Manufacturers' Monthly October 2013

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961 October 2013

Print Post Approved PP255003/00324

First temperature transmitter with display and IO-Link

INSIDE Compressors & Pneumatics >> Process Productivity >> Packaging & Labelling 3D Printing >> Manufacturing For Mining >> Manufacturing The German Way

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MA1013_003.pdf

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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 Editor: Matt McDonald Ph: (02) 8484 0645 Fax: (02) 8484 0722 matthew.mcdonald@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 Editor-at-Large: Alan Johnson Ph: (02) 8484 0725 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

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PM

Inside OCTOBER 2013

4 Editorial ■ What does the lack of a

Manufacturing Minister mean for the industry?

For daily news visit manmonthly.com.au

24

6 Comment ■ Enabling felxibility in a factory

8 Analysis News ■ What’s happening

Which adhesive is right for you?

12 What’s New

24 Fasteners & Adhesives

■ Inductive angle sensors ■ Hi-tech welder

■ Understanding fast-curing

■ Avionics kit ■ Temperature bath

adhesive systems ■ Low viscosity, two part epoxy ■ Tamper detection paste

16 IT@MM

■ Multi-material adhesive

■ SICK discusses productivity,

process and innovation

food waste

■ Understanding the costs of

compressed air

costs ■ Machine tool chip trapper

approved -P a 1 ge 2 0 1 1 3 1 -8 0 / 9 0 -9 1 / 6 1 T 3 1 , 0 :1 2 1 6 : :1 1 4 8 : + 4 1 3 0 :A 0 M0

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961 October 2013

First temperature transmitter with display and IO-Link

PINSIDEa g e

specialisation

1

1 5 / 0 5 / 1 3 ,

Compressors & Pneumatics >> Process Productivity >> Packaging & Labelling 3D Printing >> Manufacturing For Mining >> Manufacturing The German Way

38 Manufacturing for Mining ■ Building in the downturn

44 Business Development ■ Pathways to high performance

36 3D Printing

46 Manufacturing Innovation

■ Growing push for additive

■ META looks to the post-election

manufacturing

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32 Hidden Champions ■ Globalisation meets

■ Compressed air and efficiency ■ Cutting your compressed air

MA 1 0 1 3 _ 0 0 1 _ . Ip F dM f

28 Labelling & Packaging ■ How packaging can help tackle

18 Compressors & Pneumatics

Cirrus Media Tower 2, Level 3, 475 Victoria Avenue, Chatswood, NSW 2067, Australia Locked Bag 4700, Chatswood Delivery Centre, NSW 2067, Australia Ph: (02) 8484 0888 Fax: (02) 8484 0633 ABN 80 132 719 861 ISSN 0025-2530 www.cirrusmedia.com.au © Copyright Cirrus Media, 2013 18,170* CAB Audited Distribution (*last two issues of Oct-Mar 2013) 16,448, CAB Oct-Mar average Printed by Bluestar Print 83 Derby Street, Silverwater, NSW 2128 Ph: (02) 9748 3411

30

future

Behind the cover INTENDED for use in the food industry, the TD temperature transmitters from ifm efector are distinguished by a compact, hygienic design and a display for local indication. Monitoring of temperature at the measuring point is easy due to the bright 4-digit LED display. They boast a fast dynamic response time of T05=1s and T09=3s.

2 : The 3 4 integrated : 2 8 P M A Eand S TG½” Tri-clamp process adapters allow quick easy

installation. No complex set-up is required because the transmitters are supplied with a pre-scaled measuring range. The range can be scaled via IO-Link 1.1.

Featuring hygienic and robust housing with high-grade stainless and IP69K protection, they are designed to operate in particularly harsh applications. They are available in probe lengths from 30-150mm. www.ifm.com/au/TD

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Manufacturers’ Monthly OCTOBER 2013 3

MA1013_004.pdf

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Editorial

COLE LATIMER – Managing Editor

editor@manmonthly.com.au

The shape of things to come What does a lack of a manufacturing minister mean for the industry?

T

he election has been and gone and the results weren’t surprising in the least.

Tony Abbott has walked into the role of our new head of Government, and he was quick to make changes.

Within hours of being appointed he slashed departments, and cut roles.

While his attack on foreign aid is not going to overly affect manufacturing, their decision to jam mining, manufacturing, science, and everything vaguely industrial together into a single industrial portfolio is disturbing.

Their promise to give manufacturing the attention and support it needed is unlikely to happen to the degree it should when the minister Ian Macfarlane also has to contend with science (and whatever that entails) and mining.

It is quite likely that manufacturing, unfortunately, will get lost amongst the crowd for Macfarlane’s attention.

So after spending what seems like years in the wilderness under a Labor Government, interspaced with Kim Carr at the helm, manufacturing is more than likely to be back out in MA 0 8 1 3the _ 0 0 0government. _ KER the cold under new We know that the Coalition

Manufacturing has not received the attention it needs. supports smaller government, but putting two high-need industries into this small? the same basket.

Manufacturing has suffered Or to lump science in with the two over the last few years, and like of them; so that the nation does not mining, is in need of governmental have a science minister for the first support, both in terms of policy and time in around 80 years.

1regulations.

2 0 1 3 - 0 7 - 0 9 T 1 0 : 3 3 : 3 2 They + 1 0need : 0 0individual ministers The way to solve this isn’t by to attend to their issues and work

directly with the sectors to formulate new plans to ensure their survival, and in turn, Australia’s survival.

The future could definitely be dark.

Many signs are pointing to it.

But, maybe we are getting ahead of ourselves.

Maybe Tony Abbott’s extended stint in hi-vis and constant factory visits over the last few months have made an impression upon him and his government.

Maybe, just maybe, manufacturing’s future will be a little brighter, a little more optimistic.

Put simply, it is too early to tell.

You can only truly judge the effect a government has had through the magic of hindsight, and while the first 100 days are telling, it is simply an arbitrary milestone that is not indicative of the true worth of a government.

History will be a harsher judge of the current and former governments than we ever can be in the present.

Let’s just hope that they begin implementing real change, to stop the current era of industrial decline in this country.

It’s time we had some leadership and support on the issue.

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MA1013_006.pdf

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Industrial COMMENT HARRY FORBES – Senior Analyst, ARC Advisory Group

Enabling flexibility in a factory Traditionally, FDT (Field Device Technology) had been associated largely with process automation and process field devices but, as Harry Forbes writes, this is no longer the case.

S

uppliers in the factory factory automation systems as well FDT, the IEC 62453 standard, is The scope of the FDT interface automation space are adopting as user-chosen factory fieldbus a software interface specification includes more than operating data FDT because it affords them technologies. End users usually for inter-operability between field communication. DTMs can be used the technical flexibility to deal prefer to standardise on one devices and automation systems. over the device’s entire life cycle. with the wide range of product automation platform and as few Its design basis is such that Functions for device configurations customers demand. fieldbuses as possible. This greatly FDT-enabled applications within the parameterisation, messaging, Factory equipment suppliers simplifies the end user’s operating automation system can manage field health monitoring, interactive and machine builders, even major and maintenance tasks over the devices regardless of the device’s functions, and online help can be ones, must comply with the system operating life of the equipment, manufacturer and regardless of the integrated into a DTM. Effective specifications demanded by end but the machine builders can find fieldbus protocol employed. This is implementations can provide support user manufacturers. As a result, themselves “sandwiched” between achieved by equipping each device from commissioning to repair. they must deliver their products their customer’s automation and with a unique software element ARC interviewed one anonymous to support one of many different fieldbus choices. This places a called a Device Type Manager global supplier of factory equipment combinations of factory automation premium on a supplier’s ability to (DTM). FDT-enabled applications that is embedding FDT into its system and fieldbus. ARC spoke be flexible. Complex machines will called “FDT Frame Applications” equipment controllers. The company with one major equipment supplier likely contain one or more embedded contain a fully defined interface to has embedded FDT into its controller that now uses FDT to increase controllers supporting proprietary DTMs, providing interoperability to such a degree that the end user product flexibility without adding machine features. So the machine between any pair of Frame does not see it, but can use the permutations to its product design. builder must integrate its own Applications and DTMs. Frame technology to configure, commission, Equipment connected _ M I Tin a1 monitor 2 0 1 3and - 0debug 9 - 1all 6 T 1 2 : 0 1 : 2 9 + 1 0 : 0 0 M A 1 0suppliers 1 3 _ 0 0must 0 _ S U H - embedded 1 2 0 1control 3 - 0 9technology - 0 4 T 1 with 2 : 1 5 : Applications 1M 3A + 11 00 1: 3typically 0 _0 0 0 0operate usually support user-chosen whatever else the end user specifies.

Microsoft environment. devices regardless of fieldbus.

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MA1013_008.pdf

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Analysis NEWS Macfarlane given ‘super portfolio’ covering industry

I

ncoming Prime Minister Tony Abbott has named his cabinet, with Groom MP Ian Macfarlane to be responsible for an expansive industry portfolio, with responsibilities including resources and energy, and manufacturing.

“This is a comprehensive portfolio that covers some of the most important drivers of economic activity for Australia,” Macfarlane said.

Among the issues that the incoming minister said needed immediate attention were undoing taxation changes made by the former government.

“At the top of the list is to restore investor confidence in the resources sector, which for the past six years has been hit with poor policy and tax grabs Rudd/Gillard M A 1 from 0 1 3the _ 0 0 0 _ F AN Governments,” he said.

A common criticism was what’s claimed is the first time there has been no specific portfolio for science since 1931.

Abbott has said responsibility for science would be shared between Macfarlance and the education minister, Chris Pyne.

“Science, as in the CSIRO, will be with industry,” Abbott said at yesterday’s press conference.

Professor Les Field the Australian Ian Macfarlane Academy of Science’s secretary for science policy, was among critics “As the minister for industry, I of the lack of a designated science want to ensure that these sectors portfolio. stay strong so Australians can “CSIRO is one aspect of science continue to earn our fair share of by all means, and it would be good if revenue from our resources and to science research, and even if higher build a strong future for the many education or at least the university as closely as 1tens2of 0 thousands 1 3 - 0 9 of - 2jobs 0 Twithin 1 2 : 0 1 : 2 sector, 3 + 1 0were : 0 linked 0 these parts of our economy.” possible with CSIRO,” he said.

Visy fined after suspending worker VISY has been fined more than $50,000 after it suspended a worker who removed two forklifts from operation at its Coburg facility over safety concerns.

It began when worker, Jon Zwart, who is also the safety officer on site, noticed malfunctioning reverse notification on two of the facility’s forklifts, according to The Age. Concerned over a potential safety issue, Zwart removed the forklifts from the factory floor.

Following this, Visy suspended Zwart and informed him that investigations into his actions would follow.

The case has now gone to court, with Federal Court judge Bernard Murphy fining Visy for infringing on Zwart’s legitimate actions as a workplace health and safety representative.

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MA1013_009.pdf

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SA Parliament backs Nyrstar smelter upgrade THE South Australian Parliament has passed a bill to help secure the redevelopment of Port Pirie’s Nyrstar lead and zinc smelter.

The legislation, which won the support of both major parties in the Legislative Council, gives the final say over any changes to the smelter’s operating licence to the State Government, not the Environment Protection Authority.

According to Manufacturing Minister Tom Kenyon, the ball is now in Nyrstar’s court to decide whether or not it will proceed with the project.

“The Government’s done pretty much everything we can now to provide all the approvals and the assistance to the company that we can, but really now it’s up to them and they’ve got to go through their feasibility process and then they’ve got to make their decision,” he said.

The proposed redevelopment will cost about $350 million. The need for such a change was outlined in ‘the Nyrstar Port Pirie Smelter Public Environmental Report’. leader Mark Parnell said the lead reduction The main environmental concern detailed in targets for Nyrstar’s Port Pirie smelter upgrade the report was the need for reduction in its lead need to be lower. emissions.

Dangerous emissions from the smelter have However, for M A 1 0 not 1 3 everyone _ 0 0 0 _was P I happy E - with 1 the 2 0 1 3 - been 0 9 - a 1health 2 T 1 concern 4 : 5 3 for : 3Port 5 + Pirie 1 0 : residents 0 0 report recommendations. South Australian Greens a long time.

Nyrstar must now make the final decision on smelter.

A study of Port Pirie residents by the Centre for Traumatic Stress Studies has found a correlation between childhood lead exposure and mental health problems later in life.

This reinforces the need for reductions in lead emissions.

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Manufacturers’ Monthly OCTOBER 2013 9

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Analysis NEWS Venezuelan government seizes toilet paper factory

The anti-dumping commission can slap import duties on dumped products.

Dumped Chinese and Korean wind towers injuring local industry

THE Venezuelan government has ordered the temporary takeover of a toilet paper factory. The move follows shortages of many basic products such as personal care items and milk.

AFP reports that the decision was made by an economic panel appointed by President Nicolas Maduro.

Announcing the move on Twitter, Vice President Jorge Arreaza said, “The temporary occupation of Manpa (Manufactora de Papel) is aimed at verifying that toilet paper industry production, marketing and distribution.”

As Reuters reports, a national agency called Sundecop announced that the occupation of the factory owned by paper producer Manpa would last for 15 days and that, during that period, the facility would be guarded by National Guard troops.

According to government data, the leftist Venezuelan government’s attempts to reform the national economy have resulted in an inflation rate of 32.9 percent and shortages of food, coffee, flour, sugar and other basics.

Venezuela sits on the world’s largest proven reserves of crude oil. However, the nation’s government has had poor relations with the US. Former President Hugo Chavez was known to make claims about alleged US plots to kill him and current President Nicolas Maduro recently claimed the White House is plotting to sabotage food, electricity and fuel supplies to Venezuela.

Weatherill: Abbott government must commit to Holden

TWO Australian wind tower manufacturers have made complaints to the Australian Anti-dumping Commission regarding Korean and Chinese wind towers being sold in Australia at below the price of production.

The wind tower industry is suffering due to factors such as uncertainty around renewable energy targets and a struggling Australian steel sector.

RPG, a major manufacturer of towers, collapsed in October last year and announced 154 redundancies.

Steve Garner, general manager of Keppel M A Prince, 1 0 1 3the _ 0biggest 0 0 _ PRI manufacturer of the steel structures

in Australia, said that an increase in dumping had been due to the US taking action on the practice

by Chinese and Vietnamese companies.

SA premier Jay Weatherill has “If this situation is allowed to repeated his warning that Holden will continue, it will destroy hundreds of cease manufacturing in Australia if manufacturing jobs in the Australian the new federal government does not clean energy sector and many more pledge further assistance. indirect jobs,” he said.

Prime Minister Tony Abbott has “Some companies started stated that the government does importing towers and the price not want to see the industry living was absolutely ridiculous,” he said. “hand to mouth”, and wants to see it “So we looked more carefully and improve its performance. recognised it’s dumping and that Weatherill has warned that if the there is injury.” federal government did not commit The anti-dumping commission can to a $275 million co-investment slap then Holden 1 import 2 0 1 duties 3 - 0 9on- products 1 1 T 0 9that : 0 3 : package 0 7 + 1 by 0 :Christmas, 0 0 are found to have been dumped. would have no future. The money would be contributed by the federal ($215 million), South Australian ($50 million) and Victorian ($10 million) governments. “[Holden] need a commitment as soon as possible, they are making decisions about $1 billion worth of investment in two new models which will secure the future of the plant for another 10 years.” Weatherill said.

SAFE-D-CANT offers a wide “The workforce has made its range of spill containment, drum contribution by agreeing to very decanting and handling solutions substantial wage restraint, so really it is over to the Commonwealth t: 1300 134 223 f: 1300 307 895 Government to see what contribution e: sales@storemasta.com.au they’re prepared to make to secure www.storemasta.com.au the future of Holden.”

PR OT EC TIN G OUR IT H EN VIRO NM EN T W IN G Sa fe -D -C an t BUND PR OD UC TS

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protecting the

10 OCTOBER 2013 Manufacturers’ Monthly

The SA government is prepared to further assist the auto sector.

Weatherill has said that Holden’s exit would cost 16,000 jobs in South Australia alone.

New industry minister Ian Macfarlane has spoken to Holden managing director Mike Devereux, and plans to visit the car maker in October.

He has said the government would assist, though added that it did not have a “pocket full of money”. manmonthly.com.au

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

Inductive angle sensors TURCK offers a new line of inductive angle sensors for rotary actuators.

Operating with the inductive resonant circuit measuring principle, these inductive angle sensors deliver enhanced valve monitoring on rotary actuators.

They are designed with an innovative open face design, providing analog or discrete outputs and flexible mounting options.

They are able to monitor three-way valves, while also detecting the valve position during cleaning cycles.

Additionally, the sensors are capable of detecting the wear of seals, saving downtime from seals that are worn from switching cycles.

The inductive angle sensors provide a freely adjustable range within 360 degrees, which is said by the company to eliminate the need for adjustment of the actuating element and reduce manual labour.

Featuring a protection rating of IP67 and a rugged, design, M A 1compact 0 1 3 _housing 0 1 2 _ N E Dthe P inductive angle sensors provide a wear-free

Hi-tech welder BOC has released a hi-tech welder, the Taurus 505, which is said by the company to be suitable for professional MIG/MAG standard welding.

Produced by Germany’s EWM, the relatively portable machine was tailored for the mining industry but is also suitable for use in other heavy applications such as production work in steel and vehicle construction.

With multi-shift operation and stable metal housing for a long The welder has high power reserves. service life, this welder is designed for versatility and safety.

Weighing 45kg, the inverter welding machine can be equipped with a roll cage. It can be carried comfortably by two people, transported in the back of a The inductive angle sensors provide accurate ute or lifted to difficult worksites by crane. valve monitoring on rotary actuators.

It has the ability to drive a voltage sensing wire feeder and is also fitted with sensing solution in harsh applications. a voltage reduction device that is compliant to AS 1674.2-2007 for Category C The sensors provide optimal performance environments. in temperatures ranging from -25 to 75 A modular welder which can be water or gas cooled, it is suitable for MIG/ degrees Celsius.

MAG, MMA and air arc gouging.

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Swedish dust and fume equipment manufacturer starts production of dust collectors in Australia Global fume and dust equipment market leader Nederman have started production of their FM range of pulse jet dust and fume collectors in Australia. The production unit has been set up in their Bayswater, Victoria head office. Country Manager Keith Sanderson states “Australia is an important market for Nederman and we recognise that our customers want easy access to these types of units. With that in mind and also bringing production back to Australia rather sending it offshore, the group decided on starting production of these units locally for the Australian market”.The FM range is suitable for a variety of dust and fume applications including explosive applications.

For more information contact Nederman Pty Ltd 03 8720 3700 www.nederman.com.au csg@nederman.com.au

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It is designed to test all the aircraft’s metallic wiring – coax, twisted pairs, or single-wires in a harness.

The kit features a rugged, hard case with altitude compensation and ATA 300 certification.

It is designed to secure the TDR and all accessories individually from accidental loss.

This is an anti-FOD (Foreign Object Damage) must for aviation facilities.

The kit’s lid is labelled to ensure all accessories are present and to make it easy for technicians locate them (again this is an anti-FOD requirement).

The accessories include eight specialised test leads for connecting to standard aircraft connectors.

In addition, a certificate of calibration for the E20/20 Step TDR is included as standard.

The TDR’s cable list has an aircraft wiringMlist Engineers A 1pre-installed.

0 1 3 _ 0 1 3 _ S Pcan R customise and create individual aircraft

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The kit comes with a hard case. lists using the included ETDR PC Vision software.

Tekmark Australia 1 2 0 1 3 - 0 9 - 1 9 T 1300 1 5 :615 2 882 5 : www.tekmark.net.au

THE NATA Calibrated Grant GR150-S5 temperature bath is a water/oil bath and circulator for calibration of temperature probes and analytical procedures.

It is suitable for applications requiring high precision temperature control in the range of ambient to 100ºC for water and up to 150ºC for silicon oil.

The temperature bath has a stability of ±0.005ºC, uniformity of ±0.02ºC and display resolution of 0.1ºC. Also included with this unit is a timer function that enables reaction timing, a variable high temperature alarm setting, and a user calibration facility for optimum accuracy at the required operating temperature.

It features a clear and easy-to-read digital temperature controller and display, as well as a heater timer for early starts/ late shutdowns.

Stainless steel tank dimensions are 300 mm x 150 mm x 150 mm.

Further features include a relay for 3 switching 9 + 1 0 :external 0 0 devices on/off; a dual-position bridge plate; and a

The temperature bath features a digital temperature controller. range of convenient programming features.

Techrentals 1300 603 601 www.techrentals.com.au

FOOD, F OOD, BEVER BEVERAGE, PHARMACEUTICAL, PETROCHEMICAL AND ALL INDUSTRIAL APPLICATIONS TIONS Mixing units, hose stations, water-saving nozzles, and wash down accessories.

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What’sNEW Energy efficient compact compressor

Temporary roof anchors

ATLAS Copco has released a very compact SAFEMASTER oil-injected rotary screw compressor from 7 Height Safety to 37 kW: the 7-37 GA VSD+.

Solutions has It has a small footprint and is said developed a by the company to deliver significant temporary roof improvements in free air delivery (up to anchor for use on 12%), and energy-efficiency. It requires metal deck and on average 50% less energy than a corrugated comparable idling compressor. sheeting roofs.

It offers variable speed (frequencyThe ‘Portable controlled), will be suitable for most Roof Anchor’ is industries and aims to contribute to the rated at 15kN and green economy needs. designed for single The compressor is said by the company person use.

The roof anchors are intended for single person use. to deliver better performances, with less It is energy consumed, low noise levels and a recommended compact footprint. With the GA VSD+, a for tradesmen who work on residential roofs which do not have permanent fall arrest variable speed drive compressor achieves systems installed. better performances even at full load than The fixing of the anchor to the roof is simple – remove 4 roof screws, put the anchor a comparable idling compressor. in place and replace the screws through the anchor into their original holes.

This innovation will enable all The removal is just a reversal, and leaves the roof as you found it. compressor users to switch over to The roof anchor is used by connecting the snap hook of your rope line (which is variable speed drive compressors, an already connected to your harness via an energy absorber) to the energy absorber important step towards a more sustainable The compressor was developed in-house. permanently connected to the roof anchor. industry. Further features include a more This allows the user to move out from the anchorage point to the work area in a full efficient fan, a robust air intake system, and a new drive train.

360 degrees around the anchor point.

Atlas Copco Safemaster Height Safety Solutions 1300 213 347 MA 1 0 1 3 _ 0 0 0 _ N O R 1 2 0 1 3 - 0 9 - 1 6 T 11300 0 :812 1 155 0 : 3 6 + 1 0 : 0 0 www.atlascopco.com.au www.safemasterhs.net.au

14 OCTOBER 2013 Manufacturers’ Monthly

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The monitor features The monitor features a widescreen ratio of 16:9. a widescreen ratio of 16:9, providing 40% more screen area than traditional 4:3 aspect ratio displays.

Resolution is full HD (1920 x 1080). Furthermore, with the addition of four-finger multi-touch capabilities it provides greater control and viewing of the information displayed such as zoom, slides, twist, etc.

Other features include: RS-232 & USB dual touch interface, VGA & DVI-D dual video input port, 0 to 50°C operating temperature, and IP65 front panel.

The panel glass is hardened to 7H on the Mohs scale, which is the same hardness as the mineral quartz.

The monitor can be mounted on panels, on walls, or by a stand using the VESA hole behind the unit.

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The solenoid controller simplifies timed pulse cleaning of dust collector filters.

Category II 3D and may be used with any type of cartridge dust collection system that utilizes diaphragm valves.

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Expanded sign range NOW that Signet has made 25 additions to its sign range, the company claims to offer signs for almost every warehouse and site application. The new signs are in the house keeping, danger, warning and emergency sign sections. They include Spill control station emergency signs, Beware of vehicles warning signs, Chemical storage area danger signs, Mandatory protective clothing signs, and High voltage danger signs.

The signs are available in a selection of materials including colorbond metal, polypropylene, core flute and self sticking outdoor vinyl.

The company also offers sign mounting solutions. Within this category, it has added pole brackets and fence

The signs are available in a selection of materials. mounts to its previously available mounting tapes. â&#x20AC;&#x2DC;Buy-to-demandâ&#x20AC;&#x2122; signs and custommade signs are also available.

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Rotary screw air compressors THE new KHE range of screw compressors from Southern Cross Compressors has been designed with the intention of focusing on energy efficiency and reliability without sacrificing output.

The rotary screw air compressors are available in models from 15kW to 400kW and offer a number of features including direct drive, a laminar flow inlet controller, and centrifugal high pressure cooling fans. In addition, they feature single pass oil coolers, triple discharge bearings, and stainless steel control piping.

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TechnologyIT@MM SICK discusses productivity, process and innovation From optimising factory processes to having a hand in massive movements of iron ore to checking in bags at airports: sensors are everywhere, making things work. So is SICK. Brent Balinski reports.

The importance of customer feedback

check-in vision to become reality.

“By using RFID technology, barcode technology, and unique “The Qantas bag drop, new RFID antenna technology that generation check-in is probably one was developed for us in Australia, of the most high-profile provisions we combined the smart sensing of sensor technologies that touch technologies to enable the new virtually everybody, the travelling generation check-in to become public,” explained David Duncan, reality.” managing director of SICK in SICK, while not a minnow, falls well within the Hidden Champion definition.

Duncan’s company is the Australia.

Australian subsidiary – one of more “We were able to develop and “One is from the customer; if the than 50 subsidiaries worldwide – of take Qantas’s vision and provide A classic Hidden Champion customer has a vision that they wish AG, the necessary M A 1 0sensing 1 3 _ 0technologies 1 6 _ G R A - SICK 1 2 0 1the 3 -German 0 9 - 2sensor 3 T 1 and 1 : 0 8 : A4 prime 5 + 1 example 0 : 0 0 of the “Hidden to try and improve or to reduce costs automation specialists. to allow their new generation Champion” concept popularised or – in one area in particular for by management and strategy guru mining – improve safety, these are Professor Hermann Simon (see usually the drivers for innovation. elsewhere in this magazine for an And innovation can be not only interview with Simon) of Simonproduct, it can also be structure, it Kucher & Partners, SICK is a highly can be organisational as part of that specialised company that operates process.” off most people’s radars yet has a global reach, enabled by innovation, Solutions to boost a superior focus, and a close productivity understanding of and collaboration with its customers.

Upping productivity is a big part of Send your part, see the mark SICK’s technology is found in what SICK offers those it is partners countless applications in factories to, according to Duncan. and elsewhere.

“There are a number of areas Factory automation is one of of innovation that our sensing its three specialties, with the other technologies drive, and also two being logistics automation and the innovation of our sensor process automation. technologies is driven by the However, there are other requirements of the customer,” applications, with a notable case explained Duncan. being the use of SICK’s technology Closeness to the customer has to protect the Mona Lisa in the also been important in working in Louvre Museum. developing solutions for mining As with other Hidden companies, for example with Rio Champions, innovation is often Tinto on its automated Mine Of The led by a deep understanding of the Future project, as well as in serving needs and close relationship with the many companies in the oil and gas customer. sector.

“Innovation usually comes from “We supply the world’s most two sources,” explained Duncan accurate ultrasonic flow meter Scan barcode to see video demonstration during a visit by Manufacturers’ for custody transfer of gas,” said Monthly to SICK’s Heidelberg West Duncan. factory, which opened last year.

“We also provide significant 16 OCTOBER 2013 Manufacturers’ Monthly

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sensor technologies through our gas analyser systems, that are provided to underground coal mines, where we analyse and monitor the atmosphere in underground coal mines, where we are looking for various levels of toxic gases such as methane and others,” explained Duncan, whose company’s sensors are used where a canary might’ve been in the past.

Investing in R&D Another quality of Hidden Champions is the emphasis on investing in innovation. It is often a response to clients’ specific issues, and it is on average twice that spent by other companies.

While SICK, with global revenues of 971.3 billion Euros, isn’t a minnow, it’s hardly a huge consumer brand, and falls within the Hidden Champion definition.

It also shares the emphasis on innovation.

SICK’s team of research and development engineers numbers about 300, said Duncan, and he puts the company’s R&D investment at about 10 per cent of revenue.

“There’s a strong link between headquarters R&D who predominantly develop products as part of that process, and a lot of the R&D in Australia is done on the application of those products,” he said.

“And A M 0that 5 1is3one _ 0of 0 the 0 _ SPI . pd exciting parts of the international

manmonthly.com.au

SICK’s technology has been used at the the Louvre Museum to protect the Mona Lisa.

presented at the Hanover Machine corporation, because SICK AG, our Tool Exhibition in 1952. headquarters, and also the local Since then the company has SICK company, work together. What registered firsts in many areas, we’re striving for is a global partner including the first high-speed, highwith local competence.” quality colour 3D camera.

Following its founder’s lead “That’s a clear alignment with Innovation is hugely important to the philosophy of SICK and also the company, and has been since the vision, which is Independence, founder Erwin Sick went into Innovation and Leadership,” pointed business in 1946. out Duncan.

He went on to register a patent “...Dr Erwin Sick, was an for the world’s first light curtain – soMhis Alegacy fwhich P ahas g echanged 1 1 industrial 5 / 0 4 / safety 1 3 , 9 inventor... : 4 4 : 3 And 1 A E S Tto the organisation, which is recognised – with the first marketable version

in the vision statement, is that we continue to build innovative products, leading technology products that solve and/or develop market areas for sensing.”

Duncan will address SICK’s dedication to invention at the Australia Germany Business Conference, on October 31. He will discuss how the Australian chapter of SICK goes about, “continuing the spirit of Erwin Sick as an inventor, as a developer of innovative products.”

Manufacturers’ Monthly OCTOBER 2013 17

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Compressors& PNEUMATICS Ignore that machine at your peril With electricity costs continuing to rise, many manufacturers are still failing to realise that compressed air is their most expensive utility. Alan Johnson reports.

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hugging away in a corner of almost every factory sits the ubiquitous air compressor, often totally ignored (until it breaks down). However, according to industry professionals, this is a very expensive strategy.

For when it comes to operating costs, research shows that it takes 7 to 8hp of electricity to produce just 1hp in an air tool, yet this high energy cost is often overlooked by manufacturers.

Nash Bakhit, Product Manager with Atlas Copco, says companies who ignore their air compressors are making a costly mistake. “It’s false economy.”

“My advice for manufacturers is to monitor exactly how much air they actually need, and be aware of their energy consumption used to run their compressed air system.

“The cost of the electricity used to run a compressor can add up to 70% of the total cost of running a compressor,” Bakhit told Manufacturers’ Monthly.

“Manufacturers should be aware, however, that there are numerous energy management systems available, all designed to reduce energy consumption in many different ways, including heat recovery systems, compressor control systems, which can control up 30 compressors, plus air and energy audits.

“It’s also false economy for companies to ignore their compressor’s maintenance schedules, or to run their machines flat out all day and every day with no maintenance. I’ve seen companies who have done this and needed to replace their machines in under 5 years. That strategy is crazy,” he said.

Surveys Bakhit suggests a good first step for manufacturers is to invest in an air measurement survey.

“With our specialised equipment, we can measure the air flow, the 18 OCTOBER 2013 Manufacturers’ Monthly

With ES central controllers it is possible to manage air compressors based on demand. air pressure, and take some power measurements from the compressor.

“We then compare all these measurements and provide the client with a better solution than the existing system.”

Bakhit says he can recommend a number of different options, ranging from cost-effective compressor management systems right through to the latest energy-saving VSD (Variable Speed Drive) compressors.

“For example, a company might have four or five air compressors running all the time, sometimes running unloaded continuously. This scenario is wasting a lot of energy, and money.

“But with our ES central controllers we are able to manage these air compressors based on demand.

“When demand is low, for example, we can set the limits so only compressor number 1 is

running, but when more air is needed it will select compressor number 2.

“Then if we have high demand, the controller might select the highest capacity compressor, say number 3, and stop 1 and 2. It’s a very good system with a number of variants.

“With the central controller, a company’s most economic and efficient machines are prioritised to reduce downtime and match workload requirements,” he said.

Bakhit explained that the system works on any brand of compressor, it doesn’t have to be Atlas Copco machines.

“And if the machine is quite old, and a competitor’s machine, we have a Comms box, what we call the translator, to translate the compressors communications to the controller to understand its language and manage up to five compressors.

“The ES central controller is a

very cost effective option, because if the machines old but still serviceable, we can manage the compressors efficiently, plus manage the maintenance of the compressors.

“So rather than just sell the customer new machines, we are able to offer the customer a number of options depending on the applications.”

Bakhit says to help customers further reduce costs; the controllers are able to accurately control the pressure in the system.

“For example, a standard load and un-load compressor would run on a pressure band of 1bar, but an ES controller can minimise that to 0.5 of a bar or less.

“The lower the pressure, the lower the losses, less energy consumption and lower energy cost,” Bakhit explained.

“Manufacturers should know, a properly managed compressed air network will save energy, reduce maintenance, decrease downtime, increase production and improve product quality,” he said.

Waste heat Bakhit says waste heat recovery systems are another way for manufacturers can cut their energy costs; by reusing the heat generated by the air compressor for a variety of applications.

“The systems are becoming increasingly popular in Australia; they are not just for European companies.

“One local manufacturer, for example, is using the heat generated by the factory’s air compressor to heat the company’s hot water system; for the workers’ showers etc.

It’s basically free hot water.”

Bakhit said in another application, the heat generated by the factory’s air compressor is used to heat boilers used in the manufacturing process.

“Wherever a company uses heat in its process, the system comes into the equation,” Bakhit said. manmonthly.com.au

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Variable demand To further reduce operating costs, Bakhit says the companies load/ unload air compressors offer two pressure band running positions.

“What this means is that during the day the machine can run on an average of 7 bar, or it could be 8 or 10 bar, whatever the factory needs during the day.

“Then during the night, when there’s not much load, the machines can run on a lower pressure band which could be 4 bar or if no air is needed say between 9am and 6am we can have them on a programmed stop. With a VSD, when no air is needed, the machine will stop completely.”

Bakhit explained that VSD compressors run based on demand, Compressor controllers have the ability to considerably reduce a compressor’s energy if higher air flows are needed, the consumption. machine will ramp up to maximum speed to provide maximum air flow.

“If minimum air flows are needed, an ROI of less than three years with Leaks the machine will ramp down to idle VSD compressors, in some cases.

Bakhit acknowledges that nearly speed to supply just the air needed, “It really depends on the site every compressed air system has or even M A stop 1 0 1if 3no_air 0 0is0needed.” _ EXI 1and2the 0 1application, 3 - 0 9 - 1and 6 Tsizing 1 0 :the 2 3 : 1 some 4 + 1air 0 :leaks, 0 0 but to varying 1013companies HP ATG ManMonthly.pdf 1 13/09/2013 10:50:27 AM Bakhit says can expect compressors correctly,” he said. degrees.

“Air leaks in a system can cost a company huge amounts of money.

“In some cases, the leaks in the system are so bad that we see machines running just to feed these leaks.

“So if we can find and stop these leaks we can make substantial energy savings,” he said.

Bakhit explained that one of the company’s energy management systems measures not just the air flow and pressure, but also an air leak detection survey.

“We take some ultrasonic measurements of the air, and with some quick calculations we can give the customer an idea of what these leaks are costing the company and how much it would cost the company to fix the leaks.”

He admits some leaks are so small that they are not cost effective to fix, but says most are.

“When a customer sees that the factory’s air leaks are equivalent to a 45kW machine running 365 days a year, he starts to take the air leaks seriously,” Bakhit concluded.

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Manufacturers’ Monthly OCTOBER 2013 19

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Compressors & PNEUMATICS

Air industry answers its critics European research shows that, with innovation, it is possible to save energy and further exploit the advantages of compressed air technology. Sabine Appel writes.

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ompressed air technology is indispensable to industry. It is no longer possible to imagine manufacturing without it.

It is compressed air technology which enables the filling of widespread PET bottles, and it’s compressed air that helps in the purification of water in sewage treatment facilities.

However, the economic and energy efficiency of compressed air often leads to criticism of the technology.

Compressed air technology expert, Prof. AP Weiß at Germany’s Amberg-Weiden University

compressed air as used in operations is indeed a form of rational energy usage of the future; when it is used correctly there is no need for anyone to shy away from making comparisons.

“Today, compressed air is more efficient than ever before. However, if the factor of heat recovery is not considered, a company will realise no economic advantage.”

However, Weiß predicts compressed air systems will be used

more and more in the decentralised monitoring of excess renewable energy.

Today, compressed air is more efficient than ever before. of Applied Sciences says that, in the past, the focus was on efficacy rather than the expenditure/ benefit ratio.

“However, climate protection and energy conversion have called for people to revise their thinking, with the focus now on efficiency,” Weiß says.

“As it is, economic and scientific fields have for a long time pursued new examples whereby proven technology goes hand in hand with innovation.

“The common aims are clearly outlined: continuous improvement of the energy efficiency of compressed air, and to make compressed air technology sustainable.

“When one makes use of the full potential, 20 OCTOBER 2013 Manufacturers’ Monthly

Heat recovery While Kaeser Compressors’ Erwin Ruppelt says compressed air audits have the potential to reduce energy consumption related to the generation of compressed air by a one third, he believes compressed air technology is capable of even more.

“In the domain of heat recovery, more valuable heat energy can be saved,” Ruppelt says.

He points out that 100% of the drive energy supplied to a compressor is converted into heat.

“Up to 96% of this energy can be used a ‘second time’ – either for heat purposes or as process heat!”

He says that specific use of compressor waste heat allows not only a reduction in consumed electrical energy but also a reduction in heat energy requirements.

“One company, for example, was able to save a total of 552,000kWh; 36% of the total heating costs of the company,” Ruppelt says.

Energy savings A recent study conducted by the European Union shows that 18% of electrical energy in industry is consumed in the generation of compressed air.

According to the study, a third of this electricity can be saved with the application of appropriate technology and more efficient systems.

The Amberg-Weiden University works in close collaboration with the industrial sector (including Deprag) in the development of innovative compressed air machines/tools.

For example, the development of fastrunning turbines for compressed air, CO2, natural gas, steam and other vapours, and the conception of generators necessary have lead to Deprag’s Green Energy turbine system – a technology with which small residual quantities of process gases can be profitably converted to electricity.

The turbine motor is said to offer unsurpassed output in terms of power to size ratio, as it is only half as big as a vane motor.

Deprag’s Compressed Air Motors Project Manager Dagmar Dübbelde says that by exchanging a vane motor the size of a fist for turbine motor of equal size, he can double motor output on the spot. He adds that the turbine requires no lubrication and there are no wear parts.

Dübbelde says that, compared to electrical motors, compressed air motors and compressed air-operated tools distinguish themselves for their high output in terms of short-term-sudden release of power (impact tools), speed (cylinders), overload and usability under duress, high duty cycles, robustness and relative immunity to humidity and dirt.

“In addition there is the EX protection of the compressed air motors,” Dübbelde says.

“In an explosion-risk environment, where a single spark can pose a significant threat, electronic tools can only be used under specific circumstances, but there are no such pre-requisites with compressed air equipment.”

Economics However, critics fault the economics of compressed air technology. They claim the energy consumption for compressors is higher than the manmonthly.com.au

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same amount of power used directly by electrical tools.

But Dübbelde says compressed air motors and electrical motors cannot be compared one-on-one.

“The application is determined by the drive solution. For example, in a packing machine, a motor should produce 450rpm with no load.

In application, a load torque value of 25Nm is induced at a reduced speed for an extended period of time at the end of the packaging line.”

Dübbelde points out that electric motors cannot be overloaded over extended periods as they would overheat.

Thus, an electric motor for said packaging machine’s load torque would require an output of 1170W. “A calculation for a compressed air motor is completely different. For this application we would select a compressed air motor with a nominal torque of 15Nm and a nominal speed of 275rpm,” Dübbelde says.

“Given that the working torque is less than the nominal torque, the motor runs at close to the no-load torque, at 450rpm, under low demand. Based on this, the required output of the compressed air motor is only 430W. “When applying a compressed air motor, only one third of the output of an electrical motor needs Kaeser Compressors’ M 31 portable compressor features energy-saving compressor Sigma Profile rotors. to be considered for this packaging machine.”

As such, Dübbelde says that “the energy He points out that compressed air motors are “As such, pneumatic motors must be carefully balance compressed a 3 - at operate designed for their use in such a way that it saves M A of 1 0the 1 3 _ 0 2 1 _ air A Tmotor L - appears 1 2 in 0 1 0 their 9 - 1 most 9 T 1effective 4 : 3 9 when : 0 7 they + 1 0 : 0 0 close to completely different light.” energy and running costs.”

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Manufacturers’ Monthly OCTOBER 2013 21

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Compressors & PNEUMATICS

The electricity to run an air compressor is about 70% of its cost of ownership.

Cutting your compressed air costs Compressed air is a costly form of energy, here’s what NOT to do to improve your plant’s efficiency. ABB’s Philip Lewin writes.

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sed in around 80% of all manufacturing, compressed air is one of the most expensive sources of energy in a plant and costs as much as eight times the price of electricity.

The electricity to run an air compressor is about 70% of its cost of ownership, far greater than the costs of buying and maintaining the compressor itself.

On average, compressed air is around 10% of manufacturing’s energy costs, but in certain industries this can be as much as 20%. Yet in a US Department of Energy study, only 20% of manufacturers have addressed the energy efficiency of their compressed air systems.

So why is such a common and expensive source of energy used so inefficiently?

A good part of the explanation can go back to the adage, “if it ain’t broke, don’t fix it.”

As long as the compressed air is there to do the job it’s supposed to do, there is no reason to worry about it.

22 OCTOBER 2013 Manufacturers’ Monthly

So here are 10 ways to help air compressors continue wasting air: 1. Don’t know your real cost of compressed air. There are simple calculations you can make based on your air compressor’s operating hours and work load that will tell you how much it actually costs you to run your compressor. If you can’t see the cost, you can’t see the savings opportunities.

2. Continue using compressed air inappropriately. In many factories it’s easy to find idle equipment still drawing compressed air. It’s also common to find compressed air being used when far more efficient alternatives are available – for example an electric fan requires far less energy for cooling than compressed air, and vacuums are much more efficient for cleaning debris than a compressed air nozzle.

3. Just ignore leaks. Most manufacturing processes require air compressed to around 80-90psi, while many

manufacturers compress air to over 110psi just to compensate for leaks in the system. For every 2psi in increased compression, you use around 1% more energy.

4. Compress air at the maximum pressure you can. Many manufacturers run large air compressor to meet the needs of their maximum demand consumers. For example if the majority of a plant’s processes require 80psi and one process requires 95psi, a factory will compress all its air to 95psi. It is often far more efficient to compress air at the average load, and then implement a local booster for individual higher demand processes.

5. Don’t worry about air quality.

Air quality should be matched to the end use, but it’s wasteful to delivery higher quality air than you need.

6. Don’t conduct an air demand analysis. You might find out that your average demand is far below the capacity you are compressing.

Some compressors run well at

7.

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9.

10.

full capacity, but become very inefficient at lower capacities.

If your average demand is low, it’s often more efficient to have one robust compressor for peak demand, and then a smaller one for average loads.

Never match compressed air supply to demand. There are a number of control and storage technologies for compressed air that can accommodate occasional demand peaks. These allow you to run smaller compressors at higher energy efficiency levels.

Don’t connect your compressor motor to a VSD (variable speed drive). VSD’s can help match the motor speed to the demand, making sure they only do the work that is necessary.

Forget about receivers and filters. These are supply buffers that help accommodate demand spikes, which mean you can compress air closer to your average demand, not your peak demand.

Ignore opportunities to capture and reuse waste heat. manmonthly.com.au

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It removes the solids such as chips, swarf and shavings out of used coolants and other liquids.

The device vacuums the coolant or liquid that is filled with debris into the included 55 gallon drum, trapping all the solids in a reusable filter bag.

With a turn of the flow valve, clean liquid pumps back out.

Powered by compressed air, the device has no motors or impellers to clog or wear out.

Safe operation is assured with a built-in pressure/vacuum relief and an automatic safety shutoff valve that prevents spills or overfilling.

Compressed Air Australia A D _ M A N M C A P O C T _ 1 2 . p1300 d f787 688, Pa ge www.caasafety.com.au

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Fasteners& ADHESIVES Understanding fast-curing adhesive systems There are several fast-curing adhesive systems on the market, the key is knowing which one is right for your application. Alan Johnson spoke to the experts at MasterBond to find out more.

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2 0 1 3 - 0 9 - 2 3 T1 1 : 0 7 : 1 6 + 1 0 : 0 0 There are benefits and trade-offs to consider when choosing an adhesive.

T

he most commonly used fast curing compounds on the market today are one and two part epoxies, one and two part silicones, Cyanoacrylates (CAs) and UV and LED curing compounds.

All have special attributes, but not all manufacturers know which ones to use where and when.

Alan Johnson – Starting with one part epoxies, can you tell me about their benefits and trade-offs, with respect to fast curing?

MasterBond – The curing times vary from snap curing systems to systems curing within around 60 minutes upon exposure to heat.

These heat curing adhesives can potentially save hours or days worth of cure time versus certain standard room temperature curing two part epoxies.

In addition to a speedy cure,

24 OCTOBER 2013 Manufacturers’ Monthly

they also offer an “unlimited” working time at room temperature, since the cure tends to be initiated typically with at least a 250°F heat cycle.

In applications with complex assemblies or fixturing procedures, this working time advantage helps justify the use of this type of adhesive.

The need for a heat cycle in an oven can rule out certain applications where heat addition might not be practical.

Some of the faster heat curing one component adhesives might be exothermic in thicker sections.

This tends to rule out its usage in some casting or potting applications.

AJ – For two part epoxies, what are some of the benefits and trade-offs for a fast curing assembly process?

MB – With set up times as fast as a

few minutes at room temperature, the necessity for adding heat to initiate the cure can be avoided.

Some two-part fast cure epoxies can be a good choice in certain applications where one part heat curing epoxies cannot be used.

When automatically mixed and dispensed, the difficulty of manually applying such a system can be overcome.

The speed and performance of two-part fast cure epoxies tend to offset the difficulties of mixing in applications that have both assembly bottlenecks and stringent property requirements.

It’s also worth noting that some two-part fast curing epoxies can generate more heat during the cure compared to slower curing systems.

Like the one part epoxies, these fast curing systems may not be ideal for some potting or encapsulating type applications. manmonthly.com.au

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AJ – What about one part silicones?

MB – These adhesives can typically reach a tack-free state within 3 to 15 minutes.

The cure cycle for these systems can vary from minutes or hours to setup and days to fully cure depending on the accessibility to moisture and the geometry of the set up.

AJ – How do one part silicones compare to two part silicones?

MB – Depending on the configuration of the assembly, two-part silicones may not set up as quickly as their one part counterparts.

Typically, they can be cured with the addition of moderate heat to about 150 to 200ºF in a few hours.

However, in thicker sections and for larger cross sections, where the accessibility to moisture would be limited, two part silicones might be preferred.

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AJ – Cyanocrylates are simple to apply. What other characteristics do they exhibit?

MB – That’s true, with no need for ovens and no inherent need for specialized dispensing equipment, they are among the easiest system to apply.

They are also capable of setting up in less than a minute and reaching a full cure very quickly.

Over the years, they’ve staked out a place in fast moving assembly lines for medical devices, electronics and industrial applications.

Their chief drawback is that they have a somewhat limited range of properties.

Compared to epoxies and silicones, CA adhesives are brittle with poor resistance to impacts, thermal cycling and high temperatures.

Also, CAs have an erratic resistance to moisture, so they are not the safest choice for use in consistently wet or humid environments.

PM

AJ – UV and LED curable adhesives can cure almost instantly upon exposure to a light source. What are their benefits?

AJ – What caveats should the engineer be aware of when determining if a fast cure adhesive is necessary for the application?

MB – Benefits include optical clarity, MB – Engineers should always moisture resistance and strong bonds question the need for speed when to many different substrates. selecting adhesives.

Since they require light (UV or Although fast curing adhesives visible depending on the product) to offer numerous advantages they fully cure, they offer good control of have certain trade-offs when dealing working life if kept away from light with certain kinds of bonding, prior to use. sealing and potting applications.

But they can be problematic in Proper precautions need to be applications where the joint design taken in some scenarios by the or depth creates shadows that light means of automated mixing and cannot reach. dispensing to circumvent any Good design practice, however, complications during assembly can limit these shadows. There are operations. also “dual cure” products available It is important to account for that combine a UV light cure with a working time needs during the secondary heat cure. These can be assembly process, especially in a good workaround for design with some situations where it leaves no shadows. time to position parts correctly in a Some light curing adhesives also fixture. have superior chemical resistance, Slower curing adhesives are though not quite up to the level of preferred with longer open times in certain M A 1chemically 0 1 3 _ 0 resistant 0 0 _ M Eone T and 1 applications 2 0 1 3 - 0with 9 - difficult 0 4 T 1 fixturing 2 : 1 3 : 2 7 + 1 0 : 0 0 two part epoxies. processes.

Low viscosity, two part epoxy SUITABLE for large castings, Master Bond’s new EP21LVSP6 two part epoxy combines a low viscosity and low exotherm with a working life of 3-5 hours.

It can also be used for bonding, sealing and coating applications in aerospace, electronic, electrical, optical and other specialty industries.

The epoxy has a noncritical one to one mix ratio, by weight or volume and its processing is facilitated with colour coding—Part A is clear and Part B is amber clear. It is formulated to cure at room temperature or more rapidly at elevated temperatures.

According to the company, the epoxy bonds well to a variety of similar and dissimilar substrates such as metals, composites, glass, ceramics, rubbers and plastics.

The epoxy is said to have a tensile strength of over 7,000psi, a tensile lap manmonthly.com.au

The epoxy is available in a variety of packing options, including a gun dispenser. shear strength greater than 2,500psi and is able to withstand chemicals including water, oil, fuel, acids and bases.

It is a competent electrical insulator over the temperature range of -60°F to +250°F. Master Bond www.masterbond.com Manufacturers’ Monthly OCTOBER 2013 25

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Fasteners & ADHESIVES Multi-material adhesive

The paste becomes brittle once it cures completely, so that any future movement will break the seal alerting service personnel/ inspectors.

Tamper detection paste HENKEL Australia has released Loctite7414 Torque Marque, a fast drying paste to be used in production to visually detect any movement in the adjustment of parts.

The paste has been developed for use on compression fittings, studs, nuts, parts and assemblies after they have been set to proper tension or position.

The company says the paste has excellent adhesion to metals, including aluminium, magnesium, F D 0 5titanium, 1 3 _ 0stainless 0 0 _ I steel D Eand . pcopper, df Pa and is non-corrosive to these metals.

26 OCTOBER 2013 Manufacturers’ Monthly

Drying in approximately 1-2 minutes, the paste becomes brittle once it cures completely. Any future adjustment or movement will break the seal so service personnel or inspectors can visually detect any changes or tampering with equipment.

The blue high viscous (non-drip) paste is simply applied across the fastener/component interface to visually detect any movement in the adjustment of parts.

Henkel Australia ge 1 1 5 / 0 4 / 1 3 , 1 0 :1300 0 3813: 440 2 2 www.loctite.com.au

HENKEL Australia has released a new multi-material adhesive, Loctite 3090, which is said to represent the latest development in 2-component adhesive technology by combining high gap filling properties with high bond strength and fast cure.

The company says the adhesive offers the same high bond strength and fast cure of Loctite’s instant adhesives an industry benchmark, plus it can fill gaps up to 5mm.

Suitable for most plastics, wood, leather, cardboard, fabrics, the adhesive can also bond headlight tabs and mirrors.

The adhesive also features improved handling: the clear instant adhesive is a high-viscosity gel, which allows easier application to vertical surfaces – without dripping.

Another new feature is the convenient 2-chamber syringe packaging enabling precise and clean application. Unlike onecomponent systems, Loctite 3090 does not depend on the moisture in the air to cure, but has an additional activator.

The two components are dispensed using one of the seven integrated static mixers included, to ensure that the components are always mixed in the right ratio and that curing is triggered within the defined timeframe, regardless of humidity and temperature.

Working time of the adhesive is 90 – 180 sec @ 25°C, handling strength 2 – 4 min, and is full strength in 24 hours (Lapshear strength, ISO 4587, after 24hours, 22 °C).

The adhesive’s temperature resistance is -20° to +80 °C (short term 100 °C), and can withstand contact with standard industrial fluids except alkaline and acid fluids.

Henkel Australia 1300 813 440 AM AEST www.loctite.com.au

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Labelling& PACKAGING Waste not, want not: how packaging can help tackle food waste With the global population set to soar and the growth of our agricultural industry threatened by climate change and competing land uses, Australia needs to toss out food waste – and packaging is the key. Danielle Bowling reports.

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round 40 percent of all food intended for human consumption in developed countries ends up as waste.

In Australia, 4.2 million tonnes of food sees its way to landfill each year: 2.7 million tonnes from households and 1.5 million from the commercial and industrial sector.

And with the global demand for food expected to jump 77 percent by 2050 (compared to 2007), food and beverage manufacturers need to reassess not only how they go about making their products, but what they’re doing to ensure they survive the supply chain and, at the end of the day, are consumed, not wasted.

RMIT University recently released a report, commissioned by CHEP Australia, titled The Role of Packaging in Minimising Food Waste in the Supply Chain of the Future,, which examined where and why food waste occurs along the food supply chain.

An Australian-first, the research draws on an international literature review as well as interviews with representatives from 15 organisations from within Australia’s food and packaging industries, focusing on food waste that occurs prior to consumption.

Australia’s food manufacturing industry is the second largest non-domestic contributor to food waste, sending 312,000 tonnes to landfill each year, beaten only by the food services sector, which generates 661,000 tonnes of food waste annually.

But this doesn’t mean our food and beverage manufacturers are wasteful or negligent – most of the food waste that occurs in the industry is unavoidable, and almost 90 percent is recovered and used as 28 OCTOBER 2013 Manufacturers’ Monthly

animal feed, compost, or energy.

Helen Lewis, adjunct professor and environmental consultant at RMIT University, told Food magazine, “The recovery rate in the food manufacturing sector is already very high, so the focus needs to be on reducing the amount of waste that is generated in the first place.

unpredictable weather conditions in agricultural production; products not meeting retailers’ quality and/or appearance specifications; and issues in distribution including damage in transit/storage due to packaging failures and inadequate remaining shelf lives.

The report then went on to identify a number of opportunities to reduce food waste through

Food manufacturing is the second largest contributor to the food waste generated by Australia’s commerical and industrial sector.

“Most manufacturers can do more to reduce the amount of waste they generate in distribution and at a retail level by looking more closely at where and why this occurs. For example, if manufacturers don’t specify their distribution packaging carefully, it may fail during transport or handling and result in products being damaged and thrown away. There is definitely an opportunity to improve the level of packaging expertise within companies to ensure packaging is specified correctly,” she says.

Report recommendations The study lists a number of reasons for food loss and waste at each stage of the supply chain, including damage from pests and disease as well as

packaging improvements. These include: 1) Distribution packaging that provides better protection and shelf life for fresh produce as it moves from the farm to the processor, wholesaler or retailer 2) Distribution packaging that supports recovery of surplus and unsaleable fresh produce from farms and redirects it to food rescue organisations 3) Improved design of secondary packaging to ensure that it is fit for purpose, i.e. that it adequately protects food products as they move through the supply chain 4) A continuing shift to pre-packed and processed foods to extend the shelf life of food products and

reduce waste in distribution and at the point of consumption 5) Adoption of new packaging materials and technologies to extend shelf life of foods (see table below) 6) Education of manufacturers, retailers and consumers about the meaning of use-by and best before date marks on primary packaging to ensure that these are used appropriately 7) Product and packaging developments to cater for changing consumption patterns and smaller households 8) Collaboration between manufacturers and retailers to improve the industry’s understanding of food waste in the supply chain, with greater attention given to where and why this occurs 9) More synchronised supply chains that use intelligent packaging and data sharing to reduce excess or out-ofdate stock 10) Increase use of retail ready packaging to reduce double handling and damage and improve stock turnover, while ensuring that it’s designed for effective product protection and recoverability at end of life.

This list of recommendations indicates that improvements can be made to both primary packaging and secondary/tertiary packaging in order to protect a product up until it’s on a retailer’s shelf, while also boosting its longevity once it’s there.

CHEP Australia has a significant interest in the study’s findings, not just because it commissioned the report but also because it describes its pallet, container and crate pooling services as an inherently sustainable business model, manmonthly.com.au

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preventing one-way packaging and minimising resources.

Phillip Austin, president of CHEP Australia and New Zealand, said the company’s reusable plastic crates are a good example of both primary and secondary/tertiary packaging that can extend shelf life.

“CHEP’s reusable plastic crates eliminate the need to repack produce as it moves through the supply chain, which reduces the opportunity for damage during handling. The strength of the crate and better ventilation and cooling rates also help to protect the produce,” he told Food magazine.

“Reusable packaging is more robust than one-way cartons and less susceptible to piercing by sharp objects or crushing as it moves through the supply chain.”

Austin said an independent life cycle assessment of CHEP’s reusable plastic crates shows they save 8,000 tonnes of solid waste, 64,000 tonnes of carbon emissions and 460 million litresMof A water 1 0 1 from 3 _ 0the 0 0supply _ J A chain B every year.

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CHEP’s reusable plastic crates are a good example of both primary and secondary/ tertiary packaging that can extend shelf life.

An Australian grower interviewed used as much for retail display as as part of the RMIT University study they were originally. Plastic crates (all interviewees remain anonymous) allow us to wet the product, which agrees that reusable plastic crates helps extend shelf life (unlike can improve efficiencies and extends cardboard),” the grower said. produce’s saleability.

Primary packaging “Plastic crates allow for better ventilation and better protection.

While of course secondary/tertiary They also support better transport packaging technologies such as utilisation because the pallets can be reusable plastic crates can have stacked higher. They don’t require a positive influence on reducing 1as much 2 0 1stretch 3 - 0 9wrap.

- 1 6There T 1 0is:less 1 6 : 1 food 0 + 1waste, 0 : 0a 0large proportion of handling, although the crates aren’t the industry’s focus, as the issue

of sustainability becomes more and more prominent, will be on developments in primary packaging, as this is where shelf life is a key consideration in packaging design.

Confusion surrounding the meaning of ‘use by’ and ‘best before’ dates is a significant contributor to food waste in Australia. Consumers often dispose of products when they’re still of a good, edible quality, and poor stock rotation systems or materials handling processes could see perfectly good foods discarded by manufacturers, which not only wastes food but comes at a significant cost to the company as well.

“There does appear to be a lot of confusion about the difference between use by and best before dates, and when a food is still safe to eat. It’s a problem for consumers, who may get the two mixed up and throw away food that is still edible,” Lewis says.

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Manufacturers’ Monthly OCTOBER 2013 29

>>

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Labelling & PACKAGING Protection Authority and run in or have thermal sensors, to provide partnership with retailers, food better ‘on demand’ feedback to manufacturers, local government various supply chain stakeholders.” authorities and community groups Helen Lewis agrees that these in an effort to reduce food waste in ‘smart’ technologies could be a gamethe state. changer in the food manufacturing While 97 percent of respondents industry. in its Food Waste Avoidance “Smart labels will become more Benchmark study believed they store important as technologies improve their food correctly and poor storage and costs come down. They can help doesn’t contribute to food waste, companies to track and manage those that did identify poor storage inventories to reduce waste in the as a contributor to waste cited a supply chain. They can also be used lack of understanding of storage by manufacturers, retailers and instructions/conditions and not consumers to identify when a food using food before its used by or best has spent time outside of its required before date as the main contributors. temperature range,” she told Food Sixty-four percent of respondents magazine. knew the difference between use by Will more packaging help? and best before dates, but the Food Many don’t know the difference between use by and best before dates.

Waste Avoidance Benchmark study It might seem a little ironic that specific product categories, such as concluded that more work can be one of the strongest themes of the to enhance shelf life extends beyond seafood,” she says. done to clarify these definitions and RMIT University study is the need processed foods. Despite what many “The trend towards more reduce consumer confusion. to extend shelf life and reduce food may argue, keeping fresh produce in packaging, particularly for fresh “Food manufacturers can help by waste by increasing the amount of its natural state isn’t necessarily the produce, involves a conscious tradeensuring that the dates are clearly packaging used on food products. best option when it comes to product off. We will end up using more marked on the packaging, not If food manufacturers and longevity. packaging to reduce food waste, hidden under a seam or written in producers are to curb the amount of The challenge, according to and some of this packaging is not tiny font. They need to be readable. waste they send to landfill, shouldn’t the study, is to find a balance or yet widely recyclable. However, They can also provide more they be reducing their reliance on establish “trade-offs” between in most cases the benefits appear information to consumers about the packaging, not increasing it? convenience, packaging, shelf life to outweigh the costs from an meaning of date marks and how to The RMIT University report says and product waste. environmental point of view. store food correctly to extend its that the industry can reduce food However it’s a case by case, or This is because we know that the life,” Lewis says. waste by supporting a growing shift rather product by product, situation.

Where today’s use by and towards processed and pre-packed A fresh produce supplier interviewed environmental footprint of food is best before dates sometimes fall foods, while also considering product for the research noted that plastic so much greater than the impact of short, ‘intelligent’ or ‘interactive’ and packaging developments that film around a bunch of fresh herbs the packaging, when you consider packaging technologies represent cater for single or smaller serve can extend its shelf life from two all of the energy, water, land and opportunities for both manufacturers products, therefore reducing waste to five days. Packing fresh herbs in chemicals that go into growing, and consumers to be given real time by meeting the needs of single and punnets (another growing consumer processing and transporting food information on a product’s quality. two person households. trend) doubles this again. over its life cycle.

The RMIT University study says But this theory of using packaging However, some cut vegetables “A small amount of packaging “Supply chain collaboration that are washed, peeled and can extend the product’s shelf life and data sharing cut before hitting retailers’ and ensure that it gets consumed could be facilitated shelves suffer a reduced rather than thrown away. To manage by ‘intelligent’ shelf life thanks to faster this trade-off it’s important that all or ‘interactive’ physiological deterioration packaging is designed to minimise packaging and microbial degradation. environmental impacts and to be technologies.

If Australia follows recyclable at the end of its life.”

Intelligent food current trends in countries So less isn’t necessarily best packaging can such as the US, we will when it comes to packaging and provide real soon be seeing a lot more sustainability. No doubt consumers time use-by or pre-packed fresh produce, in Australia are becoming more expiration data, says Helen Lewis. environmentally conscious, but product tracing “This is already they’re also seeking convenient, and temperature happening, partly in affordable meal solutions, so as The indicators, which response to consumer Role of Packaging in Minimising Food are either timeinterest in convenient Waste in the Supply Chain of the based, activated and pre-prepared foods Future suggests, food manufacturers by certain such as salad mixes, need to establish “trade-offs” to chemicals, which use multiensure all parties – consumers, driven by layer and modified businesses and of course the radio frequency atmosphere packaging. environment – are not only happy identification More sophisticated and healthy, but are getting the most Keeping fresh produce in its natural state isn’t necessarily the best option data (RFID), out of their food – for the long term. when it comes to product longevity. packaging is being developed for 30 OCTOBER 2013 Manufacturers’ Monthly

manmonthly.com.au

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25/09/13,

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HiddenCHAMPIONS Who are the Hidden Champions?

Ahead of Professor Hermann Simon’s visit to Australia for the Productivity, Process and Innovation conference, we will be considering his Hidden Champions concept, which has been used to help explain Germany’s export success. Brent Balinski reports.

Everywhere but unnoticed Have you drunk a Coke lately?

Gone to the theatre? Made a phone call or swiped a smartcard? Then you’ve used a product made by a Hidden Champion – a worldleading company in its niche though unnoticed by most.

In our above examples Jungbunzlauer produces the citric acid used in every Coca Cola, Hans Gerriets is the sole producer worldwide of large stage curtains, and Delo produces the electronic adhesives used in 80 per cent of the world’s smartcards and half of all mobile phones.

Germany’s unusually high share of the world’s Hidden Champions goes a long way to explaining the country’s strength in exports, and contributes to an estimated quarter to all of these.

Professor Hermann Simon, founder and chairman of international strategy and marketing consultants Simon-Kucher & Partners, has been studying the Hidden Champions phenomenon since 1986, popularising the term in his 1996 book of the same name.

To qualify for the title, a firm needs to: a) Be the leader in its market on its continent or in the top three worldwide; b) Have a turnover of less than $US 4 billion; and c) Have a low level of recognition with the general public.

Though not explicitly manufacturing businesses – for example Belfor, a global leader in disaster recovery services – many produce niche products.

By Simon’s measurements, there are 2,746 such companies. For reasons that will be considered later, many (1,307) are German. However, they also exist in the United States (366), Japan (220) and elsewhere.

Simon-Kucher & Partners’ Australian branch has identified a 32 OCTOBER 2013 Manufacturers’ Monthly

number of these businesses over here.

“Especially in the mining sector, there are some which grew with the mining boom and have specialised worldwide in certain solutions,” explained Christoph Petzoldt, SK&P’s Australian managing director.

“For example Mine Arc. They do rescue capsules for underground mines, and I think there are only two companies doing that worldwide,” he told Manufacturers’ Monthly.

“So they are extremely specialised.”

Australia has its specialists in manufacturing and other industries, with locallybased examples noticed by Petzoldt’s

Delo, a Hidden Champion, produces the electronic adhesives used in half of the world’s mobile phones.

company including Resmed, SAGE Automation, CHEP and ANCA.

Specialisation and globalisation Bayswater-based CNC tool grinder specialist ANCA (incidentally, this magazine’s Manufacturer of The Year for 2013) is an excellent local example of Simon’s concept.

“You have to travel all over the world and have arms and legs extending into the global marketplace, and you have the intelligence coming back to the company about what are the new developments, what are the new areas, what are the customers’ needs and wants around the world,” CEO Grant Anderson told Manufacturers’ Monthly

Having a global customer base and a set of products that answered its demands neatly has also had other benefits.

“From a business risk point of view, it balances the markets which we sell into. That is, in recent times the China market has softened, whilst that’s been offset to some degree by the US, which has been absolutely booming.”

ANCA also invests heavily in R&D, with this equal to approximately a tenth of its revenue.

Another Hidden Champions is SICK AG, a German industrial sensor and automation specialist.

SICK Australia is among more than 50 of its worldwide subsidiaries.

SICK would, like ANCA, not be recognised by many outside

the industries it serves, but within them has a global reputation for excellence.

It also has a sharp focus married with a global reach.

“Globalisation is the necessary complement to specialisation,” Simon told Manufacturers’ Monthly.

“Specialisation and focus make a market small. Globalisation makes it big.”

SICK has partnered with countless companies (see elsewhere in this magazine for more on this) to bring about unique solutions to a highly specialised area.

“The main industry segments we provide sensor technology to are factory automation, logistics automation and process automation,” SICK’s managing >> manmonthly.com.au

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Hidden CHAMPIONS >> director David Duncan told Manufacturers’ Monthly.

“One of the things often quoted to me in the marketplace is if there’s a difficult sensing application, we go to SICK, and they will solve it for us.”

This comes with an investment in R&D that Duncan puts at ten per cent of revenue before he relates a story about a project with an unnamed mining company to illustrate how SICK matches working with a local customer to worldwide excellence.

“What happens is when the application is fed back to Germany, we have to do some form of local adaptation and feedback to Germany to do some further R&D on the development of product and we then take that into the application of the product,” he explained.

Collaboration between the subsidiary and German headquarters led to consideration of how the technology was applied, a customised solution provided, and a customer’s needs met.

“And that is one of the exciting parts of the international corporation, because SICK AG, our headquarters, and also the local SICK company work together.”

Closeness to customer Germany’s Mittelstand (middlesized) companies – which employ over 60 per cent of the country’s workers, make up over 99 per cent of its firms and are famous for their manufacturing strength – are known for their closeness to their customers.

As well as qualities such as generally having a long-term vision and close ties to their region, the Hidden Champions tier of the Mittelstand has a proportionately high number of people in each company that will deal with and thus be better able to understand customers.

“More employees (37%) have regular customer contact than in large corporations (7.5%),” said Professor Simon of his research.

“The involvement of top management is much deeper in the case of the Hidden Champions, and there is less friction between the various functions involved.”

Importantly, Simon explained, the R&D was highly productive.

“Innovation is one of the pillars of the Hidden Champions’ success,” he noted.

“Large corporations have six patents per 1,000 employees, the Hidden Champions have 31. The costs of a Hidden Champion patent are only about one fifth of those in a large corporation. The challenge of innovation is to integrate technology and customer needs. 65% of the Hidden Champions claim that they are successful in doing this, whereas only 19% of large corporations say this.

“Closeness to customer plays a crucial role, but technology is equally important.. You need both.

This integration is much easier to achieve in a smaller company since their customer contacts are much more intensive.”

The focus of a Hidden Champion

is related to its closeness to its customers, though Petzoldt suggested that it might be hard to guess the exact nature of the relationship.

“You may argue whether they are close to the customer because they are specialised, or they are specialised because they are so close to the customer” he offered.

Growth, leadership and employees Since Simon’s original Hidden Champions book was published, his research has shown that not only has the number of firms matching his concept grown, but that his 1996 cohort had fared excellently.

A decade-long study of Simon’s original 450 companies published in a London Business School journal found that 82 per cent of the subjects had defended or extended their dominance, while only 18 per cent had lost their lead (6 per cent dissolved), supporting the idea that Simon’s concept is a highly sustainable model.

“On average they are today five times larger than 15 years ago,” Simon said he’d found.

“The main growth driver for them is globalisation, but innovation is also very important.”

About two-thirds of the companies are family-owned, with leaders not only committed to success but feeling an extra emotional attachment to their organisation.

Hidden Champions are also in the main (but not entirely)

privately-owned. Simon and supporters of his concept have said that this helps firms remain focussed on the long-term, with leaders better able to weather difficulties without panicking.

“There are examples here in Australia, there are two companies which have about 50 per cent in, I think it was, fish food for aquarium fish,” related Petzoldt.

“And one is family-owned and the other is part of a larger corporation.

“The family-owned one went through years of very, very low margins but they are still around and the others are now owned by private equity because they couldn’t make it any more.

“It’s an advantage if you are not having shareholders sitting somewhere and pointing at you. You can have a longer-term perspective.

It’s not a guarantee you’ll survive, but also if it’s a family business, it’s always a perception that it’s your money, and you’ll be a little more careful with your money than other people’s money [laughs].”

In his 2009 book Hidden Champions of The 21st Century, Simon singles out those at the top as most important for the continued success of this style of company.

He describes the leadership of Hidden Champions as being authoritarian on principles and values, but flexible when it comes to details.

On the whole, workers at Hidden Champions were much more likely to be retained. Turnover rates were

P Find

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2.7 per cent annually, compared to the average of 7.3 per cent for Germany.

Explanations Simon believes there is no single explanation for Germany’s comparatively high share of Hidden Champions, but a number of things contribute to their globally-oriented nature.

Germany’s proximity to other markets certainly encourages exports, but similarly-located countries such as France and Italy are nowhere near as successful per capita.

“More important are the orientation, the value systems, and also the history of a country,” explained the Professor.

“The vocational training system for example is deeply rooted in German history... and it’s a general attitude of Germans to go international very quickly. Until the late 19th Century Germany had not been a nation state, unlike France, Japan or the US. German entrepreneurs who wanted to grow had to internationalise at a very early stage, and this has become part of the DNA of German entrepreneurs.”

Acknowledging there are advantages enjoyed by Germany, he stressed that a lack of these shouldn’t lead to excuses. In terms of isolation, he points to the world leader in electric fences.

“Gallagher is based in New Zealand, even further away from ‘the world’ than Australia, yet they

CNC tool grinder specialist ANCA is an example of an Australian Hidden Champion.

are world market leader for electric fences,” he explained.

The role of manufacturing Manufacturing is incredibly important for profiting from an increasingly globalised world, according to Simon.

Benefiting from globalisation, in terms of employment and export revenue, depends on having strength in manufacturing.

“The Americans and the French have many strong service companies,” he noted.

“But where do companies such as McDonald’s, Starbucks, Hilton or Accor create new jobs? They do that in Beijing, Mumbai and Sao Paulo, the locations where they open their new stores or hotels.

“With a strong manufacturing base you can profit from growth in emerging countries and still create jobs in your home country through exporting. This is the opposite of what experts preached only a few years ago when Germany was blamed for its inability to manage the transition to the service economy.

“Luckily we did not follow this fashion, and today the US, the UK and France are desperately trying to rebuild their manufacturing base. This is very difficult and time-consuming. It’s not just a matter of building a new plant.

You need qualified workers, a deep infrastructure of suppliers etc. That can’t be rebuilt in a few years; it takes a decade or more.”

Regarding Australia, Simon believes we have the potential to be successful in manufacturing, and should be encouraging this.

Germany is the envy of many in the manufacturing world, with its Mittelstand tradition, the reputation of “Made In Germany”, and its much-admired vocational training system.

However – like Australia – it’s a costly environment, and it’s not ranked favourably in terms of productivity.

What’s stopping Australia from taking a few lessons from Germany?

Simon says with a few changes in attitude, Australia could pull itself up.

“Australia has a good base to build manufacturing companies,” he said.

“What it also needs is a society that values engineering and science rather than white collar jobs in finance or other service sectors.

“Given its raw material base Australia should aim at not just selling raw materials and try to go further down the value chain to create higher value.”

For more information on Productivity Process & Innovation Event – at which Professor Simon will be giving the keynote address on “Hidden Champions – The Vanguard of Globalia: Why are German companies so successful, and what can we learn from them?”

– turn to the events page of this magazine or visit www.australiagermany.com.

The easiest way to find products and suppliers

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3DPRINTING Growing push for additive manufacturing Hartley Henderson investigates the rish and rise of 3D printing in Australia and Asia.

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here has been a lot of discussion lately about the future potential of additive manufacturing, otherwise known as 3D printing, and whether it could even lead to the next industrial revolution.

A recent meeting in Melbourne hosted by CSIRO was aimed at facilitating the establishment of an Additive Manufacturing Network by bringing together the research and development, service provider and end-user communities to share information and visions for the future of this emerging technology.

Keynote speaker at the meeting, former CEO of Siemens Australia and New Zealand, and current chair of Manufacturing Excellence Taskforce of Australia (known as META), Albert Goller, believes that too many Australian manufacturing companies today are focussed on customers within only one industry: “There is a need for manufacturers to adapt to servicing across a diverse range of different industries, including textiles, rail and defence.

“We must develop greater flexibility with a focus on mass customisation, shorter cycle times in developing a product and bringing it to market, and sustainability by bringing the supply chain under control.

“Much greater attention must be given to agility, connectivity, collaboration, and creativity in order to provide a flexible solution for manufacturing industry in this country.”

R&D programs At Monash University’s ARC Centre of Excellence for Design in Light Metals there is a focus on the utilisation of laser melting additive

such as landing wheels. At Swinburne University of Technology a new Manufacturing and Design Centre is being built that will include a ‘Factory of the Future’ which is scheduled to open in 2014 and include five studios with advanced equipment including 3D printing.

End user view Conventionally machined aircraft component in titanium (left) and topology optimised and additively manufactured from titanium powder (right).

commercialisation. Historically Australia has not been good at such collaboration and there is a need to create a win/win situation between stakeholders.”

Launched in 2011, RMIT University’s $20M Advanced Manufacturing Precinct includes a key focus on the advancement of both metal and polymer based additive manufacturing technologies.

RMIT’s Prof Milan Brandt says additive manufacturing research includes topography optimisation in design, manipulation of structures, materials research and manufacturing process optimisation.

“The global market for additive manufacturing is said to be growing at about 16 percent per annum and is projected to reach US$3.5bn by 2015,” he said.

“Our additive manufacturing research in the Precinct is focused in four main areas: aerospace and automotive engineering, bioengineering, sports engineering, and design.

“In current projects we are working on the development of direct manufacturing of small scale components, as well Hinge manufactured in stainless steel highlights the technology’s ability to reduce as repair technologies several subtractive manufacturing processes to a one-process operation. for aircraft systems,

36 OCTOBER 2013 Manufacturers’ Monthly

manufacturing machines. The Centre is pursuing a joint program with CSIRO and Deakin University to manufacture a small engine utilising additive manufacturing technology.

Director of the Centre, Prof Xinhua Wu, believes that additive manufacturing will revolutionise 21st Century manufacturing industry through a range of benefits including very short lead times and low manpower requirements.

“However, there are also some challenges that need to be addressed in commercialising additive manufacturing, such as material properties, repeatability and the ability of shop floor engineers to redesign,” she said.

“There is a need for close collaboration between experts in materials, design, engineering and

Michael Edwards, general manager, Boeing Research and Technology Australia, says the company, which manufactures various aircraft components in Australia, is focused on innovative ways to reduce lead time and the cost of development programs.

“We are looking at additive manufacturing and digital design, together with a major investment in up-skilling, as solutions to shortening the supply chain. This could play a significant role in assisting to develop the very big markets of Asia on our doorstep,” he said.

“There is a need for change and to make a paradigm shift in development programs because they are getting longer and more expensive.”

Edwards sees additive manufacturing as the start of a potential new industrial revolution, but emphasises the need for industry sectors to work more collaboratively, and for stronger strategic alliances between industry and R&D organisations.

Service provider role A number of companies are now providing additive manufacturing services, including AMS (Advanced Manufacturing Services, part of the Breseight Group), which has a range of advanced manufacturing machines including those that the company says are capable of building in metals such as cobalt chrome, stainless steel, aluminium and titanium, as well as plastics.

Breseight’s CEO, Marc Perez, says that the range of additive manufacturing applications and solutions is set to expand, including in the areas of medical, military, manmonthly.com.au

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“Increasingly in the future, it will not be the big companies that eat the small, but the quick enterprises that eat the slow,” he said.

Following the CSIRO-hosted meeting, an Inaugural Committee has been formed to come up with future arrangements for the establishment and operation of a national Additive Manufacturing Network, to be driven by all stakeholders.

Dr Swee Mak, Future Manufacturing Flagship director, says CSIRO’s objective in initiating the Additive Manufacturing Network is to facilitate greater engagement between Australian industry and advanced technical resource providers.

“We use our Arcam facility to partner with interested Australian manufacturers to facilitate the uptake of additive manufacturing technologies in their businesses,” he said.

John Barnes, who leads CSIRO’s Titanium Technologies, believes that additive manufacturing has reached its tipping point.

“While it is unlikely to fully replace conventional manufacturing technologies, thanks to the savings in time, risk, and materials it offers, future factories are just as likely to include 3D printers as conventional milling machines, presses, foundries and injection moulding machines,” he said. manmonthly.com.au

Singapore perspective At the National University of Singapore (NUS) significant additive manufacturing research and education programs are underway.

Prof Ian Gibson, at NUS’s Engineering Design and Innovation Centre, points out that a major benefit of additive manufacturing is in waste reduction because of its layer-by-layer additive process, compared with traditional metal machining that takes away layers to form an object and can result in substantial waste.

“Often, no assembly is involved with the additive manufacturing process, which is capable of producing rapid prototypes, and people are now also realising that this technology is feasible as a direct manufacturing process,” he told Manufacturers’ Monthly during a recent interview in Singapore.

“Three major industries have evolved through the use of additive manufacturing. The automotive industry has shortened product development processes in parallel with manufacturing processes, and in the aerospace industry additive manufacturing is used to deal with engineering complexities involving external as well as internal geometry.

“New niche markets can be developed through the use of additive manufacturing to provide low cost design and quick response to the requirements of consumers. Mass production and mass customisation have got to work hand in hand.”

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ManufacturingFOR MINING Mining manufacturing: Building in the downturn Now that the mining boom has slowed down, how has one of the world’s largest mining machinery manufacturers responded? Cole Latimer writes.

E

veryone knows what happens when you buy a house at the top of the market.

You sometimes bite off more than you can chew.

So what happens when you buy another mining machinery manufacturer at the top of the market?

Caterpillar found this out first hand when it acquired Bucyrus for US$8 billion in 2010, and completed it the following year as the mining boom reached its heights.

But unlike a house, integrating 1000s of workers and distributors make the task slightly more difficult – so how has Cat bedded down the Bucyrus buy following the peak of the mining boom and the abrupt downturn?

And importantly how have its Australian distributors incorporated these changes?

The past The acquisition itself well known, and was at the time one of the largest mergers of companies in the world.

In fact the Bucyrus acquisition is also the largest acquisition in Caterpillar’s history and is larger than every other one put together.

Speaking to Manufacturers’ Monthly following the move in 2011, the company explained that the timing was right to make a move.

“We had been aiming to dramatically expand our product range to become ‘the single source solution’, and had been looking at the ways in which we could do that, but these plans had been put on hold while we all suffered from the global downturn,” Tony Johnson, Caterpillar Resources Division’s marketing manager, explained.

“As we came out of the global financial crisis, we were better placed than most as we had a 38 OCTOBER 2013 Manufacturers’ Monthly

How has lower demand affected mining manufacturers? recession plan in place, a ‘trough plan’. This allowed us to survive the recession in a fairly healthy position.

“Having looked at Bucyrus before, and not seen it as a viable option then, our new relatively strengthened position in the market allowed us to make the move.”

Caterpillar’s Resources Group president Steve Wunning stated that “this acquisition was all about growth and new opportunities, broadening our range of surface and underground mining products.

At the time they stressed that a major part of the two companies coming together was effectively sorting out the dealer network, and who would now be selling what.

Caterpillar told Manufacturers’ Monthly that is has increased its focus on the distribution and dealer network.

An early way in which it sought to address this was by expanding its set network regions, growing from five ‘super regions’ up to 15 “to provide greater support for our dealers and to drill down on customers’ demand,” Johnson explained.

Clearly there were big plans ready to be rolled out, and effective returns pegged on the horizon.

But the short, sharp end of the mining boom put an end to all of that.

Suddenly plans that were firm looking into the future were no longer such, and the future looked very uncertain for the world’s mining industry, especially Australia’s.

Dealing with the present So with the downturn biting and massive layoffs for companies through out mining what did Cat do?

It didn’t take its eye off the ball in bringing the two companies together, and neither did its dealers.

At a recent Caterpillar event in Brisbane, held at the tail-end of AIMEX, Cat explained the current situation, how it weathered the downturn, what is has planned for the future, and how the dealers will be a part of this, with Hastings Deering providing a unique dealer perspective.

Australian dealer Hastings Deering (which is the Caterpillar dealer for Queensland, the Northern Territory, Papua New Guinea, New Caledonia and the Solomon Islands) was actually the first in the world to get the selling rights for Bucyrus equipment, with WesTrac, which

supplies for NSW, Western Australia, and the ACT signing up in April last year.

The dealer for Victoria and Tasmania, William Adams, and Cavpower, which supplies South Australia are currently in the works, while the major dealer for Indonesia – PT Trakindo Utama, is expected to be on board by the end of the year.

These dealers all now have to communicate to the market that what was Bucyrus is now Caterpillar.

But according to Andrew Ransley, Caterpillar Global Mining’s general manager for Asia Pacific, the brand change was the easy part, and the current major step it is going through is streamlining all the services, categorising the new multitude of parts, and providing the support have been the most challenging.

“Product support has been the most difficult part so far, 1.2 million part numbers, standardising warranties,” Ransley explained.

Overall the company has increased parts by 20 per cent, and “changing all the parts numbers is an enormous task, so we have built warehouses to centralise distribution and smooth the problem”.

According to Ransley they have created nine new parts centres globally, doubled the Melbourne distribution centre, and have just broke ground in Queensland for a new distribution centre to deal with the issue.

“For instance we need to cross reference 18 000 hoses for equipment to provide the levels of support that the customers expect”.

And it is providing that customer support that has driven the manufacturer, with Ransley stating that “we’ve also had to learn a lot about draglines”.

In-house training has been a major part of this learning experience, with manmonthly.com.au

>>

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Manufacturing FOR MINING Cat holding “Big Iron University”, which is aimed at getting its staff up to date with both the new changes and the new equipment.

This learning, combined with the changing demands for more efficient machinery, has already shown through, Cat says, with new technology being developed as a result.

It is now focusing internally on more technology integration, safety innovations, and increasing the lifecycle of machines while reducing the cost and fuel consumption which has led to innovations such as fully LNG vehicles on site.

“We can even run rope shovels off generators now; it’s all about trying to reduce the cycle cost for all operators.”

Hastings Deering assembles the equipment at its QLD site.

executive general manger -mining, explained “we were already one of the world’s largest Caterpillar On the ground dealers, operating in 140 centres So how are the aforementioned across ten countries, so for us it dealers and manufacturers adapting simply a bigger sandpit to play in to these new challenges? with new equipment”.

Hastings Deering had a unique Since it purchased the distribution insight, as one of Cat’s 200 dealers rights for the Bucyrus for US$350 that cover more than 1000 locations; million it has increased its scope of it leapt onto the new distribution work and even put together the pink opportunity. at 3Rio A D _ M A N M B A C A P R _ 1 1 . plongwall df Pshearer a g e installed 1 9 / 0 / 1 1 , Adrian Carney, Hastings’ Tinto’s new Kestrel North coal mine.

40 OCTOBER 2013 Manufacturers’ Monthly

The business is also expanding from its heritage listed site in Archerfield, Queensland, where it employs around 500 people, and also acts as a registered training organisation, which it says helps to train an average of 100 people annually to the ‘Cat Standard’.

In fact due to the size of the boom and the fairly restrictive size of the hangers Hastings has bought additional 2 : 3 3 land P M at Williamsburg for assembly of the larger pieces

of capital equipment and continual operation, as its current facility is located near residential housing which restricts operating hours.

However despite the growth, the company did accede that the levels of equipment passing through its doors are half of what they were a year ago, even with the heavy level of capital equipment being assembled and transported for BMA’s Caval Ridge coal mine.

While there Manufacturers’ Monthly saw a number of Cat 793s being assemble for the mine, with a fleet of 14 all up expected to pass through its doors.

But it isn’t just large equipment that the facility has focused on, diversifying its offering with aftermarket services.

Hastings SOS testing centre at Archerfield is one of the highest quality in the world – this was highlighted by the fact that out of 17 high level particulate counters available in the world, this facility had four.

On a tour through the facility they explained to Manufacturers’ Monthly that its customers from around the country, and overseas, send their

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“For instance, 40 to 60 per cent of all engine failure is coolant related, so by testing what the mechanism’s fluids are like we can see what is wearing and how, and are able to pick up very particular types of wear.”

By regularly monitoring “we are able to build up a history of maintenance to get a better idea of what’s ‘normal’ and to understand when failure will occur, as we have that baseline for predictive maintenance”.

Cutting back The site is heritage listed. oils, fluids, coolant, diesel, hydraulic oil and the like to be monitored for minute changes in the fluids.

These minute changes, such as excessive particles, higher than average microscopic bits of metal, contaminants or chemical changes in the sample then the lab is able to advise the right course of action for the client.

“What we’re trying to do is uncover what is going on in the machinery M A 1 0and 1 3provide _ 0 0 0predictive _ I ND maintenance advice,” Hastings said.

Electric Cylinders Screw Jack Systems

While the decline of the mining It focuses heavily on after-market service for its machinery clients. boom has seen the manufacturer cut jobs at its plants globally, reductions we have had to make 350 positions due to the existing the Australian manufacturing earlier in the year”. market conditions. arm, principally the underground “We regularly monitor our machinery arm, has remained workforce in line with our The China issue essentially unaffected compared to production rates.

Not all of the company’s focus has been the global reduction.

“It is extremely hard to forecast on making the two Cat and Bucyrus However it did cut 70 workers what will happen in the industry, businesses into a streamlined entity. from the facilty in Burnie Tasmania, however hopefully we will get some In late 2011 it also paid US$887 after cutting 100 from the site earlier more orders and be able to employ million to get a greater footprint in this year. more agency employees in the China’s mining industry, purchasing At the time Cat said “we have future.”

ERA Mining Machinery. had another reduction today in our Despite this, it has still espcaed At the time it was a 33 per cent premium on ERA’s most recent share 1casual 2 0workforce 1 3 - 0 9 of - agency 2 3 T 1 workers 3 : 4 1 : 1 better 1 + 1 than 0 : 0its 0 NSW and WA dealer and it is much in line with the WesTrac, which was forced to cut price.

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Manufacturers’ Monthly OCTOBER 2013 41

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Manufacturing FOR MINING ERA itself was a coal mining equipment manufacturer specialising in hydraulic roof supports, and Cat’s takeover represented a bet mining growth in China would continue strengthen.

According to The Wall Street Journal Caterpillar had been losing market share in China, which represents nearly half of world demand for construction equipment.

In 2010 Cat had seven per cent of China’s excavator market, trailling behind rivals Komatsu and Sany, which accounted for 15 and nine per cent respectively.

Prior to the ERA acquisition Caterpillar construction equipment group president Richard Lavin said the company had “undershot” the market in China and needed to catch up.

However unlike the Bucyrus buy, this was not smooth sailing.

Earlier this year Caterpillar carried out a series of internal investigations after claims of misconduct at ERA. The mining machinery manufacturer stated that it “has uncovered M A 1 0deliberate, 1 3 _ 0 4 multi-year, 2 _ GRA co-ordinated accounting misconduct

It has seen cut-backs at its factory in Tasmania, as mining slows down. concealed” at the recently acquisition. We believe it was acquired ERA Mining Machinery perpetrated without the knowledge company’s subsidiary Zhengzhou of any Caterpillar employee who did Siwei Mechanical & Electrical not come over to Caterpillar as part Manufacturing, in China. of the Siwei acquisition”.

“Caterpillar’s investigation Following the investigation Cat determined several Siwei senior removed several senior managers at managers engaged in deliberate the company, installing its own new misconduct beginning several years leadership team. prior to Caterpillar’s acquisition of “The actions carried out by Siwei,” it said. these individuals are offensive It went on to stress that “the and completely unacceptable,” Doug Oberhelman 1misconduct 2 0 1 3 -at 0issue 9 - commenced 2 3 T 1 1 : at 0 8 : 0 Caterpillar’s 9 + 1 0 : 0 CEO 0 Siwei well in advance of Caterpillar’s said.

“This conduct does not represent, in any way, shape or form, the way Caterpillar does business or how we expect our employees to work, which is spelled out in Caterpillar’s Worldwide Code of Conduct.

“Once our investigation confirmed that misconduct had taken place at Siwei, we moved quickly and decisively to hold the responsible leaders directly accountable for the wrongdoing. Accountability is a critical way that we measure leaders at Caterpillar, and it is my expectation that leaders set an example and are accountable for their actions and results.”

Despite the hit of $580 million, or more than 65 per cent of the acquisition cost of ERA, Caterpillar says it has not changed its view on working in China.

This was reiterated during the Cat event, with Andrew Ransley, Caterpillar Global Mining’s general manager for Asia Pacific stating that it has tried to not let the incident affect its desire for the product line.

Added to this is the fact that 70 per cent of the world’s longwall business is in China “so it’s smart to stay there,” Ransley said.

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Business DEVELOPMENT Pathways to high performance Manufacturers aren’t always competing against each other. As Hartley Henderson writes, the aim of the High Performance Consortium is to bring business people together to share ideas and learn from each other.

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44 OCTOBER 2013 Manufacturers’ Monthly

number of manufacturers in Victoria are reaping substantial benefits from involvement with a program designed as a whole of business improvement model for high potential medium sized businesses.

The High Performance Consortium LTD (HPC), a not for profit organisation, facilitates groups of up to 12 non-competing businesses to undertake a program that incorporates events, site visits, coaching and facilitated peer-to-peer forums.

Enterprises are enabled to work together in a challenging and results oriented environment aimed at assisting businesses to improve productivity and remain competitive.

HPC director, Hugh O’Donnell, says Australian manufacturers must quickly adapt to survive by addressing gaps in key areas such as innovation, leadership and strategy.

“We have proven that manufacturing organisations can use consortia to accelerate and sustain their business development momentum. They are getting better results working with other enterprises, sharing best practice, and

applying lean principles and world class manufacturing improvement approaches,” O’Donnell said.

Corex Plastics in the Melbourne suburb of Dandenong is a privately owned company that employs around 120 people and produces a wide variety of customised durable containers and boxes, from vegetable, fish and plant boxes needing wet strength, to composite boxes for automotive components.

Apart from supplying the domestic market, Corex products are exported to a range of destinations including New Zealand, South East Asia and China.

According to managing director, Simon Whiteley, the company has been involved with HPC for some 10 years and the benefits continue to be substantial.

“A key to the success of HPC is in the interaction generated through development of peer-to-peer networks and multiple contact points in participating businesses,” he told Manufacturers’ Monthly.

“We are able to see our operations from different angles and learn from each other’s experience in non-competing businesses. manmonthly.com.au

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“At Corex, the whole emphasis is on product whole-of-lifecycle involving lean and green manufacturing. Plastic doesn’t deteriorate and breakdown like paper packaging, so it is important to divert from landfill and recycle waste and used product.”

Whiteley emphasises that there must be a focus on both the raw materials supply side and the customer side, as well as waste reduction in manufacturing processes, to properly close the loop.

“We are vertically integrated as much as possible, from producing flat sheet to designing and making finished packaging, which in turn has helped to provide stability in pricing.

“Used packaging is returned from customers from around Australia, recycled, and put back into the business as raw material.

“In the last 3 years, our carbon footprint has reduced by some 75 percent, and we see the company as an environmental custodian.

“HPC is assisting us to maintain a focus on staff development and continuous learning, and through focus groups, the Consortium is giving us confidence that we have world’s best practice at the forefront.

“Specific benefits for Corex from recent involvement with HPC include a substantial reduction in product changeover time, and a 45 percent reduction in lead-time and through-put time in the production of Tote boxes.

“A central strategy for the future is to sell more into Asia. But we are faced with some significant challenges outside of our control, such as exchange rate movements, rising oil prices, and our energy costs that have increased by around 37 percent in the last 12 months, and over 100 percent in the last 5 years.”

Cultural shift Based in the Victorian regional centre of Ballarat, Gekko Systems employs some 140 people and specialises in the design and production of innovative mineral processing equipment and systems for the Australian mining industry, as well as exporting to over 40 countries. manmonthly.com.au

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A peer group workshop, underway at Gekko Systems.

CEO, Elizabeth Lewis-Gray, advises that Gekko Systems has been involved with HPC for about 5 years and many benefits have flowed from participation including a powerful cultural shift throughout the business.

“Our involvement with HPC is multi-tiered, from the CEO right down to the shop floor, and all levels have strong peer engagement in looking at work processes and providing feedback,” she told Manufacturers’ Monthly.

“In addition, people from all levels of our organisation go to other HPC participating enterprises to work on projects with their peers.

“Coaching and learning days are also organised to look at projects, such as better work flow in the factory and all parts of the business, via initiatives such as RIPA (Rapid Improvement Project Activity) and SNAP (Special Network Action Project).

“We are currently concluding a special procurement RIPA project at Gekko Systems involving a workshop where other HPC

members are invited to send participants with relevant expertise, such as finance, negotiation and procurement.

“The aim is to analyse existing arrangements and develop improved strategies, documentation, and procedures, including terms and conditions of procurement. The cross-organisational improvement team returns later to interrogate the Gekko Team responsible on the success of the project and to consider further improvements.”

Lewis-Gray says five areas have been identified where the company can get the best return on investment. She believes 10-20 percent productivity improvement and dollar savings will flow from the project.

“Involvement with HPC has resulted in significant outcomes from a range of projects including a focus on lean manufacturing where we have more than doubled our factory output without growing floor space or staff numbers,” she said.

“Very strong results have been achieved in factory work flow, stores

and logistics, and we are particularly pleased with our safety record where 1,000 days free of lost time injury have been achieved.

“It is important that we continue to drive costs down because we are a large project manufacturer that competes globally. It is particularly expensive to ship bulky products overseas, so there is a special focus on streamlining the design end of the business as well as production processes.”

HPC has been self-funded by member companies since 2006, but it recently received a Victorian Government grant to establish a second consortium (HPC2) with a focus on the northern and western metropolitan areas of Melbourne, as well as regional areas.

Corex Plastics 03 9238 1300 www.corex.net.au Gekko Systems 1300 120 914 www.gekkos.com.au HPC 0410 689 815 www.hpc.org.au Manufacturers’ Monthly OCTOBER 2013 45

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ManufacturingINNOVATION Manufacturing Innovation Precinct looks to the future Though continued government support isn’t assured, META and its members are positive about the precinct’s and their industry’s future. Brent Balinski talked to the Manufacturing Industry Innovation Precinct’s CEO Zoran Angelkovski about what’s next.

T

hough META (shorthand for Commonwealth funded, but act, and this is being expressed by Manufacturing Excellence this means getting industries, those involved in the survival and Taskforce Australia) has universities, CSIRO, with a clear growth of Australian manufacturing. only been running since the mandate to organise themselves with The survival of META is, beginning of the financial year, an innovative mindset, and in such according to the group, likely but not it has already, by its own count, a way to turn around the declining assured. The new government, while attracted 300 members. These are trend in manufacturing and make in opposition, told this magazine that made up of manufacturers, partners the industry globally competitive the Coalition would not continue to and researchers, with every single and create jobs,” explained Zoran fund the precinct. university and research institution in Angelkovski, who has been CEO META was one of ten planned the country having signed up. since late-July. precincts in the outgoing Labor (Incidentally, those who run it “META is an industry-led government’s Plan For Australian dislike the description of “precinct”, organisation.”

Jobs, and a pet project in its effort with the group’s members being The words “mandate” and to address the industry’s difficulties. located all over the country.) “industry-led” frequently come up “I think we’re quietly confident, “We’re M Aa1membership 0 1 3 _ 0 0 0 _ N A C - in1conversation, 2 0 1 3 - 0as9if- to1 remind 6 T 1 0the : 1 9 : we’ve 1 3 + got 1 0a:good 0 0 case and a good organisation, as you know. listener that there’s a necessity to value proposition to put to the government of the day, and we will work with the government of the day,” said Angelkovski.

“Both sides of politics are bi-partisan on manufacturing and they believe in manufacturing and know that manufacturing is a key component of a strong economy, creating jobs.”

The support of industry was demonstrated last month with a statement that $2 million of “valuein-kind” services had been pledged

by META’s members.

Phillip Butler, the chair of non-woven textile specialists Textor – which is a member – commented that he was lending his support due to the potential for knowledge sharing across sectors and the positive, can-do message that META was promoting.

“We have to lead the future of our own industry – and we have the potential to be a more powerful force by creating products that rival the best or are better than the rest of the world,” he said.

“META provides that platform for us to work together to build creativity and to look outside of our immediate industry to find the solutions we are looking for.”

46 OCTOBER 2013 Manufacturers’ Monthly

Which leads to one of the important ways in which META is different to any other manufacturing industry body.

“META is different by the fact that there’s a cross-sector of industries that it represents nationally,” explained the CEO. “If you look at, for example CRCs, they serve their purpose, but they’re not across the industry sectors. So our aim is to get different industry players - you could have people from chemicals and textiles sitting together, and solving an issue.”

The group has not yet had a chance to coordinate any major projects, but currently offers online Continuous Collaboration Hubs, with members linked by needs, rather than industry. It also provides assistance linking businesses with services and suppliers, and includes the Industry Collaboration Fund in its portfolio.

Angelkovski, however, is excited about what the future might bring.

In a 30-year career in the automotive industry (including at Continental, VDO Automotive Malaysia and Draexlmaier), with half of this at the CEO level, he has helped establish three greenfield sites internationally.

The task of helping build something from the ground up is something he’s familiar with.

META, which he has been a part of nearly since the beginning, fits a role that no other group has yet been able to, according to the chief executive.

“I think people were just crying out for manufacturing to get a voice. And what we help to do, of course; we’re industry-led, we listen to what industry has to say,” said Angelkovski.

“I think that’s a powerful message to whoever the audience is.” manmonthly.com.au

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