at the moment, with most terms ranging from one to five years.

“If any variable is outside these then the financiers are introduced to the prospective customer and they can discuss the details and the options such as restructuring the repayments or the GST going back in, which is a common option.

“While chattle mortgage is the most popular, for tax reasons many companies choose to use leasing, hire purchase or rental options.”

Beath says the rental option is popular with technology based assets where the customer might not need or want to own rented equipment at the end of the leasing term, especially in the IT field.

“They prefer to rent that equipment for two to three years and when new models come out, they can return the goods and go on to rent the next new model,” he explained to Manufacturers’ Monthly.

According to Beath, equipment finance has grown consistently over the past four years, despite what many economists are reporting.

“It has grown year on year and month on month, and now a recent report on capital equipment expenditure is forecasting a considerable rise into 2013/2014.

“While most of that growth is around the mining industry, figures for the manufacturing industry are showing marginal increases,” Beath told Manufacturers’ Monthly.

“For the top end of town there are a number of different options. Once the client gets over the $1m mark, that’s when we would walk them through the options.

“It’s still a chattle mortgage product, but they would need a little more analysis into it, depending on the amount of money being invested,” Beath said.

Another popular option for manufacturers is debtor finance.

“It’s a great tool, and in recent years has been one of the fastest growing products in the business finance space and can be an exceptional tool for manufacturers looking for growth if they don’t have the working capital available.

Beath’s advice for manufacturers is shop around and to talk to a broker to make sure they are getting the best deal with debtor finance.

“It depends on what industry they are in, what spread of clients they have and the purpose of the funding,” he added.

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The engineer’s choice

Manufacturers’ Monthly MAY 2013 23 1/3 ad vertical ManMonthly 1

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EndeavourAWARDS

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Manufacturers set for a gala night With all Endeavour Awards’ nominations now back from the judges and the winners locked in, all will be unveiled this month in Melbourne. Alan Johnson reports.

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ust days away now, Mirrabella and former Pacific Brands the Endeavour Awards CEO Sue Morphett, now Chair of the presentation ceremony powerful lobby group Manufacturing promises once again to be Australia, plus comment via video manufacturing’s night of nights. from Industry Minister Greg Combet.

To be held this year on Thursday To keep the evening flowing, 9 May at Melbourne’s spectacular Shane Jacobson, probably best Sofitel Hotel on Collins Street, this known for his performance as the year’s event is set to be the best ever eponymous character Kenny Smyth as the awards celebrate the 10th in the 2006 film Kenny, will be year of recognising the cream of the Master of Ceremonies for the Australia’s manufacturing industry. evening.

With more than two hundred Cole Latimer, Managing Editor Australian manufacturers in of Manufacturers’ Monthly, said this attendance, coupled with two year’s awards received close to 100 stimulating and controversial nominations. keynote speakers, the evening is “Despite our manufacturing a must attend event for all those industry going through one of the involved with the manufacturing worst periods on record, this has “The record number of finalists, industry. been one of the best results in the running across 13 categories, This Ayear’s are awards D _ Mkeynote A N M Nspeakers P A MA Y _ 1 3 .decade p d f that P athe ge 1 have 3 / 0been 4 / 1 3 , reflects 1 1 : the 1 3strength : 2 1 and A Mdiversity A E D Tof Shadow Industry Minister Sophie running,” he said.

Australia’s manufacturing industry and proves to the doomsayers that the industry is alive and well, and is in fact booming in many areas.

“Each award celebrates the achievements of the people behind some of the country’s most innovative manufacturing companies.

“However, the Endeavour awards would not be possible without the continued support of our fantastic sponsors.

“This year, Manufacturers’ Monthly welcomed BlueScope Steel as both the principle sponsor of the 2013 Australian Endeavour Awards for excellence in Australian manufacturing, and the category sponsor for the Australian Steel Innovation Award.”

Other category sponsors include Atlas Copco, BOC Ltd, EFIC (Export Finance & Insurance Corporation), Enterprise Connect, ICN (Industry Capability Network), IFM Efector, Sick, and Spectra Training. Latimer also thanked this year’s judges; Dr Ivan Cole from the CSIRO; Mark Goodsell, NSW Director of the Australian Industry Group; Derek Lark, executive director of ICN; Dr John Blakemore from Blakemore Consulting; and Stephen Johnson from NSW TAFE. 24 MAY 2013 Manufacturers’ Monthly

“I’d also like to thank all manufacturers who took the time to enter and make these awards the success they truly are,” Latimer said.

“The Endeavour Awards are Australia’s largest industry awards program dedicated solely to Australia’s manufacturing industry, and with so many finalists in this year’s program we have had to split the short-listed finalists across two editions of the magazine.

“Last month we had the finalists for Environmental Solution of the Year Award, the Australian Steel Innovation Award, Enterprise Connect’s Significant Achievement Award, the Australian Industrial Product of the Year Award, the Exporter of the Year Award, the Lifetime Achievement, the Global Integration Award, and the Safety Scheme of the Year Award.

“This month, on the following pages, we have the finalists of the remaining five categories; the Technology Application of the Year Award, the Australian Consumer/ Trade Product of the Year Award, the Young Manufacturer of the Year Award, and the Most Innovative Company Award, with the winners to be announced in the June issue of Manufacturers’ Monthly.

“As we go to print, I understand there are still some tickets available for this prestigious event, which includes dinner. So if you are in Melbourne on the ninth, please give Rebecca Jelaca a call on 02 9422 8990 or email her at rebecca.jelaca@ cirrusmedia.com.au.

“This year our awards evening is set to be one of our most exciting yet, and coming as it does just months ahead of the election, our guest speakers are likely to have more than a little to say about the future of the industry in this country.

“Plus you will be able to celebrate the achievments of Australian manufacturers and see who is crowned Manufacturer of the Year.

“I hope to see you there,” Latimer said. manmonthly.com.au

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EndeavourAWARDS Consumer Product of the Year – 2013 Finalists

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Manufacturing for the people AUSTRALASIAN PLAYGROUNDS Australasian Playgrounds Pty Ltd is a leading designer and manufacturer of commercial playground equipment and outdoor gym equipment. Its new outdoor gym equipment range, Fit-for-Parks, is designed to build healthier communities through the provision of broadly accessible exercise equipment.

Fit-for_Parks is designed for placement in parks, housing estates, retirement villages and sporting facilities. Given its placement in open spaces it is designed to be highly durable. A ‘marine grade’ specification has been developed to ensure it withstands the harsh environment of the Australian coast.

The Fit-for-Parks range was designed input from exercise physiologists and is supported by easy to follow illustrated instructional signage supported by a comprehensive web site providing additional instructions and programs to users.

The equipment design incorporates an innovative system of concealed stoppers to limit range of movement and in doing so has eliminated a major hazard found with other outdoor gym equipment offers where stoppers are not concealed presenting significant risk of injury though dangerous crush points.

The range has been promoted through numerous conferences and exhibitions, demonstrations to many existing playground clients and has generated publicity for the range resulting in more than 20 projects being won in the past 9 months.

BOC Icebitzzz was initially developed by BOC’s parent company The Linde Group, it covers the physical dry ice product (solid CO2) for a diverse range of commercial and domestic cooling needs, plus concrete solutions for specific situations, and was born out of the need to provide regional and remote customers with good quality dry ice.

Icebitzzz creates application-specific dry ice concepts for cleaning processes, temperature-controlled transport processes, cooling solutions and more. Depending on the pressure and temperature, carbon dioxide (CO2) can occur in three states: gaseous, liquid, or solid. Dry ice is CO2 in its solid state. It is made by reducing the pressure and temperature of liquid CO2 in a controlled manner; this causes it to convert into a clean, white CO2 snow. Supply options include ICEBITZZZ Onsite for large volume dry ice users who want to manage their own supply by using an ICEBITZZZ ICE3 mobile dry ice production unit. Other supply solutions 26 MAY 2013 Manufacturers’ Monthly

MATRIX COMPOSITES & ENGINEERING Matrix Composites & Engineering is involved in the research, design, testing, manufacture and service of engineered products for use in the oil and gas, and resources industries. They manufacture technically advanced products using composite and polymer materials that originate from the aerospace and defence industries.

Matrix has developed HJ HEINZ a new distributed Heinz Australia launched buoyancy module Golden Circle Healthy system that supports Life Probiotic Juice in umbilicals, hoses, cables May 2012. The product and flexible risers used range is based on immune in the oil and gas industry support platform Probi with diameters ranging Defendum and established from 90 to 600mm. The a new category of probiotic DBM includes a light juices on the Australian weight, robust module market. The juice is a and a flexible riser combination of fruit juice clamp that can be used with a mix of probiotics across a range of flexible from Probi, and is the first risers and umbilicals. non-dairy probiotic food The internal clamp is the product on the Australian distinguishing element in market. Probi Defendum the DBM system, displaying is a combination of two benefits including specific strains of bacteria, reduces installation time, Lactobacillus plantarum light weight (15kg in HEAL9 and Lactobacillus comparison to others that paracasei 8700:2 – which are 80-100kgs), no lifting have been shown in large equipment required, clinical studies to prevent reduces risk of slippages Australia’s first non-dairy probiotic drink. colds, significantly reduce which causes pipe stress/ cold symptoms and shorten cold periods, that, breakages/environmental damage, and a short together, have been shown in clinical trials manufacturing lead time. to support the body’s natural defences when The driver for the development of taken daily. the product came from clients’ concerns This was the first probiotic juice on the about issues with DBM titanium clamps Australian market and the combination of which were extremely heavy (80-100kgs), juice with the unique benefits of probiotics expensive and often slipped along the (that deliver to an untapped consumer need) riser/umbilical causing un-even buoyancy are the recipe for success. uplift along the riser/umbilical, severe pipe Probi Defendum was one of a number of stress and eventual breakage causing mass strains tested in the low pH environment of environmental damage. Clients wanted and chilled juice. Many strains did not maintain were delivered a system easy to install using their efficacy throughout the product shelf minimal labour, was cost effective, did not life due to the acidic nature of fruit juice. slip and did not prolong the project’s timeline Probi Defendum maintained its efficacy due to product deficiencies. until the end of shelf life due to the strain itself and the unique preparation and dosing MODULAR WALL SYSTEMS procedure developed at Heinz Mill Park with Modular Wall Systems has, in 9 years, have the support of their supplier. become the market leading manufacturer include ICEBITZZZ Direct where dry ice produced at BOC regional retail sites and is delivered directly to large-volume users and ICEBITZZ Collect for small users available at Gas & Gear outlets.

The level of flexibility delivers distinct advantages to regional customers.

This snow can be used as is, or it can be compressed under high pressure to form blocks, slices, pellets, or nuggets.

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in its sector, visually pleasing acoustic and boundary walling solutions. Through consistent innovation, adaptation to market changes and an unfailing drive to set the highest product and customer service standards.

SlimWall Designer Fencing is its latest innovation in the typically fencing industry. The product’s key benefit is the way its designer look incorporates proven noise reduction qualities.

SlimWall Designer Fencing’s AcoustiMax 50 panels provide a 20+db or fourfold audible reduction in traffic or neighbourhood noise.

SlimWall also adds value to any property with a custom finish to meet the architectural integrity of the home. Both sides of the fence can be painted to meet the style of individual neighbours.

Longevity of the SlimWall fence is achieved through the tolerance within the posts & panel arrangement, which allows for future ground movement. This, in combination with the composite panel technology used provides a light weight, yet strong and rigid panel that will not crack, corrode or rot.

Since launching in October 2012, Modular’s active trade partner account purchase per month has increased from 13 to 20. The additional seven active accounts have resulted from 70 trade partners having been added to Modular Wall Systems’ customer base. This demonstrates an excited market interest in the new SlimWall product.

SEELY INTERNATIONAL Manufactured by Seeley International in its factory in Albury, New South Wales, Braemar has been producing heaters for more than 50 years.

In 2012, Braemar launched the world’s first and only non-condensing five star ducted gas heating range, which delivers a five star rating without producing condensate The five star non-condensing ducted gas heating range enables the traditional five star unit, which consists of three sections, to be reduced down to two, due to removal of the section where the condensate was produced and drained. The result is a five star unit which is one third smaller. The heating range is smaller, meaning a simpler and more cost-effective installation, and is the same size as the popular three and four star series.

Braemar’s five star non-condensing heating range was launched on February 21, 2012. Up until now, there has been strong demand from specialist air conditioning dealers, for highly energy-efficient ducted gas heaters, that are small and easy for installers to manoeuvere. The Braemar five star non-condensing range meets this demand.

The THM non-condensing five star ducted gas heating range has generated revenue of more than $2.3 million, since its launch in 2012.

WRIGHTWAY PRODUCTS Wrightway is a Lismore NSW based family business involved in the design, manufacture and marketing of a range of bin accessories, and has recently introduced the new Wrightway Bin. manmonthly.com.au

The Wrightway Bin allows the bin to be manoeuvred without effort (even in tight spaces), allows smaller stature operators to complete tasks without risking their wellbeing, and eliminates damage (and replacement expense) caused by dragging bins over non-slip flooring, without compromising the integrity of the bin itself.

The bin is raised above ground level and as it never has to be dragged at any stage of relocation, worn-through bases are prevented.

The addition of two small wheels under the front of the bin makes Designed to reduce noise levels. the standard wheelie-bin more manoeuvrable in tight spaces, protects the base of the bin, and eliminates the need for the operator to carry the weight of the contents and the bin.

The creation and implementation of a wheelie-bin which does not need to be tilted may not seem like a big thing in the whole scheme of things within the manufacturing world, but this innovative solution to everyday common problems experienced by thousands of employees across the board will impact on the health and well-being of Australia’s most valuable asset, its workers, to such a degree that it D is _a M product that A A N MB O KisNmore O V _than 1 2 worthy . p d fof national P a g e recognition 1 3 / 1 and 0 / 1 2 , industry acceptance.

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Endeavour Young Manufacturer of the Year – 2013 Finalists

The industry’s future leaders and chiefs RUSSELL BYRNE Since his appointment as operations director in 2007, Russell Byrne involvement and leadership in the expansion of Archer Enterprises has seen him nominated for the Young Manufacturer of the Year award.

According to the company “Russell’s contribution has been exponential, with the standout contribution being the multiple successful comprehensive and fully integrated implementations of advanced machine tool technologies, renewing and broadening the organisation’s manufacturing capabilities”.

Specifically Byrne has been the driving force behind Archer Enterprises taking the machining capability of the business from the basic and older 2-axis CNC lathes and 3-axis CNC machining centres to the more current modern multi-axis CNC multi-tasking machine tools, including fully integrated CAD/CAM capability, skipping everything in between.

At the same time as delivering increased capability and process improvements he was able to keep up wit the normal and growing production demands of the business.

His implementations have directly lead to Archer Enterprises increasing machining production capacity by 200 per cent, including keeping output finished parts in an accumulated and orderly manner that sees no damage from part-to-part contact on output.

This increase is on top of a 66 per cent improvement on cycle time concerning the tool change process across three tools.

Due to Byrne’s improvement and leadership the business is now in a position where it can make production parts for either its own products or outside sub-contract work.

MATTHEW ARBLASTER For his role in ensuring high quality, production targets, and continuous improvements at his company’s site, Bayer’s Matthew Arblaster has been 28 MAY 2013 Manufacturers’ Monthly

nominated as the Young Manufacturer of the Year.

As production supervisor, Arblaster has overall management for the production department which includes 22 staff across 3 shifts working over 24 hours as well as the maintenance team and other associated teams.

To drive plant efficiency he has concentrated on operator and team development and ensures the shift team leaders are skilled in mentoring their teams.

Arblaster has championed the Bayer Australian Lean effort on the site, running classroom lessons on Lean theory before coaching teams implementing Lean on the floor.

Focus has been placed into 5S which has improved housekeeping, safety and efficiency.

The overall results of these efforts have increased plant efficacy 15 per cent as well as significantly improved staff engagement and culture.

In addition to production Arblaster also manages plant reliability, where he emphasis preventative and predictive maintenance planning by evaluating the criticality of the equipment and the impact of failure.

This resulted in controlling cost without exposing the plant to large costly failures.

He also placed focus on the human side of maintenance and working with HR, restructured the department to a self-managing team saving cost and improving output.

As a result downtime due to breakdowns has reduced by 70 per cent and total plant reliability, which is bench-marked against all Bayer plants globally increased by 8 per cent.

JASON OLIVER For his leadership at the helm of Black Widow Enterprises, a 4WD accessories manufacturer, Jason Oliver has been nominated as the Young Manufacturer of the Year.

Oliver is the CEO, a 29 year old who is MBA qualified. He has been in this role for 18 months after starting at manmonthly.com.au

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Black Widow as operations manager over 7 years ago.

His key achievements include introducing Lean Manufacturing into the production process; instigating and implementing ISO triple certification (ISO9001, 14001 and 18001.

Oliver was also responsible for introducing a gateway process into the new product development process, as well as the implementation of an ERP system at the company.

As operations manager he has achieved an increase in productivity by 40 per cent, a decrease in lead time by 73 per cent and a decrease in average stock holdings by a quarter.

As CEO he has seen sales increase by more than a fifth in the past year, the release of five new products including a new commercial range, introduced a management structure and released Black Widow products into new export markets.

Oliver has also been recognised for these achievements by other associations, winning the Victorian Government Manufacturing Hall of Fame Young Manufacturer of the Year award and the AAAA Kim Aunger Young Achiever award.

He has also been asked to speak at the Lean Summit and AME National Conference 2013.

JASON HAWLEY For a small business such as Green Insulation, Jason Hawley is a critical element of its team, and has been nominated as the Young Manufacturer of the Year.

Hawley provides engineering support to manufacturing as well as sales and marketing.

As any company experiencing rapid growth, Hawley’s role is quite varied and at times demanding.

He is responsible for ensuring compliance with relevant standards, tracking and improving product specification and quality, implementing continual improvement within the manufacturing environment, leading technical support, and driving innovation in product development and research.

He has recently filed for his first innovation patent, which is expected to provide significant financial and market capitalisation to the business.

His ability to think intuitively and creatively has resulted in a logical, manmonthly.com.au

useful solution that the company estimates will add significantly to the company’s overall sales.

He has also successfully implemented a system for recycling waste products in Green Insulation’s manufacturing process, reducing environmental impact and creating an untapped value stream in the order of magnitude of the average yearly salary.

Hawley is also involved in external community activities and sits on the board of Youth Without Borders, a youth-focused non-profit.

This is not only an important focus for him, but directly relates to our business’ corporate social responsibility policy and demonstrates his ability to understand company strategy.

ERIN McMULLEN In taking on a number of challenges at Unilever and leading the implementation of process changes in the business, Erin McMullen has been nominated as the Young Manufacturer of the Year.

McMullen has recently completed three years as a graduate in the Unilever Future Leaders Programme (UFLP).

Throughout the UFLP she was given the opportunity to take on various, challenging roles across different functional and operational areas of the business including materials planner, process engineer, and production leader for Deodorants in addition to a six month rotation in sales and marketing.

Following completion of the programme, Erin was promoted to the role of engineering manager.

In this role she is responsible for all aspects of engineering activities of the factory, including pillar leader for focused improvement, planned maintenance, and early equipment management.

As engineering manager of Unilever’s North Rocks factory, she has help shape the high performance culture of the site.

Through her leadership and in driving the continuous improvement mindset McMullen is helping Unilever’s North Rocks manufacturing site deliver safety excellence (ZERO Accident), quality excellence, improved productivity, and cost reduction.

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EndeavourAWARDS Technology Application of the Year – 2013 Finalists

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Manufacturing in action BOC BOC has redefined the delivery of solutions to Australian manufacturing with the roll out of its new Mini Bulk Service Offer and Mix Onsite which is specifically tailored for the welding sector.

The unique technology offers significant economic, production and space-saving advantages.

The system also helps to reduce the risk of handling injuries that are often associated with manually changing over cylinder packs.

The system is innovative in that it is delivered by a small rigid road tanker into compact high pressure vessels with an integrated process vapouriser.

High pressure filling technology reduces and minimises depressurisation losses of the vessel and the size of the delivery vehicle means tanker access is generally not a problem.

Vessel installation is also much simpler than a standard bulk installation.

BRICKWOOD HOLDINGS Brickwood Holdings is a leading manufacturer of plastic packaging products specialising in the blow moulding of plastic containers and closures, primarily for the beverage industry (principally dairy and fruit juice fillers) and operate facilities across 4 sites in Australia.

BH had reached full capacity on many of the production lines in the Cheltenham plant.

This created serious challenges meeting growing customer demands, especially during peak supply periods.

BH engaged Melbourne based OFS, a leader in real-time productivity improvement analytics for manufacturing.

The solution scope included replacing manual worksheets, data collection and processing along with the associated clunky, inaccurate Excel reports which resulted in effortless real time feedback to operators and management, the ability to quickly hone in on recurring problems and something to give the entire operation extra momentum.

BH has achieved a step change in its Overall Equipment Effectiveness (OEE) and efficiency ratings on all machines, massive increase in waste reduction and significant increase in run speed.

DELTA SHELVING SYSTEMS The goals for its EXPRESSIT project were to redefine the way Delta sold and supported Configure-To-Order (CTO) products, enable users to configure Delta products to meet 30 MAY 2013 Manufacturers’ Monthly

their specific requirements in a streamlined manner, and ensure that configured products meet the independent compliance standards required of Delta products, such as ANSI MH26.2-2007 for MantaMESH Wire Decking.

In specific terms EXPRESSIT has accomplished a 50 per cent reduction in sales administration and processing overhead; a 10 per cent reduction of indirect labour; a 61 per cent reduction of direct labour; and an 85 per cent reduction of engineering overhead.

As a result, Delta has been able to extend cost savings to EXPRESSIT users through reductions of over 20 per cent on standard products.

Inventory costs and warehousing requirements have been reduced through the adoption of a “Just In Time” inventory model previously unachievable because of CTO complications.

HJ HEINZ Heinz Australia launched Golden Circle Healthy Life Probiotic Juice in May 2012. The range is based on immune support platform Probi Defendum and established a new category of probiotic juices on the Australian market. It is a combination of fruit juice with a mix of probiotics from Probi, and is the first non-dairy probiotic food product on the Australian market.

As the first non-dairy probiotic beverage in Australia the technical challenges for the manufacturing team were significant covering supply chain, quality and manufacturing.

Not only were they required to carry out an extensive validation program, never before done in juice in Australia, they had to implement procedures and protocols to ensure the safe handling and storage of the probiotic strains at all times.

RPC TECHNOLOGIES Responding to market demand, RPC Technologies has developed a new innovative fire retardant and anti-static (FRAS) light weight mine vent duct (or LWMVD) made out of carbon fibre.

This product is a new generation of mine vent duct, which is lighter and stronger than traditional solutions, including fibreglass ducts. RPC designed and developed a foamribbed FRAS mine vent duct using carbon fibres. This new product can withstand a higher vacuum and is half the weight of its fibreglass counterpart.

SOLARONE MARKETING The FrontLiners project was created from

requests from a number of mining companies for a solar powered light that could withstand the mine site. The Initially SolarOne designed prototypes which were used at Mt Keith for BHP to prove the functionality of the technology under the prevailing conditions.

From these tests another model was made to determine ease of installations and visibility.

A final field trial was then conducted that was run for 6 months after which it was determined that the product met the design specification. A final manufacturing trial-run was made to complete the fabrication and assembly processes and later completed in September 2012.

The FrontLiners is now available for sales and in being promoted successfully with “thumbs up” from all concerned.

T.W. WOODS GROUP T.W. Woods’ innovative Australian made coal chutes have been recognised for the Technology Application of The Year award.

The chutes are smooth flowing low-height transfer chute are built to overcome space, spillage and conveyor bulking problems common in coal mining and coal handling facilities.

All of the material used in production of the chutes is Australian.

The chromium carbide material used in construction is either a Bradken Product (Duaplate) or the Arcoplate is made by Alloysteels.

Both are manufactured in Western Australia. The design has already been proven service with some of Australia’s leading coal producers. A bonus of the design also is that it has been quality engineered in T.W. Woods’ own extensive metal working facilities to easily outlast conventional designs and far exceed typical warranties.

The design enhances cost-efficiencies in the production of coal, of which Australia produces more than 500 million tons a year and is the world’s largest exporter by proportion of production. Exports alone earn more than $50 billion a year. The company’s low-height transfer chute features a conical head developed by mining specialist designers to maintain high volume high flow rates when conveyors change direction either underground or on the surface.

“The design more than covers what we do. It’s a robust simple design that’s pretty wear resistant and easy to adjust for our operations, which involve about 1200 tons and hour with throughput containing lumps up to 300-400mm,” the company said. manmonthly.com.au

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EndeavourAWARDS Most Innovative Company – 2013 Finalists

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Dedication to innovation CONFOIL Confoil has implemented a new holistic Return to Work Program with the immediate focus on caring for the injured worker from the moment the injury occurred to reducing the number of Lost Time Injuries.

Recognising the high number of mature aged workers (in 2012 one employee received their 35 year Service Award) it included personal injuries as well as work-related injuries in its policy, demonstrating the company’s commitment to its employees’ total welfare.

SEELEY INTERNATIONAL Seeley International is a highly innovative company and for 40 years has continued to develop ground-breaking technological innovations. Seeley International has continued to grow year on year and build on its position as Australian market leader in the evaporative air conditioning and ducted gas heating markets. The company has a strong desire to grow significantly by growing sales of innovative new products into new and existing markets.

BALTIMORE AIRCOIL What differentiates Baltimore Aircoil is Vision Blue – a document that has been created outlining BAC’s goal to become Carbon Neutral by the year 2020.

In the past 12 months alone it has already shown an 11 per cent reduction, through energy saving initiatives.

An analysis of BAC’s freight companies enabled BAC to assess their costs and processes. The result being, high savings were made for the company. Through networking, information on how this was done was shared fellow of 1 .members A D _ M Athen N MA D F J with UN_ 1 0 pdf P athe ge 1 manufacturing group CCMC.

DOWNER RAIL The key to Downer’s innovation is the legacy it has built to leave behind at its Cardiff facility: a highly trained team of manufacturing professionals armed with the tools for taking the industry into the 21st century. The team at Cardiff can apply the lean manufacturing methodologies taught by Downer to any future manufacturing project they are part of.

Over the next 10 years Downer intends to adapt its business model to ensure sustainability in a changing marketplace.

It will achieve this by shifting its focus to growing its service revenue.

DUEBEL Deubel Bicycles started early January 2009 with the goal to successfully design and manufacture in Australia outstanding full suspended mountain bike frames. To date it has only 2 employees yet since production has managed and sponsored racing teams using the very same frame it designed and manufactured, the Deubel 2UP frame. These frames are currently 90% made in Australia.

The company is always innovating and coming up with new designs to make the Deubel 2UP even more versatile than now and there are even plans to produce a carbon fibre frame manufactured in Sydney.

SAGE AUTOMATION SAGE designs and constructs automation and industrial control systems as well as provides specialised professional technical support and process improvement for a diverse range of industries including, manufacturing, defence, infrastructure, resources and utilities.

In 2010, SAGE Automation participated in the 20th South Australian Thinker-inResidence program.

A key outcome was the $1M investment SAGE made throughout 2011/towards creating a world class manufacturing capability.

ANCA Innovation has been the competitive advantage of ANCA since the company was launched. ANCA launched the first Australian made CNC and when ANCA’s first CNC tool grinder was launched in the US in 1986 there was only one similar brand in the US. From the beginning, ANCA has done things that haven’t been done before. They were first to market with game changing product features such as true 3D simulation and Windows style Graphical Users Interface. ANCA is on a mission for continuous improvement in everything it does.

WASCA WASCA sees itself not as a supplier of washers, but a provider of solutions.

WASCA will further enhance its technology to ensure it is always ready to provide innovative solutions.

WASCA’s plan for the next 10 years is to continue to supply washers and stamped components and provide solutions to all the of 9industries, 1 , 0 at 3 2 forefront 6 / 0 5 / 1remaining 0 1 1 : 0 0 AM design and manufacture in its field.

RPC TECHNOLOGIES Responding to market demand, RPC Technologies has developed a new innovative Fire Retardant and Anti-Static (FRAS) Light Weight Mine Vent Duct (or LWMVD) made out of carbon fibre. This product is a new generation of Mine Vent Duct, which is lighter and stronger than traditional solutions. The plans for the next 10 years are to strengthen the RPC Brand, strength service and support to the Australian market.

sales

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Preview NMW, AUSTECH: 7-10 MAY 2013

The industry on show The latest developments and technology will be showcased at National Manufacturing Week.

T

hat time of year is upon us where Australia’s manufacturing industry gathers together to see the latest developments and innovations – National Manufacturing Week.

The event recently won the praise of prime minister Julia Gillard, who stated that “National Manufacturing Week 2013 will showcase Australian manufacturing industries to the world and encourage Australian manufacturers to develop innovative and internationally leading products.

“This is important because manufacturing makes a significant contribution to a broad-based and diversified economy, helping drive innovation in industry.

“The manufacturing industry is currently facing some tough challenges including a high exchange rate, rapid technological change and increased global competition.

However, the Asian Century also offers unique opportunities to renew Australia’s productivity drive and to become more competitive in providing high-quality manufacturing products. Australian manufacturers will be advantaged by a wider set of business opportunities as Asian incomes rise and global value chains expand. Through focusing on their areas of expertise, building niche markets and joining regional value chains, Australia’s manufacturers can build their A D _ on MA N Msuccess.”

ROBAP R_ 1 3 Paul Baker, the exhibition director

Austech, the welding and machining show, will be held in conjunction with NMW. for NMW 2013 added that the event meet representatives from emerging has made its mark on the industry industry sectors to discuss areas of over the last 14 years. potential synergy.

“NMW is the event that brings “Overall, NMW 2013 will be an industry together under one roof. As important event for industry – and well as providing access to products we are extremely pleased to have and services from more than 300 the Prime Minister’s praise for it,” exhibitors, NMW is the forum in Baker said. which manufacturers meet with Coupled with NMW will also suppliers, and each other, to seek out be the Austech Exhibition, which new solutions for growth. is Australia’s premier advanced “NMW 2013 will be no exception. precision manufacturing and Alongside the product showcase, this machine tool exhibition, and also year’s event offers a rolling program the only annual show in the nation at:the -of product P a g edemonstrations, 1 2 0 1 3 - and 0 3 - 1 1 T targeted 1 8 : 0 0 2 6metalworking, + 1 1 : 0 0 opportunities for manufacturers to machine tool, and ancillary market.

There will be a number of different focuses at NMW, in particular ERP, Food manufacturing, and the small, but growing Defence industry.

Mining will also be playing a role; Baker stating that “IBISWorld estimates that there will be significant annual growth in the manufacture of mining and construction machinery alone – let alone the allied products and services required to keep resources sector operations on track – making it a valuable sector for industry suppliers”.

The growth of ERP at the show also highlights the importance of NMW’s Information Technology Product.

According to exhibition director Paul Baker “we surveyed 400 manufacturing industry personnel on their business outlook – and their consistent feedback was that they see opportunities arising from areas such as technological innovation, as well as cost efficiency & optimisation – all of which are heavily reliant on information systems.

“With this in mind, we are excited to see that several of industry’s most significant ERP providers will be unveiling new capabilities and platforms at NMW 2013,” Baker said.

“NMW 2013 will also include live demonstrations from exhibitors whose products and services help companies automate and/or optimise their processes,” he added.

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manmonthly.com.au

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MA0513_034.pdf

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NMW Preview 7-10 MAY 2013

Welding robots

Boosting productivity

LED drivers

ABB’s IRB 1520ID robot will on highlighted on stand 3517 at NMW. These latest welding robots provide safer, high precision arc welding. Simple installation and commissioning ensures Increased safety, the robot is operational motion control and quickly after installation. welding reliability.

The compact robot requires minimum workshop space and the slim upper arm design allows easy access to narrow spaces. The design of integrated hose package and welding cablings ensures higher production uptime and lower maintenance costs. Fast restart after weld stop, optional automatic collision detection and BullsEye torch calibration provide increased welding reliability. ABB’s unique motion control increases welding quality and combined with low manipulator weight ensures energy efficiency. ABB is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 145,000 people.

ABB MA 0 5 1 3 _ 0 0 0 _ F L I 1 2 0 1 31300 - 0782 4 527 - 1 0 www.abbaustralia.com.au

AT this year’s NMW, UV Pacific will introduce new technology on stand 1325 It will unveil its Thinky Planetary Centrifugal Mixer which is designed for mixing adhesives, epoxies, silver pastes UV curing materials and This mixing process equipment will be on show. for multiple liquids and powders is a no-touch, no-blade batch mixing process the employs rotational forces of over 400Gs of acceleration to achieve uniform mixing and degassing.

It is also using the event to release Honle bluepoint LED UV Spot Lamps for bonding, fixing or encapsulating in the electronics, optical and medical sectors. These lamps are also used in fluorescence stimulation, high intensive UV irradiation in chemical, biological and pharmaceutical sectors. The units are Clean Room capable.

This unit takes LED UV light sources into the heart of the UVA range with options for heads with 365, 385 and 405 nm wavelengths all supplied from the same power supply. The Bluepoint unit can run up to 4 heads with up to 4 operation switches that can be programmed to control any combination of heads.

UV Pacific 08 8277 9721 T0 9 : 5 1 : 5 4 + 1 0 : 0 0 www.uvpacific.com

AT NMW this year, ADM Instrument Engineering is launching the Energy Safe approved Meanwell PCD Series of Constant Current LED drivers complete with 1.8m cable and mains AU plug on stand 3209.

These new units add to the large range of quality LED Drivers supplied by Meanwell for LED lighting applications.

ADM Instrument Engineering holds the largest stock of Mean Well power supplies in Australia as well as being the Australian agents for the international companies; Burster (sensors and measurement, Germany), Unimeasure (linear position transducers, USA), Midori Precisions (potentiometers, Japan), Lutron Enterprise (test and measurement, Taiwan), plus other process control suppliers.

ADM Instrument Engineering 03 9551 6922 www.admtech.com.au

www.flir.com

FLIR Systems Pty Ltd. Free Call AU: 1300 729 987 NZ: 0800 785 492 Email: info@flir.com.au

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

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

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

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

PoE Power over Ethernet (PoE )

Communication and power supplied with only one cable.

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

HIGH SENSITIVITY < 50 mK

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

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

GigE Vision™ standard compatibility

Camera interface standard developed using the Gigabit Ethernet communication protocol.

GenICam™ protocol support Disclaimer: Images for illustrative purposes only, subject to change. ISO No. FLIR20871

34 MAY 2013 Manufacturers’ Monthly

Provides a generic programming interface for all types of cameras.

manmonthly.com.au

MA0513_000_ZHA

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MA0513_036.pdf

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NMW Preview 7-10 MAY 2013

Weld cleaning systems

Test and measurement

eNsItech will feature Bestech Australia was founded in 2002 the tIG Brush stainless in Melbourne and is now one of the fastest steel Weld cleaning growing companies in Australia and New system on stand 1719.

Zealand; distributing and manufacturing sensors, It is an easy-to-use, transducers, signal conditioners and test systems portable kit which for measurement of physical parameters like cleans stainless steel Leak, Displacement, tilt, Pressure, temperature, welds and restores strain, Force, torque, Vibration, Viscosity, Level, stainless steel surfaces Flow, Material Properties and thermal Analysis. quickly, safely efficiently Bestech Australia also carries a full range of and cost-effectively. technical trainers and programmes for electrical the system uses and mechanical engineering training.

Portable stainless a proprietary electroIt will be highlighting all of these technologies steel weld cleaners. chemical process, on stand 3423 at NMW. combining low-toxicity fluids with a patented power supply and unique brush design to produce superior results. It provides one-step cleaning and passivation (tested to international standards), requires little user training, and gives welders complete control over the surface finishing of their work.

API srl is bringing two new products – from its In most applications, the tIG Brush eliminates the need for homeland, Italy – to stand 1913 at NMW this year. the highly toxic and hazardous acids (“pickling paste”) that were these latest products include cylinders, such traditionally used for this operation. the tIG Brush stainless steel as the new series of cylinders confirming to IsO Weld cleaning system has revolutionised weld cleaning and surface 15552, from 32 to 125mm diameter. finishing, enabling users to carry out the previously difficult tasks of Responding to customer demand, these new weld cleaning and surface finishing economically and without risk to cylinders feature lighter end caps and tubes, the environment. competitively priced, and with all the quality of Ensitech API’s traditional range. will0 also its_5latest valves A D _ MA N MA U S MA Y _ 1 3 1 20204735 1 3 7700 - 0 3 - 2API 0 T 8 : display 2 3A : D 5 M +A 1N 1M : S 0 which U 0PAPR_ www.tigbrush.com includes the new series of A2 valves and spool

Bestech Australia supplies state of the art instruments from world leading manufacturers, and provides quality customer service. Bestech delivers a wide range of products for university and research laboratories as well as various applications in manufacturing, military, mining, steel, rail, construction, automotive, chemical, pharmaceutical, food and water industries.

Besteh also offers simple electronic and mechanical design, repair and calibration for a complete solution for client applications.

Bestech 03 9540 5100 www.bestech.com.au

Pneumatic cylinders and valves valves, for multi-pole connection on an island sub-base. these valves feature reduced overall dimensions and high flow rates, plus a range of other features including low power consumption, fast and practical assembly.

API invites NMW visitors to the API stand for further information about these new ranges and API’s broader range of pneumatic products.

API Pneumatic 1 3 1 2michela.caprioli@api-pneumatic.com 0 1 3 - 0 3 - 1 1 T1 8 : 2 7 : 5 3 + 1 1 : 0 www.api-pneumatic.com

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manmonthly.com.au

AD_MANMHEN2MAY_13

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1

2013-03-26T11:40:16+11:00

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MA0513_038.pdf

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Stand 1000 1002 1005 1009 1010 1013 1015 1100 1105 1107 1109 1113 1115 1202 1205 1207 1209 1210 1213 1215 1300 1302 1305 1309 1310 1311 1313 1314 1325 1400 1405 1409 1410 1411 1413 1417 1419 1421 1423 1500 1505 1509 1510 1511 1513 1514 1517 1518 1520

Company Radical Torque Solutions Pty Ltd Siderval SpA Roehlen Industries Pty Ltd Concept Fasteners Pty Ltd Testequip Pty Ltd Bossard Australia Pty Ltd Kemet Australia Pty Ltd PLC Hardware 3D Systems NOF Metal Coatings Asia Pacific Co., Ltd Semikron Engineers Media Changhua Diecasting Ind. Co. Ltd Adept Turnkey Pty Ltd White International Pty Ltd KAP Components Australia Pty Ltd Mighty 8 Stores Pty. Ltd SCR International Australia Pty Ltd Supreme Steel Products Ltd Heat Treatment Australia Ezi - Duct Pty Ltd Staetite Fasteners Moreton Bay Regional Council CMEC (China) CMEC (China) Cope Air Technologies ELGI Pneumatics Direct Australia UV Pacific CMEC (China) CMEC (China) CMEC (China) CMEC (China) SEC Plating P/L Integrated Emergency & Industrial Equipment Ace Metal Treatment Services Pty Ltd CMI Springs Industrial Measurement Solutions Pty Ltd Trader International Group (ACP Magazines) CMEC (China) CMEC (China) CMEC (China) CMEC (China) Kelvindale Products Pty Ltd M.T.A Australasia Pty. Ltd. Suhner Australia Pty Ltd Tools ADasco D Machine _ LM HBUL F EB CMEC (China) Southern Cross Lubes

Stand 1521 1522 1525 1600 1605 1609 1610 1613 1614 1617 1618 1620 1700 1705 1709 1711 1713 1715 1717 1721 1723 1725 1800 1805 1809 1817 1819

_

1900 1905 1909 1911 1913 1914 1915 1917 1923 2000 2002 2005 2007 2009 2010 2013 2014 2015 12021 3 2025 2100

.

Company GBOS Dragon Sourcing International Metal Spray Supplies Australia CMEC (China) CMEC (China) CMEC (China) CMEC (China) Clic Australia Rostech Surface Finishing Pty Ltd Mackay Consolidated Industries Pty Ltd CMEC (China) Aufast International PTY LTD CMEC (China) CMEC (China) CMEC (China) Omron Electronics Sullair Aust Pty Ltd Advanced Technology Pneumatics CMEC (China) New Fire Co.,Ltd Metal Science Technologies Pty Ltd Techspan Australia CMEC (China) CMEC (China) CMEC (China) CMEC (China) Manufacturing Electronic Services/Welding Equipment Sales & Service Pty Ltd CMEC (China) CMEC (China) CMEC (China) CGB Precision Products API Pneumatic Dotech Better Springs Gullco International Pty Ltd Fein Power Tools ABSS Cirrus Media Pty limited Nitto Kohki Australia Woodland Metal Spinning China Manufacturing KLINGSPOR Australia Pty Ltd ITW Polymers & Fluids Risen Machinery Co. PTY LTD Australia Hanke Pty Ltd Tanjant p d Tool f Co PtyPLtda g e 1 Tooltechnic Systems (AUST) PTY LTD Blackwoods

Stand 2108

6 /

2113 2114 2117 2119 2121 2125 2213 2221 2225 2300 2302 2303 2305 2309 2311 2313 2315 2317 2322 2405 2407 2408 2409 2410 2413 2500 2505 2507 2509 2511 2513 2514 2515 2517 2522 2523 2602 2605 2611 2614 2622 2700 2702 2705 27072 1 2709 2711

Company Department of Industry, Innovation, Science and Research and Tertiary Education EnDuraSim Powerbox Australia Hypertherm, Inc Supagas Pty Ltd SAI Global CST Smart Steel Cryonomic Midway Metals Global Track Australia Pty Ltd Pipeline Dynamics Wuhan Restar Materials Handling QHDC Australia Millsom Hoists Pty Ltd Unirack Cold Jet Australia Revolution Materials - BIO - Chem Vative Pferd Australia Pty Ltd Ensitech Southern Cross Compressors Australia Pty Ltd Conon Pty Ltd Australian Inhibitor Pty Ltd The Supply Chain & Logistics Assoc of Australia Kockums Bulk Systems Pty Ltd Zhenfa Solar Power Australia Pty Ltd Sage Pronto Software Macpro Technologies Amazing Super Health Advanced Protective Technologies Centralised Pumping Systems Australian Taxation Office Chase Performance Smenco Pty Ltd Welding Technology Institute of Aust MITECH Co.,Ltd. Star Business Solutions ERP Software Luxottica Retail Obara Australia Binzel Pty Ltd Epicor Software Syspro Australia Pty Ltd ECi M1 / Intercad 1 2Pty, Ltd 3 : 3 5 P M General Marking Australia Sun Industries

Stand

Company

Stand

2713 2714 2715 2717 2722 2800 2802 2805 2806 2807 2809 2810 2811 2814 2815 2900 2905

Laboratory Systems Group JYX Group Pty Ltd Vostro Institute BOC Limited BOC Limited Cincom Systems Edge Software Altair Industry Update Magazine Aware Business Systems Pty Ltd Flexicon Australia Pty Ltd National Safety Council of Australia Ltd A1 Testing & Tagging Pty Ltd CMEC (China) Jubilee Spring Co. Cutler Brands TAITRA (Taiwan External Trade Development Council HW Technologies CMEC (China) PLC Options Saint-Gobain Abrasives Welding & Machinery Australia Tesuco UBLeds Co. Ltd Soanar Portable Analytical Solutions Pty Ltd CMEC (China) Dawntronic Australia Pty Ltd Sheffield Blades Pty Ltd Camfil Farr Australia Oliver Technologies Pty Ltd Duons TAITRA (Taiwan External Trade Development Council Brainchild Electronic Co., Ltd CMEC (China) Torema Australia Pty Ltd CMEC (China) Sunlec International Blackwoods Blackwoods TAITRA (Taiwan External Trade Development Council ADM Instrument Engineering Permark Industries (NZ) TAITRA (Taiwan External Trade Development Council BAC Systems Pty Ltd

3311 3313 3314 3315 3317 3318 3319 3410 3413 3414 3415 3417 3418 3422 3423 3505

2911 2913 2914 2917 2919 2922 3000 3010 3011 3014 3015 3019 3022 3025 3100 3105 3109 3111 3113 3114 3115 3117 3121 3202 3209 3215 3305 3309

Company

White Industries Australian Calibrating Services (A’sia) Pty Ltd IICA Conference Secretariat Eastern Pneumatics + Hydraulics Pty Ltd Lavender Composites Duromer Products Pacific Urethanes CMEC (China) Oceanic Controls HBM Australia Marsh Springs & Metal Products VGL Impex P/L Composites Australia Vision Systems Engineering (Aust) Pty Ltd Bestech Australia Pty Ltd TAITRA (Taiwan External Trade Development Council 3507 Modular Components & Automation 3509 Advanced Robotics Australia 3511 Edmund Optics Singapore 3513 Apex Dynamics Australia Pty Ltd 3514 Global Automation Asia-Pacific Pty Ltd 3517 ABB Australia Pty Ltd 3520 Leussink Engineering Pty Ltd 3522 Bosch Rexroth Pty Ltd 3605 Radius Benders Pty Ltd 3609 Ronson Gears Pty Ltd 3613 Daanet Pty Ltd 3622 Rose Plastic (Kunshan) Co., Ltd 3705 Blue Water Engineering Pty Ltd 3707 EBM Papst 3709 Furnace Engineering Pty Ltd 3710 Tecno Platform 3713 Boscotek Industrial Storage 3717 Treotham Automation Pty Ltd 3721 Trilogiq Australia Cleantech Lounge Department of Industry, Innovation, Science and Research and Tertiary Education Demo A Techspan Australia Demo B CST Smart Steel Demo C Ensitech Demo D Pferd Australia Pty Ltd Demo F Binzel Pty Ltd Demo G Smenco Pty Ltd Demo H BOC Limited Demo I Saint-Gobain Abrasives Demo L Manufacturing Electronic Services/Welding Equipment Sales & Service Pty Ltd

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38 MAY 2013 Manufacturers’ Monthly

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MA0513_039.pdf

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manmonthly.com.au

Manufacturers’ Monthly MAY 2013 39

MA0513_040.pdf

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Austech Preview

7-10 may 2013

Laser machining Raymax will be demonstrating a range of new developments and machinery at austech in may.

For micromachining applications, Raymax will be showcasing new developments in JDSU’s high-power diode lasers. Since there is no physical contact between the laser and the workpiece, the advantages are readily apparent: no tool wear, no tool changes, and no tool breaking. In addition, lasers assist in the miniaturisation process by providing a highly focused beam that can process very small feature sizes.

This focused beam has the benefit of reducing thermal effects during material processing enabling thinner and more delicate processing capabilities. For marking and engraving, Raymax offers FOBa’s range of compact high-performance marking and engraving manual laser workstations.

The compact manual laser workstation FOBa m1000 on display is a small desktop machine featuring an automatic Z-axis for flexible use.

The machines are easily integrated into the workplace and are suitable for laser-aided processing Plastic welding and machining will be on display. in the auto parts industry, the marking of parts such as tools and metal components as well as medical Raymax will also host German made diode lasers technology. from Laserline.

These workstations are also used for marking plastics another application on show is laser cladding, the across a number AD _ M A NofMindustries R E N M where A Y _ batching 1 3 . p is df P a g process e 1 of3adding / 0 4 a/ pure 1 3 metal , 1or1 an : alloy 1 4 :in3powder 1 AM required for traceability marks. form to a component damaged by wear, corrosion, or

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abrasion, thus restoring parts to their original strength and capacity.

Raymax 02 9979 7646 AEDT www.raymax.com.au

...build tomorrow at: See us h 2013 Austec 522B Stand

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40 MAY 2013 Manufacturers’ Monthly

3/27/2013 10:32:42 AM

manmonthly.com.au

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Austech Preview 7-10 MAY 2013

3D printing Once considered science fiction, the ability to do 3D printing has long become a reality, especially in the manufacturing world.

Here, the trend is going to pick up steam in 2013, and Tasman Machinery will use the opportunity of the upcoming Austech exhibition to demonstrate the latest technology Additive manufacturing advancements. on show.

As an alternative to conventional subtractive manufacturing methods such as milling or turning, Tasman Machinery will be displaying a full suite of additive manufacturing technologies, including both FDM from Stratasys and Polyjet technologies from Objet.

Tasman will have a Stratasys Fortus 400mc 3D Production System onsite, as well as workholding tools or end-use parts.

Tasman Machinery www.tasmanmachinery.com.au

Screws and bolts.

FOR ALL THIS AND MORE

Fasteners Fuji Fasteners is an Australian cold forming manufacturer and importer of quality fasteners â&#x20AC;&#x201C; screws, bolts, lock nuts, wheel studs, solid rivets, headed pins, sems assemblies and weld studs.

Visitors to the Fuji Fasteners stand at Austech 2013, will see an extensive manmonthly.com.au

range of fastener examples produced by Fuji Fasteners at its South Dandenong factory.

The stand will be manned by the company directors.

Fuji Fasteners 03 9706 6652 www.fujifasteners.com.au

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CNC lathes HS CNC Machines together with Qumac Engineering Services will showcase for the first time in Australia the Feeler HT-30Y multi-axis CNC lathe, which has become the company’s number one selling multi-axis centre.

The machine features C & Y axis milling capabilities combined with a built-in spindle motor and a 12-station BMT-60 turret with a powerful milling function, as well as a Fanuc 31i controller.

Mal Durdin, Director of HS CNC Machines, representatives of Qumac Engineering Services Suitable for a and technical experts from the company’s range of sheetmetal overseas suppliers will be on hand at stand 579 bending applications. over the four days of Austech 2013, which will run from 7 to 10 May 2013 at the Melbourne Exhibition Centre.

“The relationship between HS CNC and the LEADINg Australian sheetmetal equipment supplier, Sheetmetal Taiwanese group spans more than 15 years, Machinery, will once again showcase its innovative range of providing Australian customers with long-term bending, folding, laser cutting and materials handling solutions support and knowledge,” Durdin says. to the manufacturing industry at Austech 2013 in Melbourne, “We are excited to be able to demonstrate the Stand 582. Sheetmetal Machinery Australia will exhibit the RAS Feeler multi-axis lathe and vertical machining centre XL folding centre which offers technical excellence with 3200 at Austech. mm folding length at 1.5 mm mild steel capacity. The machine “It is a great opportunity to introduce people to is suitable for efficient bending of sheetmetal parts in low to the HS CNC and Qumac teams, but also to have medium high volume jobs and other applications. the opportunity to speak directly with the technical Sheetmetal Machinery Australia experts during the exhibition. We will also have at the1 full MA 0 5 1 3 _ 0 0 0 _ P R O 1 2 0031 9758 3 - 9377 0 4 - 0our 9 stand T 1 0information : 0 3 : 1 on 3 + 0 :range 0 0 of Mori Seiki www.sheetmetalmachinery.com.au CNC machine tools.”

Sheetmetal working

A STEP IN THE RIGHT DIRECTION Effective Cutting Width 1.0 - 5.5m Effective Cutting Length Infinite

Multi-axis milling and machining centres.

Included in the display will be the MT range of power rotary tooling accessories from MT Marchetti of Italy, as well as two new four-axis vertical machining centres from the popular Feeler VMP series.

The machines’ rugged construction manufactured from high-quality cast iron assures optimum rigidity and stability, making it ideal for precision jobs.

The 10,000-rpm spindle produces fine surface finishes required by many industries.

HS CNC Machines 03 9763 8207 www.hscnc.com.au

The PCS SR cutting machine will make light work of even the heaviest steel plate It’s been designed to be efficient, of high quality and cost effective.

• Up to 6 gas torches • Plasma Cutting • Plasma Bevel

• Light duty single-spindle drill • Inkjet marking • PCS Turbogas

Solid Welded Construction

Partners

+61 3 9305 2555

www.profilecuttingsystems.com

42 MAY 2013 Manufacturers’ Monthly

manmonthly.com.au

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See us on stand number 646

Get your silent bid in!

A range of Ex-Demo Metrology and Scanning equipment will be sold through a Silent Auction to be held at Austech 2013.

Don’t miss out on this opportunity to get the equipment you want at the price you choose to pay!

• Offers can only be made by completing one of our bid forms and placing it in the Silent Auction box on our stand #646

• All items will have a published reserve well below the manufacturers list price • The highest bid above the reserve will secure the equipment • Any items sold prior to the Silent Auction may be withdrawn Auction closes 3:00pm Friday 10th May 2013 To find out more call us on 1-800-283-095 or visit us at www.hitechmetrology.com.au

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WHY BUY A TECHNI WATERJET MACHINE? • Australian Manufacturer & Exporter • Worlds 3rd Largest Manufacturer Of Waterjet Machines • More Than 500 Installations Across 20 Countries • Inventor Of The Electric Servo Pump (Quantum ESP) • Cuts Virtually Any Material Up To 200mm Thick • Lowest Running Costs In Industry • Bevel Cutting – Up To 60 Degrees • Extensive Range Of Machines To Choose From

TECHJET-X3® FEATURES • Linear Encoder Feedback with laser-calibrated mapping, offers the greatest accuracy in the industry.

• Submerged cutting for almost silent operation.

• Precision Stainless Steel Band drive providing smooth movement at rapid speeds with extreme accuracy.

• Tech-Sense™ to monitor the cutting head and pause the program prior to any blockage, making “Lights Out” operating a reality.

Austech Preview 7-10 MAY 2013

Precision lathes It is not often that you are given an opportunity to see the processes involved in producing high-precision parts for industries such as the exacting medical sector. At the forthcoming Austech exhibition, Swisstec Australia will be providing visitors a rare insight into how a part such as a bone screw is taken from concept to product to assured tolerances. to show this process, Swisstec Australia has teamed up with Delcam Australia, a specialist in CAD/CAM software, and Renishaw Pty Ltd who will provide the final testing and gauging of the product turned and milled in Swisstec’s recently released tornos St-26 CNC lathe.

“Adopting the latest machining technologies is key for shops to accurately and repeatedly create medical components,” says Peter Staebner, of Swisstec. “Swiss-style lathes offer a good combination of precision and repeatability for these applications thanks in part to their guide-bushing

design, which provides support for the workpieces very close to the cut.” the tornos St-26 CNC Swiss-style lathe features 7-axis functionality and a sliding headstock. the machine boasts up to 36 tools, 16 of which can be used at any one time, with or without a guide brush.

“It has the capacity to produce anything from a repetition item like a washer to a highly precise item like a bone screw. the 23-mm capacity means the tornos can produce highly specialised parts.” to visualise the complexity of the design capabilities, Delcam will be demonstrating the design composed on the company’s ‘Partmaker’ software via a big screen on the stand. the part will then be manufactured onsite by the tornos lathe and Renishaw will be utilising its expertise in gauging and measurement to show the precision that has been achieved by the machine.

Swisstec 03 9769 3988 www.swisstec.com.au

Be l Cuttin g ve QUANTUM NXT FEATURES • Most Efficient Waterjet Pump – up to 60% more efficient than standard hydraulic intensifiers.

• Most Quiet – <68dBA with almost silent operation.

• Environmentally Friendly – significantly less consumption of water & power, compared to standard hydraulic intensifiers.

• Lowest Cooling Water Requirement – up to 75% less cooling water than standard hydraulic intensifiers.

For exacting industries.

Lean manufacturing Precision Waterjet Cutting Machines for a quote or more info please contact TECHNI Waterjet on

1800 15 9616 www.techniwaterjet.com

44 MAY 2013 Manufacturers’ Monthly

Innovation Through Passion

LeANeR times call for leaner manufacturing processes. Learn how lean manufacturing techniques can help your business from leading Australian Lean Manufacturing and Project Management company tXM during Austech 2013 in Melbourne, stand 501 to be held at the Melbourne exhibition Centre from 7 to 10 May 2013.

Visitors will be given the opportunity to discuss their lean manufacturing needs with tXM. the company will be showcasing the recently launched online store that provides many of the key visual tools needed to improve the lean production systems and assist with managing routine daily tasks, problem solving and planning production.

TXM Lean Solutions www.txm.com.au

manmonthly.com.au

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What’sNew

Brought to you by

See more new products at manmonthly.com.au

Hazard cordoning Recoila has developed new equipment that allows manufacturers to cordon off dangerous section yet still allow thoroughfare if needs be.

Traditionally, businesses have used traffic cones, bollards, wall mounted signage, free standing signs or a combination of these methods to deter customers, visitors or unauthorized staff.

When access needs to be made available multiple times a day, bollards and similar barrier methods become cumbersome to move and are sometimes not put back in place by staff, and in the case with wall signage, are occasionally not seen at all.

Recoila has created a solution for areas that are designated as both thoroughfare and restricted access – a wall mounted safety barrier reel, fitted with 15 metres of retractable barrier tape or chain, in high visibility orange or yellow respectively.

When mounted on the side wall of a doorway or access way, the BaR Series reels allow A Dstaff _ Mto A easily N M Munwind E T M up A Yto_ 1 3 fifteen metres of chain or tape and attach

Security routers WeiDMUlleR has released new gigabit Wan/lan industrial ethernet security routers.

The Wan/lan industrial ethernet router translates addresses between different networks using protocols such as port forwarding, 1:1 naT or masquerading to protect all the ethernet devices of the hidden network and to ensure safe integration into the network. in addition, the router also enables access to infrastructure from around Retractable the world, supporting up to 10 VPn barrier tapes and chains. connections using openVPn as well as iPSec technologies to deliver high-level it to a hook on the opposite wall. The security with minimum effort. barrier is quickly and easily retracted The model also boasts an inbuilt SPi when pedestrian or vehicular access is firewall to prevent unwanted remote necessary. network access.

The reels have a durable impact The fully functional firewall can be and UV resistant outer case coupled configured to meet individual rules for with a heavy duty spring mechanism, both layer 2 (ethernet) and layer 3 (iP) making them ideal for harsh industrial transport to deliver top-level security. environments. it also has an auto-learning feature ReCoila that adapts automatically to the network . pdf P a g e 1 3 02 / 09621 4 /8988 1 3 , traffic 1 2it :sees.

0 1 This : 5 feature 9 P provides M AEDT www.recoila.com.au inexperienced network people with highly effective protection. Generated rules can be edited or deleted.

Performance driven, the industrial security router is highly reliable and robust. it supports Modbus TcP commands and also features two digital inputs and

Has an autolearning feature to automatically adapt to traffic. outputs for functions and alarms. The gigabit Wan/lan ports enable highspeed throughput of data in corporate networks. operable in temperatures from -20ºc to +70ºc the router conveniently runs on minimal power from 7V to 36Vdc and can be battery or solar operated at fixed installations or on vehicles. Housed in a rugged Din rail mount case to withstand demanding environments, the router is suitable for use in mining, road and transport, and water industries.

Weidmuller 02 9671 9999 info@weidmuller.com.au www.weidmuller.com.au

Profile grinding GleaSon corporation has released new profile grinding options for its wheel grinding machines. it has now added the option to its 300TWG threaded wheel grinding machines, providing more flexibility in the threaded wheel grinding process, especially for medium to large size batch production.

With the addition of a profile grinding option, the machine is also well-suited to smaller batch and high-precision production, making the 300TWG is now a universal gear grinder.

The combination of the two processes covers the full range of production possibilities.

With the integration of the new dressable profile grinding option, the already successful 300TWG Threaded Wheel Grinding Machine becomes more flexible, allowing the configuration of this 46 MAY 2013 Manufacturers’ Monthly

Universal gear grinding. machine to meet nearly any customer requirement.

Depending on the customer’s application, it may be used either as a threaded wheel or a profile grinding machine. User-friendly, graphically supported software simplifies the process, yet offers a high degree of sophistication and control.”

Gleason Corporation www.gleason.com manmonthly.com.au

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Better.

Enough said

New products Loctite速 401 406 454 When it comes to instant bonding, Loctite is the industry leader and has the most comprehensive range. Our next-generation 401, 406 and 454 have been enhanced to consistently withstand higher temperatures and ensure fast and superior adhesion.

To view our complete range of products and receive your FREE Loctite Wallchart, visit loctite.com.au/MM

STRENGTH IN BRAND

STRENGTH IN SUPPORT

STRENGTH IN PRODUCT

STRENGTH IN INNOVATION

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What’sNEW

Brought to you by

Pedestrian pallet trucks

Handheld test and measurement

YaLE has launched new pedestrian pallet trucks designed to offer greater comfort and ease of operation.

Dubbed the Yale mP20, they are built offering a choice of 1125 or 1173mm long forks, with a 670mm fork spread and a 2000kg load capacity.

Yale’s mP20 pedestrian pallet trucks incorporate clever design features which enhance ease of use and operator comfort. these include an impactresistant, ergonomically designed midmount control handle with cushioned return spring plus a large, turn-table steel bearing for improved manoeuvrability with reduced steering effort.

Performance is also enhanced by a short tilt control arm which delivers a tight turning radius, while cost of ownership is reduced due to lowmaintenance brushless aC traction control and the tough and durable

ComPaCt, lightweight and flexible will be the focus of the display by olympus industrial Business Unit (iBD) at austech 2013. Located on stand #790 in hall 7, the company’s display will feature some of the smallest models in its industryleading portfolio of innovative test, measurement, and imaging instruments. one featured product will be the palm-sized iPLEx Ultralite industrial videoscope. Weighing just 700 grams, the compact, durable body delivers highquality images from inspections in tough and confined areas. the ergonomic design allows the device to fit snugly into the palm of your hand, to support speedy, fatiguefree operation even during prolonged inspections. other products to be highlighting include the i-SPEED range of high-speed video cameras and the magna-mike 8600 thickness gauge. the i-SPEED cameras can record up to one million frames per second even under extremely low light conditions. the magna-mike 8600 is a portable thickness gauge that uses a simple magnetic method to make

The trucks have a 2000kg load capacity.

new frame design. Yale mP20 Pedestrian Pallet trucks are ideal for use in applications including logistics operations, intensive vehicle and trailer charging and discharging, cross docking and horizontal transport over medium to long distances.

Yale www.yale.com

Knife edge rolls trEotham automation has released new knife edge rolls for lubricationfree belt deflection.

Sliding or rolling knife edges are used in conveyor belts in a number of industries including the food and beverage industry, mining and heavy Allows narrow deflection radii. fabrication. the robust iglidur P210 rolling knife edge distinguishes itself by low humidity consumption as well as a proper material resistance and a high service life. the US FDa conformant all-round material iglidur a180 is for applications with low to moderate loads in a direct environment of food and humidity and iglidur a350 for medium to high load applications.

MA 0 5 1 3 _ 0 0 0 _ P T R 1 2 0 1 3 - 0 4 - Treotham 1 1 T 2 Automation 0 : 1 3 : 3 www.treotham.com.au

48 MAY 2013 Manufacturers’ Monthly

Built to withstand inspection site drops and falls. reliable and repeatable measurements on nonferrous materials. the videoscope comes with either a 2 or 3.5 metre insertion tube, both of which offer quick and accurate articulation. insertion tubes are available in 4 or 6 mm diameters.

Olympus-IMS www.olympus-ims.com

Compact serial device server Lantronix, represented by Soanar in australia and new Zealand, have announced the launch and worldwide availability of its new xDirect device server. this product is a compact serial-to-Ethernet device server that provides quick and easy connectivity to virtually any device or machine with a serial interface.

With plug-and-play simplicity and a small form factor, xDirect is suitable for a variety of markets from security to industrial automation to medical and more. it has an integrated Ethernet port and serial cable, and multiple power options. xDirect also features a built-in Web server that enables users to access and configure the unit using a standard Web browser on a PC, smart phone or tablet.

Soanar www.soanar.com 6 + 1 0 : 0 0

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Materials HANDLING Automated handling The new Dematic RapidStore Mini Load (ML) systems provide increased performance in the automated storage and handling of products in distribution centres and raw materials stores.

Ideal for handling cartons, cases, totes and trays weighing up to 450kg, the RapidStore ML system finds use in kitting, buffering, staging and sequencing stock in manufacturing and distribution applications.

Dematic RapidStore ML and ML+ Storage & Retrieval Machines (SRMs) provide the ideal interface between bulk reserve stock and online stock in picking and assembly applications. They can be designed to meet height and throughput constraints, and tailored to meet any storage and handling requirements. efficiently breaking goods down from bulk unit loads such as pallets to smaller loads for picking or kitting is often key to effective operations in a distribution centre or raw materials store.

RapidStore ML and ML+ systems can be integrated with a comprehensive range of conveyors, diverts, merges and accumulation conveyors, as well as a full range of conveyor sorting systems to transport stock to and from the system in precisely the right sequence to meet the exacting needs of high-speed kitting and order fulfilment applications.

Fitted with new generation load handling devices (LhDs), high-speed RapidStore SRMs can quickly select, A Dand _ M A away N M KaEvariety R D EofC _ 1 2 . retrieve put

Scissor lifts SnoRkeL has launched its latest range of self propelled scissor lifts. The new S1030e low level access platforms are part of its self propelled miniscissor lift series. The new Snorkel S1030e delivers increased productivity and efficiency benefits over push-around low-level access platforms.

Providing a 3 metre maximum platform height, the S1030e is powered by a DC electric drive train.

It has a high amp/hour rating for an extended operating period between battery charges.

With a gross weight of 495kg, it is still lightweight enough for many floors with load-bearing restrictions.

Measuring 77 centimetres wide the machine passes through standard interior doorways.

Snorkel 1300 900 700 www.snorkelusa.com

Aids in picking and assembly applications.

range of applications, according to the company. Designed for ultra high-speed load handling, RapidStore LhDs use precision telescoping arms and belt drives to handle goods quickly and effectively, and are available in fixed or flexible variants allowing the handling of multiple load sizes.

A wide range of LhDs enables the efficient handling of single, double or triple loads in side-by-side or stacked configurations on double-masted SRMs, making it possible to handle and transfer up to six loads simultaneously for optimum performance.

Dematic pdf P a g e 1 2 9 /0219486 0 / 5555 1 2 , www.dematic.com/au

containers holding stock across a wide

Low level access with zero turn radius.

Floating blade plough FLexCo have released a new heavy duty floating blade plough for conveyors.

According to the company, unlike previous belt ploughs this latest version features a patent pending failsafe fixed frame and a floating blade for better cleaning and extended blade life.

This eliminates the need for manual adjustment as the blades wear, whilst maintaining constant contact with the belt and ensuring superior cleaning performance throughout the life of the blade. The fail-safe fixed frame means that as the blades wear the frame will never touch the belt, minimising conveyor : 3 8 : Designed 2 2 P to M maximise A E D Twide belt2damage. and high speed belt applications, the

Designed with a failsafe fixed frame. heavy-Duty Floating Blade Belt Plough ejects rogue material on both sides of the conveyor while deflecting shields prevent rocks and debris from rebounding over the plough. This eliminates conveyor belt damage and belt mistracking problems.

Flexco www.flexco.com

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

Pressure Cleaners

Sydney Melbourne Brisbane Perth Adelaide

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(02) 9737 9797 (03) 8769 1500 (07) 3865 2551 (08) 9277 9651 (08) 8340 8060

Pumps All Sizes

Material Lifts

ÂŽ

1300 537 742 | sales@kerrick.com.au | www.kerrick.com.au 50 MAY 2013 Manufacturersâ&#x20AC;&#x2122; Monthly

manmonthly.com.au

MM0513_000_COM

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Tired of the same routine?

Buy a Vac that lasts!

Stop throwing your money away on electric vacuum cleaners that are sure to fail. EXAIR vacuums have been engineered to withstand the dust, dirt, chips and liquids common to industrial environments. Ours have no electric motors or other moving parts to clog or wear out.

EXAIR’s 30 Day Unconditional Guarantee assures your complete satisfaction. Let our five year “Built To Last” warranty give you the peace of mind that your vacuum will always work and end your trips to the dumpster.

Two-Way Drum Pump

Chip Vacuum Has No Moving Parts

Vacuum, Blow and Transfer

Heavy Duty Vacuum Resists Wear

The compressed air powered Reversible Drum Vac™ will quickly fill or empty a 44 gallon drum in 90 seconds. Coolant sumps can be easily refilled, floor spills vacuumed or contaminated liquids transferred to filtration tanks in minutes.

Chip Vac™ is powered by compressed air and vacuums chips directly into a 44 gallon drum. It is easy to move from drum to drum to keep materials separate for recycling.

Clean chips from floors, fixtures, work surfaces and machines.

The Vac-u-Gun™ uses compressed air to provide solutions to a wide variety of industrial housekeeping problems.

This versatile tool is a vacuum gun, blow gun and a transfer tool all in one. Three Vac-u-Gun systems with tools are available.

Heavy Duty Dry Vac™ attaches to an ordinary 44 gallon open-top drum to turn it into a powerful, industrial duty vacuum cleaner. It has been engineered to vacuum more dry materials in less time than ordinary vacs. Ideal for abrasives.

• Durable stainless steel

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• 5 and 44 gallon models are now available

• 5 and 44 gallon models are now available

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Distributors of

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Intelligent Compressed Air® Products For Industry

Quiet only 77 dBA!

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Product FOCUS: PUMPS & VALVES Corrosive industry pumps

Pump failure prevention

CAsT 316 stainless steel “sFQ” series pumps, supplied by Australian pump Industries, are specifically designed for corrosive water applications.

The sFQ series is unique in that even the stator housings are cast and machined 316 stainless steel.

Casings, impellers and suction covers are also cast 316 stainless steel.

The grade of stainless steel used has a higher content of carbon for strength.

It also has a high proportion of nickel and molybdenium for improved corrosion resistance.

No welds are required which means no pitting and reduced oxidisation.

This material is also capable of withstanding abrasive liquids.

The sFQ range includes 2” and 3” ports with heads to 44 metres and flows to 2,000 lpm. They feature a high capacity semi open style impeller that will perform in even the toughest conditions.

Tsurumi pumps also include a unique anti-wicking cable gland, which prevents waterAfrom inside D _ wicking M A N Tdown SUM A Y the _ 1 3 . p cable. The motor is protected even if the

Vespel has released wear rings, bushings, and bearing designed to reduce pump failures The Vespel CR-6100, available from Fluid seals, is a carbon fibre reinforced polymer that replaces metal and other composite materials in valve seats, line shaft bearings, pump wear rings and bushings.

A customer who installed Vespel CR-6100 wear rings, throat bushings and pressure reducing bushings in two multistage gasoline shipping pumps was able to prevent pump failures while benefiting from a 7 per cent efficiency gain and a 90 per cent reduction in overall vibration levels.

The pumps have been in service for over four years without failure, where the previous MTBR was 12 months.

Key features of the Vespel CR-6100 components such as non-metallic properties, low coefficient of friction, and excellent dimensional stability allow them to withstand short duration off-design conditions 1 0 : 5 1including : 2 0 start-up, A M Aslow-rolling, EDT low-flow, cavitation, or run-dry situations.

Built from cast and machined 316 stainless steel. cable is damaged or the end accidentally immersed. All Tsurumi pumps have a double silicon carbide mechanical seal.

A patented oil lifter ensures the mechanical seal faces are always lubricated and cooled. df P a g e 1 2 7 / Aussie 0 3 / Pumps 1 3 , www.aussiepumps.com.au

The components are nonmetallic and low fricton.

The pump remains available for service, resulting in potentially lower repair cost.

With these characteristics, clearance at wear components can be reduced, resulting in efficiency gains that lead to significant operating cost reductions, particularly when applied to populations of pumps.

Fluid Seals 02 9438 1622 www.fluidseals.com.au

A world of cable carrier options TSUBAKI KABELSCHLEPP cable carriers: • Full range of options to suit your requirements – plastic, steel and combined hybrid materials • Available in 1 mm width increments • Over 100,000 variants in steel and plastic material • Standard widths from 6 mm to 2,500 mm • From single chain link to harnessed assemblies ready for installation • Comprehensive range of cables carried in stock

Cable Stock

Available NOW

Tsubaki Australia Pty. Limited Sydney 02 9704 2500

Melbourne 03 9215 2888

Email: sales@tsubaki.com.au

52 MAY 2013 Manufacturers’ Monthly

Brisbane 07 3273 0600

Perth 08 6254 0000

Web: www.tsubaki.com.au

manmonthly.com.au

AD_FENBLAAPR_13

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‘Don’t Gamble with Safety’ Out Now! Q Share in over $70,000 in rewards for playing it safe Q Widest range of safety product innovation Q Hints and tips to improve your workplace safety Q All the big safety brands

Phone 13 73 23 or visit www.winwithblackwoods.com to request your copy today!

We have the widest range of safety products and solutions as well as On Site Services: Lockout / Tagout procedures and products Hand protection, awareness and glove selection program First Aid component maintenance and training Traffic management solutions Safety harness inspection and toolbox talks Prescription eyewear programs

Signage and identification assessment Environmental spill control Dangerous goods assessment Workplace drug and alcohol testing Emergency response Customer embroidery, screen printing and colour coding

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Rules & REGULATIONS Trading on reputation Will new Industry Participation rules ensure a manufacturing revival, or is it simply reinforcing existing industry trends. Brent Balinski investigates.

E

ven in the context of the high Australian dollar’s effect on manufacturing in the last few years, the March quarter employment figures from were particularly bad – 30,800 jobs lost.

Last year the federal government assembled a team of experts – the PM’s taskforce, in shorthand – to deliver a set of recommendations on what could be done to overcome the sector’s difficulties, which get trotted out, along with the pronouncements that Australian manufacturing’s decline is terminal, every time a factory closes.

The government’s big response to the taskforce’s report – delivered last August – was announced in February: the Industry A D _ MA NM K E V Mand AY_ 1 3 Innovation Statement, A Plan For

54 MAY 2013 Manufacturers’ Monthly

The Government is trying to increase Australian manufacturing’s footprint.

Australian Jobs. Though the title “It addresses a very serious issue -didn’t 1 specify 2 0 1 3it,- the 0 3jobs - 2targeted 6 T 1 1 : 3 5 for : 5the 9 +Australian 1 1 : 0 0community,” were manufacturing ones.

Australian Made’s CEO, Ian Harrison,

told Manufacturers’ Monthly not long after the statement was released.

“And that issue is the enormous challenges facing the manufacturing and processing industries in Australia. The ongoing strength of the Australian dollar is creating challenges for the manufacturing and processing industries. We have become a high-cost country and the strength of the currency is compounding that problem.”

Submissions for Jobs Bill (the other major parts of Gillard’s announcement involved a network of ten innovation precincts and $350 million in funding for the Innovation Investment Fund – with measures such as an extension of the Enterprise Connect program) closed on April 12. Under the

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Miners claim 80% of content is already sourced locally. bill, scheduled to be introduced to Parliament mid-year and – if passed – take effect at the beginning of 2014, projects with a capital expenditure of $500 million or more must submit an Australian Industry Participation Plan to prove that adequate consideration was given to local firms to provide goods and services. A new body, the Australian Industry Participation Authority, would oversee this.

Projects worth $2 billion or more will have to include Australian Industry Opportunity Officers “embedded in the procurement teams of individual companies.”

Mining companies, the main parties affected by the Jobs Bill, are unimpressed by it.

Mitch Hooke, then CEO of the NSW Minerals Council, said that mining companies already sourced more than 80 per cent of their goods and services locally.

A submission to the Industry department on the draft bill by the Minerals Council of Australia, which represents heavyweights including BHP Billiton and Rio Tinto, claimed that jobs would actually be threatened, and that its commercially sensitive details about its members’ operations would be revealed in Australian Industry Participation Plans.

“Rather than supporting the creation and retention of Australian jobs, the draft bill threatens jobs by tying up projects in red tape and reducing competitiveness,” its submission read. Submitting participation plans would also, they manmonthly.com.au

claimed reveal details of projects before “proper due-diligence and fiduciary responsibility requirements.”

Simon Cowan, a research fellow at the pro-free-market Centre For Independent Studies, also sees potential problems with the bill designed to protect Australian manufacturing jobs.

“I think the most obvious problem is that it really is adding a significant amount of red tape to businesses, who are already facing quite a lot of red tape,” he told Manufacturers’ Monthly.

Cowan compared the Participation Plan to similar programs implemented in the Defence department, where more paperwork though no benefit were the outcomes.

“In Defence they’re called Australian Industry Capability Plans rather than Australian Industry Participation Arrangements,” he said. “The short answer is that they haven’t been particularly successful in increasing the amount of work going to Australian companies.

“The idea behind that was allowing competitive Australian industry to bid for Defence contracts.

The problem being, of course, that companies that looking to bid for large Defence contracts in Australia were already looking for Australian suppliers who could do things more efficiently and cheaper than their existing suppliers.

“So whatever happened was you were really sort of forcing people to do what they would be naturally doing anyway.”

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Automotive’sFUTURE Is supporting the car industry expensive compared to our heavily subsidised lives?

Outrage over subsidises for a failing automotive industry has risen, but is it warranted?

Remy Davison* takes the anger to task.

H

olden’s announcement of job cuts demonstrates the dual impacts of the strong Australian dollar and import penetration upon the beleaguered domestic automotive industry.

500 jobs will go.

A myopic view of the industry is that it is merely about vehicles.

However, local manufacturers Toyota, Ford, and Holden are only one part of a much broader automotive components manufacturing industry.

Holden has received $1.8 billion in industry assistance in the last 10 years. That works out at about $8.10 for every Australian man, woman and child, assuming a population of around 22 million. An informal poll in The Age indicates that as many as 75% of readers are opposed to the maintenance of government subsidies and bailouts to the industry. It’s clear that any parochialism or sentimental attachment to locally made cars is MA 5 1distant 3 _ 0 past.

0 0 _Yes, T U IRama relic of0the fully aware of ERP, the effective

With so much subsidised in Australia, is the continued support of the automotive industry and the hundreds of jobs it creates not worth backing, Davison asks. rate of protection, which is a less than $18 per person over the complex multiplier based upon the last decade. So it cost you, the longdirect and indirect flow-through suffering Australian taxpayer, the costs of tariffs and other forms princely sum of $1.80 per annum to of protection for a given industry prevent the collapse of plants like 1sector.

2 0 As 1 3Kim - 0Carr 4 - 1 1 T 2recently 0 : 2 2 : 1 Elizabeth, 5 + 1 0 : Fishermans 0 0 noted Bend, Altona, the industy received subsidies of Geelong and Broadmeadows.

But the flat-earth policies of the free-trade think tanks, who opine that subsidies should be removed at all costs, invariably have no solutions to the systematic deindustrialisation and large-scale unemployment their prescriptions will inevitably bring.

These “free-traders” ignore the deep asymmetries wrought by industrial subsidies that persist throughout the rest of the world economy. They propagate the Ricardian fallacy that whatever cannot be produced efficiently locally should be imported.

Car imports, in this case.

So, think this $18-per-capita car subsidy is too much? Think again.

You – yes, you, subsidise the banks to the tune of $763 per annum, plus all the fees and charges they generously impose upon you. Not quite the chunk of change ($83 billion) the US government affords its banks in subsidies, but still.

And the mining industry doesn’t have clean hands either. They get at least $4 billion per annum. >>

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Automotive’s FUTURE >> Queensland alone spends $1.4 billion

permanently into a system of auto occurs, the following problems in subsidies. industry subsidies and protection emerge. First, how do you retrain Let’s be clear about this: virtually from 1948. Whitlam slashed tariffs and redeploy workers aged 40–55 to every industry in Australia is across the board, but delivered compete effectively in alternative subsidised, directly or indirectly, via no industry plan. John Button labour markets? And retraining – government hand-outs. rationalised the industry, but set even if it works – takes real time.

We’ll try a little quiz first. Tick Soviet-style production quotas and Moreover, any retraining costs any box that applies to you: sought no innovation. Howard, Rudd invariably fall upon government, Your child care; your private and Gillard merely trod water. meaning taxpayers are forced to (and public) health insurance; your The reason the industry failed to shell out in any case. Not to mention wheat; your private schools; your innovate behind high tariff walls the inevitable social security costs universities; your accountant; Your was because it catered virtually associated with the fallout from private-sector big law firm; your exclusively for the domestic market deindustrialisation.

National Broadband Network; your for the first few decades of its Second: what industries will first home; your nursing home; your existence. Governments were equally replace labour-intensive heavy negative gearing; your ABC; your to blame as they did not attach industry in manufacturing hubs? superannuation tax breaks; actors conditionality to the complex system Third: Australian manufacturing and the arts in general; corporate of tariffs and subsidies that could employment still dwarfs mining welfare. Don’t kid yourself if you’re have compelled the industry to employment, although the gap has in business. Tax breaks infiltrate invest in new technologies or truly narrowed. Mining will not take up every part of the scaly Australian innovative products. Manufacturing the slack, nor is it geared to absorb subsidy serpent. Virtually every provides stable wages and working the existing automotive industry business input is tax deductible. conditions across a range of skills base.

You. Are. Subsidised. industry sectors (some 2009 and Fourth: the auto components I am not defending the poor 2011 statistics are here and here). industry manufactures parts for business decisions by the industry, It also employs around 1 million imported (as well as local) products. or the incompetent government workers directly, contributes almost However, they achieve scale policy that has prevailed since 10% of GDP, and accounts for through supplying the downstream John McEwan was Trade and around one third of exports. But car-makers, without which it is Industry minister. Federal and state when deindustrialisation hollows unlikely most small and medium A D _ M Alocked N M E themselves M O M A Y _ 1 3 -out 1manufacturing 2 0 1 3 - 0and 3 - downsizing 2 6 T 1 0 : 2 9 auto : 2 6components + 1 1 : 0 0firms would be able governments ManMon_AU_3406_13153_EMO Hannover 2013 22.03.13 09:54 Seite 1

w INFO: VDW – Generalkommissariat EMO Hannover 2013 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Tel. +49 69 756081-0 · Fax +49 69 756081-74 emo@vdw.de · www.emo-hannover.de 58 MAY 2013 Manufacturers’ Monthly

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to derive sufficient revenue streams in the absence of volume production.

In other words, they need local volume in order to be serious about export-geared production.

Fifth: it is inefficient to waste the considerable investments, accumulated over decades, in the skills and training regimes embedded in the automotive, materials and production engineering sectors.

The industry’s problems are not entirely of their own making. The high Australian dollar exchange rate; the free-trade agreement with Thailand in 2007; weak world demand, combined with the economics of surplus capacity in the global automotive industry have all contributed to the downsizing of the industry. Essentially, the industry has become a victim of the law of diminishing returns: despite increased subsidies, jobs in the sector have decreased in rough correlation with outputs. In other words, neither jobs nor the industry will be saved via incremental productivity gains. *This article originally appeared in full on The Conversation.

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