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DIALLING INTOÂ THE RIGHT STRATEGY

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CEO: John Murphy Publisher: Christine Clancy Group Managing Editor (Northern): Syed Shah syed.shah@primecreative.com.au Journalist: Caroline Tung caroline.tung@primecreative.com.au

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6 Editor’s Note

25 Welding

38 Sustainability

8 Comment

26 Plant Maintenance

40 Gases In Manufacturing

11 News@MM

28 Inventory Management

42 Endeavour Awards Spotlight

16 Industry Focus

31 Robotics Technology

48 What’s New

19 Issues & Insights

34 Manufacturing Strategies

22 Construction

36 Tests & Measurements

Copyright Manufacturers’ Monthly is owned by Prime Creative Media and published by John Murphy. All material in Manufacturers’ Monthly is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on information published. The opinions expressed in Manufacturers’ Monthly are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2019

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4 APRIL 2020 Manufacturers’ Monthly

Behind the cover In this issue of Manufacturers’ Monthly, we bring you the stories from the suppliers and the industry who still believe that during this trying period, there is opportunituy for growth and more importantly, preparation for greater profit when the cycle reaches the other side. It is true that the current economic climate is not looking too great at the moment with many smaller businesses trying to shift into the right gear. To the untrained eye, the COVID-19 effect has seemingly pushed the uncertainty to a new level. We have learned from the past century, post industrial revolution, the

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global economy functions in cycles. Downturns are poised to come and go. Some biggerefficiency and harder than compact others. The current one, probably ® MOVIGEAR harder than the rest. But, like with performance every other cycle, there is a turning innovation point when revenues will return to normal and profits return. However, these are not achieved without effort, innovation and the right strategy. During the Industrial Internet 4.0 Summit, our team caught up with seveal leading IIoT evangelists who talked up the need for adoption by smaller companies in Australia – the call is the same as the past few years – it is critical in a time of crisis. Read more about it in this issue.

MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

APRIL 2020

DIALLING INTO THE RIGHT STRATEGY

Being the backbone of any powered and intelligent baggage system, conveyor systems are critical assets proven to be one of the most resource and power demanding systems in an Airport. Looking to maximize your baggage system’s availability, effectiveness and return on investment? Look no further than SEW’s latest decentralized drive technology and solutions, offering up to 70% energy savings, up to 50% reduction in total install power, significant reduction in setup & recovery time/effort/cost, seamless integration into existing and new systems. Putting emphasis on real time access to drive system and conveyor feedback data, resulting in predictive maintenance and forecasting, SEW is able to assist Australian Airports in gaining complete control over their critical assets, and therefore exercising continuous improvement.

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Comment

SYED SHAH – Managing Editor, Manufacturers’ Monthly

Disruption and innovation in a time of crisis

HE virtual lockdown of the country has made Australians concerned to different degrees. Questions like: “How will we cope? Will there be jobs?” continue to swirl around. Broader questions surrounding the health of the economy in the ensuing months and the end of the pandemic which could signal market recovery, continue to go unanswered. However, the answer to investment around improving productivity in industrial processes, for increased productivity, has changed into a more positive note. Of course, cost cutting in a time of crisis is needed to keep operational costs going but foresight from forward thinking suppliers will show that only with advanced and lean processes, is that achievable. In a situation as uncertain as the COVID-19 pandemic (as declared by the World Health Organisation), technology and data have become more critical than ever for businesses who want to survive

6 APRIL 2020 Manufacturers’ Monthly

and thrive. And manufacturing SMEs which make up the bulk of the manufacturing companies in Australia understand this. Previously, there has been much debate about the “end” or even the “death” of manufacturing in Australia. What made up a quarter of Australia’s GDP for many decades in economic activity in this country that has been more or less driven by resources, construction, services, agriculture, and not much more; a sector that once dominated Australia’s industrial landscape, is no longer once it was, for sure. Indeed, for many outside the manufacturing industry, the manufacturing sector is frequently associated with Australia’s past. With the closure of large automotive plants as reported through the mainstream media, it looked that way. It is a fact that manufacturing is currently much smaller than it once was decades ago. Manufacturing

remains a significant part of Australia’s economic activity, supporting over a million jobs, according to a report from AMGC, Advanced Manufacturing: A New Definition for a New Era. There remains much potential for the sector going forward into the future if Australia can stay at the top of the pack in innovative and advanced manufacturing techniques, technologies and processes. What should manufacturers be looking at then to keep competitive? The answer: Industry 4.0 technologies and methods such as robotics and automation, artificial intelligence and machine learning, additive manufacturing (otherwise known as 3D printing) and data analytics. In issue of Manufacturers’ Monthly, our lead feature covers highlights from this year’s Industrial Internet 4.0 Summit, which took place at The University of Technology, Sydney. Last year’s

speakers mentioned that Industry 4.0 technologies were readily available to exploit the availability of data that already exists across manufacturing operations. This year, the consensus was for manufacturers to join the future of manufacturing with digitally-enabled, data-driven automated technologies that can reduce costs, improve profits, and make the sector more competitive. And with the current climate, this is the way forward. We are also celebrating the excellence in manufacturing in the country with the Endeavour Awards. Despite not being able to hold a physical ceremony down the road for a bit, Manufacturers’ Monthly is still proud to be going ahead with the awards and will be announcing the winners in a couple of editions’ time. Nominations are still open at the moment. For now, check out our Endeavour Awards sponsor stories in this issue. Stay safe, healthy and most of all, positive!

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Shelley Thomas. Image courtesy of Australian Centre for Robotics Vision and QUT

Left to right: PhD Researcher Andrew Razjigaev, Professor Ross Crawford and Professor Jonathan Roberts.

A way towards the future for welding: robotics

ELD Australia’s mission is to facilitate the growth of a world-class welding industry in Australia. For this reason, we strongly support the Advanced Robotics Manufacturing (ARM) Hub, which is due to open in Brisbane in the coming months. A not-for-profit company, the ARM Hub has the potential to be a catalyst for Australia’s uptake of advanced manufacturing technologies and processes. It will bring world-leading expertise in advanced robotics and designled manufacturing to the aid of Australian businesses and their global supply chains. When it comes to the adoption of robotics, Australian SMEs are lagging behind other developed countries by a long way – by a factor of 10 in some cases. The Hub will help encourage and facilitate SMEs to go beyond “business as usual” and transform their strategies and operations, through the uptake of digital technologies, robotics and automation.

8 APRIL 2020 Manufacturers’ Monthly

The Story of the ARM Hub The ARM Hub was born out of a collaborative project involving Queensland University of Technology (QUT), the Innovative Manufacturing Cooperative Research Centre (IMCRC), and UAP (Urban Art Projects) – a design and manufacturing company that specialises in delivering public art and large creative projects. After securing funding from the IMCRC, UAP and QUT collaborated on a project called Design Robotics. The aim of the project was to “teach robots to see” (enabling a robot to look at an object before fettling or polishing) in order to improve the mass customisation capabilities of robotic manufacture. The project was all about turning a “dumb” robot into a smart robot – one able to make decisions about its assigned tasks. The response to the Design Robotics project from local industry was incredible, particularly its “open innovation network” component which was designed to showcase the project to other companies. So, the Design Robotics project model was scaled up,

resulting in the ARM Hub concept. In July 2019, the Queensland Government announced funding of $7.71 million over four years to support the establishment of the ARM Hub. With additional investment from the QUT, UAP and other partners, an $18m company is set to emerge – a company with a mandate to support and grow advanced manufacturing jobs right across Australia. The Hub will provide services to small-to-medium and microenterprise manufacturers, helping them become successful advanced manufacturing businesses. The Hub will also collaborate with large companies to help drive digital transformation and support local supply chain development.

How the Hub Will Work The ARM Hub will provide practical production and manufacturing advice in a real-life factory environment, enabling Australian manufacturers to learn about cutting-edge robotic technologies and design techniques, and develop industry skill and expertise to apply to their own

businesses. It will provide three key services.

Industry engagement Through industry engagement services, the ARM Hub will share its knowledge with manufacturers. After companies attend a business assessment workshop, the ARM Hub will typically undertake site visits of factories, perform an assessment of a company’s existing manufacturing processes, and then deliver a workshop to align their business processes and needs with a new manufacturing model.

Commercial Solutions The Hub’s commercial solutions services will involve working with a company to adopt advanced technology. This might involve an adoption sprint, or a demonstration project where the Hub will model a solution to confirm that it will work successfully within the company’s facilities. Where relevant, the Hub will help companies access grant funding to offset the costs of these projects. manmonthly.com.au

Brokering research and development

Fabrication using augmented reality.

Image courtesy of UAP

This service will help facilitate new manufacturing solutions for mid to long-term outcomes, and will tap into Australia’s research investments to help companies financially de-risk their digital transformation needs. Typically, research and development projects will involve multiple companies and research institutions collaborating to solve challenges and create new intellectual property.

IMCRC’s futuremap The Hub will also have access to IMCRC’s futuremap – a business diagnostic tool designed to help Australian manufacturing SMEs assess their current state of business and identify areas of focus and potential investment to transform and future-proof their business. futuremap enables manufacturers to map their maturity levels and capabilities in Projekt2 02.05.19 12:48 Seite 1 the areas of market positioning;

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leadership, strategy and change management; innovation and use of technology; and digital manufacturing (Industry 4.0). It then produces a point-intime self-assessment and report that identifies both immediate and medium-term opportunities for growth and potential investment.

Contributing to the transformation of welding As a critical enabler of Australianbased manufacturing, the welding industry is poised to benefit from the adoption of advanced manufacturing technologies and processes. Innovation based on robotic vision, collaborative robotics (or cobots), augmented reality and virtual reality, is transforming

everything from how we train and certify welders to how welding is performed in a variety of industrial settings. The ARM Hub will contribute to the wider transformation of welding, across all the industry sectors we enable. Weld Australia is keen to collaborate with the ARM Hub to explore new innovations and practices that will equip our welders with globally competitive skills and create a critical base for the re-shoring of manufacturing to Australia. We strongly support the vision for the ARM Hub to be a commercially operating “learning factory” where SME manufacturers use the technology and services and can see “demonstration” commercial projects in action. This is a critical resource in ensuring the broader adoption of Industry 4.0 across industry and positioning Queensland as a global leader. For more information, visit www.armhub.com.au

Manufacturers’ Monthly APRIL 2020 9

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News@MM Victorian government announces $1.7 billion support package The Victorian government announced in March that it will provide a $500 million fund to help public infrastructure workers find work as part of a $1.7 billion package to save jobs. The Working with Victoria Fund will support employment in response to the pandemic and afford security for Victorians. Premier Daniel Andrews said the government will continue to work closely with businesses and unions to provide support over the coming months. “We’ve listened to business and workers and now we’re taking unique and unprecedented action to help businesses and their workers through this crisis,” he said. Payments have already started flowing for small-to-medium

The Victorian state government is facilitating job matching to help workers find short-term or casual work. businesses with a payroll of less than $3 million and employ about 400,000 workers. The government is facilitating job matching to help workers find short-term or casual work. Treasurer Tim Pallas said the Victorian government was “working in lock-step” with the federal government to deliver financial

support for businesses. “This is the first of many announcements we will make to help Victorian businesses to help them through,” he said. Businesses will be able to defer payroll tax for the first three months of the 2020/21 financial year, which will free up a further $83m in cash flow.

Land tax payments will also be deferred for eligible small businesses renting government buildings. Private landlords are also encouraged to undertake these measures. The 2020-21 Victorian budget will be deferred due to the COVID-19 pandemic in line with all governments.

$3 million for world-first solar hydro power plant Australian renewable energy startup RayGen Resources will receive $3 million for a feasibility to test to build a world-first solar power plant near Mildura in north-western Victoria. The 4 MW/50 MWh “solar hydro” plant is expected to offer energy storage at a lower cost compared to recent battery projects to supply “critically needed” power to the West Murray region. RayGen CEO Richard Payne said Australia’s transition into renewables will require energy storage that can store power costeffectively for up to weeks and be deployable on a large scale around the world. “RayGen has developed an innovative solar-plus-storage product that captures sunlight with mirrors and stores energy in water,” he said. “Our technology provides firm renewable power at low cost, while manmonthly.com.au

The plant will be based near Mildura in north-western Victoria.

conserving natural resources and our environment.” The thermal storage developed by RayGen will be applied to

the company’s existing PV Ultra technology to store energy as a temperature difference between two reservoirs.

PV Ultra is a tower-mounted, concentrated solar PV technology that combines low-cost solar collection heliostats and highefficiency solar conversion through PV solar cells to generate electricity and heat at the same time. Heat generated as a by-product will be captured to improve efficiency. RayGen has partnered with AGL and GHD on the initial phase of the project, which will include technical and commercial feasibility studies, commercial assessment, a connection agreement and planning permit. AGL interim executive manager of wholesale markets Dominique Van Den Berg said the company is committed to providing sustainable, secure and affordable energy for Australia. Construction of the project is expected to start this year and aims to be commissioned by 2021. Manufacturers’ Monthly APRIL 2020 11

News@MM PMB signs deal to design batteries for defence submarines Australian supplier PMB Defence and Greek enterprise Systems Sunlight S.A have signed subcontracts to design the main storage batteries for the Attack class submarines.

The batteries will power twelve regional submarines, which will be designed and built in Australia for the Australian Navy under the federal government’s $50 billion

Defence minister Linda Reynolds said the design of the batteries are “critical” to the overall design of the submarine.

Attack class program. Defence minister Linda Reynolds said the design of the batteries are “critical” to the overall design of the submarine and serve as the watercraft’s main power source. “The selection of these two companies to develop designs of this subsystem is another significant milestone in the design and delivery of the Attack class submarine program,” she said. “A competitive process will ensure the final designer selected will deliver the very best battery technology to meet the key performance requirements of the Attack class submarine.” The Department of Defence has engaged PMB to explore a new battery technology that could offer “significantly improved performance” and potentially replace lead-acid

batteries over the life of the Attack class submarine. Defence industry minister Melissa Price said the program provided “significant opportunities” for the Australian defence industry. “This commitment will provide enormous opportunities for more local companies to be part this world-class advanced manufacturing project,” she said. PMB, a supplier of energy and specialised engineering solutions for submarine platforms based in Adelaide, is currently contracted to the Department of Defence for the supply and sustainment of batteries of the Collins class submarine fleet at their facility in Osborne. Further contracts to manufacture batteries in Australia for the Attack fleet will be rewarded following a selection process for the design.

170 small businesses promoted in military catalogue More than 170 Australian small businesses across the country have been featured in the latest Australian Military Sales Catalogue released today by the Department of Defence. The document, Australian Defence Sales Catalogue, features information about support services available to the defence industry sector to increase opportunities for exports. Defence industry minister Melissa Price said the number of businesses promoted jumped by 49 per cent from the 2019 edition. “Small businesses from each Australian state and territory are represented in the catalogue, highlighting the strength of Australia’s defence industry sector,” she said. “More than 100 of these companies offer engineering services, 75 companies are involved in through-life support 12 APRIL 2020 Manufacturers’ Monthly

and sustainment and over 40 companies are involved in skilling and training.” The catalogue also features counter-drone technology, medical, logistics, cyber security, and surplus equipment and platforms from the Australian Defence Force. The 2020 edition includes sections on the Australian Defence Exports Office, Defence Export Controls, Centre for Defence Industry Capability, Team Defence Australia, Austrade and Export Finance Australia. It forms part of the Federal government’s $1.6 million investment to continue building the capacity and capability of Australia’s defence industry, with the purpose to inform foreign government customers of Australian defence exports. Sales are available to Australia’s international partners on a government-to-government and commercial-to-government basis.

Defence industry minister Melissa Price said the number of businesses promoted jumped by 49 per cent from the 2019 edition.

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News@MM $15 billion lending for SMEs announced

Small lenders are critical to the Australian lending market. The federal government has announced $15 billion in lending for small businesses as part of its $100 billion “bridge” to support the Australian economy through the spread of coronavirus. The Australian Office of Financial

Management (AOFM) will be provided with the investment, which will be facilitated through authorised deposit-taking institutions (ADI) lenders over a 12-month period. Treasurer Josh Frydenberg said the loans will mean customers

of SMEs can continue to access affordable credit in spite of “significant challenges”. “Small lenders are critical to Australia’s lending markets, often driving innovation and providing competition for

larger lenders,” he said. The loan, which will also be available for non-ADI lenders in wholesale funding markets, complements the $90bn facility announced yesterday by the Reserve Bank. “Combined, these measures will support the continued ability of lenders to support their customers and in doing so the Australian economy,” Frydenberg said. The government will provide the AOFM with investment with guidelines on undertaking investments, following plans to introduce enabling laws starting March 23. Assets purchased by the AOFM will not be limited to residential mortgage-backed securities. The Office will have the ability to invest in a range of asset-backed securities and warehouse facilities. The AOFM is expected to begin investing in April.

New industry training hub kicks off in Burnie A new industry training hub launched in Burnie in north-west Tasmania will help senior high school students build skills and choose jobs to meet regional demand. The Burnie hub is the first of 10 facilities on trial in regional Australia to tackle youth unemployment as part of the federal government’s $50.6 million initiative to train skilled workers. Vocational education, training and apprenticeships assistance minister Steve Irons said the hubs will be “crucial” to address skills shortages and strengthen the workforce as part of the government’s broader $585 million Delivering Skills of Today and Tomorrow package. “New technologies, changing consumer preferences, and industry demands for new skills are shaking up industries across Australia,” he said. manmonthly.com.au

Employment, skills, small business and family business minister Michaelia Cash said the latest investment will prepare a new generation of workers for employment. “Young people can face longer periods of unemployment than other age groups, and in regional areas they are particularly at risk of falling into the trap of long-term welfare dependency,” she said. On-ground career facilitators will be engaged to form partnerships with local employers, schools and career advisors and educators to help students. Federal member of Braddon Gavin Pearce said Damien Peirce has been appointed to provide services for Burnie and surrounding area. “Damian will create better links between local industry, employers and schools and help young people finishing their secondary education

The Burnie hub is the first of 10 facilities on trial in regional Australia to tackle youth unemployment. to find pathways towards job opportunities,” he said. “The Morrison Government’s Training Hub will ensure we are

fostering the development of more skilled workers in our local area so that industry in North West Tasmania thrives.” Manufacturers’ Monthly APRIL 2020 13

News@MM NSW government announces review into training for tradies New South Wales premier Gladys Berejiklian has announced a review into TAFE and training for tradespeople to be led by David Gonski AC and Professor Peter Shergold AC. The review will consider a HECSstyle program for TAFE students, greater industry involvement and aims to increase employment prospects for trades graduates. Issues that will be examined by the review include opportunities to resolve skills shortages, increased collaborations between TAFE NSW and industry, and better integration of secondary, tertiary and vocation learning. “We want students to think of TAFE the same way they think of university, as a leading institution for furthering their education and gaining the skills of the

future,” Berejiklian said. “For some new high-tech and highend jobs, TAFE could become a better option for students than university. “We need more tradies in existing trades, but we also need to prepare workers in new areas like 3D printing, robotics and other technology industries to provide the jobs of the future in places like the Western Sydney Aerotropolis and the Sydney Tech Hub.” The state government will invest $2.3 billion into the Vocational Education and Training sector, which includes about $585 million in Commonwealth funding “We want students to think of TAFE the same way they think of university, as a leading institution for furthering their education and gaining the skills of the future,” Berejiklian said.

The state government will invest $2.3 billion into the Vocational Education and Training sector.

Amaero launches 3D printing facility in Adelaide The facility is established by the University of Adelaide with funding from the SA government.

14 APRIL 2020 Manufacturers’ Monthly

Metal additive manufacturer Amaero has launched its first 3D printing facility in Adelaide in partnership with the University of Adelaide. The facility, established by the university with funding from the South Australian government, contains three Renishaw AM 400 3D printing machines and ancillary equipment. Amaero recently joined the site as an industry partner. Amaero CEO Barrie Finnin believes South Australia is fast becoming a centre of aerospace and the defence industry. “Additive manufacturing is one of the most promising sectors of the Australian economy, and it is growing in strategic importance,” he said. “Amaero is proud to be leader in this field and we look forward to collaborating with the University of Adelaide to further develop

skills in this field.” A Strategic Partnership Agreement between Amaero and the University of Adelaide will focus on developing manufacturing capability in the state. Innovation and skills minister David Pisoni said the state government is focused on future industries such as defence, health and industrial manufacturing, which made South Australia a “natural fit” for Amaero. “This facility is a key enabler to help with the adoption of metal 3D printing by local companies that will drive innovation and the translation into newto-world and new-to-industry products, services and processes,” he said. The Adelaide facility is the latest in addition to other sites in Melbourne and El Segundo, California. manmonthly.com.au

Industry Focus Financing SME innovation It can be difficult for small-to-medium-sized manufacturing companies to find the financing necessary for investment in new and innovative technologies. Manufacturers’ Monthly looks at how this can be made easier.

Universal Robots is launching a financial services leasing program.

16 APRIL 2020 Manufacturers’ Monthly

MALL-TO-MEDIUM enterprises (SMEs) make up the vast majority of manufacturing companies in Australia. SMEs tend to have much smaller budgets, frequently making investment in research and development, let alone new equipment and technology, a real difficulty. Outside of reinvestment of profits back into the business and other forms of private equity, financing for capital outlay is typically provided through bank loans, overdrafts, and other financial instruments, or, less frequently, through raising money on capital markets.

Compared with larger companies, SMEs often have a tougher time accessing funding on favourable terms. This, of course, comes down mainly to size: SME revenue streams are usually more volatile and less dependable, increasing creditors’ perception of the riskiness of lending. However, alongside these methods, there are several ways that manufacturing SMEs can make life easier in getting access to machinery, equipment, and technology. One such method has recently been announced by collaborative robot manufacturer Universal Robots. In partnership

with global finance company DLL, Universal Robots is launching a financial services leasing program to give Australian manufacturers immediate access to the collaborative robots, or “cobots” they manufacture without upfront capital investment. This partnership between the automation solutions manufacturer and the financial services company enables all manufacturers, regardless of size or capital equipment budgets, to reap the benefits of automation without worrying about cash flow and seasonal fluctuations. “Universal Robots Finance is manmonthly.com.au

Industry Focus something that has been set up because we recognise that in our particular group of purchasers or end users, which are typically SMEs, the budget for capital expense is tight,” Darrell Adams, Universal Robots’ head of sales for Southeast Asia and

Schemes like the ones Universal Robots offer are important in keeping manufacturing in Australia competitive.

Oceania, told Manufacturers’ Monthly. “These are businesses that are trying to grow, and they are generally trying to grow really quickly – they’re generally scaling at between 50 and 70 per cent every year when they’re at this phase. And we recognise that we’ve gotten to a point now as a company where we can help these businesses grow at the same rate that we typically grow which is at that 60 to 70 per cent growth rate.” Adams said that the idea behind the program is to give people the opportunity to put cash flow back into their business to allow manmonthly.com.au

them to continue to invest in other opportunities as well to help them grow their business. “With that in mind, we set up a program with a well-known financial institution that effectively gives our end users and our partners the capability to lease to own the robots over a period that they agree with the leasing company. This moves the cost of that robot outlay from a capital expense to potentially just an operational expense, which allows them to better deal with the ebbs and flows in their business,” Adams explained. Once a company gets to the end of their contract, they can return the robot as well, which also gives them the opportunity to potentially update their equipment, or they can purchase the robot and continue using it. Adams said that this “automation as a service” model could have a lot of potential within the sector in the future. “As our collaborative robots get more dexterous and more capable, we’re going to get to the point where people will see the robot as something that they can lease and then take back out of their business when they no longer need it,” he said. “So, I think in the future we will see collaborative robots become automation as a service. In fact, there are already people talking about this kind of setup as part of discussions around the move to Industry 4.0 and Industry 5.0.” Indeed, it is possible that applications such as 3D printing, which can be used to very quickly produce products for specific customer needs in the short term, can be leased for limited periods before the either sending back the 3D printer to the distributor or leasing agent (if the job has been finished) or extend the lease or purchase the machine if the contract with the customer has been extended. Adams said that these kinds of arrangements offer expanded opportunities to SMEs that otherwise may not have the capital or the cash flow to fulfil customer orders or to move into new markets. “The ability now to offer a robot or an automation process as a service gives people an extra avenue to help

grow their business potentially at a much quicker rate than what they’d previously had available to them, given their cash flow,” Adams said. “And cash flow is typically the killer of SMEs – it is what usually either slows them down or is not managed appropriately, and a SME can end up in a scenario where they don’t have enough to continue the business. This is something we are trying to help with.” Adams said that schemes like these, which help SMEs keep up with developments in advanced automation technologies and techniques, was important in keeping manufacturing in Australia competitive. “It can help SMEs automate more of their processes without causing much disruption. There is a lot to be said for picking up new technology like, for example, with mobile phones – we’re all waiting for our contract to expire to get moving to the next version,” Adams said. “If Australian manufacturers incorporate that ethos into their own businesses and look at automation and business change the same way, I think it would have a positive effect on the growth of manufacturing SMEs in Australia.”

Demonstrating the benefits of innovation Another means for SMEs to get help is through grants and co-funding schemes run by government bodies. The Advanced Manufacturing Growth Centre (AMGC), established in 2015 by the federal government, has been focused on boosting the uptake of advanced technologies in the manufacturing industry through its cofunding scheme. “What we at AMGC are doing is co-funding innovative projects in advanced manufacturing and getting companies ready to commercialise their products, processes or services. We co-fund these projects through matched funding – for every dollar we put in, we expect the project participants to match that,” Jens Goennemann, AMGC’s managing director, explained. Usually, each project that AMGC cofunds has several partners, including a partnership with a research institution.

The program allows businesses to continue to invest in other opportunities as well to help them grow. This setup provides a vehicle to utilise and commercialise research for the advancement of Australian industry. AMGC currently has 60 diverse projects up and running, with AMGC’s contribution averaging at $250,000 per project. “The projects range from additive manufacturing and the internet of things (IoT) through to new and innovative materials – there is no sub-sector we have not touched.” Speaking of how manufacturers can secure additional funding with AMGC, Goennemann said that the body was looking for projects that can demonstrate the benefits of advanced manufacturing techniques to the wider Australian manufacturing sector. “We are an organisation that demonstrates our research findings through our funding of innovative projects, and then provide other manufacturers with ideas and examples of what we have evidence that works,” Goennemann said. “For example, if you have a project idea which makes a manufacturer better in what they are doing, or cheaper, and which also improves global competitiveness, that is the kind of project proposition that we find interesting because these are the ones that create additional revenue and additional jobs in the manufacturing sector. “We have put $20 million into co-funded projects, accompanied by another $20 million from project participants, and the return of additional revenue on that investment is approximately $550 million, along with 1,500 additional jobs. So that is a massive impact.” Manufacturers’ Monthly APRIL 2020 17

Issues & Insights Governments at federal and state levels have established grant schemes and other conduits for R&D partnerships between research institutions and SMEs.

Great rewards in a challenging future Small-to-medium manufacturing companies face challenges when making the move to Industry 4.0. Manufacturers’ Monthly attended the recent Industrial Internet 4.0 Summit to find out how they can overcome them.

OR manufacturing in Australia, the majority are small-to-medium enterprises (SMEs). Despite the association of technologies such as robotics, artificial intelligence and machine learning with MNCs, SMEs, too, have much to gain from the adoption of advanced manufacturing techniques. However, not everything is as simple as it looks. There are barriers and challenges to the uptake of new technologies. A recent report on industrial digitalisation from RMIT University researchers states that while disruptive changes associated with Industry 4.0 technologies are already escalating rapidly across industries, many local SMEs are still holding back despite the massive potential to be realised. The report, Demystifying Industry 4.0: Helping SMEs lay the tracks for Australia’s digitalisation express train, was developed out of indepth interviews with over a dozen company executives and ongoing engagement with the local advanced manufacturing sector. “Despite the rapidly approaching wave of industrial change, most Australian businesses are still grappling with how to implement or progress beyond entry-level I4.0 [Industry 4.0] technologies and practices,” the report states. According to an international 2017 digital transformation study conducted manmonthly.com.au

by SAP and Oxford Economics a large majority of surveyed company leaders thought that digital transformation would be a crucial factor in business survival over the future five years. Only three per cent of these companies, however, had completed Industry 4.0 transformations across their entire operations. This three per cent, nonetheless, experienced stronger revenue growth and profitability, along with increased customer satisfaction and employee engagement. Concerns that Australia’s manufacturing sector, in particular, was missing out on the opportunities presented by Industry 4.0 were also aired at this year’s Industrial Internet 4.0 Summit, held at the University of Technology, Sydney, at the end of February. During a panel discussion on the first morning of the event, Emeritus Professor Roy Green, Australia’s poor showing in the recent Harvard Economic Complexity Index, which measures the diversity and the research intensity of a country’s export mix, was cause for concern. Australia came in at 93, in between Senegal and Pakistan. “Our economy is highly skewed towards the export of unprocessed raw materials, to which we aren’t adding much value, and which not very diverse in terms of the range of products that we actually export. And the question is how we address that,” said Green.

“We are in the post-mining-boom transition towards a supposedly more knowledge-based economy, and we see the signs of success to some degree, but it is going to take a lot more effort to move ourselves out of the primary commodity mindset and into a manufacturing mindset.” According to Green, it is imperative that Australian industry lifts its productivity to be able to compete in global markets. “First, we need to innovate – it is a case of innovate or die. Second, we need to understand what is meant by ‘smart specialisation’. For us, particularly as we are a smaller country, the future is not in low-cost mass production – we can’t compete in this area. We can compete, however, with SMEs engaged in flexible specialisation, finding which areas of competitive capability they are good at or can be good at, and then focusing with laser-like intensity on those areas,” Green explained. “What they produce doesn’t have to be a finished product; it can be part of a value chain. The really world class companies that we have in Australia are focused on one or two things that they are doing extremely well.” The third element that Australian industry needs to focus on, he said, is introducing more diversification in the nation’s export mix by undertaking the research and development that is essential to a high-skill, high-

productivity and high wage economy. Ingrid Marsh, director of industry Development at NSW Treasury, said that SMEs are often too busy running their businesses trying to keep costs down to stop to think about making effective digital transformations to their operations. “That means one of things we need to be thinking of is helping companies people can learn different modalities of running a manufacturing workplace and provide information to business leaders in a flexible way so that they can access it at a time that suits them,” Marsh said. “But then you need to balance that with the fact that they probably need to take a step back from their business to actually understand what their problems are and what strategic approach they need to take going forward. Bernard Kornfeld, co-Founder and chief scientist at FactoryOne, agreed. “About 90 per cent of Australian manufacturers have 199 employees or fewer. I’ve lived on both sides – I’ve been an academic, and I’ve run factories, and the truth is that if a company has 199 people or less, and their focus is on day to day operations,” Kornfeld said. “So, I think we have to go back to the question of what problem we are trying to solve. While we may recognise the great potential from the variety of sensors, we also have to place ourselves Manufacturers’ Monthly APRIL 2020 19

Issues & Insights in the context of somebody whose focus today might be OEE; tomorrow it might be too much overtime, etc. I think everybody has to go from the place of recognising what is possible but placing themselves in the situation of someone in a factory. For some SMEs, they feel they are just too small, and it is just too hard.” A 2016 study from Coleman Parkes Research found that Australian and New Zealand businesses were wasting $56 billion per year on non-essential, time-consuming administrative tasks, which equates to approximately $3,900 lost per employee, per year. But these losses can be reversed by embracing Industry 4.0 technology, helping employees re-focus on core tasks and duties. Neil Baker, CEO & co-founder of Medulla, said that if SME manufacturers could find the time to understand their own particular industry problems and challenges, and what they needed to respond to those challenges, the flexibility of current technologies would work in their favour. “I believe that a lot of SMEs at the point where they have the opportunity to find services and systems that are able to be readily plugged in much easier than they used to be. It is a real exciting time – you can just go and buy services that provide your business value very quickly that are easy to implement and are designed to be easy to implement, as opposed to old enterprise systems,” Baker said. Mel Ireland, membership relationship executive at the Australian Industry (Ai) Group, said that another challenge was educating manufacturers about what technologies and methods were available. “Those of us here in the room recognise all the concepts, all the enabling technologies – we know what they are. A lot of SMEs that I speak to on a daily basis, particularly in regional Queensland, don’t know much about them,” Ireland said. “I have actually had a conservation within the last four months, where, when talking about enabling technologies, I mentioned IoT. I was interrupted and asked, ‘What does IoT stand for? Internet of Things? You’ve made that up, haven’t you?’ Some 20 APRIL 2020 Manufacturers’ Monthly

Australian businesses need to get a start on how to implement or progress beyond entry-level Industry 4.0. SMEs are genuinely not aware of these terms we use on a day to day basis, let alone the technologies that can be applied to their existing business or how that is going to help them. And it is not until we get the education right for SMEs that they can then identify that they do actually have a problem, and how to find something or someone to fix it.” Ireland said that Ai Group was focused on providing information, whether online or through events, that can guide manufacturers in the right direction. For example, over the last two years Ai Group has run a women in manufacturing event in conjunction with the Queensland Department of Industry. “We have got close to one thousand students, teachers, mums and dads, small businesses talking about manufacturing, and, with enabling technology. We are trying to shift from that message about what manufacturing truly is today,” she said. “There is a lot of information out there. The role of Ai Group or other associations is about fostering that collective and collaborative approach: it is about sharing information, about being able to match up one business to another that have similar problems. Those connections are starting to create a sense of trust that will help businesses talk to each other.” Alongside university hubs that facilitate industry partnerships, governments at federal and state levels have also established grant schemes and other conduits for R&D partnerships between research institutions and SMEs. To help remove

the barriers that confront SMEs in transitioning to Industry 4.0, the federal government, for instance, has established Advanced Manufacturing Growth Centre (AMGC), and the Innovative Manufacturing Cooperative Research Centre (IMCRC), whose aim is to enable manufacturers to get on board with the transformations being wrought by technological innovation and development. Speaking on an Industrial Internet 4.0 Summit panel, Neil Baker, CEO & Co-Founder of Medulla, said that SME manufacturers should draw on the help and assistance of government-funded bodies and programmes in making links and partnerships with cuttingedge industrial research and know-how. “I have worked with AMGC quite a fair bit, and I think there is a lot of opportunity there to be able to collaborate and get funding to onboard advanced manufacturing technology projects. From my experience, while you need to put in lengthy applications and collaborate with other groups to really build a strong business case together, it is a great opportunity to accelerate advanced manufacturing,” he said. In 2018, the NSW government released its NSW advanced manufacturing industry development strategy, which is targeting the development of high- value, high-skills services in the state’s manufacturing sector, particularly in pre- and postproduction processes such as R&D and design. Alongside supporting access to NSW and Commonwealth funding programs, one of the aims of the

strategy is to “[S]trengthen the capacity for industry, government and research institutions to engage and collaborate”. Among the enabling bodies for this collaboration is the NSW Smart Sensing Network (NSSN). Established in 2016 with funding from the state government, the NSSN has particular focus on unlocking the potentials of smart sensor research in manufacturing and other industries, including the infrastructure and energy sectors. Referring to the NSSN, Marsh said that the network could help businesses not only can they get access to the right kind of expertise across the NSW universities, but also help them understand what their own particular problems and needs are. “What we often find with businesses is that they will come to you and tell you the symptom of their problem, but they won’t actually be able to articulate what the problem is. So, helping businesses to unpack that is actually a really critical role that we can play, and we can do that throught the Small Business Connect programme as well,” she said. “We are also doing a lot around skilling to address the education gap. We have the Smart and Skilled programme, which provides subsidised VET training. For businesses there is also tailored training that is fully subsidised.” The RMIT report released in late February indicates that having committed top management team and having a clear implementation strategy are key requisites for success in transitioning to Industry 4.0 technology. “Before investing in Industry 4.0 solutions, a business needs to develop a specific understanding of which data is most essential to capture, who within their organisation will use it, and how that data can be presented to these people in meaningful ways that meet their needs,” said RMIT University’s Dr Ben Cheng, who led the project. Indeed, the findings of the report indicate that having a clear strategy can mitigate the seeming complexity of Industry 4.0. Moreover, beginning the transition to Industry 4.0 technologies, even at an entry-level, can bring significant benefits. manmonthly.com.au

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BIM is a modelling process that builds on a basic 3D model to support multiple applications for viewing information on a certain project.

Why Australian manufacturers need to build up to BIM 7D Manufacturers’ Monthly speaks with Total Construction about Building Information Modelling and how it will revolutionise architecture for Australian businesses.

MAGINE clicking through the model for your new home or office and being able to learn exact details like window materials or when the air conditioner was last cleaned. That is the direction architecture planning is heading in Australia if builders are to survive well into the future, according to leading Australian construction company Total Construction. The concept is called Building Information Modelling (BIM), a modelling process that builds on a basic 3D model to support multiple applications for viewing information on a certain project. Total Construction (ECG) general manager Rob Blythman said although there are currently no Australian companies using a 7D BIM model, it will eventually prove useful and for businesses in terms of manufacturing operations and maintenance that can be used by an entire design team. He thinks of a BIM model like 22 APRIL 2020 Manufacturers’ Monthly

a physical plaster model but in a portable digital form. “Your BIM is your foundation and you can take it to anyone, it’s a global standard for them to work with, and you own it,” Blythman said. A 4D model provides site planning and scheduling, while a 5D model gives a real time cost evaluation. 6D gives project managers the ability to flag certain parts and notify about maintenance. “The objective for most companies is to get to the 5D and 6D,” Blythman said. “If you could fly through a 3D model, look at every room and go ‘Okay, I need to look at that piece of equipment, when was it last maintained?’ You can just click on it and it tells you. “A 7D model is where you can have all the training requirements listed, and it will tell you the parts that are required – so it’s an extrapolation of 6D but in far greater detail.”

Total Construction offers 3D scanning to assess the entire layout of a building and then uploads information in the form of images into a BIM modelling software. “You set it up to have a look at the room and it spins at 1000rpms,” Blythman explained. “It just takes multiple pictures of everything, and what that builds up is the 3D model of the internal layout and all the equipment in there as well.” Process design engineer Tom Franks believes the advantage of BIM modelling is that it is owned by a BIM manager and acts as a central model that is continuously live-fed. “You’ll have your structural engineers, your mechanical engineers and your electrical engineers put in a design – they’ve all got services that need to go into the ceiling, for example,” he said. “It will pick up that your fire sprinklers have clashed with your electrical cabling and it won’t be at the eleventh hour when its being

installed on site. It makes that project run a lot more smoothly.” At the end of a project, a BIM model is handed back to the client to cross-check all information involved in a project. “From a building perspective, the BIM manager managing that build up manages the changes made as the build goes on,” Blythman explained. “Once the building is finished and people move in, the BIM is handed over to the client and the client will have their own BIM manager on staff to manage that.” And it’s not only a matter of convenience for design and construction purposes. Blythman believes in order for Australian manufacturers to stay competitive and remain cost effective, companies will eventually push for higher levels of BIM modelling. “If you don’t have BIM, you’ll be wasting a lot of labour resource on maintaining your operation,” he said. “Ultimately that’s what the manmonthly.com.au

Construction owners and boards of manufacturing plants will look at, is cost saving. “Like anything, you’ve got to spend money to get the cost saving over the long term, so you have got to spend that short-term money for long-term gain.” Many multinational companies are increasingly demanding their consultants to use BIMs as part of on-site projects they own, according to Blythman. “If they’re doing an extension to a building, they’ll say ‘Right, as part of that we want a total building done with BIM because we don’t have one here – we have one in Japan, we have one in our operations in the UK, in the US, but we don’t have one in the Australian operations,” he said. For businesses who cannot afford services worth up to the millions, Total Construction helps companies assemble a team to achieve a BIM building. “It may not get to the 7D level, but if you’ve got a foundation to build off it becomes the new norm moving forward,” Blythman said. “They’ve got that base model that they can then, when they want to expand it and do more with the BIM, they just add to it.” Total Construction believes BIM models will eventually become a backbone for Australian businesses, and not only a tool.

Total Construction helps companies assemble a team to achieve a BIM building. “If the project is going to be a BIM project, everyone working on that project needs to be across BIM models, and has to have some accessibility to the BIM model,” Franks said. “There are different types of accessibility you can have with the BIM model: you can have just read-

only, you can have read – upload, read – download, you can have read – download – upload. So, you can edit the actual model. “Anyone on that BIM project will have to know how to use it.” Although labour costs remain high, Blythman believes BIM modelling will become more

affordable and more common. “The difference is that, now, it’s getting cheaper to do it, and that’s where we will see it start to filter down to the SMEs as opposed to the big end of town,” he said. “Everyone wants to be like the big manufacturers, so they’ll all be looking at this.”

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Manufacturers’ Monthly APRIL 2020 23

software for good products

Welding Getting competitive The success of Australian manufacturing will depend on its adoption of automation. One Australian company is helping manufacturers automate their welding processes.

Robotic Automation is the Australian distributor for Yasakawa’s Motoman range of robots.

OR Australian manufacturers to remain competitive, the key message from industry bodies is to work smarter, not harder. In research conducted by the Advanced Manufacturing Growth Centre (AMGC) it was found that the manufacturers in Australia who are globally competitive are those who make smarter use of technology. In its report Advanced manufacturing: A new definition for a new era, the growth centre for the manufacturing industry highlighted that those successful firms adopt automation technology 1.3 times more than less successful companies. Making this investment in advanced automation technology can assist Australian manufacturers overcoming challenges such as low tariffs at home and low-cost competitors overseas, as the Innovative Manufacturing Cooperative manmonthly.com.au

Research Centre (IMCRC) identified in its 2018-2019 Annual Highlights report. But often this is easier said than done. In Australia, manufacturers need a trusted partner who can be relied upon to deliver a cost-effective and reliable solution. Robotic Automation is located in Sydney and Melbourne and can provide knowledge, expertise, and support for manufacturers looking to automate their operations. The company is the local distributor of Yaskawa’s Motoman range of robots. Robotic Automation has a range of arc welding robots that can assist with welding applications, and Ricardo Panizo, manager – robot sales is the local expert who can assist Australian industry. “We have a robot that has very high accuracy and that leads to repeatability and consistency,” said Panizo. “Especially with

car manufacturers and airplane manufacturing, you want something that is consistent, something that is always the same result. While there’s nothing wrong with manual welding, except it can be fatiguing and it can be very hard on humans, especially with the type of heat and the fumes expelled through the process of welding.” While these are often the reasons why companies adopt an automated welding process, Panizo has found that other benefits emerge once the robot is in place. “Quality, consistency, and occupational health and safety mindsets will kick off a process to replace a manual welding with an automated welding process. Then cycle times may also improve. If a welding process will take 30 minutes the first time and the second time it’s five, it is recommended to automate that process.” In Australia, Robotic Automation has supplied automotive parts manufacturers, as well as the local branch of international aerospace manufacturers. In these cases, Panizo has seen manufacturers adopt exactly what the AMGC was predicting – that employees work smarter, not harder. “Most people will have the perception that a robotic welder will just replace welding personnel, but we try to change that concept,” he said. “We try to challenge customers to come up with better designs. We find that a lot of customers will come on board when they realise the different kinds of techniques we can use.” Being a local supplier of a major international robot manufacturer, Robotic Automation is able to provide Australian manufacturers with a fully integrated solution. “We can provide a complete solution from a concept to a turnkey solution. In our case, we handle it from the concept to when it’s decommissioned. We do the training, the servicing, and the

support, we’ve got the ongoing consultation with the customer.” For arc welding applications, Robotic Welding offers the Motoman VA and MA series, including the world’s first seven-axis robot and models with payloads of up to 15kg. In addition, Robotic Automation provides and supports a production suite which enables manufacturers to flexibly program the robot to their particular specifications. “Motoman is one of the pioneers in developing a production suite that allows you to –without interrupting the system that is already running and performing – create new programs, modify programs, implement new solutions without disturbing the process, using an offline software,” said Panizo. Since the 80s, Robotic Automation has been working hand-in-hand with Australian manufacturers to enable them to be ahead in their field and knows that Australian manufacturing has the potential to continue to grow.

The company supplies a wide variety of manufacturers with advanced solutions.

Manufacturers’ Monthly APRIL 2020 25

Plant Maintenance Reducing operational costs through good lubrication Extending the life of heavy gear for cement manufacturers is crucial for them to save operational costs associated with maintenance. Manufacturers’ Monthly finds out why from the John Sample Group.

How can lubrication solutions reduce operational costs while contributing to emissions reduction? When it comes to cement manufacturing, it is generally common that all machinery must run continuously even under the harshest working conditions. Cement mill equipment must withstand 26 APRIL 2020 Manufacturers’ Monthly

Large gear drives are generally used in the material conversion industries like the cement industry.

Credit: images courtesy of SKF

EMENT manufacturing is a vital part of the Australian economy and a significant national industry that employs over 1,300 people directly and more than 5,000 indirectly – many based in regional Australia. With the presence of over 20 cement manufacturers across the country, this industry produces an average of nine million tonnes of cement per year, which represents around one percent of total global production. According to the Cement Industry Federation, a national body entity that represents the Australian cement industry, in recent years, the Australian cement industry recorded a turnover of $2.4 billion, and since 1990s the industry has moved towards more energy-efficient production technology in order to adopt leadingedge practices to reduce costs and emissions. Cement mills are large manufacturing sites capable of producing vast quantities of cement per year. These plants require significant investments associated with installation, maintenance and upgrading. Therefore, any unwanted downtime due to lack of maintenance might cost millions of dollars in financial losses. It is crucial for cement manufacturers to find solutions aimed at boosting production under environmental guidelines while reducing operational costs associated with maintenance.

high vibration, shock loads, slow speeds and a high concentration of particulates. All of which means that contamination, loss of lubricant and even improper mounting techniques will likely lead to failures for pinions or trunnions. The lack of lubricant during operating hours might cause costly downtime and repairs within the whole operation, which means companies have to face extra high costs that could be anticipated through customised lubrication solutions. By implementing customised lubrication solutions, cement mills will drastically increase durability, reliability and productivity by avoiding undesired breakdowns; and enhance safety as unsafe manual lubrication is eliminated. Furthermore, a customised lubrication solution will help minimise friction which will lead to a reduction in energy consumption, heat generation, wear and noise. Additionally, it will decrease operating expenses, mitigate product contamination and corrosion, and

minimise lubricant consumption and maintenance.

Extending the lifetime of large gear drives is essential for cement manufacturing Large gear drives are used to transmit movement under very heavy loads. They are generally used in the material conversion industries including the cement industry. The forces transmitted from one gear to another are such that the metal on metal friction immediately causes pronounced wear on the surfaces in contact. Experience has shown that even with precise positioning of the gears, only 50 to 60 per cent of the initial area bears the load. Lubrication is therefore essential to ensure trouble-free operation of these gear drives to extend their mechanical lifetime. John Sample Group, through its JSG Industrial Systems business, provides access to products and solutions from SKF and Lincoln Lubrication within the Asia Pacific region. JSG Industrial Systems has been the front runner in delivering

lubrication solutions from SKF which has the engineering competence to design state of the art bearing assemblies, incorporating customised lubrication systems that greatly extend maintenance shutdown periods allowing higher productivity and lower costs. JSG Industrial Systems provides SKF automatic lubrication systems for the lubrication of open gears that sprays the lubricant directly onto the gear teeth. This solution, known as Grease Spray System, is designed to protect pinions and trunnions from harsh operating conditions and prevent failure. The Grease Spray System has demonstrated its efficiency on numerous cement plants across the globe. The spray lubrication system is fully automated. The control unit, dedicated to this application, allows the possibility of continuous or cyclic lubrication. As a result, it is perfectly suited to the requirements of open gears, whether for running-in lubrication (continuous) or regular service lubrication (cyclic). The entire lubrication installation is equipped with numerous monitoring and safety devices to guarantee optimum operation. JSG Industrial Systems designs, develops, and supplies engineered industrial systems which increase assets lifetime, reduce operational risk and contribute to environmental sustainability. The company provides access to products and services in industrial lubrication, liquid flow management, and fire suppression for a variety of global sectors including manufacturing, pulp and paper mills, transportation, mining, food and beverage, agriculture, marine, energy, and construction. For more information, contact your JSG Industrial Systems representative on 1300 277 454 or visit www.jsgindustrial.com manmonthly.com.au

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Software Insights for intelligence Having a partner in a time of crisis can be a business’s key advantage. Manufacturers’ Monthly finds out more from Unleashed Software. Having accurate information during a crisis can enable a business to weather uncertainty.

URING a crisis or challenging economic circumstances, there is an explosive proliferation of information about what to do and what effects the crisis may have. Much of this information is speculation and unfounded rumour, and even the official information is broadly targeted and irrelevant for some. Thus, having accurate information in a crisis is a valuable commodity, and the current COVID-19 situation is no exception. Unleashed Software, an inventory management system designed for manufacturers, is continuing to provide accurate, relevant, and up to date information for manufacturers. Danielle Dadello, country manager for Unleashed Software, explains how Unleashed is supporting manufacturers now. “At the moment if you’re a customer of Unleashed we’re

28 APRIL 2020 Manufacturers’ Monthly

providing the visibility of how much stock they have on hand, whether or not there’s a slowdown in the supply of goods to them, and what their important products are that may sell, what makes them the most money in the business, and their most important customers.” Basic decisions during times of heightened uncertainty on data can ensure a business continues to function, and potentially even thrive during a tightening of supply chains. “The business might have a gut feeling of who their high value customers are that they need to keep serving to keep the business open but we really show how many sales they would normally be getting, how much they’re currently getting, and where they should focus their efforts,” said Dadello. “To protect their brand they want to make sure that they have the right amount of stock reserved for their high value

customers and be able to work with them in the right way and to keep them happy.” Unleashed’s core function is giving businesses insights into their operations. Starting at purchasing and inventory, Unleashed’s dashboards and reports can guide businesses in their operations. “If you don’t know how much stock you have on hand or what products are getting you the most bang for your buck, then it’s really difficult to get a handle on where you should focus your energy in the business,” said Dadello. Unleashed is continuing to develop tools for its users to give them analytical insights into the health of their business and areas for improvement. “We have loads of reports that are going to help you identify what’s your best-selling product, who are your best customers, your low and

high stock levels, and also your lead times for normal supplies. “Those lead times may be skewed at the moment, as things are slowing down a little bit, but our software can tell you what purchase orders you have placed that you’re not going to get in time, and how to work with your suppliers.” Currently emerging from its beta phase is Unleashed’s new Business Intelligence module, which will allow for further advancements in supply, production, and sales forecasting. “Having a BI tool will allow you to dig in and forecast on where you should be spending your energy in the business,” said Dadello. While conditions are different for each business, so far flexibility is key, and Dadello outlines how Unleashed can help in this respect. “We are seeing a mixture of people who quickly want to get into manmonthly.com.au

Software We’ve seen a trend with customers needing to source from other suppliers and that is an option during this time, but it is important to keep lines of communication open with your suppliers and understand who they are and what they can give you and when they foresee that they can give you supplies. inventory management because they’re not able to cope with demand and some of them that have reduced sales to customers. Then there are some that would love to get going but have not been able to get the supplies that they need.” As a platform that enables businesses to quickly and easily adapt to these conditions, Unleashed can be a key competitive advantage as supply chains reroute. “We’ve seen a trend with customers needing to source from

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other suppliers and that is an option during this time, but it is important to keep lines of communication open with your suppliers and understand who they are and what they can give you and when they foresee that they can give you supplies,” said Dadello. The final piece of the puzzle is ensuring that staff and customers are able to stick with the business as working and purchasing patterns change. As a cloud-based platform, Unleashed can incorporate the rise of working from home, both

internally and with customers. Unleashed’s B2B online store enables customers to connect with other manufacturing businesses easily and with customers, without having to deal with phone calls and emails. “One of the things that have come out of this is being online is key to business success and you can see the difference in customers that simply don’t have anything online that can be readily available if you need to work from home when staff isolate,” said Dadello. “Having that online presence is key to business success, but also something like a B2B allows you to open up more sales channels.” Besides the particular products and services and Unleashed offers, Dadello notes that at times of uncertainty there is value in businesses coming together. “Not only are we giving visibility on where they should focus and where their products are, but we want to help them in terms of

Danielle Dadello is working to ensure businesses perform during a trying period. recommendations on cash flow and give insights into what other businesses are doing to support themselves through this time,” she said. “We want to create that community feeling as well as providing a technology stack that is going to help their business perform.”

Manufacturers’ Monthly APRIL 2020 29

JUNE 2020 – PACKAGING, WRAPPING & LABELLING EQUIPMENT For many operations, the final steps of packaging, wrapping and labelling their goods can turn into a bottleneck. These final processes can also affect the quality of a product in the hands of the consumer. In June 2020, we will speak with companies providing solutions to every level of manufacturing operation. In every edition of Manufacturers’ Monthly, we’re proud to work with our commercial partners on content that helps connect you with your future customers.

Booking deadline: 29 APRIL 2020

To book contact DANILO CORTUCCI now danilo.cortucci@primecreative.com.au | 0434 419 663

Robotics Technology Collaborative Robots: Designing for Productivity & Safety Steven Keeping for Mouser Electronics explains the benefits of working with collaborative robots in industrial environments.

Figure 1: Industrial robots operate behind safety barriers.

NDUSTRIAL robots are commonplace in factories because they provide an effective alternative to manual workers for repetitive, high-volume assembly line tasks. The machines can continuously repeat high-precision tasks for many years with only the occasional interruption for routine maintenance. Boosted productivity ensures a return on the initial high capital investment. But relatively low-cost human workers remain the best option for low-volume, high-mix, intricate assembly work because they are dexterous, flexible, and able to solve problems that would grind a machine to a halt. Collaborative robots – the lightweight, compact, and relatively inexpensive cousins of full-size industrial robots – are now being introduced to combine the advantages of robots with the assets of humans. However, because collaborative robots share the workspace with humans, new engineering techniques are required to maximise productivity while keeping the workers safe.

Sharing the Workspace Collaborative robots fill a niche in a manufacturing environment where the product mix is consolidating and manmonthly.com.au

volumes are increasing but not to the extent that justifies full automation. The robots can do the picking of parts, lifting and fetching, and repetitive, routine actions while the humans work on the intricate fabrication and intellectual challenges of the process. Collaboration is not a natural extension for traditional industrial robots. The International Organization for Standardization (ISO) defines an industrial robot as “An automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes, which can be either fixed in place or mobile for use in industrial automation applications.” The description fits a machine purpose-designed for maximum productivity without human assistance. It’s not surprising that from the introduction of industrial robots in the 1970s, a division on the factory floor has remained a requirement for the safe automation of their highvolume applications. Today, workers are kept well away and the machines are enclosed behind metal barriers to eliminate the hazards posed by rapidly moving and heavy mechanical parts (Figure 1). Basic external sensor technology provokes an emergency stop of the industrial robots when someone or something crosses a beam or triggers a switch by opening the barrier. And when technicians do intentionally enter the robots’ operating envelopes for maintenance or reprogramming, the machines are powered-down with their arms locked in a safe position. Maximising speed, strength, and precision remain important for collaborative robots, but to maximise the advantages of collaborative working, humans and robots need to work in harmony. And to justify the introduction of a collaborative robot, it must cost no more than the equivalent for human labor. A robot that’s moving parts into position and adding quick-

drying adhesive is of little value if a human coworker still has the previous two to three workpieces to fit together. But more importantly than that, robots must be constantly aware of where the humans are positioned, how they are moving, and the force they’re applying when contact is made (whether intentionally or unintentionally) to ensure safe working. The key design objectives for collaborative robots can be summarised as achieving: • Safe interaction with human workers and delicate assembly equipment • Reduced costs to justify use of robotic labour applications • Robotic operations at a rate compatible with human capabilities • Clean and low-noise operations • Compact and light form factors • Simple and fast programming by non-expert workers to cope with high-mix production • Collaborative Robot System Design Guidelines Key factors in collaborative robot design relate to the fact that the machine and human share the same workspace (Figure 2). The designer needs not only to ensure that efficiency is high but also that the robot is constantly aware of the sometimes-unpredictable movements of its coworker and can react in a safe manner. The designer also needs to ensure that the robot doesn’t apply excessive force if there’s intentional or unintentional contact between itself and the human. This adds complexity, because unlike industrial robots in which safety systems are not an intrinsic part of the robot, collaborative robots contain safety systems that are generally integrated into its own structure and controlled by its own systems. Fortunately, guidance on these design challenges comes in the form of international safety standards for collaborative robots, which have

been developed in parallel with the rapid introduction of these robots in the workplace. For example, the International Organization for Standardization (ISO) provides some guidelines for designing collaborative robots in its ISO 10218 document, and a technical specification (TS) created by the organisation, the ISO/TS 15066, focuses on the safety of collaborative robots. ISO/TS 15066 highlights the importance of safety-related control system integrity with regards to controlling process parameters such as speed and force. (Note: ISO/TS 15066 represents a voluntary document and is not a standard; however, it is expected to form the basis of a standard in the future.) ISO/TS 15066 also provides general information for a collaborative robot designer to use, such as information explaining the need for a risk assessment of hazards in the workspace. For example, even the best robot design can’t be considered safe if it allows the robot to wave around a sharp object with its manipulator. In another example, the workspace could be dangerous if it’s closed in by fixed objects that cause a worker to become trapped then crushed by robot movement. The key sections of ISO/TS 15066 address the design of workspaces,

Figure 2: Collaoborative robots share the same space as co-workers.

Manufacturers’ Monthly APRIL 2020 31

Robotics Technology

Figure 3: Small robots use harmonic geared joints to reduce size and weight. design of a robot’s operations, and the transitions between a robot’s collaborative and non-collaborative operations. Specifically, the document provides extensive details for implementing the following collaborative-operation requirements, which creates safe, efficient solutions that fulfil the design objectives mentioned above:

between a collaborative robot (or any workpiece) and a worker when both are working in the collaborative workspace. Contact can either be quasi-static, such as the clamping part of a worker’s body between a robot’s manipulator and a fixed object, or transient, such as the knocking into a part of a coworker’s body where the worker is able to recoil.

Safety-Rated Monitored Stop

Design Safety Challenges

A safety-rated monitored stop is an assured robot stop without removing power and occurs when a human worker enters the collaborative workspace. The system ensures that the robot and human don’t move at the same time and is primarily employed when the robot is rapidly moving heavy parts through the workspace. Before a hand-guided operation can start, a robot must perform a safety-rated monitored stop. During the operation, a worker is in direct contact with the robot arm and can utilize hand controls to move it. This operation is used for lift assists or highly variable “tool” applications.

With some adaptations to limit cost, size, and complexity, collaborative robot designers can employ existing industrial robot technology for some systems while still implementing the work methods described above. For example, the safety-rated monitored stop is an established technology for industrial robots that uses safety barriers to implement an emergency stop when a human enters the operational envelope. Speed and separation monitoring demands new engineering techniques considering industrial robots are designed to come to a dead halt when a person breaches the work zone. In contrast, collaborative robots will keep moving, albeit at a reduced speed, when workers are sharing the workspace, unless an approach is close enough to trigger a safety-rated monitored stop. Key to implementing such systems is integrating sensors into the robot’s control systems so that the closed-loop feedback enables rapid motor response when speed reduction is necessary. But the most difficult design challenge is power and force limiting. Designers can learn little from industrial robot design because its emphasis is on load capacity and speed. An annex for ISO/TS 15066 offers help by suggesting limits to quasi-static and transient forces for pain thresholds as well as minor,

Speed and Separation Monitoring This collaborative work method is perhaps the most relevant, as it allows the operator and robot to move simultaneously within the workplace by equipping the robot with sensors to monitor how close in proximity the worker is. At large separations, the robot continues to operate at medium speed, but upon closer approaches, the robot reduces its speed, and at very close approaches, it comes to a complete safety-rated monitored stop.

Power and Force Limiting Power and force limiting are required in applications where there could be intentional or unintentional contact 32 APRIL 2020 Manufacturers’ Monthly

reversible, and irreversible injury thresholds for humans. Transient force thresholds can be twice as high as quasi-static ones, because they occur within a shorter timeframe and the worker is able to recoil. While research continues on pain and injury thresholds, the present guidelines recommend lowering clamping risks by reducing a robot’s speed to less than 250mm/s and its force to less than 150N during speed and separation monitoring operations, though transient forces can be twice as high but must not be applied for longer than 500ms. Meeting these thresholds is challenging. For example, a 2kg robot arm carrying a 0.5kg load and moving at 1m/s must decelerate at 60m/s2 to limit its crushing force to below 150N if unintentional contact occurs. In that time, the arm will travel 8mm, which is acceptable for collaborative operation. An identical robot arm carrying a 3kg load would need to decelerate at 19m/s2 to limit its crushing force to less than 150N, during which time it will have travelled 27mm (which is acceptable with padding). This example illustrates that the robot designer must consider the differing dynamic forces generated by collaborative robots with different payload and speed of movement capabilities. Other advice in the ISO guidelines includes: • Eliminating pinch and crush points on the robot • Reducing robot inertia and mass • Reducing robot velocity when it approaches a fixed surface, so it can stop quickly • Increasing the surface area of contact points • Organising the workspace layout to limit clamping points and to allow recoil after transient collisions

Case Study: The Collaborative Robot Joint A major challenge in collaborative robot design is engineering lightweight, compact joints that are also able to quickly react to forces acting on the manipulator – such as impact with a coworker – to eliminate the risk of injury. Harmonic gears are finding

favour for small robots because they enable designers to reduce joint size and weight in comparison to using conventional mesh gears (Figure 3). However, because harmonic gears use a flexure to transmit motion between input and output, the joint exhibits low rotary stiffness compared to a mesh gear alternative.

Conclusion Collaborative robots are making their mark in workspaces shared with humans as combining robot muscle with human dexterity and problem-solving skills is dramatically improving productivity. Factory managers are just recently beginning to appreciate the number of assembly applications – currently performed solely by human labour – that collaborative robots can be used for. That’s why the impact of collaborative robots is predicted to increase, with growth expectations roughly set to equal the size of today’s entire quantity of industrial robotics by 2025. But it’s still early for the technology, and engineers are now learning that only some of the design techniques used in engineering industrial robots are truly applicable for their collaborative cousins. A new design methodology is required to ensure that collaborative robots remain safe around coworkers while still bringing speed, precision, and load-handling benefits to the job. Designing collaborative robots is a nascent discipline, and as such, there is little guidance to draw upon. But international safety standards for collaborative robots are being developed in parallel with the introduction of the first wave models into the workplace. The ISO 10218 standard provides specific guidelines for collaborative robots, while ISO/TS 15066 establishes safety parameters for collaborative operations. And suppliers are doing their part by teaming electronics and sensors up with advanced mechanical assemblies to create new critical components, such as specialised joints specifically engineered for the unique demands placed on collaborative robots during everyday duties, operations, and interactions. manmonthly.com.au

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Digital Transformation How to optimise your digital transformation When deciding to implement digital technology to enhance a business’s operations, it can be difficult to know where to start. Managing the change can be complex, with decisions requiring trade-offs across impacts to business, benefits and investments/costs. That’s where digital services provider firm, BDO can help optimise and deliver transformation.

BDO believe there is opportunity for manufacturers to harness new technologies.

HILE BDO has been operating its full gamut of services – spanning audit, insurance, tax, compliance, and advisory services for a range of industries since 1975 – in the last six years, they have amped up their technology and digital focus; allowing them to help manufacturer’s optimise value from their digital implementation. BDO’s technology advisory partner, Kamal Prasad, says technological change complicated the manufacturing sector a decade ago, when the predictability of the supply chain was disrupted, and these changes have accelerated today. “Ten years ago, manufacturing was a linear process. Manufacturers would buy the product, manufacture, and distribute it. Today, the supply chain has become an interconnected network, driven by technological change and globalisation,” Kamal Prasad said. “Now, manufacturers have more options. They can buy from a network of suppliers; they can manufacture beyond their own borders and they

34 APRIL 2020 Manufacturers’ Monthly

have multiple paths to distribution. This speed and movement across networks have increased complexity for manufacturer’s, making it hard for old systems and processes to keep up.” What the firm noticed when they made the decision to expand their offerings to include technology and digital advisory services, was the speed and its inevitable complexities that were impacting organisations across the spectrum. For manufacturers, managing and optimising value from digital innovation was becoming overwhelming. BDO believed there was opportunity for manufacturers to harness new technologies; create new business models; reinvent their existing practices to deliver profitable growth; create leaner organisations to drive efficiencies; create a dataconnected business and leverage data to make more effective day-today decisions. However, with studies showing that only 30 per cent of digital programs are successful, to harness the power of digital requires a change in organisational mindset.

As such, BDO expanded its technology and digital advisory services in order help their clients optimise value from and help derisk digital programs – with a focus on the selecting and enabling the right digital capability and bringing processes, people and system to fundamentally shift the dial on digital for their clients. Kamal says this distinction between technology and digital implementation is important in the way you tackle change. “When we talk about digital, it’s about how you use the information enabled by constant technological disruption. To make the most of it can mean a whole of company change,” Kamal said. He says this change needs to be a continuous strategic negotiation for business. “The first challenge we tackle with our clients, is that change is ongoing - how your business sets itself up to handle adaption is key. Clients tend to think of digital as a project with a defined start date and a defined end date. This is not the case, digital is here to stay.” “Whereas previously, we had the luxury of time to implement a project for a set period and a predictable outcome, the speed of change and disruption makes that harder today.” He explains that because new functionalities, apps, and other such disruptors, such as Industry 4.0 technologies, are constantly emerging, this presents a new way of adopting and embedding these digital innovations. “Disruption is not an isolated event, it’s an entirely different way of doing business. So, you have to pursue a whole of company change, rather than just a technology implementation.” “Today, organisations must think about how they apply digital more

broadly in terms of its effects on the whole business. However, for successful adaption they must implement technology in a small and agile manner – it’s quite a paradox really.” “If you start thinking like that, you will start to see your customers differently; you will see your distribution differently, and you will see your suppliers differently.” BDO guides their clients in undertaking this challenge but acknowledges that there is no silver bullet, with each digital transformation being different from the next. According to Kamal, trying to apply the concepts of a successful case study or imitate it does not lead to success. “There are two big things challenges clients tend to struggle with. The first is where to start, and then the second one is at what pace to change?” Defining the issues, breaking it down and adjusting methodologies for each client is critical, otherwise it can quickly become overwhelming. Then it is about adjusting the pace so that it becomes whole organisation initiative and aligned with their objectives and culture. These things make the digital transformation journey unique to every client.” For example, one of the clients that Kamal was working started with the question: Why is your working capital not in line with where your industry peers are? “The moment we started unpacking the business issues, we realised that there were challenges around their business processes - in terms of how they engage with their customers, how they get their customer information and how they feed that back into the manufacturing. The existing setup did not enable the speed that is required in the fast-changing business environment. So, the focus shifted quickly to process changes manmonthly.com.au

Digital Transformation that are required and then came the technology part.” When the team started working on the initiatives to implement digital processes throughout the firm, they did so in an agile manner, by defining what challenges and issues should be tackled every four weeks. “At the end of every four weeks we would take stock of what we had achieved, or not, and what types of adjustments we needed to make. So, we did it in a more incremental manner rather than doing it all at once, then we could reflect on the whole project after three months’ time. As part of this process, there were elements around technology, analytics, process change, that arose and were addressed quickly and appropriately. The agile approach quickly started delivering business outcomes through improved customer service and also started to create a positive impact on working capital.” Kamal gives another example of a robotics process change that enabled a client to significantly improve their productivity. The client had a large team supporting order management processes and the team’s workload was only growing – exponentially. “The business was growing, but with growing product portfolio and customer service offering, the load on the team was growing. When we looked at their processes, we realised that a good percentage of what they Digitalising the manufacturing process can help overcome challenges.

manmonthly.com.au

Manufacturers can buy from a network of suppliers; they can manufacture beyond their own borders and they have multiple paths to distribution. were doing had the ability to be automated by a robot,” he said. “The pilot was extremely successful - we were able to improve responsiveness and streamline the process. However, the biggest impact was the improvement in employee engagement – their people now had more time to focus on more meaningful and strategic challenges. While, initially, we thought there might have some level of resistance to the change, with the bot ‘taking’ their job; they were actually so much happier

that they didn’t have to do all those repetitive tasks anymore.” Kamal says apart from process and cost improvements, digital has the potential to address a range of challenges. “A lot of their workforce is aging, the people who are working on that production line are now they are reaching retirement age. A lot of the knowledge about how manufacturing happens, how the machine needs to be adjusted, how the product needs to be handled, all of that knowledge

will leave the company. So, the big challenge for companies is how they overcome the risk of losing all of that knowledge, as their people enter a phase where they will no longer be able to work. This is where Industry 4.0 can add value.” “By capturing sensor data from their production lines, we can now track the types of changes that operators make and whether it’s because of the type of product that’s going in, the level of humidity, the temperature, or other environmental factors. Advanced analytics can help correlate all of those things. And done over a period of time, you can codify all of that information to make it more systematic,” Kamal said. Overall, Kamal says being able to keep an open mind to keep refining or adjusting their digital transformation journey is the hardest challenge facing manufacturers, above implementation. “When you’re setting the business direction, you need to be broad minded and when you implement you need to do so in small steps, so that you can measure value and interpret it along the way, not at the end of a period of time. “New disruptors could emerge at any time, you need to respond to these changes as quickly as possible, even if it takes you from the path you were originally on.” Manufacturers’ Monthly APRIL 2020 35

Tests & Measurement The right machine for the right job Test Machines Australia highlights that when it comes to testing equipment, there is a reason to choose a team with local knowledge. Manufacturers’ Monthly explains.

UY local or import? It’s a question as common in the supermarket aisles as in a manufacturing business, and while the standard answer may be determined by any number of considerations, when purchasing testing equipment, the value of local precision cannot be understated, said Paul Cibotto of Test Machines Australia. “Anyone can buy a machine online, the machines all look the same, all say they’re the best, and you don’t know until they arrive and all of a sudden it doesn’t do what you want.” This can lead to a complicated communication process with the original supplier or manufacturer, located at a distance from the user, with barriers of time zone and language, and all the while the machine is sitting idle. “This can drag on for days and days and all this time the machine is there, and it looks pretty, but it’s a big paperweight,” said Cibotto. One alternative is to look for a local distributor of an international

Test Machines Australia can find the right machine to fit each client’s requirements.

36 APRIL 2020 Manufacturers’ Monthly

Not every job or every requirement is the same, it’s not all textbook, sometimes it’s a little bit weird and wonderful, and so we will custom design a specialised machine or fixture and have it all running on your machine before it gets sent to you. brand of equipment. “If you buy off a guy that buys out of a catalogue, the dealers and distributors place the order and take the profit, but they don’t understand the machines either, so when there’s a breakdown or an issue, they then have to go back to the parent company,” said Cibotto. “The salesperson is not able to make a decision or know what’s inside the machine, he doesn’t know the machine he’s just sold out of a catalogue.” The route that Cibotto recommends going with is finding a local manufacturer of equipment. “Test Machines Australia used to actually manufacture tensile testing machines – in the 90s and early 2000s, we used to manufacture them ourselves here – we would design and manufacture them. We actually know what’s in the machine.” Today, Test Machines Australia has their equipment assembled overseas, but to Australian specifications, and with Australian support. “We manufacture the machines to our designs; we actually know what’s in the machines because we specified everything that’s in the machines. Come repair time or warranty time, it’s actually done all through us, we cover the warranty,” said Cibotto. “What that means is that when you make the phone call to us with a problem, we’re able to get onto

it straight away. We send out a technician straight away to repair it as fast as possible.” Formed as a business four years ago, Test Machines Australia was the result of a group splitting off from an Australian manufacturer of testing equipment that chose to no longer incorporate design work. This means that the entire Test Machines Australia team know the machines they are selling. “We could see people weren’t designing machines for the particular application, they were selling catalogue machines, and we could see a niche market selling the correct machines for the correct jobs, so we branched off and Test Machines Australia was born out of that,” recalled Cibotto. While the company may be young, the team have decades of experience working with manufacturers to ensure that the products they are selling meet specified requirements, with minimal impacts on production. “We understand the importance of downtime because these machines are there to help a factory run. If a business can’t test the product, effectively the factory can’t send the product out the door and if you can’t send the product out the door, they’ve got no money coming in. We understand that the days and hours are important.” This understanding supports Cibotto’s belief in the value of

buying locally as the machines can be designed to the individual requirements that a customer may have, and not have to be retrofitted from a standard design. “Not every job or every requirement is the same, it’s not all textbook, sometimes it’s a little bit weird and wonderful, and so we will custom design a specialised machine or fixture and have it all running on your machine before it gets sent to you.” Starting from this understanding, the Test Machines Australia team is able to advise when an application is possible, and when an alternative may have to be found. “Doing a compression test at fast speed, for example, on paper, yes it’s possible, but in real life you’ll destroy the machine. I tell them all this before we sell them a machine, because if the machine fails, it’s not covered by the warranty. We redesign it to suit their application, we work with the customer to sort out the right machine for their application because quite often they’re going off what they see on the internet or they don’t know what’s available and what their options are.” To give customers the right support, the Test Machines Australia team are made up of specialists who know their field from the inside. “Our staff are engineers that went into sales, not salespeople turning into engineers, so a lot of them have a trade background, some have an electrical trade background and some have a mechanical trade background. Everyone has been involved in manufacturing themselves, not just working with a company that manufactures and through that they’ve gone through the design phases where they’ve come up with their own ideas and their own concepts,” said Cibotto. “We have a big emphasis on staff that can do things, not manmonthly.com.au

Tests & Measurement just on paper.” Validating this focus on engineering skills has been the decision by international manufacturers of test machines to appoint Test Machines Australia as the local warranty and service agent. “They trust us to look after their machines because the overseas brands don’t have any service representation here, so they’ll get us to fix it for them.” The outcome of this dedication to local manufacturing and skills can be seen to Cibotto when an

Australian manufacturer requires someone to fix a machine that has broken down, something that occurs all too often. Cibotto recalls one experience where the customer overloaded the machine and physically broke the machine. “We got called in to assess the machine, found out that the ball screws were all broken, and the manufacturer wouldn’t help them, support them, and wouldn’t even tell them the part they needed to replace.” Having a first-hand knowledge

of the kinds of machine that had broken down, Cibotto’s team were able to come in and help. “We were able to disassemble the machine and replace all the broken parts, this is not a job for someone that doesn’t know how the machines are put together. We were able to go in there, realign it and reset up and in a day and a half. “No one wanted to touch it, no one wanted to help them, so they went for a couple of months with this machine not working and they’re getting their product tested outside which was costing them a

fortune,” he said. Ultimately, said Cibotto, the company is not focused on selling equipment, but providing a lifetime of service. “We’re not about selling you your first machine, anyone can sell you one machine, but if the machine is really good and the company is very good, you’ll buy your next machine and the one after that because you they trust the company. If your machine is a piece of junk, a customer won’t buy another one off you, so your second machine, that’s when you prove yourself.”

The team at Test Machines Australia have a hands-on knowledge of the sensitive testing equipment.

manmonthly.com.au

Manufacturers’ Monthly APRIL 2020 37

Sustainability New flexible solution for old rubber tyres Flexiroc and Tyre Stewardship Australia join forces to ramp up Australia’s use of end-of-life tyres.

Blast testing at Australia’s only national blast simulation facility, at the University of Wollongong

USTRALIAN entrepreneur Gary Bullock has come up with an ingenious way to make buildings fire and blast-proof. His invention, Protectiflex, is a concrete material that combines recycled rubber tyres and composite fibres in a cement matrix that can be sprayed onto buildings. Bullock, a structural engineer, established his company Flexiroc Australia in 2014, after he bought the rights to a rubber concrete made from recycled tyres. The company is recycling 10,000 tyres from Australia and another 500,000 tyres from around the world to include in blast-proof materials. Protectiflex has been tested at Australia’s national blast facility at the University of Wollongong and has so far delivered results beyond Bullock’s expectations.

38 APRIL 2020 Manufacturers’ Monthly

“In a normal explosion, that block work would disintegrate,” he explained. “What it does is it takes all the energy from the blast and it holds it all together. “So effectively, it’s enhancing the blast protection of that wall. If you have an existing wall, it means you can spray that wall and make it blast resistant.” Protectiflex can be used for a wide range of purposes where blast protection is needed, such as defence, heavy industry and in the petrochemical industry. It is also environmentally friendly, durable, light weight, and about 30 per cent lighter than concrete which can be used to make thinner lighter structures. “You can apply this material to either to an existing building or to a new building and do it as part of

the new building structure,” Bullock said. “Basically, it will enhance the blast resistance of that structure.” Testing panels from various building parts made up of concrete masonry blocks are coated with a thin layer of thin, which enhanced brittle block works. Professor Alex Remennikov from the University of Wollongong’s Faculty of Engineering said masonry walls form a common building component that are vulnerable to blast loads, created by terrorist attacks or accidental explosions. “The blast simulation facility was established to overcome the challenges associated with live explosive testing, such as very high cost, safety, efficiency and repeatability of test results,” he said. “We’ve used a blast simulator,

which is the only available facility in Australia and the southern hemisphere for blast testing of elements of buildings.” Protectiflex panels were tested at pressures 50 kilopascal and 100 kilopascals at the University of Wollongong, home to Australia’s only national blast simulation facility. “These panels have demonstrated exceptional performance because they didn’t develop any damage, cracks, and stayed intact,” Remennikov said. A coated masonry wall will endure far larger blast loads than a standard wall, Bullock said. “We’re getting very good protection of the masonry wall with smaller deflections and it’s totally intact,” he said. During test runs, sprayed Protectiflex walls were hit with shock loadings similar to a car bomb explosion from 20 metres away. In the past, Protectiflex walls have been used in either castin-place or precast construction methods. The spray on product provides another construction method to the technology making it more cost and time effective, especially when integrating with other construction materials. The spray-on application can be applied to both new and existing walls and buildings to develop or enhance their blast, ballistic and fire-resistance ratings. “We are confident these tests will prove the spray-on composite creates blast resistant walls,” he said. “The ProtectiFlex blast tests will demonstrate how spray-on retrofit could add strength and stiffness to concrete masonry walls, protecting occupants behind it from the blast loads. ProtectiFlex can be applied across a range of sectors including defence, government, critical manmonthly.com.au

Sustainability infrastructure, petrochemical and retail. The product has undergone rigorous testing and has achieved the highest levels of protection accreditation in areas of blast testing simulating car bomb and hand-carried explosives, weapon effects testing from an extensive range of projectiles at the highest level of international ballistic rating testing, and two-hour fire and flame testing. “ProtectiFlex is not only a great way to protect human life and critical assets, it’s also lightweight, eco- friendly, cost-effective and incredibly versatile in its form and application,” Bullock said. “Although today’s experiment involves testing how the spray-on product handles blasts, we hope to conduct further studies in the future proving it performs just as well in fire, ballistic and weapons tests,” he said. Tyre Stewardship Australia (TSA) is a keen supporter of Protectiflex

and provides support for similar organisations. TSA CEO Lina Goodmans said the product was a “fantastic use” of end-of-life tyres. “This innovative product made from recycled tyres could potentially save lives,” she said. “Although more than half of Australia’s old tyres are recycled, upcycled or processed to make other products, like ProtectiFlex. Each year in Australia, about 56 million tyres go to waste, and roughly 40 million are recovered or refused from that number. “Protectiflex is such an innovative product. If it is used in Australia, it is going to protect people in buildings,” Goodman said. “We want them to be incredibly successful in the market, if they’re successful, it means more waste tyres are being used in applications that are really innovative.” TSA is a voluntary product stewardship scheme that helps the industry find new markets

Managing director of Flexiroc Australia Pty Ltd, Gary Bullock who produces the blast, ballistic and fire-resistant material, Protectiflex.

for waste tyres. Goodman believed it was the organisation’s responsibility is to help Australia consume more waste tyres. “We want to see projects like Protectiflex really ramp up,” she said.

“We really want to make sure waste tyres are not causing environmental and social harm and lots of new markets are being developed in Australia for this waste product. “We really want to be the custodians of our own waste.”

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1300 65 75 64 Manufacturers’ Monthly APRIL 2020 39

Gases in Manufacturing Fuelling the industry with a clean gas How Air Liquide recycles existing carbon dioxide emissions as a clean alternative to other methods of CO2 production.

NDUSTRIAL carbon dioxide (CO2) serves a variety of key applications across industries. It is widely used in the food and beverage industries for carbonation of liquid drinks. It can also be used as a shielding gas in welding processes or as a refrigerant with a lower global warming potential than traditional HFCs. There is an increasing amount of CO2 in the atmosphere, but as of today this is generally not economic to recover, so industrial gas companies need to identify a suitable CO2 emission source to give it a second life by p¬urifying it to food or industrial grade for commercial use. Manufacturers’ Monthly reached out to industrial gas-producing specialist company, Air Liquide,

to talk about how CO2 emitted into the atmosphere by chemical and oil and gas industries can be captured and recycled for industrial purposes. Frank De Pasquale is the business unit manager for CO2 and H2 for the company in Australia. He has been with Air Liquide for 15 years. “Unlike some of our competitors, we never produce additional CO2 from burning natural gas; we recycle and purify existing CO2 emissions from others. We are proud of this commitment which is part of our Corporate Climate Objectives,” says De Pasquale. All CO2 emissions are a mixture of CO2 and various impurities, but it is what makes up those impurities that matter when it comes to

commercialising the product. “It could be 99.99 per cent CO2 but has 20 parts per billion of benzene in it, which at parts per billion level is not very much,” said De Pasquale. “However, such a little amount of this kind of impurity means that the CO2 is not suitable for the food industry.” And how does Air Liquide source its CO2? There are several avenues it utilises. Currently it sources feedstock CO2 from seven different industrial processes, all of which emit CO2 as they make their products – three produce ammonia, one is a power station, one is a steam boiler (both are combustion flue gas sources), while there is one that produces ethylene oxide and another is from a natural gas producer. Each

feedstock source has its own set of impurities that has to be dealt with, and then the gas has to be collected so it can be made commercially viable. Take ethylene oxide as example. “We can get CO2 from a chemical process, such as ethylene oxide production,” said De Pasquale. “When ethylene is reacted with oxygen, it makes ethylene oxide and CO2. The process then requires CO2 to be removed, which we can capture, then purify for the food industry.

Air Liquide’s CO2 production plant in Torrens Island, South Australia.

40 APRIL 2020 Manufacturers’ Monthly

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Gases in Manufacturing Liquid CO2 is vaporised and compressed into blocks and pellets of various sizes.

“However, ammonia plants are definitely the best feedstock source; CO2 produced this way has the least amount of impurities in it.” The reason for this, said De Pasquale, is that to make ammonia you need to have a reaction between hydrogen and nitrogen which results in a relatively ‘clean’ stream of CO2 containing less impurities than other emission sources. “As you go from ammonia to ethylene oxide to natural gas processing to flue gas – you get different levels of purity for CO2 and different impurities that you will need to deal with,” he said. The cost of production varies greatly because it’s based on the processes used within the different disciplines to ensure food and beverage grade quality. In most processes, there are a few steps. “Typically, there is some level of compression – there is also, as a general rule, a degree of filtration manmonthly.com.au

and drying, followed by liquefaction and distillation, to purify the feedstock to the required quality,” said De Pasquale. “The process produces CO2 in liquid form, which is approximately -22°C and 20 bar pressure. Not only does producing liquid aid in the purification process, it also allows us to transport it more economically than you would if it was in a gaseous form.” Once it is trucked to a customer’s site, it is loaded into a bulk cryogenic tank, and the customer uses it in a gaseous or liquid form depending on the application. Vaporisation is made possible using a simple air heat exchange system. “We use our proprietary remote telemetry systems installed on each cryogenic vessel at customer site to always deliver on-time while optimising our fleet management.” Because CO2 is sourced from existing industrial and energy production plants’ exhausts,

production and distribution of this molecule can be challenging and depends on actual production rates and overhauls of these sources. “We also produce dry ice in all the states of Australia, using dedicated automated equipment. Liquid CO2 is vaporised and compressed into blocks and pellets of various sizes. Blocks can then be sliced into standard or custom width for use in airline catering for instance,” De Pasquale said. Dry ice is the solid form of CO2 which we all know from the smoke effects in theatres or in fancy cocktails. CO2 is not liquid at atmospheric pressure and directly changes from solid to gas form (sublimation) at -78.5°C. This property is the primary reason why it is used in cold chain transportation or industrial cleaning: it leaves no residue or liquid to clean or evacuate. And because it is recycled CO2, it is not emitting any additional CO2 in the atmosphere. Manufacturers’ Monthly APRIL 2020 41

Additive Manufacturing Sensor applications in advanced additive manufacturing Additive manufacturing is fast becoming a mainstay in advanced manufacturing. Bestech Australia’s Wirhan Prationo takes a look at how sensor technology is overcoming challenges in additive manufacturing processes.

DDITIVE manufacturing, generally referred to as 3D printing, has become prominent in the manufacturing industry as it is a cost-effective and flexible manufacturing technique in comparison with traditional manufacturing processes. Technological advancement in additive manufacturing has revolutionised the manufacturing industry with its design-driven approach and rapid prototyping capabilities. The technology has proven to be beneficial to a wide range of industry sectors by offering distinguishing benefits such as reduced material usage and manufacturing automation. These allow for the manufacture of highly complex structures at a higher production rate and improved production efficiency. The technology is highly utilised in series productions and by OEM suppliers to create distinctive profiles based on new and custom geometries, faster development cycles and the ability to meet sustainability goals. The medical industry has become the pioneer of this technology by adapting bioprinting for creating 3D printed organs from human cells. The 3D printed organs will be utilised in medical research for the development of accurate, targeted and a more personalised treatment solution to treat patient-specific illnesses. It is also theoretically possible to create viable and fully-functioning organs from 3D printing; however, there is still a long way to go to achieve this kind of breakthrough. In the transport and building industry, 3D printing offers an opportunity for cheaper and more efficient manufacturing methods when compared with traditional manufacturing. 3D printing has been

42 APRIL 2020 Manufacturers’ Monthly

Bestech Australia offers a wide selection of precise and high-performing displacement sensors from Micro-Epsilon for applications in additive manufacturing.

used to monitor the thickness of the coating during the laser deposition process. As the laser is used to metallurgically bond the coating material with the base material, certain imperfections may occur. Laser profile scanners typically have a high scanning resolution to reliably detect these anomalies during the deposition.

Quality monitoring and inspection

widely used in rapid prototyping applications as it is a cost-effective solution in product testing. The recent developments in 3D printing have observed a need to expand into creating functional structures and components that are more specific and objective-driven to drive more value to the business. Considering the rapid advances in additive manufacturing, it is undeniable that sensors should be implemented as part of the system to improve the customised products in terms of functionality, preciseness and quality. Specialising in sensors and instrumentation, Bestech Australia offers a wide selection of precise and high-performing displacement sensors from MicroEpsilon for applications in additive manufacturing such as laser sensors, laser profile scanners, inductive eddy-current displacement sensors and capacitive measurement systems. These non-contact sensors are well-suited for a wide range of industrial measurement applications due to their ability to provide accurate and reliable results on different components or surfaces. They can also be easily integrated

with existing industrial interfaces. For further insight, some examples applications of these sensors in 3D printing are discussed below.

Surface contour and edge detection in laser cladding Laser cladding or Laser Metal Deposition is a manufacturing technique of applying powder substances to modify and enhance surfaces of an object. The powder is sprayed into the protective gas stream and melted with the help of a laser. This technique has been widely used in surface coating or development of innovative alloy materials in the advanced laboratory. Sensors are used to control the trajectory of the deposition tracks to ensure that the products are manufactured with the highest precision. The laser profile scanners can detect the contour, profile as well as identify the edge and boundary of the shape with high accuracy. The laser scanner can be used to determine the welding path by taking the profile before the deposition. The resulting profile is used to determine the guidance of the weld head. The laser scanners can also be

The success in the manufacturing industry is all about quality and efficiency. A reliable monitoring system is needed to check the quality of the printed products to ensure that the products meet the standards. The blue laser scanner technology can be used for this monitoring application. The generated 3D images are compared with the CAD data in the computer. A logic control can be designed to accept or reject the products based on the comparison. Blue laser scanners are essentially the laser profile scanners with an operating wavelength near that of the ultraviolet range. Due to the short operating wavelength, the laser projected from the sensor does not penetrate the object deeply. Therefore, blue laser scanners offer better accuracy and higher resolution scanning as compared with the conventional laser profile scanner. Examples of applications include monitoring of small components, surface etching or embossment depth.

Distance control in print head Adjusting the distance in print head is crucial to ensure the quality of the final product in additive manufacturing. In 3D printing applications, the print head has to be positioned at an exact height for manmonthly.com.au

a flawless process. It is necessary to ensure that the print head is always positioned at the same height at all times. A non-contact laser triangulation sensor offers high precision and a high-speed measurement for this type of application. More importantly, laser sensors are typically compact and small in size, which makes them easy to be integrated with machinery. The sensors can also compensate for surface reflection and against different materials. As an example, the exact height positioning of the print head is crucial in the assembly of the printed circuit board. This is required to enable smooth progress during printing, soldering and parts assembly. In addition, the laser sensor can also reliably detect the thickness of the glue bead, which is generally applied on the soldered circuit to protect it from damage. The head positioning also directly affects the final quality of the printed products. Laser triangulation

sensors typically offer fast distance measurement up to 4kHz. This enables the system to readjust the process when errors are detected.

High precision position monitoring In selective laser sintering, a laser is used as a power source to solidify the powdered material into a compact form. During the process, the building platform is lowered with every melt cycle by a defined value which corresponds to the required print resolution. An inductive eddy current measurement system can be used to monitor the building platform to ensure that the print head is aligned in parallel. Unlike the laser-based displacement sensors, an eddy current sensor is more suitable for this type of application due to the environment. Eddy current sensors are robust and resistant to oil, dirt, dust and extreme environments such as high pressure or high temperature. They are also miniature in size which

the position of the squeegee as it can measure accurately with subnanometer resolutions. The sensors are connected to the multi-channel controller making it ideal for synchronous detection of multiple sensors for measuring at multiple locations. It also has a high-frequency response for dynamic and high-speed measurement, which is ideal for this type of measurement. This system is ideal to be used for long term measurement in a clean environment. In summary, the selection of sensors for test and measurement in additive manufacturing is limitless. Although there is a wide range of precision sensors available in the market, there is no sensor that can be used in all measurement applications. Selection of the suitable sensors highly depends on the operating environment and the type of surface materials to be measured. When applied correctly, the industry will enjoy the benefit and reap the positive return which further accelerate growth in the field.

makes them ideal to be integrated with industrial plants and machinery. The eddy current sensor is one of the most advanced non-contact technologies in the market for measuring displacement and position in an industrial environment due to its robustness, high precision and excellent frequency response. In another application, sensors are also needed to monitor the position of the squeegee blade. A squeegee blade is commonly used in a 3D printing system to ensure repeatable and consistent printing quality. The blade moves over the powder bed and applies the next powder layer to the component design on the assembly space. The squeeze needs to be tilted at a precise angle in order to spread the material evenly on the building platform. Two synchronised, highresolution sensors used at each end of the squeegee are needed to measure its exact tilt angle. Capacitive displacement sensors are recommended for monitoring

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Conveying Powered Drive Sytems Getting the most out of your baggage conveyor system Maximising the value of a Baggage System is a challenge, Osem Jibrail talks to Manufacturers’ Monthly about how SEW can make the journey easier.

EY topics such as system availability, operational effectiveness and return on investment come to mind when thinking of an airport’s baggage handling system as a critical asset. Taking into account the initial outlay for a brand new system, alongside the projected operational and maintenance related investments, it is no doubt a long and complex journey to converge onto suitable and future-proofing solutions. Osem Jibrail speaks to Manufacturers’ Monthly about how SEW can make the journey easier from a conveyor powered drive system perspective, using their latest Movi-C drive system technology. Airports can be stressful at the best of times. Whether queuing up at the baggage check-in, waiting to board the plane itself, or hanging around waiting for the plane to taxi to a gate once it’s arrived at its destination, there are other places most people would rather be. Also, there is the chance luggage might get lost and end up in another state or part of the world altogether. There are two main hurdles once the aeroplane is parked – customs and baggage collection. Going through customs for most is a formality, however baggage collection can be a different story. Many systems, sub-systems and processes would need to operate

Conveyor systems are a critical asset at airports.

44 APRIL 2020 Manufacturers’ Monthly

effectively for a bag to reach its desired destination, and therefore be available for collection by travellers. This is not lost on Osem Jibrail, who is SEW Eurodrive’s national industry specialist for airports. When it comes to installing new conveyors and the equipment that drives them – such as geared motors and variable speed drives / control gear – Jibrail believes it’s not just about supplying the drive solution and leaving it at that. He said it’s important to work with the customer from start to finish to ensure complete customer satisfaction and operational effectiveness. “Conveyors systems are a critical asset at airports. They hold a lot of risk to the operation of the airport,” he said. “This is a risk where a few flights could be grounded, or people from the other side of the world don’t get their bags. Surveys over the years have shown customer satisfaction at airports and with airlines is important.” Jibrail said it is his role to approach Airports, as the end users, conveyor system OEMs and integrators, as well as consultants who are involved in this industry, and learn about what they do, what they want, what they find useful, what problems they have and how SEW can help solve them. He does this in conjunction with using

SEW work with customers right from the beginning of their projects to learn all of their stakeholders’ pain points to get the best outcomes. SEW’s products and solutions Whether they’d be off the shelf, customised or both. “This is why we try and be involved with the integrators, and airport authorities as early as possible in the project proposals and inceptions,” he said. “We try and instil redundancies, and we try and instil Plan Bs. We also try to ensure the drive systems and solutions we offer are simple and do not require a great deal of training to install, commission and diagnose”. SEW is also aware that there is huge drive among many different organisations to ensure that supplied equipment are compliant to the highest energy efficiency standards and as well as sustainability demands, not only made by governments but the general public as well. This is another reason they like to be involved at the scoping stage of a project. “We aim to be involved early on in the project, this way we are able to work from the ground up in achieving such targets as reducing the peak power draw of the system as a whole, and reducing the average energy consumption of a system as much as possible, by articulating our motor selections to suit the system’s operational demands,’” he said. “What we try and do is take our time in learning about the applications and

customer needs, and then standardise that as much as possible, therefore reducing drive system variants and complexity. “We size up to demand, we don’t chuck in an unrealistic safety factor for the sake of it. We take the big picture into account as we size and select conveyor drive systems. We perceive ourselves as a partner to the stakeholder, to the airport, not just a supplier.” Jibrail also backs SEW’s ability to meet company’s needs simply due to the scale of the company both in Australia and overseas. Its stock holdings are high, which means its delivery times are quicker, which helps them to supply on demand almost as soon as a part is required. “We have a big engineering force in terms of our level of expertise and training,” he said. “We take the time to invest in those traits in our engineering team. How that is useful in the airport solution business is that we are able to align ourselves with the customer’s requirements and come up with the most suitable solutions rather than just supply what’s on the shelf.” “Getting deeper into an industry and learning the pain points, what problems are there to solve, speaking our stakeholders’ language – this is what we do.” manmonthly.com.au

Instrumentation Supporting the industry and meeting its needs This year, at the Endeavour Awards, Vega Australia, will sponsor the Australian Industrial Product of the Year Award. Manufacturers’ Monthly speaks to managing director John Leadbetter and takes a look at some new devices the company has released.

EGA was formed in Germany in 1959 and has been located in Australia since 1987. With more than 60 years’ experience and thirty-three years supplying to the Australian market, the company is well known for its agile approach to product development. Returning once again as a sponsor of the Australian Industrial Product of the Year award at this year’s Endeavour Awards, Vega Australia is proud to be involved in supporting success in the manufacturing industry, says the company’s managing director, John Leadbetter. “At end of the day, it is about supporting Australian manufacturing, it is about supporting the industry,” said Leadbetter. “We at Vega Australia are showing the commitment of an Australian company towards Australian business. We believe that although we are a German-owned company, we have commitments locally – and that is to support local manufacturing.” Leadbetter said that Vega’s repeat sponsorship of the Product of the Year award was a natural fit, as the company is itself a leader in this area.

“We are very proud of the fact that, internationally, we have been in the recipient’s position of being awarded for our products. And we, therefore, know what it takes to reach that pinnacle,” he said. “In sponsoring this award, Vega is sponsoring the achievements, the dedication, the commitment, and the resilience of a company that can achieve that success. “There is a lot of competition out there these days, and for a company to stand out or be picked out as winner of the Product of the Year award means that you have something different, something new, something better than what everyone else has. “And this is what we strive to do as well. We are not the only company in the world that makes instruments, but we would like to think that people who buy our products are getting the best in class.” Several of Vega’s own recent product releases have been aimed towards the automation and manufacturing industry. “We have been associated with the manufacturing industry now for a number of years. We have listened to

Vega returns in 2020 to sponsor Endeavour Awards’ Australian Industrial Product of the Year Award.

manmonthly.com.au

Vega released pressure transmitters to suit manufacturers in multiple indutries.

industry, we have taken feedback, and we have designed some of our products to be more in tune with what manufacturers need,” said Leadbetter. Among the adaptions that Vega has made to its new products is the addition of Bluetooth communication, allowing its level and pressure transmitters to suit manufacturers looking to adopt Industrial Internet of Things (IIoT) capabilities. “The industry is telling us what we need to do; we’re not asking the industry to adapt to us. It is a case of meeting the industry’s needs. The industry has requirements, so we have built our equipment to suit those requirements.” Vega has recently released pressure transmitters to suit manufacturers in the food and beverage and pharmaceutical industries, where companies are not looking for the ruggedness required in mining and resources industries but for strict hygiene approvals. The VEGABAR 38, for example, is a universal pressure transmitter with ceramic measuring cell for measuring gases, vapours and liquids up to 130 °C. The optional universal connection for hygienic adapters ensures reduced installation effort and leaner stock keeping. The sensor has a display with on-site operation and coloured 360° switching status indication. The pressure transmitter provides integration into control systems through IO-Link communication.

Vega has also added a new compact 80 GHz instrument series to its portfolio of radar sensors. It is especially suitable for price-sensitive applications, such as those found in the water/wastewater industry or in auxiliary process loops in process automation. Vega designed a new radar microchip especially for this purpose, which is characterised by its extremely small size, fast start up time and low energy consumption. The end result is a particularly compact and versatile radar sensor. They are available both as compact version with cable connection housing and as a standard version with a fixed IP68 cable connection. The radar sensors maintain steady, accurate measurements without effect or loss of echo from external influences such as solar gain, air temperature fluctuations, weather conditions vapours, buildup or condensation. The VEGAPULS instruments are complemented by the optional VEGAMET controllers. These feature a large graphic display that can be used to visualise all measured values. Both the sensors and the controllers can be operated easily via Bluetooth with a smartphone or tablet. This makes setup, display and diagnostics considerably easier, especially in harsh environments or in hazardous areas. Manufacturers’ Monthly APRIL 2020 45

Skills & Training Combining flexibility and innovation Although often operating behind-the-scenes, IBSA has an important role to play in Australian manufacturing.

HE work of ensuring that vocational education courses are up to date is one that is often unseen or unknown to the wider industry. But it is an area that is critical to the future success of the manufacturing industry. At part of this year’s Endeavour Awards, now to be delivered online, the Excellence in Manufacturing Skills Development award will once again be presented to a company or educational institution that is leading the way in training and education. Supporting this award is Innovation & Business Skills Australia (IBSA) and Phil Clarke, general manager industry engagement, explained why the awards are significant for the developer of qualifications for the manufacturing industry. “We have a fundamental responsibility to promote skill development in our sector and one way of doing that is through awards like these, where we recognise high performance and that in turn we believe communicates and inspires others to follow best practice,” said Clarke. Those programs that have gone on to win this award combine the best practices of skills and education with an understanding of how the industry is shifting as new technologies and needs emerge. While the winners may be the most outstanding in their field, what IBSA does every day is ensure that training packages are as up to date as they can be. “Because qualifications are made up of units, it’s relatively easy to add additional units as necessary,” said Clarke. “The key to it is us keeping them up to date, and the packages themselves already have units that relate to technical advances, so it’s not as if TAFE institutes are training people to work in the 60s, the qualifications do evolve over time and we do build those technological changes into them.”

46 APRIL 2020 Manufacturers’ Monthly

IBSA has been developing courses to teach the rapidly transforming skills needed in modern manufacturing. Driving these changes today is the rapid pace of technological innovation and the adoption of advanced processes by manufacturers globally and in Australia. Collected under the umbrella term Industry 4.0, these changes are requiring the next generation of welders, fitters and turners, and boiler makers to have a set of skills that are different from their predecessors. “There’s no doubt that the digitisation of production methods is changing the nature of work and so we have to be able to ensure that that’s kept up to date,” said Clarke. Predicting what this will mean for the careers of current apprentices and trainees may seem like an impossible task, but it is the one that IBSA must to do make training packages fit for the future. To predict what skills will be required of today’s graduates, IBSA

creates an annual skills forecast. “Essentially it’s a piece of research, analysis and consultation. There are nine of those to cover each of our training packages and it’s a degree of labour market analysis and they’re also talking about the technological changes that are going on and the directions that industries are expected to go in.” This work is done as part of IBSA’s mandate as a skills service organisation, which provides the background for industry reference committees to develop qualifications for the manufacturing sector. In its most recent report, IBSA grappled with a range of challenges and opportunities ranging from the demand for engineering skills due to major defence projects, the move from the production of products to the delivery of services in the manufacturing sector, and the growth of manufacturing of bespoke, high-

quality products. At the same time, IBSA acknowledges that there are fundamental skills that continue to be in demand and must be retained in an aging workforce. For Clarke, it is a matter of ensuring the system is able to both accommodate the new and retain the existing skills. “There are core skills that are important, and the trades still provide a lot of those core skills. Those skills need to be acknowledged, so it is a question of how that’s supplemented and added to over a person’s working life. “A training package or qualification in Australia is unitised so you can pick and choose, and so it is a pretty flexible system in that regard,” said Clarke. Ensuring the system retains this flexibility while ensuring that best practices are adopted and celebrated will be IBSA’s mission going forward. manmonthly.com.au

Networking Meeting the needs of the market: A key for industry success Industry Capability Network (ICN) has a strong belief in companies that have made a difference with their supply chain networks and are sponsoring this year’s Global Supply Chain Integration Award.

ETURNING to the Endeavour Awards this year is Industry Capability Network (ICN). As a business network, ICN has been helping bring together Australian and New Zealand companies on projects for over 30 years. With support from the Australian and New Zealand state and territory governments, ICN has helped local suppliers with $30 billion worth of contracts so far. ICN will be sponsoring the Global Supply Chain Integration award at this year’s Endeavour Awards. “The Endeavour Awards give the opportunity for manufacturers and industry to really showcase their capabilities and their innovative activities in the local marketplace to a wider audience,” ICN executive director, Derek Lark said. The Global Supply Chain Integration award recognises one Australian-based company that has shown it can connect to global supply chains through strong and

innovative business practices. “Clearly for our sponsored award, it’s all about where the companies have been able to make a difference and enter into a supply chain by being able to tailor their offerings,” Lark said. Lark believes increasing market demands are making manufacturers trend towards meeting market needs in sectors outside of their comfort zones. “I think manufacturers are really getting smarter in terms of their agility to meet market needs,” he said. “Market needs are changing fairly rapidly. “You see a lot of manufacturers able to move from their traditional sectors into sectors where there’s more activity happening, such as in defence or in the health sector and those things.” And despite the impact of the coronavirus on international trade, local manufacturers are receiving a boost.

Lark believes increasing market demands are making manufacturers trend towards meeting market needs in sectors ourside of their comfort zone.

manmonthly.com.au

ICN executive director, Derek Lark. “I think the current problems with the coronavirus is also exposing a lot of Australian manufacturers to market opportunities that might have otherwise not been, seeing as people start to search for local supplies for goods that may be difficult to attain,” Lark continued. Lark says entrants should study the criteria closely when

submitting an application. “As a judge in the past, I can tell you that the thing that the judges really look for is people who answer the criteria that the award is being judged on. It’s very hard to judge an entrant when they haven’t given you sufficient information and data around the questions that are being asked and those applications are the ones that generally get set to one side because there’s just not enough information for you to make a decision on,” he said. “I think everyone is really keen to see who the overall winner is on the night, but all the awards are very valuable and it’s great to see who is entered, who got shortlisted and what the winners in each category are. It’s always exciting to find that out. “We’re really excited to be back on board.” Each year, the Endeavour Awards celebrate the best the manufacturing industry has to offer. Its winners have been some of most innovative and forward-thinking manufacturers in the sector. Now in its 17th year, the 2020 Endeavour Awards will showcase a wide range of accolades up for grabs. Manufacturers’ Monthly APRIL 2020 47

What’sNew Emergency Temporary security barriers if your project is placed on hold The COVID-19 pandemic has created challenging circumstances. The Australian Trellis Door Company (ADTC) sees that this unique situation risks placing many commercial construction and fitout projects on hold midstream. Should businesses find themselves in a position where their project has been placed on hold mid construction or should they find themselves unable to secure supply of a commercial door to finish off commercial projects, the ATDC can provide temporary security barriers quickly to provide these projects with immediate temporary lock up. ATDC’s trackless security barriers are available to hire or rent for short, medium- or long-term leases or even to purchase if required. They are very cost effective. And they are also an excellent crowd control and access control device. The security barriers are trackless and mobile and are available in standard heights of 2020mm or 2520mm high or customised to any particular requirements. They require no overhead supporting structure to secure them nor to lock them. Wall mounted or floor mounted locking options are available. They are finished in either a black or white powdercoat. For further information on ATDC’s full range of temporary security barriers visit their website at www.trellisdoors.com.au/products/commercial-security/ barriers-and-cafe-barriers.

Company: Australian Trellis Door Company Phone: 1800 657 7435 Web: www.trellisdoors.com.au

Starter kit 4-port IO-Link master with IoT core and MQTT interface The robust components IO-Link temperature sensor, plug-in power supply with interchangeable adapter, Ethernet and sensor cable ensure fast and user-friendly connection of the automation technology to the IT world. • 4-port IO-Link master with IoT core and MQTT interface • Start-up package for IoT applications for download • IO-Link parameter setting software “LR DEVICE” on USB stick • Including IO-Link temperature sensor, plug-in power supply with interchangeable adapter, Ethernet and sensor cable. Starter kit IO-Link master With this starter kit you can immediately try out the IoT core interface of the IO-Link master on your desk.Connect the IO-Link temperature sensor to the IO-Link master and transmit the value of the sensor to different IoT software environments via TCP/IP JSON or MQTT. This is how you easily connect robust components fromautomation technology to the IT world. Start-up package for IoT applications for download In this IoT start-up package, you will find practical examples on how to simply read and process temperature values with an internet browser, Excel, Postman or NodeRed.

Advantages and customer benefits IoT core interface for the IT world The IoT core allows access to all data ranges of the IO-Link master and sensors. Established HTTP calls and JSON commands allow reading or writing of information. Connection to the IT world is made via the IoT core interface. In addition, ifm offers further IO-Link masters with different fieldbus interfaces for the automation level.

48 APRIL 2020 Manufacturers’ Monthly

Display measured values in the internet browser or in Excel The quickest and simplest HTTP call can be made using an internet browser or Excel. The start-up package contains a small example of how you can display the temperature value in every internet browser. You can also record temperature values in Excel for subsequent analysis and optimisation of your installation. Sensor configuration with LR DEVICE The intuitive software finds all IO-Link masters in the network and creates an overview of the whole plant. In addition, all sensors connected are indicated with the respective parameters. This means that parameter setting of all sensors in the system is possible from one central point. Easy sensor connection The sensors and actuators are connected via standard M12 connection cables without screening. Up to 4 IO-Link sensors can be connected and supplied with a total of up to 3.6A. The cable can be up to 20m long. Secure digital data The sensor data is transferred digitally. Unlike analogue signals, contact resistance and EMC interference cannot corrupt the signals. Company: ifm efector Phone: 1300 365 088 Web: www.ifm.com/au/en

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Operational visibility enables optimised business outcomes Available from Control Logic is Red Lion’s award-winning Crimson 3.1 family of “Data Stations” and operator touch interface panels for multi-vender cloud connectivity. With a growing list of 300 industrial built-in protocols including the newly released MQTT, SQL and OPC connectors, its user-friendly and always free platform provides companies with a smart yet economic option when deciding to transform business decisions to the cloud. Built from the ground-up and developed for over 15 years, the Crimson 3.1 configuration platform offers proven industrial reliability with simplified drag and drop development. It solves the remote firmware, configuration and version tracking problem that Linux OS boxes fail to overcome. Additionally, its compatibility with other manufacturers such as ABB, Emerson, Rockwell Automation, Schneider and Siemens, makes the Red Lion Crimson 3.1 platform a desirable option. The Crimson 3.1 platform exposes PLC and machine data beyond the operational environment, enabling enterprise business systems to a smooth transition of direct access to reliable real-time and historical operational data using MQTT. According to Red Lion, this can dramatically simplify system architectures, increase scalability and accelerate data integration initiatives with no additional hardware or expensive software customisation required. Control Logic 1800 557 705 www.controllogic.com.au

Allplastics clear polycarbonate machine guards Employee safety is paramount in the workplace. Many industrial accidents can be prevented by providing machinery with proper guarding. Allplastics Engineering can provide, cut, fabricate and CNC rout a range of clear polycarbonate brands including Lexan, Makrolon, Palram, Safeguard and for a variety of industries such as food and beverage, material handling, mining, packaging and pharmaceuticals where operators need to see through the guards but should not risk their fingers and hands. It also helps on assembly lines where WHS regulations require processes or machinery to be guarded for the safety of workers. The SafeWork NSW states that guarding must be securely mounted. If access is required to parts of the plant during operation, maintenance or cleaning, the guarding should be an interlocked physical barrier that allows access when there is no risk –and prevents access at all other times. Polycarbonate is 250 times the strength of normal glass and half the weight of if it. Available from 1 mm to 12.7 mm thick, polycarbonate is virtually unbreakable and covered by a warranty from the manufacturer. This makes it the preferred choice of engineers when designing guards for machinery. In applications where the guards are constantly being cleaned and are subjected to constant wear Allplastics provides mar resistant grade polycarbonate which has a special coating on both sides of the clear polycarbonate to minimise guards and barriers being easily damaged or marked. Brands such as Lexan MR10 and Makrolon AR2 are available in thicknesses ranging from 3mm to 12.7mm. Allplastics can provide CNC routered shapes to match drawings or broken guards. The company’s experienced fabrication personnel can bend or construct chutes, guards, boxes or covers for a diverse range of applications. For situations such as curved lathe guards or surrounds Allplastics can supply thin gauge polycarbonate which can be cold bent and secured by a frame.

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In addition to clear polycarbonate guards Allplastics can also fabricate opal polycarbonate where visibility is more important than clarity or yellow high-density polyethylene for even higher visibility. Features: • Outstanding toughness • Good chemical resistance to solvents and cleaners • Good electrical insulation • Outstanding weatherability • Temperature: -40C° to 130C° Sheet Sizes: • Size (mm): 2440 x 1220 and 2440 x 1830 • Thickness (mm):1 – 12 Company: Allplastics Phone: (02) 9417 6111 Web: www.allplastics.com.au

Manufacturers’ Monthly APRIL 2020 49

What’sNew Think outside the box with an integrated enclosure solution When defining an enclosure system, the highest value of an enclosure lies with what is inside it. Integrating important parts into the enclosure can greatly enhance the system by both protecting electronics and determining how the end user will interact with it. The ability to assemble, fabricate (via machining or additive manufacturing), and verify can offer a high level of integration.

• Maintenance of protection class of case; • Electrical testing and compliance for all PDUs; •D elivered fully assembled and verified as single part number. Erntec can employ our experienced assembly, design, and fabrication capabilities to integrate your system with a single part number ready for shipping. Company: Erntec Pty Ltd Phone: (03) 9756 4000 Web: www.erntec.net

Advantages of such integration include: • System reliability, • Value-add features of existing enclosure, • Risk mitigation, • Lower total cost of ownership, • One-part number for customised fully qualified system. One such example of this type of integration is the design, fabrication, and assembly of additional features for plastic case used for a medical device, as pictured. Features of the system are: • Additive manufactured parts to merge with existing look of the case; •M etal fabricated parts designed to add a telescopic mount, power chord compartments and a lockable latch; •C omplex inner mounting frames to fit a wide range of electronic and electrical components;

Sullair two-stage tandem screw compressors Since 1965, Sullair has designed and manufactured its own rotors and airend assemblies in Michigan City, Indiana. The award winning rotary screw design sets the industry standards and delivers the quality and reliability one expects from a leader. Utilising modern technologies, equipment and advanced manufacturing techniques, Sullair designs, manufactures, assembles, and tests compressed air and vacuum products. Sullair products are known around the world for their universally applicable design, outstanding craftsmanship and superior quality. Superior end-to-end design Sullair Two-Stage (TS) Series tandem compressors use two sets of rotors arranged in an end-to-end design that achieve higher efficiencies than other two-stage rotor arrangements. This design is based on proven Sullair technology used in its singlestage units, which has set the standards for efficiency and reliability in single-stage compressors for more than five decades. The industry standard since its introduction in 1984, the TS Series tandem compressors offer unmatched full-load efficiency; providing significant energy savings compared with Single-Stage compressors. With the tandem’s variable capacity control, featuring spiral valve technology, further operating efficiencies can be achieved during part-load operation.

Broad operating range The TS range are available from 75 to 450 kilowatt, with capacities from 434 to 2900 cfm and pressure ratings of 6.9 to 12.1 bar. Extended bearing life By dividing the compression ratio across two-stages, the two-stage tandem will significantly exceed the life of the average single-stage compressor. Company: Sullair Australia Phone: 1300 266 773 Web: www.sullair.com.au

Rotary screw reliability Sullair TS tandem models use a two-stage rotary screw air end, featuring Sullair rugged bearing design: tapered roller bearings on the discharge end and cylindrical roller bearings on the inlet for high load carrying capacity.

50 APRIL 2020 Manufacturers’ Monthly

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Low-cost level measurement. Radar sensor for water management. Reliable level measurement in water treatment facilities, pump stations and rain overflow basins. Open channel flow measurement and water level monitoring.

VEGAPULS WL S 61 ▪ Measuring range up to 8 m

▪ Can be used outdoors without restriction ▪ Flood-proof IP 68 housing

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Further information: www.vega.com/wls61

Phone 1800 817 135