Manfuacturers' Monthly June 2023

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

JUNE 2023

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

JUNE 2023

Ego The

Pharmaceuticals

story

Official Industry Partners

INSIDE >> 28

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41

ifm unlocking digital transformation

Elexon upskilling for defence jobs

Onshoring with additive

>>

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Inside­­

JUNE 2023

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Manufacturers’ Monthly Contents­­­­­­ 6 Editor’s Note

36 Energy Chains

8 Comment

38 Procurement & Supply Chain

10 News

40, 49 Compressors

20 Manufacturer Focus

43 Additive Manufacturing

24 Engineering Focus

46 Events

28 Sustainable Materials

52 What’s New

30 Digital Transformation

54 Last Word

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, 2021 Articles All articles submitted for publication become the property of the publisher.

The Editor reserves the right to adjust any article to conform with the

32 Skills & Training

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4 JUNE 2023 Manufacturers’ Monthly

In the June edition of Manufacturers’ Monthly, we explore the world of Defence, specifically how businesses are upskilling staff and improving processes to enter the market. Defence is its own world, so manufacturers need to adapt to certain skills and practices to fit in, better yet, to thrive. Elexon Electronics is undergoing an agile transformation to strengthen its defence offering.

The global electronics player has been on a journey to become more prevalent in Australia’s defence space. Part of this is applying a Lean manufacturing approach, but applies it across its entire business, not just manufacturing operations. Elsewhere, Markforged continues to excel in its Defence

applications. In fact, Naval Sea Systems Command (NAVSEA) has installed Markforged additive manufacturing equipment aboard nine surface ships, including three aircraft carriers, and aboard four submarines.

Elsewhere in this insightful edition, we learn about how one company is using high-tech medical gels from Indigenous spinifex grass. The cellulose found in spinifex is the longest, thinnest nanocellulose that has been found in nature ¬–the fibres are three to four nanometres thick, about 20,000 times thinner than a human hair.

We hope you enjoy the latest in manufacturing news and insights. Happy Reading!

Ego The

Pharmaceuticals

story

Official Industry Partners

INSIDE >> 41

28

32

Onshoring with additive

ifm unlocking digital transformation

Elexon upskilling for defence jobs

>>

manmonthly.com.au

220.10 076.23

220.10 076.23

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Editor’s Note

BILLY FRIEND – Editor, Manufacturers’ Monthly

Bright skies ahead

W

HY do we love manufacturing? Partly it’s the people. Partly it’s the tech.

Partly it’s the cruciality of its existence.

Those realities came together when I attended all four days of the Australian Manufacturing Week last month.

The aisles were abuzz with industry chatter, as well as like-minded people catching up face to face. The event left no stone unturned, covering every aspect of manufacturing technology, from the largest machine tools down to the smallest precision cutting tools, as well as state-of-the-art support systems, software and accessories, and the myriad services that are essential to any manufacturing operation.

The wide spectrum of technologies really stood out this year. As did the positive tone that we are indeed enjoying somewhat of a manufacturing resurgence as a country.

This notion was exemplified by

the Ai Group’s recent Australian CEO expectations for 2023 report, which gave insight into the challenges facing all industries, including manufacturing, as well as the expectations for 2023.

It appears the overall consensus from CEOs is that 2023 will be a positive year, after encouraging trends were identified in the later months of 2022.

Business conditions, turnover, employment and investment all improved through 2022 but challenges around supply chain, inflation and chronic labour shortages still created headaches.

Ninety per cent of CEOs expect to be affected by staff shortages and will undertake a range of training programs to improve staff retention.

When compared to other industries, manufacturing has the challenge of not being able to offer remote working options for employees. Studies have shown that businesses offering a hybrid working environment have better staff retention.

It will be important for manufacturers to find ways to make the industry more appealing to those already within it as well as newcomers. A myriad of suggestions spring to mind, but the main focus for retaining staff has to be around listening. More manufacturing businesses are deploying continuous improvement methods, which hopes to make those on the factory floor feel more connected to the decision makers in the office upstairs.

Whilst many within industry are nervous about inflation and interest rates continuing to rise, business results are still expected to improve as we emerge from the COVID pandemic.

Forty-nine per cent of CEOs expect business conditions to be stronger in 2023 than 2022, while only 30 per cent expect deterioration. Despite optimism about the direction of our industry, there is still trepidation in the air.

Seventy-eight per cent of CEOs say supply chain issues are currently

impacting their business and 88 per cent plan to invest to reduce their vulnerabilities in 2023.

Manufacturing was most affected during 2022 by supply chain issues with 88 per cent in total saying they faced supply issues throughout the year.

More businesses are taking a holistic approach when creating value chains with long term resistance, establishing resilient risk management operations capability.

That capability should be technologyled. We are seeing businesses succeed by leveraging platforms that support applied analytics, artificial intelligence and machine learning. It should also ensure end-to-end supply chain transparency.

Whilst it has been a difficult period for manufacturing, the resilience shown over recent years is mightily impressive. The team at Manufacturers’ Monthly is excited to tell stories of continued resilience and celebrate manufacturers making their mark on Australia and the world.

Victorian Minister for Industry and Innovation Ben Carroll welcomes the crowd at Australian Manufacturing Week.

6 JUNE 2023 Manufacturers’ Monthly

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Weld member survey reveals labour shortages will make manufacturing the renewable energy revolution almost impossible without government support

D

ISTRIBUTED in March 2023 and completed by over 130 companies, Weld Australia’s 2023 Member Survey results demonstrate that Australia’s welding and fabrication industry is facing a whole raft of challenges that will make the delivery of the Federal Government’s plans for a renewable energy revolution almost impossible—from labour shortages that are inhibiting the growth of the welding industry, through to rising material and labour costs.

The Federal Government must step in and provide real support to industry to make the renewable energy revolution a reality.

Skilled labour shortages When asked to select their top two factors, 60 per cent of respondents indicated that labour shortages are most likely to inhibit the growth of their business in 2023. When asked what their main concern is right now, 45 per cent confirmed that labour shortages was on the top of their list.

50 per cent of welding workshops are operating at 80 per cent of their capacity 8 JUNE 2023 Manufacturers’ Monthly

or below. When asked why this is, a lack of skilled workers was the overwhelming answer.

With a considerable volume of work being onshored and a greater sentiment in the market to ‘buy local’, Australian fabrication companies are so strapped for skilled welders that they are operating well below capacity. They are being forced to turn down jobs because they simply don’t have the manpower to complete the work.

How then, will Australian fabricators cope with the influx of work required to make the Federal Government’s renewable energy revolution reality?

The Federal Government has legislated emissions reductions targets of 43 per cent (on 2005 levels) by 2030 and net zero by 2050. These targets will necessitate the construction of new infrastructure on a massive scale. Australia’s existing renewable energy generation of 64GW is forecast to grow to over 218GW by 2050.

This will comprise 90GW of wind, 39GW of solar, 18.7GW of water, and 35.9GW of battery storage.

It is expected that over 11,000 wind towers will need to be produced, each

requiring 500 tonnes of plate steel for onshore towers, or 750 tonnes for offshore wind towers. To connect all this new generation to consumers, AEMO estimates more than 10,000km of new transmission lines and 25,000 transmission towers (at 30 to 60 tonnes of steel per tower) will need to be constructed.

All this the renewable energy infrastructure will require a veritable army of skilled workers, including welders. Australia will have a shortfall of at least 70,000 welders by 2030.

And yet, 45 per cent of survey respondents (compared to 47 per cent in 2022) have a pipeline of work that extends for six months or longer—this protracted pipeline is necessary in the face of ongoing skills shortages. Another 33 per cent of respondents have a pipeline of work that extends between three and six months. By way of context, this is a marked increase on Weld Australia’s 2020 member survey results; the most common answers were less than one month (at 28 per cent), one month (19 per cent), and two months (16 per cent).

Government support vital to making the renewable energy revolution a reality While our governments can wish, and hope, and make public pledges about Australia’s transition to renewable energy, at the moment, we simply do not have the sovereign manufacturing capability to make this a reality.

According to the results of our survey, at 62 per cent, the majority of the Australian welding industry supports the Government’s carbon emissions reduction targets.

However, 75 per cent of the welding and fabrication industry believes that Australia’s governments are not doing anywhere near enough to support industry in achieving these targets. Our governments will need to consider policy and funding opportunities, reduce red tape and regulatory barriers, and support local investment to enable the renewable energy transition.

Australia’s Federal and state governments can wish their renewable energy policies into existence, but without a massive investment in manmonthly.com.au

Industry needs real support from the Federal Government to achieve renewable energy targets. fabrication and steelmaking facilities, skills and training in each state, and real, practical support for local industry, it will not be achievable.

The welding industry is already investing in its own sustainability performance and credentials, and has made significant headway in the last 12 months. Some of these measures include: installing LED or sensor lighting (80 per cent; up from 53 per cent in 2022); waste reduction programs (78 per cent; up from 46 per cent in 2022); recycling, upcycing and repurposing programs (75 per cent; up from 46 per cent in 2022); and implementing a net zero carbon plan (50 per cent; up from 13 per cent in 2022).

Overcoming labour shortages In the meantime, the welding industry is already taking steps to help overcome these labour shortages. 60 per cent of respondents indicated that they are training or upskilling their existing staff, another 55 per cent are either increasing wages or improving employee benefits, and 32 per cent are leveraging different manmonthly.com.au

talent pools, such as apprentices, females and prisoners.

Another 57 per cent are either investing in automation and technology, or changing their operational processes.

Given these figures, it is little surprise that investment priorities for 2023 include staff training and development (32 per cent), business process improvements (30 per cent) and plant and equipment (25 per cent). Some fabricators are also looking to advanced welding technology to help overcome skilled labour shortages, including investments in Industry 4.0 (40 per cent), robots (36 per cent) and cobots (35 per cent).

The welding industry strongly supports investment into TAFE to help combat labour shortages; 21 per cent support free TAFE for apprentices, 14 per cent support increased funding to upgrade TAFE facilities, and 64 per cent support both options.

45 per cent (respectively) of respondents indicating that they could inhibit their business growth this year.

Only 47 per cent of respondents indicated that their gross profit margin had increased over the last 12 months to help cover these rising overheads.

Alarmingly, the welding industry expects these overheads to continue to rise this year, with 82 per cent expecting even higher materials prices and 85 per cent expecting even higher energy prices.

Despite these concerns, market sentiment remains very positive. 88 per cent of respondents rated the prospects of their business as either strong or steady – a 6 per cent increase on 2022 levels. On average, respondents are 90 per cent confident that their business will be in operation in 12 months’ time (a 23 per cent improvement compared to 2020).

Rising costs

National manufacturing summit

Australia’s welding industry is also concerned about rising labour costs and rising material costs, with 50 per cent and

Given the sheer volume of challenges and opportunities on the horizon in the renewable energy industry,

Weld Australia, in conjunction with the Australia Institute’s Centre for Future Work, will host the 2023 National Manufacturing Summit at Old Parliament House on 2 and 3 August.

With the theme of Renewable Energy: Challenges and Opportunities, the aim of the Summit is to help industry leverage the opportunities currently available in the renewable energy sector, and translate these into action.

The Summit will gather industry leading representatives from all the major stakeholders in Australia’s manufacturing sector—business, unions, universities, the financial sector, suppliers, and government—to discuss the sector’s prospects, and identify promising, pragmatic policy measures designed to support an industrial turnaround. Government Ministers and international experts will delve into the challenges and opportunities of the renewable energy revolution.

Register now for the Summit via: manufacturingsummit.com.au.

Manufacturers’ Monthly JUNE 2023 9

News @MM Proposed design for Bedford’s new advanced manufacturing hub.

Bedford to open $45 million advanced manufacturing hub Bedford, Leyton Property and Leyton Funds are partnering to create a state-of-the-art manufacturing hub in Adelaide’s north, unveiling plans for what is believed will be Australia’s largest social enterprise site.

The hub will offer employment opportunities to people of all abilities and will specialise in the advanced manufacture of furniture and the supply of components to the commercial joinery and construction industry.

The development will be located on what is expected to be one of South Australia’s largest commercial greenfield development sites on Main North Road in Salisbury South.

“The investment will significantly increase Bedford’s manufacturing capability to deliver a world-class commercial product to the market. This will include an investment in the latest automation and robotics technology,” said Bedford COO of Social Enterprises Sam Hunter.

10 JUNE 2023 Manufacturers’ Monthly

Adjacent to the new advanced manufacturing facility will be a first-class Food and Beverage hub with hospitality retail offerings including: • Commercial kitchen • Beverage production facilities • Public entertainment area The hub will be home to Bedford’s first social enterprise called Cultivate Food & Beverage, which recently opened its first site in Brooklyn Park. This social enterprise has a unique offering, delivering a full supply chain solution to medium and large size food and beverage producers with a national footprint.

Approximately 100 jobs are expected to be created during construction. The centre will provide ongoing employment for more than 200 people when complete.

Bedford CEO Myron Mann said that, pending council approval, construction was expected to begin later this year and be completed in 2025.

“Bedford has a long and successful history of manufacturing in South Australia,” said Mann.

“This investment in our future will enable us to grow, innovate and manufacture at scale while remaining true to our purpose to provide choices in skill-building and career pathways.

“As a social enterprise it will be a vibrant place to work, offering highvalue roles and transferrable skills for employees of all abilities. Jobs will include joiners, machine operators, production workers, chefs, supervisors and apprentices, in a supportive and inclusive environment.

“The site has been strategically chosen for its freight route among other strategic reasons. It will support Bedford to maintain and grow our existing manufacturing contracts and provide opportunities for new partnerships, in particular food and beverage producers north of Adelaide and across the state.

“We are pleased to work with Leyton Property as our development partner and Leyton Funds as our long-term investment partner to help us bring our vision for the site to life.”

“Leyton Property is thrilled to be working with Bedford on this exciting property development,” said Leyton Property managing director Hamish Brown.

“As a real estate asset, this will be an exceptional new industrial property, well located and highly accessible with a strong tenant in the Bedford Group.”

“We will co-invest with Bedford to own this premium grade industrial property together. This project fits with our investment objectives as well as supporting long-term social benefits,” said Leyton Funds managing director Warwick Mittiga.

“As a social enterprise, it provides a platform to support Bedford to grow employment pathways.”

Bedford’s investment forms part of its five-year masterplan announced in November 2022.

Bedford engaged property advisory firm Broadway Property to source and secure the site and guide the joint venture partnership arrangements. manmonthly.com.au

News @MM Skills and training investment to meet critical challenges The Federal Government has offered $3.7 billion for a five-year National Skills Agreement (NSA) to be negotiated with states and territories, in addition to $400 million to support another 300,000 TAFE and VET Fee-Free places.

Subject to successful negotiation of the NSA, this will take total Commonwealth investment in state and territory training systems to $12.8 billion over five years.

Subject to successful negotiations, funds will be available in line with the vision and guiding principles agreed at National Cabinet prior to the Jobs and Skills Summit, to support major reform areas including: • Foundation skills: a coordinated effort to ensure that Australian adults lacking language, literacy, numeracy and digital skills can gain essential skills for work, career progression and successful completion of a vocational education training course or an apprenticeship. Lack of foundation skills is estimated to impact three

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million Australians.

300,000 Fee-Fee TAFE courses: in essential sectors such as care and support (aged, disability, veterans and early childhood and education), clean economy, manufacturing and sovereign capability (including defence industries), construction, agriculture, hospitality, tourism, cybersecurity and technology.

Closing the Gap for First Nations students and apprentices – working closely with First Nations people, their communities and training providers to support skill development that works for them and supports their career opportunities.

Women’s participation and gender equality – coordinated effort to support women to successfully enrol and complete VET courses and apprenticeships, with an emphasis on accessing skills in better paid occupations including trades traditionally dominated by men. Men

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will also be encouraged to participate and gain skills in fields where women have been historically overrepresented, such as care.

Completion rates and support for students who face barriers: coordinated national effort to lift completion rates and improve outcomes for VET students and apprentices, with a focus on students facing barriers and historically underrepresented in the workforce, including those with a disability.

Centres of Excellence: TAFE Centres of Excellence to partner with industry, universities, and governments to address critical challenges in our economy such as transition to a clean economy, manufacturing and sovereign capability and care and support.

TAFE at the heart: supporting highquality vocational education and training, curriculum development, research and innovation through

leadership networks and collaboration.

• VET Workforce capability: to be developed in partnership with the sector a VET Workforce Blueprint will strengthen the sector and support a high-quality VET workforce, which teaches up to date industry relevant curriculum.

Strides have already been made through the government’s partnership approach, with delivery of a 12-month agreement that has created 180,000 Fee-Free TAFE and Vocational Education Training places this year.

Australia is facing an acute skill shortage, with the number of occupations experiencing a skills shortage almost doubling from 152 in 2021 to 286 in 2022. Furthermore, 60 per cent of total employment growth is in jobs for which VET is the primary pathway.

All governments have committed to working in partnership to negotiate the NSA to be in place by 1 January 2024.

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Manufacturers’ Monthly JUNE 2023 11

ogress ed and assets.

News @MM The gold sensor researchers have used for electronic medical implants.

Flexible gold sensor unlocks new generation of medical implants A thin, flexible gold sensor engineered at The University of Queensland (UQ) is both flexible and sensitive enough to enable a more streamlined future for electronic medical implants and real-time sensing applications.

Using a brand-new engineering method, researchers at UQ’s Australian Institute for Bioengineering and Nanotechnology (AIBN) were able to produce the small film-like sensor.

The intricate approach used by Dr Mostafa Kamal Masud and PhD candidate Aditya Ashok represents a breakthrough in the field of flexible nanoarchitecture and, ultimately, suggests a new way to miniaturise and improve medical devices for diagnostics, biological sensing, and 12 JUNE 2023 Manufacturers’ Monthly

neurological exploration.

“Although modern implanted electronics have developed rapidly over the past 60 years, most commercially available devices are still built on relatively similar – and limiting – design concepts such as thick ceramic or titanium packaging,” said Dr Masud.

“We are offering a new route toward miniaturised, flexible, implanted medical devices that will diagnose and treat chronic diseases and help improve the lives of millions of people.”

The film-like sensor designed by Dr Masud and Ashok represents a novel approach to the field of mesoporous materials, which are highly porous substances with traits that benefit

diagnostics, catalysis, and drug delivery.

Using a novel hybrid fabrication process under the guidance of senior AIBN group leader Professor Yusuke Yamauchi, Dr Masud and Ashok were able to synthesise a mesoporous gold film that acts as an electrode for biosensing and bioimplant applications.

The flexibility and sensitivity of the gold film make it an ideal wearable system for real-time monitoring of body glucose, while Dr Masud said there was strong potential for implanted nerve recording applications.

“The demand for a simple and robust fabrication process with this kind of flexible electronics is enormous,” Dr Masud said.

“Our aim here is to see this sensor embedded in wearable devices – but the potential and possibilities in this field are vast. We’re going to be exploring more in our coming projects.”

The research was published as an inside cover feature for the nano-micro journal Small.

Dr Masud and Ashok acknowledge Dr Hoang-Phuong Phan from the School of Mechanical and Manufacturing Engineering at the University of New South Wales as a key collaborator in their broader work.

This includes research on implanted bioelectrodes, as published in the journal Proceedings in the National Academy of Science. manmonthly.com.au

News @MM $4.1 billion funding for local missile manufacturing The Federal Government funding will acquire more long-range strike systems and manufacture longer-range munitions in Australia, delivering on the priorities of the Defence Strategic Review.

A key recommendation of the Review is the need to accelerate and expand weapons systems, including land-based maritime strikes and long-range missile launchers.

Complemented by investments to replenish our guided weapons and explosive ordnance (GWEO) stocks and to establish sovereign missile and munition manufacturing facilities in Australia.

The Federal Government is moving immediately to respond to the Review and commit real funding to these programs and capabilities.

This investment in key capabilities will see the Australian Army’s current range for artillery grow from 40 kilometres to in excess of 500 kilometres. $1.6 billion for long-range strike capabilities

This investment will grow the ADF’s ability to accurately strike targets at longer ranges and expand our acquisition of long-range missile systems, including: • Accelerating the delivery of additional High Mobility Artillery Rocket Systems (HIMARS) and associated battle management and support systems; and • accelerating the acquisition of Precision Strike Missiles (PRISM) to deliver multi-domain strike effects. $2.5 billion for Guided Weapons & Explosive Ordnance Enterprise (GWEO) Investment in the GWEO Enterprise will fund: • Manufacturing guided weapons and their critical components to improve our self-reliance, with concrete, costed plans presented for Government consideration by the mid-2024 to: • Manufacture selected long-range strike missiles and increase local maintenance of air defence missiles; and

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Manufacture other types of munitions, including 155mm artillery ammunition and sea mines Critical enablers needed to underpin an expanded GWEO Enterprise, including increasing our testing and research capabilities and rapidly expanding our storage and distribution network to accommodate a growing GWEO inventory; and Acquiring more stocks of guided

weapons, supplementing other Defence weapons acquisitions programs.

This announcement is part of the Government’s $19 billion commitment over the forward estimates to achieving the priorities as set out in the Government’s response to the Review, and will see more than double the investment for GWEO than what was previously provisioned.

The ADF will strengthen its missile capability.

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Manufacturers’ Monthly JUNE 2023 13

News @MM Mars Wrigley invests $28.8 million in local manufacturing The investment at Mars Wrigley’s Ballarat factory comes as its sustainable packaging hits shelves nationwide, building on more than $67 million invested since 2021.

In a world first for the company, Mars Wrigley’s MARS BAR, SNICKERS, and MILKY WAY will switch to new packaging which can be recycled via traditional kerbside recycling bins.

Available on shelves from 10 April, the new paper-based packaging is a result of extensive research and development trials from Mars Wrigley’s manufacturing site in Ballarat and is set to eliminate more than 360 tonnes of plastic from the company’s value chain – enough to stretch from Melbourne to London and back.

This latest investment will enable Mars Wrigley to continue modernising its manufacturing operations through key equipment upgrades, paving the way for further development of sustainable packaging solutions and enabling greater innovation across its filled bar and Bitesize portfolios.

Andrew Leakey, general manager of Mars Wrigley says, “I’m proud that we are leading world-class innovation

in packaging and sustainability from Australia in what is a world-first for us as a business.

“We are the first Mars Wrigley market in the world to launch a recyclable paper-based packaging at this size and scale, and it speaks volumes to the commitment of our team locally who have been working on this project for almost three years.

“When we embarked on this journey, there wasn’t a playbook or roadmap for us to follow but we were committed to finding a solution and cementing our position as a leader in sustainability.

“We trialled many different materials and approaches before we landed on our paper-based solution, but one thing that was non-negotiable for us was to ensure that consumers could recycle our packaging within our current recycling infrastructure. Seeing our bars on shelf now is an incredibly proud moment for me.

“Continued innovation and investment in sustainable solutions is critical to ensure that we can meet our 2025 packaging targets and commitments, as well as continuing to build Australia’s modern manufacturing

capabilities and the future of Australianmade products.”

With Australia’s 2025 National Packaging Targets only a mere two years away, continuing to drive forward innovation in sustainability relies on the collaboration of business, industry and Government.

Mars Wrigley worked closely with Amcor, a global leader in developing and producing responsible packaging solutions, over the last three years to find a suitable material that would maintain the freshness of the product, whilst being recyclable in Australia’s existing recycling infrastructure.

Manufactured in Australia, the new packaging has enabled Mars Wrigley to reduce its virgin plastic use.

Richard Smith, Amcor’s director of sustainability, Asia Pacific says, “We are proud to be partnering with our customers to deliver innovative sustainable solutions to the local market, helping Australian brands to meet the National Packaging Targets.

“We want to be part of the solution, advancing the development of our packaging technology to create a local circular economy for flexible packaging.

We are excited to continue innovating with Mars Wrigley to meet Australian consumers’ changing needs.”

Brooke Donnelly, Coles’ general manager of sustainability welcomes the introduction of Mars Wrigley’s alternative packaging onto supermarket shelves and believes business innovation and collaboration are necessary to drive forward sustainable solutions for consumers.

“It’s encouraging to see Australian manufacturers take steps towards providing sustainable alternatives to plastic packaging. In order to drive further innovation and achieve mutual sustainability goals, it’s important for organisations to collaborate and work together. With businesses increasingly measured on their impact on society and the environment, sustainable innovation can be a key driver of both societal and commercial success” As part of the company’s commitment to its $1 billion Sustainable in a Generation plan, Mars Wrigley has said it is committed both in Australia and globally to supporting and creating a circular economy where packaging never becomes waste.

Mars Wrigley’s recycled wrapper chocolate bars.

14 JUNE 2023 Manufacturers’ Monthly

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News @MM Global pharma manufacturer solidifies Australian biotech foothold Contract development and manufacturing organisation (CDMO) PCI Pharma Services (PCI) announced the operational launch of three new state-of-the-art automated sterile fill-finish machines at its Melbourne and San Diego facilities.

“As the capacity for CDMOs worldwide to take on new projects shrinks, we’re excited to be able to offer integrated PCI Pharma Services has three new machines at its Melbourne facility.

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sterile fill-finish capabilities, alongside our clinical packaging facilities, to new and existing clients in Melbourne and San Diego,” said Brad Payne, chief operating officer, PCI Pharma Services.

“Our increased capacity, stockpile of standardised components, including glass, and technical expertise means we can start running batches as soon as needed.

This will cut down on the wait times many local biotech and pharmaceutical companies are facing and begin to help alleviate the global capacity shortage for sterile drug product and downstream packaging.”

The new innovative machinery from Cytiva can be used to fill various sterile medications into vials and syringes for small-to-mid-scale client needs.

The equipment, paired with PCI’s end-to-end services, accelerates company’s drug proof of concept studies, and drastically decreases the average turnaround time from proposal signing to the injectable product’s distribution.

The Microcell Vial Filler at Melbourne further enhances the early-stage services offered and brings additional capacity to Australia—the world’s leading Phase I environment.

These advanced machines expedite the filling process with automation and

remove the need for human intervention in a sterile environment, creating compliance advantages over standard equipment.

“There are less barriers to entry to start a clinical trial in Australia, as well as significant cost benefits, and with Melbourne being an especially popular place to conduct phase I trials, we knew we needed to bring this capability and added capacity to the local market,” said Tim Roberts, chief commercial officer, PCI Pharma Services.

“In addition, we are then able to take our clients through their lifecycle journeys with the expansions and advanced capabilities in our New Hampshire and Madison campuses. With successful recent inspections at our Bedford facility by the Brazilian (ANVISA) and Japanese (PDMA) regulatory authorities, our global reach to supply life-changing therapies to patients quickly and safely is wider than before.”

Manufacturers’ Monthly JUNE 2023 15

News @MM Coles opens first Automated Distribution Centre in QLD The state-of-the-art facility in Redbank is the first Australian Automated Distribution Centre (ADC) that uses the global leading Witron technology and is the largest of its kind in the Southern Hemisphere.

Prime minister Anthony Albanese MP, Queensland premier Annastacia Palaszczuk MP, Coles Group chairman James Graham and Coles Group CEO Steven Cain officially opened the ADC at Goodman’s Redbank Motorway Estate in Queensland earlier this week, This is the first of two Witron facilities to open here and comes after Coles Group’s biggest investment into technology in the company’s 109-year history.

More than one billion dollars is being invested, with the second ADC opening in Kemps Creek, NSW in 2024.

Prime minister Albanese said the world-leading technology will help advance supermarket supply chains.

“This technology is not only a first for Australia, but also a win for the state of Queensland. As we’ve seen during the pandemic and natural disasters, resilient supply chains are essential when it comes to feeding our nation and providing Australians with essential supplies.

“Coles is one of the biggest employers in this country and its team was pivotal in ensuring food security during challenging times. A facility like this one in Redbank shows how retailers and manufacturers can look to the future to improve the productivity, safety and sustainability of their operations for all Australians.”

“The decision to invest in and build this Australian-first facility here in Queensland is a testament to the strength of the Queensland economy,” premier Palaszczuk said.

“Coles’ investment will drive productivity growth in Queensland while ensuring food security to one of the fastest growing regions in the country.

“It’s great to see Queensland lead the way with the arrival of world leading technology at the Redbank Distribution Centre. The distribution centre will be powered by renewable electricity provided by Queensland’s publicly owned energy company CleanCo.” The ADCs are designed to create safer and more sustainable outcomes for team 16 JUNE 2023 Manufacturers’ Monthly

Anthony Albanese at the launch of Coles’ Automated Distribution Centre. members and suppliers, and better onshelf availability for customers.

The state-of-the-art facility in Redbank is located 30 kilometres southwest of Brisbane and will service 219 Coles supermarkets in Queensland and Northern New South Wales, as far north as Port Douglas and as far south as Laurieton in NSW. When operating at full capacity, the site can process up to four million cases per week, the equivalent of 32 million units sold in stores. Over the course of a year, this is around 1.6 billion sales units.

Coles CEO Steven Cain said this was one of the most significant moments since Coles was founded in 1914 and five years in the making.

“Modernising our operations is how we improve efficiency and availability in our stores and deliver higher service levels for our customers, team members and suppliers,” Cain said.

“Our new ADCs can process twice the number of cases and hold twice the number of pallets compared to one of our

current DCs. The ADCs enable us to half our current total footprint, leading to a more productive and sustainable business model.

“Over 90 percent of the cases processed in these automated distribution centres will be processed fully by automation or ergonomically which will be a step-change for the safety of our team as it eliminates almost 18 million kilograms of manual handling in the supply chain each week once the ADC is running close to full capacity.”

Coles Group chairman James Graham said he would like to thank all those involved for their dedication to this very important project.

“I’m proud of our team, partners and suppliers who’ve worked together for over five years to create this state-ofthe-art facility. Over 3,000 people came together, contributing more than 2.5 million work hours to plan and design the facility, construct the building and install and commission the automation,” he said.

The Redbank ADC has LED and sensor

lighting to reduce energy consumption and is fitted with a 180,000 litres of harvested rainwater storage for toilet flushing and landscape irrigation.

There are plans for 3.5-megawatt solar installation which will be among the largest rooftop solar solutions in the Coles network. To minimise food waste, the edible food that can’t be sold in the ADC will be donated to Coles community partner SecondBite.

WITRON Logistik + Informatik CEO Helmut Prieschenk said Coles has partnered with the market leader in warehouse automation systems for major food retailers globally.

“We have been engaged to build 93 automated distribution centres in 13 different countries, with the latest for Coles being the largest ambient system Witron has ever built,” Prieschenk said.

“Witron will work with Coles to provide a technology focused, multidisciplinary team for day-to-day operations, technical expertise and maintenance support.” manmonthly.com.au

News @MM Australian manufacturer Tritium enters Malaysian market KuroEV, a Malaysian electric vehicle (EV) charger, installer and management services provider, has purchased Tritium fast chargers to be deployed across Malaysia.

With only 600 charging stations currently available for the over 10,000 EVs registered in the country, Tritium’s entry into the Malaysian market comes at a crucial time.

The Malaysian government has recognised the need for increased EV charging infrastructure and has pledged to build 10,000 EV charging stations by 2025 in partnership with the private sector.

This initiative is part of the government’s broader goal to achieve net-zero emissions by 2050, which includes targets for 30 per cent renewable energy capacity by 2025 and maintaining 50 per cent of the nation’s land as natural forest.

“We are excited to partner with KuroEV to bring Tritium’s world-

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leading charging technology to the Malaysian market and expanding our footprint in the Asia Pacific region,” said Tritium CEO Jane Hunter.

“Our fast chargers will provide reliable, high-quality charging solutions to EV drivers in Malaysia, and we look forward to supporting KuroEV in their efforts to create a comprehensive charging network across the country.”

KuroEV plans to deploy Tritium chargers at various locations throughout Malaysia, including offices, shopping malls, and commercial hubs.

The company also intends to create its own charging network in the future, featuring solar, on-site energy storage, EV charging, cafes, and other premium services available at their sites.

“We are delighted to work with Tritium, a global leader in EV fast charging technology, to offer the latest fast charging solutions to our customers in Malaysia. With Tritium’s

Tritium has now entered the Malaysian market. fast chargers, we can provide a seamless and reliable charging experience to EV drivers across the country, helping to accelerate the transition to a cleaner and more sustainable future,” said KuroEV Founder Ken Too. “This investment is just the first step in our plans to create a worldclass charging network that combines solar, storage, and other innovative

technologies to offer a truly premium charging experience.”

KuroEV offers affordable lease-toown options to help businesses install chargers and launch charge point operator businesses.

Founded in 2001, Tritium designs and manufactures proprietary hardware and software to create advanced and reliable DC fast chargers for electric vehicles.

Manufacturers’ Monthly JUNE 2023 17

News @MM

Driv

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to

Jim Chalmers announced an investment of $392 million in an Industry Growth Program.

Federal Budget lays foundation for Industry Growth Program Treasurer Jim Chalmers released the 2023-24 Federal Budget in Canberra last night, which includes an investment of over $500 million into the future economic growth in science and industry.

At the centrepiece of this industry investment is the new $392 million Industry Growth Program, which will offer advice and grants to start-ups and small-to-medium businesses, to help them commercialise their ideas and grow.

According to a media release by minister for industry and science Ed Husic, “This will enable emerging businesses to become the big employers of the future, backing our innovators with investment and advice so they can make the jump from brilliant idea to business plan to a growing enterprise.”

Through grants and mentorship, Australia’s new Industry Growth Program will expand the pipeline of investmentready projects for the $15 billion National Reconstruction Fund to consider in coming years.

18 JUNE 2023 Manufacturers’ Monthly

This end-to-end approach will maximise the return on taxpayers’ investments and provide a clear pathway for our entrepreneurs to turn their ideas into thriving businesses in Australia instead of overseas.

Support for critical minerals including rare earths that are crucial components of low-emissions technologies such as batteries, electric vehicles and solar panels, also attracted new support.

Minister for Resources Madeline King said: “We’re developing the critical minerals industry…to make batteries and other green technologies – an integral part of our plan for Australia to become a renewable energy superpower.”

Budget funding includes: • $57.1 million for the established Critical Minerals International Partnerships Program. This is aimed at stepping up international engagement, to attract investment from like-minded partners and accelerate projects of strategic interest

And $21.2 million to ensure the ongoing operations of the Critical Minerals Office – which is driving policies, programmes and international engagement.

Additionally, the Government will invest $101 million in the responsible development of Australia’s quantum and artificial intelligence industries.

This funding will work in tandem with Australia’s first National Quantum Strategy, which the Government announced last week, and the Government’s $15 billion National Reconstruction Fund.

“We are also delivering on our election commitment to establish a Powering Australia Industry Growth Centre, with a $15 million investment to support local manufacturing of renewable energy technology,” Husic added.

The Budget focuses on Australia’s potential as a renewable energy superpower, with $2 billion allocated for a new Hydrogen Headstart program to scale

•

up development of Australia’s renewable hydrogen industry.

Chalmers said, “Australians have shown resilience in the face of heightened global uncertainty, persistent inflation and higher interest rates, which are combining to slow our economy.

“The best response to these challenges is a responsible budget that strikes the right balance between easing cost of living pressures, securing the essential services people rely on and laying the foundations for future growth.

“It does this while strengthening our fiscal position, with a budget surplus now forecast in 2022 23, and lower deficits and debt compared to recent budgets.”

Overall, the Federal Budget aims to: • Deliver cost of living relief, • Strengthen Medicare, • Invest in a stronger and more secure economy, • Broaden opportunity, and • Strengthen the nation’s finances and funding priorities. manmonthly.com.au

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Manufacturing Focus

Innovation and empathy: Inside a dermatology success story Billy Friend sits down with managing director of Ego Pharmaceuticals Alan Oppenheim to learn about the company’s journey from developing formulas in bathtubs to its recent factory expansions supporting the production of 9 million kilograms of pharmaceutical products every year.

20 JUNE 2023 Manufacturers’ Monthly

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Manufacturer Focus

Alan Oppenheim on a tour of Ego’s facility with Minister Ben Carroll.

A

FTER Alan Oppenheim finished his morning play at preschool, he would be taken across the road to Ego Pharmaceuticals’ first factory, where he would sit on a table, watching Pinetarsol Solution be put into glass bottles and labelled by the company’s second ever employee, Eunice.

“Sometimes I would get a label and attempt to put it on the bottle myself,” he said. “Four year olds aren’t particularly ambidextrous, and you need to get the label straight, so I suspect almost every label I put on Eunice had to take off and start again. She could label bottles faster than a machine could. When my father bought the first automated machine, it was surprising how slow it was compared to Eunice.”

Alan’s father, Gerald Oppenheim, founded Ego in 1953 with his wife, Rae, after they saw a need for products to restore and maintain healthy skin.

Gerald’s father Erwin was a successful dermatologist himself in Germany – the family had emigrated to Australia in 1939, when Gerald was 13 years old. In the laundry of Gerald and Rae’s suburban Melbourne home, they developed Ego Pine Tar Bath Solution, later called Pinetarsol, which remains one of Australia’s most widely used itch and inflammation skin treatments.

As a chemist, Gerald was uniquely positioned to formulate innovative manmonthly.com.au

products that people needed to treat their skin. Rae, being a nurse, communicated the benefits of the products to dermatologists across Australia. When Alan suffered cradle cap as a baby, his father formulated a product to ease the skin condition, which remains the only product of its kind around the world.

From the beginning, the husband and wife team established Ego as innovators in the scientific development of dermatology products.

Gerald grew the business by working with dermatologists, visiting them at different conferences around the country.

The professionals understood the value of the products, but the trouble was you could only get a small amount of sales from this. In the mid 1970s, Ego begun to enter some pharmacies. In 1975, the trajectory of the company changed when Gerald was asked by Melbourne’s Queen Victoria Hospital to develop a specialist bath oil for its dermatology patients.

“The aptly named Dr. David Nurse wanted a bath oil for children with eczema in hospital,” he said. “My father formulated a bath oil with minimal chance of irritation as a service line for the Queen Victoria Hospital. We made a bucket full of the product and we labelled it QV bath oil. Everyone thought it didn’t matter at the time because it was just a service line, kind of a nuisance in the back Manufacturers’ Monthly JUNE 2023 21

Manufacturing Focus

Managing director Alan Oppenheim with minister Ben Carroll and scientific and operations director Dr Jane Oppenheim.

corner. Then years later, patients loved the product and went to the pharmacy after leaving the hospital to ask for some QV bath oil. The pharmacies didn’t know the product existed, but the feedback was relayed to my dad and he had some bottles printed, did a pharmacy run and transformed the business.”

Ego’s QV Bath Oil, named in honour of the hospital, is a household name over four decades on. But that product just scratches the surface of Ego’s production today. Last year, Ego produced an equivalent of 50,000 full bathtubs of product, including 2.4 million kilograms of QV Gentle Wash alone. The Australian manufacturer produces over 120 products for all types of skin needs, sold in many different sizes, targeting anything from eczema, to head lice to anti-aging: • SunSense® - In 1988, Ego was the first company to use a combination of a physical blocker and UV absorber in sunscreen and make it cosmetically acceptable.

• DermAid® – To the best of the company’s knowledge, it was the first company to produce a dissolved hydrocortisone cream.

• Aqium® – Dr Jane Oppenheim created the hand sanitiser market in Australia when Ego launched Aqium in 2000.

22 JUNE 2023 Manufacturers’ Monthly

Ego continues to make Aqium in its $20 million facility designed to make flammable alcoholic products to world class pharmaceutical quality. During COVID- 19, Ego increased production by more than 100 per cent to meet the rapidly rising demand.

• MOOV® Headlice - Ego was the first company to have a headlice product that had been clinically tested to the international GCP Guidelines for clinical trials.

• QV® Dermcare - Ego was the first company to introduce products with ceramides into Australia at a cosmetic level. This was the QV Intensive with Ceramides range, which was rebranded to QV Dermcare in 2021.

The tried and tested formulas have global reach, with exported product equating to about 50 per cent of the business. Ego is sold in over 15 countries beyond Australia and New Zealand – the UK, Asia, and Middle East being the top buyers. Today, Ego employs 517 people (54 per cent female, 46 per cent male) in Australia, but over 700 in total globally.

To support this growth, Ego’s facility underwent a $25 million facelift over the COVID pandemic, including installation of new LED lights, sprinkler system, fire detection system, solar panels and

Ego has set its sights on new cream and filling lines to increase production at its Braeside manufacturing facility.

replacing air conditioning systems with one centralised lower energy system.

Air conditioning in pharmaceutical production is different to other manufacturing sectors, because it needs extremely clean air in the clean rooms, using fine filters.

Dr Jane Oppenheim, scientific and operations director at Ego, was in charge of the upgrade which was completed in the middle of last year. Jane explained Ego is determined to have expertise inhouse and not just rely on contractors for its continued expansion.

“When I took over the engineering team, we had two engineers with some electricians and fitters. We now have a team of over 50,” she said. “Over time, we’ve been able to develop the engineering team to really run the project.”

Ego has worked with the same one company on all of its structural engineering consulting for 15 years, developing a functional team of external and internal engineers who understand how each other work. Jane credits this as the main reason why Ego has delivered so many projects on time and on budget, including the 50 million, five-year facility called Oppenheim Way in Dandenong South.

“We bought the land as a team. We rezoned it as a team. We did a master plan as a team and we built the main office building as a team,” she said. “It is our Global Support Centre where a lot of the new manufacturing will be done. We’ve recently started the first expansion of this which is very exciting.”

From making its formula in bathtubs, Ego has progressed to become a local manufacturing powerhouse for the people of the world. This year, the company has announced it is expanding production capacity by 50 per cent as part of a $35 million project.

The project will add new cream and filling lines to Ego’s Braeside manufacturing facility and extend its distribution centre in Dandenong South, increasing capability and capacity to support local and fast-growing export markets.

“Keeping our high-technology manufacturing in Australia has and always will be important to us,” he said. “This grant will help us further in creating good jobs to support our local economy as we continue to grow and will enable Ego to transform more lives through the science of healthy skin across many nations.”

Minister for industry and innovation and manufacturing sovereignty Ben Carroll told Manufacturers’ Monthly the state manmonthly.com.au

Manufacturer Focus

Ego Pharmaceuticals hold consistent ambitions to upgrade its equipment and processes.

government’s support of the expansion will create 90 new jobs.

“Ego Pharmaceuticals’ decision to expand its operations in Victoria demonstrates the strength of our nationleading advanced manufacturing industry and highly skilled workers,” Caroll said.

A demand for quality control Quality control is integral in the pharmaceutical world. Before he became managing director, Gerald was the scientific director himself, directly involved in projects such as significantly upgrading the businesses’ water purification standards.

Ego’s products are not sterile, but the goal is to produce products with very little bacteria in them. Australia’s Therapeutic Goods Administration audits processes on a frequent basis, and Ego decides to make all of its products to international pharmaceutical standards (even though some products aren’t classed as therapeutic and therefore wouldn’t require as such).

“Our job is to produce and supply a product that is really clean with really low levels of bacteria,” Alan said. “The most important ingredient for that is the water.

Water at room temperature doubles in bacteria about every half hour, which is manmonthly.com.au

really, really fast. When we’re putting water in our products, or rinsing our tanks, we are using our purified water systems that makes reverse osmosis water. We don’t go sterile because that’s a whole another level of cost, but the level of bacteria in the water is really critical and really low.”

To test the level of bacteria, chemists can’t just duck into a lab and resolve a sample in five minutes. In a microlab, staff have to grow the sample in an incubator and wait for 48 hours for the results, which is why it’s critical for bacteria levels to begin low, and if they are concerning at all, to get onto it early.

“For the purified water system, the most important ingredient is TLC – tender loving care – by the engineers who understand it and work closely with microbiologists,” he said. “Improvements might come from a particular tap where the water comes out, or it might be the system or a whole range of things. We do a lot of work to ensure the bacteria levels stay really, really low.”

The people behind the product Dr Jane Oppenheim has been working on Ego’s mixers for more than a decade, having purchased the first machine from Germany around 15 years ago.

This machine is a two-tonne, computer-

controlled mixer which makes batches of emulsions such as sunscreen and antifungal cream. Ego has another two-tonne mixer for making its Aqium Hand Sanitiser, which is flammable, thus requiring completely different engineering because of the alcohol in the formula.

When touring Ego’s facility in Braeside, Victoria, it was clear to see the company recognises the impact particular staff have had over the years. It was impossible to miss the new arrival – Ego’s gigantic new mixer, which is named after one of its dedicated employees – ‘Ravi.’

The machine weighs eight tonne empty – so big it couldn’t be shipped in a container and had to be transported in wooden crates – and came with two whole shipping containers of cables and valves.

“We then had two structural engineers, civil engineers and one computer engineer from the supplier come out from Europe with many of our engineers all working together,” he said. “We had to raise the ceiling, and literally take the roof off and raise the roof to fit it in.”

The mixer makes five tonne batches of emulsions. The oil ingredients and oil soluble ingredients are put into one container, while the water soluble ingredients are in another container.

The ingredients are heated and mixed

together, cooled and emulsified.

“The huge motor which runs the emulsifier pushes the mixture through a very fine gap to make sure that the droplets of oil in the water mixture are really small which increases the stability the product for the long term,” he explained.

The machine’s namesake – Ravi – has worked with Ego for 28 years. Described

by Jane Oppenheim as “just a really, really good sort,” Ravi has been integral to Ego’s manufacturing operations, including working a way to increase from two batches a day to three batches per day.

“Whenever I step into manufacturing, Ravi has always a good reason for change,” Jane said. “He looks at what we can do differently in the future. He gives me the floor credit and I give him the management credit, so together we are able to convince most people of plans to better production and efficiency.”

Alan Oppenheim explained that the company’s values – including considering staff as family themselves – stemmed from his family heritage.

“When you’re running a small business you don’t usually have time to put them on paper, but my mother and father lived these values – quality, our people making the difference, innovation, ethics, service and helping our customers.”

Manufacturers’ Monthly JUNE 2023 23

Engineering Focus High-tech medical gels from Indigenous spinifex grass

Spinifex grass is a resilient plant that grows abundantly in the arid Australian outback.

Manufacturers’ Monthly sits down with Tim Case, interim CEO of Trioda Wilingi and Dr Jane Fitzpatrick, CEO of ANFF, to discuss how the medical device company harnesses the abundantly available native spinifex grass to develop innovative medical gels.

24 JUNE 2023 Manufacturers’ Monthly

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Engineering Focus

T

HE Australian outback is home to some of the world’s most unique and hardy plant life. Among them is spinifex grass, a tough and spiky plant that can survive in the harshest of conditions. The humble grass, found predominantly in the arid regions of Australia, is proving to be a game-changer in the field of medical research.

For centuries, the IndjalandjiDhidhanu people – Traditional Owners of the upper Georgina River region of Northwest Queensland – have used spinifex grass for a variety of purposes, including as a source of medicine, to build shelters and using resin from the grass as an adhesive to attach spearheads, and seal water vessels. But it wasn’t until recently that scientists discovered the potential of spinifex in the field of nanotechnology.

Unleashing the potential of spinifex grass Spinifex has a unique chemistry that allows for the production of stronger, longer, thinner, and more flexible nanofibers. The nanotechnology research on spinifex grass and its properties has been twelve years in the making.

Dr Jane Fitzpatrick, chief executive officer of the Australian National Fabrication Facility (ANFF) said, “The Traditional Owners approached the University of Queensland with an idea about spinifex grass – they know it’s tough and hardy, grows well, and they’ve been

using it for thousands of years for several applications.”

In 2008, the Dugalunji Aboriginal Corporation (DAC, a parent company of Bulugudu Ltd), and the University of Queensland were awarded a discovery grant by the Australian Research Council (ARC) to explore the Aboriginal and Western scientific knowledge of spinifex grasses.

Bulugudu Ltd, led by Colin Saltmere AM, was established to further explore the potential of the nanocellulose fibres in spinifex grass.

Tim Case, interim CEO of Trioda Wilingi said, “A key part was to characterise the cellulose nanofibres in spinifex grass and that’s where ANFF stepped in. ANFF had research equipment and capabilities, and in collaboration with the Australian Institute for Bioengineering and Nanotechnology (AIBN), helped characterise the spinifex nanocellulose fibres.”

ANFF’s involvement in the project ANFF was founded in 2007 to provide open access to micro and nanofabrication equipment and capabilities to develop new products and provide improvement to current production methods. From a technical perspective, ANFF’s support revolved around the characterisation of the nanocellulose fibres from spinifex grass.

The late Dr Ian Griffiths, previous CEO of ANFF, was instrumental in recognising

Spinifex medical gels can be applied to wounds to create a strong, flexible, and water-resistant seal. the potential of spinifex nanofibers in medical gels and began negotiations to commercialise the product, which eventually led to the establishment of Trioda Wilingi. The investment opportunity was developed and led by ANFF-C, the new commercialisation arm of ANFF, which is part of Australia’s National Collaborative Research Infrastructure Strategy (NCRIS) funded by the Australian Government’s Department of Education.

“We provide expertise and equipment to people who want access to fabrication

equipment. In the initial stages, when you’re only testing ideas, some of this equipment is expensive ¬– so it makes sense to have the capability to rent the equipment for an hour or so, for research all the way through to industrial processes,” explained Dr Fitzpatrick.

“We identified that there were many great ideas that weren’t getting very far beyond their initial stages of research. Therefore, we developed our commercialisation support platform or ANFF-C. With this, we support early-stage entities that are trying to get out into the

Trioda Wilingi interim CEO Tim Case (far left) with ANFF CEO Dr Jane Fitzpatrick and Bulugudu director Colin Saltmere AM (centre)

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Manufacturers’ Monthly JUNE 2023 25

Engineering Focus

Spinfex’s unique chemistry makes it an excellent reinforcing agent. market, to develop a product or develop a company.”

Trioda Wilingi was one of those companies.

“With Trioda, we worked with all involved partners like the University of Queensland and Bulugudu to get everything lined up for it to be investable.

There are a number of different markets Trioda can go to, but we’re focusing on medical gel end markets that require high-value, low-volume manufacturing.”

Tim Case added, “Trioda Wilingi was the first project under this pilot commercialisation funding by the Federal Government that led to the formation of ANFF-C. It helps find potential commercial applications, funding, and attract external funding – and therefore was pivotal in enabling Trioda Wilingi to 26 JUNE 2023 Manufacturers’ Monthly

become an investable opportunity.

“We’ve integrated traditional knowledge of the plant and how it grows, with the latest chemical nanotechnology advances, to create the beginnings of a new industry.”

The journey from research to commercialisation Around three years ago, Mr Case was brought into the project to assist in identifying market opportunities, develop the commercialisation plan and ultimately create an investable opportunity.

“I had previously worked on another project with the late Dr Ian Griffiths.

Dr Griffiths was a polymer chemist and he worked with Professor Darren Martin, one of the inventors of the

technology, from The University of Queensland’s School of Chemical Engineering, to identify the potential of using the nanocellulose in medical gel applications,” Mr Case said.

“Medical gel applications for spinifex ticked a lot of boxes, both from a technology perspective and a commercial and scalability perspective – building a solid business case. We sadly lost Dr Griffiths in this time, and we had to pick up on all the hard work he had done – it reminds me of the quote ‘standing on the shoulders of giants’.”

In February 2023, the hard work came to fruition when Australian venture fund Uniseed and Bulugudu Ltd announced an investment of $2.6 million into Trioda Wilingi to develop injectable medical gels from cellulose nanofibres extracted from spinifex grass.

The name ‘Trioda Wilingi’ is derived from the scientific name for spinifex grass – Triodia pungens – and ‘Wilingi’ which means “special grass” in the Indjalandji language. The company’s exclusive global rights to develop the injectable spinifex medical gels have numerous potential applications including osteoarthritis, drug delivery, and cosmetic treatments.

A closer look at the applications and advantages of spinifex nanofibres The cellulose found in spinifex is the longest, thinnest nanocellulose that has been found in nature ¬–the fibres are

three to four nanometres thick, about 20,000 times thinner than a human hair. The aspect ratio or the length and width of the fibres is 500:1, which makes them both skinny and strong. This is important because it helps spinifex grass work as an excellent reinforcing agent.

There’s a global demand for cellulose nanofibres due to the vast number of potential applications, specifically in the commodities market. One of them, for instance, is recycled paper.

“When you’re trying to recycle paper, it can only be recycled so many times before the grade disappears,” Dr Fitzpatrick said. “By adding reinforcing agent into that process, you end up with paper that’s better for recycling.

Latex is another example – items such as gloves that require strength and reinforcement. Currently, Trioda will be concentrating on medical gels.”

Initial research has shown that the advantage of using spinifex nanofibers for medical gels compared to other materials is its ability to be injected and to last longer.

“As a plant material, spinifex nanocellulose is simple. It can be modified easily with fewer chemical modifications so you can add things to it and there are a number of different properties that allow this cellulose to work,” Dr Fitzpatrick said Additionally, explained Dr Fitzpatrick, the nanocellulose can be released from spinifex grass without using manmonthly.com.au

Engineering Focus

Trioda Wilingi’s novel injectable spinifex medical gels have many potential applications.

Spinifex resin has been used as an adhesive to make stone tools.

large amounts of energy, resources, and chemicals due to its tough nature.

Currently, companies use complex energy-intensive processes to make nanofibres from materials such as wood pulp, carrots, wheat straw, and sugar beet.

Tim Case added, “UQ has developed a process to extract the nanocellulose fibres that is milder, ensuring that you maintain the unique attributes of the spinifex fibres, as well as being more environmentally friendly.”

Next steps for the company The funding that Trioda received earlier this year will be spent towards taking the research further and perfecting its formulation, according to Tim Case.

“The focus of this current capital raise is on research from some preclinical studies and some animal work as part of that, which is about getting the formula right, ensuring you understand the manufacturing process to, ultimately, produce a quality gel consistently that meets its characterisation criteria. We will then subsequently look to raise further capital and move into clinical trials, ” he said.

“And we are looking to tick boxes from a data perspective, both in terms of what we must do, including from a safety perspective, and also look to support those differentiators that could mean a gel that has great market disruption potential.” manmonthly.com.au

Spinifex cellulose nanofibres tiny, hair-like structures that interlock with surfaces.

In the next five years, Mr Case is hopeful about having numerous other applications under development for spinifex grass. “We’ve had early discussions large international players within the industry and the feedback has been positive – we’re moving forward in the right direction.”

Support to Indigenous communities “Spinifex grass is an ancient and sacred material to our people. In IndjalandjiDhidhanu culture, spinifex is a sacred thing. It belongs to Country, and to us, that’s what ‘sacred’ means,” according to Colin Saltmere, director of Bulugudu and Trioda Wilingi.

Under the deal that was signed in February, a portion of any future royalty

stream will be allocated to an Indigenous STEM education fund that aims to maximise training, education, and network opportunities for Indigenous Australians.

“We’re hoping this can also lead to an increase in Indigenous participation in STEM and the effect of that over time,” Mr Case said.

“My hope is that Trioda Wilingi is the icebreaker for how spinifex may be used, and not just for medical gels – that way there will be other companies like Trioda Wilingi with other applications for spinifex grass. We are also attempting to demonstrate ways for other indigenous entrepreneurs to navigate ways to commercialise their potential.”

Dr Jane Fitzpatrick said, “With the spinifex medical gels from Trioda

Wilingi, the industry here in Australia is going to have a worldwide market.

Simultaneously, the Traditional Owners will be involved in the farming and harvesting and initial processing of the spinifex grass since they’re the ones with the license to do so.”

Additionally, creating a burgeoning industry using local spinifex grass helps ensure that manufacturing capabilities are kept within Australia.

Dr Fitzpatrick said, “Trioda was the impetus that allowed us to develop ANFF-C. Since then, we’ve done several different projects through ANFF-C, but not on the scale of Trioda Wilingi. The formation of ANFF-C has helped us remove barriers for different projects and move them towards the ability to manufacture here in Australia. And that’s really the key in the development pipeline – to keep the innovation and the tech here.”

Tim Case also stresses the importance of regional manufacturing.

“When we start looking at other applications that are high volume in nature, in terms of manufacturing scale, it has the potential to make the employment sector really viable, especially in remote areas such as Northern Queensland where spinifex is harvested. We want to see a strong regional supply chain and viable employment opportunities ¬– with the involvement of Indigenous communities.”

Manufacturers’ Monthly JUNE 2023 27

Sustainable materials

Quality is at the forefront of Volgren’s purchasing decisions.

Driving a sustainable future In the latest installment of Crafted with Capral, Manufacturers’ Monthly learns about Volgren’s journey to becoming Australia’s biggest bus body manufacturer and why the business is opting to explore new sustainability options.

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OLGREN built its first bus in 1979 with the promise of creating a more reliable, comfortable and longer-lasting vehicle with lower operating costs than others then what was available at the time.

Today, Volgren designs, manufactures and assembles public transport buses of all types across multiple technologies, including zero-emission vehicles. Thanks to its 300-strong manufacturing, operations and aftersales support teams across NSW, Victoria, Queensland and WA, its bus bodies are 90 per cent locally produced and offer the lowest lifetime cost of any bus in Australia. Volgren has the manufacturing capability for a range of buses, including a standard-route bus – which the general public go on every day – which can be from 11.9 to 12.5 metres long depending on the expectations for where the bus is going.

Although Volgren officially began trading in the 1970s, its story started in 1940s Dandenong, when local milk carrier George Grenda moved into buses. His business thrived as Dandenong grew, and by the 1970s, Grenda Bus Services was a hugely successful route bus and coach company. In 1977 Swedish vehicle manufacturer Volvo partnered with Grenda to create Volgren and introduced extruded aluminium, rather than steel, for bus body construction and the Swiss Co-Bolt system.

28 JUNE 2023 Manufacturers’ Monthly

Leading global bus body manufacturer, Marco Polo SA, acquired full ownership of Volgren in 2017, strengthening Volgren’s local capability with its technology, buying power and international experience.

In the intensely competitive world of manufacturing, innovation is essential.

Accordingly, Australia’s largest bus body manufacturer Volgren has made its name with innovative, sustainable and efficient public transport solutions.

Since 2018, Volgren has delivered dozens of hybrid and electric buses to Australian operators and is now fast-tracking delivery of Australia’s first European hydrogen fuel cell buses.

Volgren’s E-bus, the Optimus E-Bus, is one of its class’s lightest zero-emission bus bodies and operates successfully in Melbourne, Sydney, Brisbane and Perth.

The body has been effectively engineered to suit multiple electric chassis and complies with Australia’s highest safety and flammability standards for buses.

Volgren national purchasing manager Andrew Castillo says Volgren is still one of only two Australian companies manufacturing bus bodies from aluminium, rather than steel, despite aluminium’s clear advantages.

“Most buses are still built from fully welded steel. Aluminium is much lighter, resistant to corrosion, and recyclable,” Castillo said. “Moreover, the lighter a bus

is, the more people you can fit in the bus.”

The Co-Bolt process is also critical to Volgren’s production; Castillo said this system uses bolted gusseted joints.

“This avoids the risk of continuous bus vibrations fracturing welds. Our system requires no welding and results in a much longer joint life.

“Our joints are lock-tightened with very little chance of anything loosening over time. For operators it means far superior reliability than a traditional steel bus and is one of the main reasons why we can offer a 15-year warranty on our buses’ aluminium structures,” he noted.

Quality, explains Castillo, is paramount in Volgren’s business. Volgren operates rigorous quality systems and builds quality into its products through its

suppliers, logistics and production.

Capral has been Volgren’s principal aluminium supplier for at least 15 years and meets Volgren’s ethos of quality, local input and innovation, Castillo said.

“We build buses and want our supplies priced at construction-type costs, but we also want an architectural look and finish to our products. Capral has always achieved both for us.”

The supply partnership continues to drive new value for both businesses; where Capral once purely supplied extrusions, it now also machines parts.

This advance means Volgren’s teams can focus on faster assembly and minimising customer costs.

Capral’s size and capability are also crucial to Volgren, according to Castillo.

Capral is Volgren’s principal aluminium supplier.

manmonthly.com.au

Sustainable Materials “Our whole roof structure is a sheet with aluminium extrusion bows across the roof and main cant rails extending the entire bus length. Capral is one of the few players in Australia with presses large enough to extrude our parts.”

Castillo says bus body manufacturers must tailor bodies to the requirements of individual bus chassis and operators.

“Our variation is massive and requires a large engineering team,” he said. “When Australia used to build cars, Ford would build a Falcon and a Territory here, and that would be it.

Whereas we build the equivalent of a Territory, a Commodore, a Ferrari, an electric BYD and a Tesla all on the same production line.”

Even though Volgren’s ownership is now multinational, Castillo said the Volgren team remains family-focused, with experienced people providing a family-style influence.

“The teams here are always looking to improve themselves. They’re not too scared to ask if we can look at doing something better. It’s the way it’s always been at Volgren; we know what the

operators are after and work hard to give them what they need.”

Castillo emphasised that Volgren is well placed for future success and to continue contributing to Australia’s environmental sustainability.

The Volgren team are currently exploring Capral’s LocAl Lower carbon aluminium offer to further reduce the environmental impact of their builds by reducing the embodied carbon in the Aluminium products they use.

“It’s great to be part of the biggest bus manufacturer in Australia, which is leading the way for zeroemission transport.”

To watch the Volgren story, scan the QR code.

Volgren designs and manufactures public transport buses

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Manufacturers’ Monthly JUNE 2023 29

Digital Transformation

Moneo unlocked

Ifm recently hosted a captivating event at its Melbourne office featuring guest speakers from its global headquarters. Manufacturers’ Monthly was there to find out the possibilities and value to be found in moneo, an AI-assisted, self service IoT platform that integrates with existing systems.

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ROM its foundation over 50 years ago, ifm continues to be a familyowned business which implements particular virtues. The company keeps quality standards at the forefront of its work with a mindset of “making technology for everybody” – making innovation easily accessible for the largest multinational corporations as well as smaller companies serving regional markets. In the early days, no sales engineer was allowed to live further than three hours away from any customer they served, and this mentality to sit customer side remains a pillar of ifm’s operations.

This concept plays out in ifm’s operations today, exemplified by the company’s “Close to You” value.

Nadine Rahman, ifm managing director and global head of software sales and digital business, explained that ifm has a long history of being “industry diverse,” which has made the company resistant to crisis.

“Over three parameters – geography, customer base (from OEM and end user) and industries we serve – ifm upholds the notion of application expertise. With this in mind, while we use the experience we have acquired in the past 50 years to provide products which can be used

30 JUNE 2023 Manufacturers’ Monthly

in different industries, we still are very focused on providing solutions to specific problems between different industries.”

What certainly has changed from the founding years is ifm’s now global presence, with 155,000 customers worldwide and active dealings in 71 countries. With 1.2 billion Euros in sales last year, ifm has experienced a massive increase in the automation needs from its customers. The business is closely connected to Germany with its headquarters in Essen, where more than two thirds of its product portfolio is developed and manufactured, but has other product locations in Romania, Poland, the US and Singapore. Not only is ifm diversifying product locations, it is targeting specific regions for greater competency and specialisation for certain products. For instance, the company’s research and development for small optical sensors has moved to Singapore because that is where the highest level of research expertise is for that particular range of product.

Ifm has 15,000 articles in its product portfolio. Sensors have been at the core of the business, but the pursuit for automation excellence has enabled the development of different connection

technology, controllers and evaluation systems. The newest adaption of the automation expert is its software platform – moneo – which has moved ifm from a hardware sensor provider to a full solutions provider.

In 2012, German Chancellor Angela Merkel coined the term Industry 4.0.

Small to medium sized businesses in Germany began to implement technology not for technology’s sake, but as a means to serve better business outcomes. Ifm’s

journey to become a digital solutions provider begun around the same time and continues to progress today. Rahman has been instrumental in the company’s shift from champion in industrial automation to digital global player as an end-to-end Industry 4.0 solutions provider.

“We are simultaneously rebuilding and enhancing our portfolio to include software specific products as well as our core offering,” Rahman said. “Everything

Nadine Rahman fielding questions after her presentation at 2023 ifm unlocked.

manmonthly.com.au

Digital Transformation

ifm engaged with industry via its global IoT experts.

that we do around digital solutions will always revolve around sensing technologies, and making use of the data that the sensor generates. At the same time, we are also rebuilding our processes ourselves which comes with its own learnings and challenges. In order to provide our customers with the best digitally enabled product portfolio, we ourselves need to digitally transform.”

Such challenges ifm feels along with its own customers is continued supply issues, of which the company is researching and developing ways to redesign products that are not dependent on any one type of semiconductor in the future. This kind of forward-thinking was prevalent in Rahman’s presentation, but was combined with a realism that many manufacturers are only just beginning to dip their toes into digitalisation.

“The first step is to look at your current pain points,” she said. “Where do you have real business issues you want to solve? Then looking at how technology can help you solve those. For me, the key is putting the business solution first and then using technology as an enabler to be able to solve your business issues.”

The moneo platform is a self-service tool that enables successful predictive manmonthly.com.au

maintenance programs through the help of AI Methods. Many software applications have unexpected cost blowouts once purchased, however, ifm’s moneo is basically “ready to use” right from the start. Continuous evaluation of process data provides the basis on which sustainable and successful business decisions can be made. And in order to obtain such data from the manufacturing floor, reliable connection of sensors to IT infrastructure is essential. ifm’s moneo consists of a basic software as well as applications, for example, for condition monitoring or for IO-Link sensor parameter setting.

As powerful as the software is in its full range, thanks to its modular design, it is only ever as big as the customer requires.

An important strategy for ifm is making it clear to businesses that it is best to start small and ‘grow as you know’.

“We call it a land and expand offering, where the customer can start with a very easy to consume starter kit,” Rahman explained. “The actual setup of Moneo will take the customer a couple of minutes and the system will be up and running immediately. They can run analytics in real time. We’ve designed our deployment model so it is very easily able to expand

usage by simply buying more information points, which is basically the data sources you can integrate onto your installation.”

Crucially, moneo is industry and manufacturer independent, lending the solution to a huge variety of environments. When setting up its digitalisation product strategy, ifm transferred its belief that solutions need to be open-minded and accessible for all.

“We incorporated what we had been practicing for the last 50 years, which is the thinking that the world is colourful and not singular,” she noted. “It has to be open in all directions, so our customers can consume moneo in a modular fashion. We would never mandate customers to buy the full portfolio, rather they can pick and choose what they want and plug into their existing infrastructure.”

The traditional approach of identifying equipment problems by responding to alerts based on static thresholds comes with many trade-offs that can lead to compliance, economic and resource loss. ifm’s DataScience Toolbox aims to break these trade-offs by empowering operators and engineers to improve the remaining useful life of their equipment and at the same time avoid unplanned downtime

and assist compliance. ifm’s DataScience Toolbox – an element of the moneo industrial IoT software platform – simplifies the integration of Industry 4.0 concepts into existing SCADA systems. The DataScience Toolbox enables operators and engineers to leverage their knowledge and experience of equipment to harness predictive analytics and machine-learning to auto-identify anomalies and remedy minor equipment problems before they become expensive, big ones.

Rahman said ifm is committed to this open-minded approach. For example, the business is working towards bringing third party apps onto the moneo platform to leverage expertise to bring further industry specific solutions to customers.

“We don’t know everything, so we want to work with customers who are the experts in what they do to achieve the best outcome,” she said. “We want to harness expertise to bring more applications to moneo in the future.”

See how ifm can assist your business by translating your digital vision into a prioritised set of valuerich opportunities to help determine how the organisation can be set up for success in a digital world with their Digital Transformation.

Manufacturers’ Monthly JUNE 2023 31

Skills & Training

New England TAFEs producing ‘top-gun’ metal workers Thanks to a great working relationship with BOC at a local level, Tamworth and Armidale TAFE colleges are now providing training that’s creating ‘top-gun’ metal workers, up to speed in operating state-ofthe-art industrial equipment and gases used in the metal fabrication and welding trades.

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HE New England area has many thriving industries where well-trained welders and metal workers are in high demand in sectors such as agriculture, forestry, mining, manufacturing and aviation. This is one reason of many that apprenticeships are booming locally said Tony Walsh, Head Teacher of Engineering at New South Wales Department of Education and Communities and who oversees all apprentice training programs at Tamworth and Armidale TAFEs. “There’s a huge demand for apprenticeships in the metal and welding sphere. On average we used to take on around 24 to 30 students each year for both schools, now it is 50 plus, so the numbers have doubled,” he said.

“The fact that apprentice tradies are also sought-after by employers is also fuelling this demand and there are many incentives out there to get people trained, and in our case, on first class equipment and gases.”

This observation reflects the current 32 JUNE 2023 Manufacturers’ Monthly

demand for apprenticeships nation-wide, when the National Centre for Vocational Education Research (NCVER) report on apprenticeship and traineeship numbers dated 25 March 2022, revealed that across Australia, commencements for the 12 months to September 2021 had increased by 88.1 per cent compared to the previous 12-month period.

However, with such demands come a range of challenges.

The desired technology for the trainees were state-of-the art which were EWM machines from Germany, but also the understanding of how using BOC performance gases can enhance final welding and metal work results. This is where a unique relationship with the TAFEs’ local BOC representative came into being nearly five years ago, when he

reached out to Tony on the technical side of things, because understanding the full range of these machines was imperative.

The EWM machines have a technological advantage characterised by a high level of efficiency, resource conservation and sustainability. No matter what the process – whether using metal inert gas (MIG) or Metal Active Gas

The challenge For Tamworth and Armidale TAFEs, the great challenge for their welding and metal work apprentice courses was technology. Working with top class machines and gases means an apprentice gets to learn on the best, which is beneficial not just to them, but their employer too.

For some years both TAFEs had adequate equipment on which to train apprentices, however it was not state-ofthe-art, so upgrading the apprentices’ tools was high on the agenda.

Rod Brown (BOC), Tony Walsh (Head Teacher) and Ken Edler (Metal Fab Educator).

manmonthly.com.au

Skills & Training (MAG) electrodes, plasma or tungstenelectrode inert gas (TIG) welding machines – this particular range is high quality, user friendly and versatile. It also allows all apprentices to try a variety of different welding techniques.

The solution Luckily for these TAFEs, BOC’s local approach to customer relations and engagement has turned what was good basic training, into exceptional industrial, work-ready training – where BOCs technical knowledge in the industry has supported Tony and his colleagues.

BOC has worked tirelessly with Tony, other staff and students to first talk about the equipment they needed to upgrade too, and second, when they finally got funding and installation, train them on how best to use it with the gases BOC has been supplying both TAFEs for many years.

After 23 years teaching in TAFE and coming from industry itself, Tony said the relationship with BOC over the past four years has made all the difference.

“It was around three years ago when

we finally managed to get TAFE funding for six new machines, then 12 months later a tornado and bad weather smashed skylights in the Armidale workshop and rain destroyed the older equipment. We therefore had the perfect opportunity to upgrade. Now we have 30 machines in Tamworth and 15 in Armidale,” he said.

“These new EWM machines have lifted the technology and features we can offer apprentices and their employers, as they have a broad range. They can be used as a basic welding machine for beginners and then they open up to a full range of features to progress apprentices through their studies.

“The students are now really enjoying using the huge range of technical features of the machines. Before we only had a basic welder with two dials. This total upgrade would not have been possible without the support, technical expertise and encouragement of the BOC team,” Tony said.

Benefits The key benefits of this unique working relationship are that students are getting

first-hand experience on the best technology available learning that the finished weld appearance and quality of work is fully dependent on the machine and the gas mix used.

Excelling in using these techniques are what makes these apprentices ‘top guns’ – especially as you need to ‘fire’ the wire used for the weld through a gun-like tool, usually done by hand but can also be done by robots, or a mixture of both – a cobot (collaborative robot used to automate welding processes).

A robot is next on these New England TAFEs’ wish list, so watch this space.

The ultimate benefit is that this approach has helped transform how Tamworth and Armidale TAFEs can better prepare the future generation of welding apprentices and equip them with the skills needed for the real world.

For welders this means understanding how using BOC performance gases and EWM high end machines can help achieve quality output, higher productivity and cost efficiencies for the metal fabrication businesses they work for.

The relationship between BOC and

these two TAFE colleges is ongoing and they are exchanging ideas and knowledge on a regular basis.

“BOC always provides great demonstrations when there’s a new product or new use for a gas,” said Tony.

At the end of November last year, an open day/training event was hosted by BOC and its robotic partner, Diverseco.

This three-day event was held at the BOC Gas & Gear in Tamworth showcasing the latest cobot technology, along with EWM welders including the Xnet welding management system and the Soldamatic augmented reality welding simulator from Weld Australia.

TAFE students and customers were invited, and interest proved high, with three days’ worth of personalised welding application demonstrations and expert advice sessions soon booking out. BOC demonstrations clearly showcased how having the latest welding technology and the right partnership can make a difference to customers’ productivity.

For more information visit BOC at www.boc-gas.com.au/en/index.html

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Manufacturers’ Monthly JUNE 2023 33

Skills & Training

Elexon goes Agile to win Defence jobs Already established as a global electronics player, Elexon Electronics is undergoing an agile transformation to strengthen its defence offering. Manufacturers’ Monthly investigates the skills and training initiatives the Australian company is putting in place to grow its presence in major defence projects.

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VER the past 16 years, Elexon Electronics has pioneered various highly innovative and commercially successful products for a range of industries such as mining, pathology, automotive and recently defence.

The leading difference for Elexon is its ability to design, engineer, prototype, test and manufacture complex electronics in-house, from high-precision custom PCB boards assembly to software and final assembly.

Over the past few years, Elexon has been on a journey to become more prevalent in Australia’s defence space.

Frank Faller, Elexon CEO, explained that instead of taking manufacturing offshore, government support helped to significantly increase Elexon’s design, prototyping and manufacturing capability, with a strong focus on Industry 4.0 interconnectedness.

To become a valued Defence supplier, Elexon had to make sure its operations exceeded industry standards.

34 JUNE 2023 Manufacturers’ Monthly

Following engagement with the Centre for Defence Industry Capability (CDIC), Elexon received government support for its Cyber Security Uplift, ISO 14001 and AS 9100D management standards installations. The successful implementation of environmental management standards ISO 14001 and aerospace quality standards AS 9100D involved Elexon upgrading its physical and cyber security to protect IP – both Elexon’s and that of trusted Defence partners.

“We made a decision to continue manufacturing because it is our core competency. We see the value of having the engineers sitting next to their product being built,” said Faller. “There is four main pillars which have been critical to our early success to be defenceready: cyber security uplift, quality and management systems, manufacturing equipment upgrades and team development and upskilling.”

Having amassed an impressive career in electronics manufacturing, working

with Siemens and Bosch previously, Faller knows all too well that you need quality people to make the technology tick. Faller has brought his own expertise in lean and agile transformation of processes to push the limits of Elexon’s standards and processes.

“When I started at Elexon after working at large organisations, I was really impressed that the company lived and breathed quality,” he noted.

“10 years ago, this small business implemented serial number tracking on all its products, not because it was a customer requirement, but because it was recognised as the way to capture product lifecycle data and continuously improve.”

With the first three ‘pillars’ of Elexon’s defence-readiness plan in place, the company is working tirelessly on upskilling its team. Faller explained that the company now has the ‘toys’ like amazing traceability software systems well and truly established, so it is focused on finding better methods to best utilise its access to powerful technology.

“All this wouldn’t work without having a highly skilled, motivated team – I think upskilling also always helps to motivate the team,” Faller said. “We are implementing Lean manufacturing principles and applying an agile approach. Project management is another crucial factor when it comes to Defence.”

Elexon recently received government funding through the Skilling Australia’s Defence Industry Grants (SADI) program aimed to support upskilling of its staff in preparation for more large-scale defence projects. The SADI program gives grants to businesses over three years to help develop defence sector skills and human resources practices and training plans, reducing barriers for SMEs. Alex Teoh has jumped on board to be an instrumental part of Elexon’s progress. Teoh – who started his career as an industrial engineer – has decades of experience as an Improvement Intervention consultant in Lean and Agile transformation, business improvement and operational excellent manmonthly.com.au

Skills & Training implementation initiatives for SME and organisations globally. Teoh teaches and coaches world class operational excellence practices, performance measurement, continuous improvement programs for all businesses, non-profit organisations and government agencies.

As a certified Shingo Institute facilitator, he actively teaches principle based improvement and culture transformation through Shingo Model.

From April last year, Teoh officially started working with Elexon, beginning with simple onboarding sessions with staff and the management team. He explained that the process of upskilling must happen before implementation.

“In the early phase, it’s important to establish a baseline of training,” he said. “We trained four Elexon members on green belt programs while the rest of the staff were trained at a white belt level. This lays the foundations for future work because everyone speaks the same language and has some initial experience of making small-step improvement.”

From August, Elexon engaged with Teoh in the “real stuff” – running diagnostics, value stream mapping (VSM) workshops and identifying the changes needed for major projects. From the start of this year, Elexon has moved to a third phase, what Teoh labels as “implementation support”.

“Implementation support is what we do really well compared to others – providing actual onsite support to ensure the right outcomes are being achieved,” Teoh said. “Other programs I’ve seen are like a driving school which teaches road rules but then asks people to go on a highway the first time they’re behind the wheel.”

One practical example of Elexon’s continuous improvement is its visual management systems – the business is in need of a communication system which can digest information changing very quickly. Teoh implemented an agile operating system with scrum board to be used across all departments as a project management tool to help visualise backlog items and work progress.

“The scrum board helps to prioritise tasks clearly and help inter-department communications,” he noted. “Everyone becomes aware of what is important on the site so there’s no confusion about the priorities.”

Frank Faller explained how Teoh has helped Elexon become more efficient, noticing the meetings the company conducts are a lot more productive and efficient now.

“It’s from management meetings to individual department meetings, to have the agile methodology is really a common theme for us,” Faller said. “We’re also seeing how people have adopted

Frank Faller and Alex Teoh have formed a dynamic partnership to bolster Elexon’s Defence offering. the methodology. Alex has planted the seed and put lots of water in and now it’s growing. The scrumboard is an example of an initiative leading to really good results.”

Elexon takes a Lean manufacturing approach, but applies it across its entire business, not just manufacturing operations.

Mapping out priorities helps Elexon staff be on the same page for all projects.

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“It really comes down to the entire team. We invest heavily in building up our team to have a strong foundation of communication. It’s important to give feedback to everybody in the team so that we are all pulling to the same direction. We separate the need for short term actions and long-term visions – both are critical to be on the same page about,” he said Faller laid out Elexon’s ambitions for the remainder of 2023 and beyond.

Elexon has IP which will be extremely useful for Defence projects, so the company is looking to build on its pedigree to make the most of this.

“Our objective is specifically in defence to become really a trusted, reliable partner in the Defence sector, starting in the manufacturing sector,” he added. “We want to prove that we are a major Defence player, which will open the door for us to develop products which are needed in the Defence market.

“We would like to become part of the global supply chain for some of these primes, meaning we will serve the export as well as the Australian market. You can only achieve this sort of growth if you always deliver on what you promise in terms of time and quality.

This is why we need our lean processes and project management in place to deal with situations changing quickly.”

Manufacturers’ Monthly JUNE 2023 35

Energy Chains Predictive Maintenance: the next evolution of energy chains Manufacturers’ Monthly speaks with Treotham national sales manager and energy chain expert John Sharp about how ‘smart plastics’ are bringing crucial real time data to operators to avoid downtime.

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NERGY chains are used to carry and guide power to moving parts of machines or structures, with the power coming from electrical, hydraulic, or pneumatic sources. The key element of cable guides is the symbiosis of the components moving against each other, including cables, hoses, interior separation elements, strain relief devices and guide troughs.

The engineered plastic chain has integrated rollers built into the sides of the link which operators can put cables into to drag backwards and forwards along a trolley.

In comparison to more traditional energy supply systems, such as festoon systems, energy chains have become a more reliable and efficient option for heavy industrial operations.

For instance, a traditional festoon system needs the additional infrastructure to park the skateboards at the back reach of a crane; an energy chain eliminates the extra steel required to build this, along with the added cost.

According to national sales manager

John Sharp, energy chains provide longer service life, largely because wind does not degrade the cables over time as it would with a festoon system.

“If you look at a chain, it is plastic on plastic, which translates to super low friction and low wear,” he said. “If you have a festoon that is outdoors, even when you go home for the day the cables are degrading just sitting there.”

Treotham Automation is the sole distributor and partner for igus’ range of energy chains for the Australian market. The next step for igus has been its maintenance feature, where sensors can provide real-time data on wear to prevent a shutdown or unplanned failure.

“The worst case for a production environment is unplanned stoppages,” Sharp explained. “Normally, you rely on somebody doing physical inspections and adjustments. This is a step forward from that because the sensors can be measuring multiple or stand alone units to pick up a maintenance alert or get in front of a future problem.”

The high stakes nature of production

environments has given birth to industry 4.0, where businesses want to be proactive about the maintenance of machines and systems.

A study by FM Global - one of the world’s largest industrial property insurers – showed that 28 per cent of losses of more than $3 million were because of system failure. A further 62 per cent of the damage caused by system failure was down to a lack of maintenance.

If an energy supply system fails or a cable breaks, the whole machine will stop. Recently, the new generation of energy chains has introduced predictable maintenance, leveraging industry 4.0 to provide an extra level of assurance to customers.

“Australia is a slow adopter of this sort of technology. In Europe, all the big machine builders are using it because it’s a simple feature from the machine,” he explained. “You can pull data from it yourself or send the data to igus who can say when you need to do some maintenance.”

i.Sense uses values and data measured by sensors. igus has developed the i.Sense system to bring intelligence to its energy chains, with various options:

i.Sense EC.P: push/pull force monitoring Force measuring sensors mounted on the moving end detect the force required to move the chain over the travel during operation. The push/pull forces are transmitted to a module in the machine control cabinet, which, if the pre-set force limits are exceeded, sends a signal to the customer’s control system, which usually stops the machine as quickly as possible.

igus’ condition monitoring system brings smart monitoring to its energy chains.

36 JUNE 2023 Manufacturers’ Monthly

manmonthly.com.au

s.

Energy Chains The EC.P (formerly PPDS) push/pull detection system has been in use for more than 10 years in over 1000 installations and has become a standard feature for crane manufacturers and operators.

i.Sense EC.B: breakage detection An inflexible special rope is guided by separators in the neutral axis of an energy chain system and is connected to a length measuring system at the end of the rope.

In case of a break in the energy chain or even a single side part of the energy chain, the system detects this relative change in length of the rope and also switches off the system. Thanks to the early detection of the breakage of a side part, the system can be ready for operation again with a very short repair time of just a few minutes. The EC.B breakage detection system has already been commonly used in automation environments with linear robots and other machines.

i.Sense CF.P: cable pull force monitoring For long travels, for instance on crane systems, the cable tails must be checked regularly and readjusted if necessary. If this inspection and readjustment is not performed, in the worst case the inner crossbar will abrade the outer jacket of the cable. As a consequence, short circuits can lead to cable fires or protracted failures. The CF.P system measures the increased tensile forces at the strain relief clamps, so that here too, timely information can be given to the plant The right data communicated effectively can mitigate the disastrous impacts of downtime.

operator. The evaluation module installed in the control cabinet evaluates the signals communicated by the sensors on the energy chain. The reference values of this evaluation come from the millions of data points collected in the industry’s largest laboratory operated by igus in Cologne, Germany.

According to Sharp, energy chains are being more regularly used in Australia, but remain misunderstood.

“I think the first misconception is people size the chain system based on what will fit in it,” he said. “We are looking at it like a bridge trust to carry a load over a certain distance, or if it’s a gliding application, we’re looking at what it tolerates in push and pull. If it’s specified badly in the beginning, whoever’s installing it can make some fundamental errors.”

With the igus range of energy chains, no two systems are identical because no two machines have the exact same cable package. The products are mass customisable, ensuring that they suit any crane operator’s needs in relation to size, the travel length of the machine, speed, and acceleration.

“From day one, we select the chain which is going to be strong enough to carry the push and pull of the motion,” Sharp said. “As far as detailing the rest of the chain, that’s really individual. This creates two selection criteria: one is choosing the right series of products for the job, the other is tailoring the accessories inside the chain to suit your cable package.”

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Manufacturers’ Monthly JUNE 2023 37

Procurement & Supply Chain Improving the competitiveness of Australian manufacturers Global Sourcing Services is a leading provider of procurement solutions for Australian manufacturers and businesses. By leveraging its extensive network of suppliers, Global Sourcing Services enables clients to access high-quality products at factory-direct prices, while also providing local Australian support. Manufacturers’ Monthly spoke with GSS Director Daniel Crundall to learn more about how the company’s procurement solutions are boosting the competitiveness of Australian businesses.

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ROWING up in Zimbabwe, Daniel Crundall developed an interest for ‘how things are made’ at an early age. Crundall’s father owned a large plastic injection moulding and hardware distribution business, which is where he recalls becoming fascinated by manufacturing processes, spending weekends walking the factory floor asking questions about how it all worked.

After moving to Australia in 2002, some years later Crundall and his sister started Global Sourcing Services (GSS).

The small family business has become a 15-strong company, with employees across Australia and Vietnam, and a network of more than 100 trusted factories across Asia.

GSS has become the go-to provider for all the procurement needs of a range of businesses, a significant portion of which are Australian manufacturers. The team is comprised of passionate sourcing, engineering, and logistics experts, who add value by collaborating with clients to gain a deep understanding of their unique requirements and deliver tailor-made solutions that enhance competitiveness, productivity, and growth. GSS acts as an extension of their clients’ team, with the goals of saving time, reducing costs, and mitigating risk.

“We offer our clients the ultimate combination of cost competitiveness and convenience,” Crundall explains. “With factory-direct pricing and personalised support from our local Australian team, we ensure that your orders are managed seamlessly.”

GSS works with a network of trusted offshore manufacturers to produce a range of customised products as well as off-the-shelf components.

“Plastic moulding, fabrication, machining, casting, forging, assemblies, and sheet metal work are our core

38 JUNE 2023 Manufacturers’ Monthly

GSS has become a go-to provider of all procurement needs for a range of businesses.

processes,” Crundall said. “Within that, we serve a lot of industries including automotive, medical, agriculture, commercial products, retail products, and many others.”

GSS’s success can be attributed to their authentic approach in addressing their clients’ pain points. According to Crundall, quality and cost have always been persistent challenges, but with changing societal and economic landscapes, new obstacles such as the demand for locally-made products and difficulty in recruiting skilled staff have also arisen.

The push for Australia-made is real, and it is important. It is also important

to recognise that Australia does not make everything, nor should we. To compete globally, manufacturing processes often use components sourced from global supply chains. GSS exists to bridge the supply gap, enabling local manufacturers to focus on their core competencies by providing consistent supply of componentry that meet quality expectations. GSS also enables clients to grow their product range into areas they may never have diversified into, allowing them to expand their offering by leveraging established supply chains.

“Some people think we are competition to Australian manufacturers, which is an interesting one because

most of our clients are manufacturers.

In fact, over half of our products are exported directly to international markets, benefitting the Australian economy. The truth is, many of the components that are used to manufacture locally made products are sourced from overseas, making GSS a valuable partner in providing access to factory pricing without the hassle of buying through a wholesaler or attempting offshore manufacturing independently,” he said.

The scarcity of skilled labour has also emerged as a significant challenge for Australian manufacturers. Particularly in the last three years, Crundall has noticed that a key advantage for GSS clients has manmonthly.com.au

Procurement &Supply Chain

GSS helps clients grow their product range. been the ability to focus on making highvalue products despite a lack of staff.

“Time and time again, clients that I visit are really struggling to find fabricators and machine operators for their factories,” Crundall noted. “Local manufacturers produce high-value products, but they often get bogged down with producing the many components required for those products. This means that their skilled resources are diverted away from their core business. At GSS, we can take care of supplying some of the core components, leaving manufacturers free to focus on developing new products and working on their high-value items.

This way, they can grow their business without sacrificing the expertise of their experienced staff.”

GSS uses a multi-step process to achieve consistency in its end-to-end procurement solutions. According to Crundall, the key to GSS’s success lies in taking the time to understand the unique requirements of each business and product, and tailoring solutions accordingly. This personalised approach is where GSS adds the most value.

“First, we typically receive our clients’ drawings or samples,” he said. “Then, we utilise our trusted network to determine the best partners for the job, whether it be for a simple machined component or a complex fully-assembled product.

We provide a cost estimate at this stage, allowing our clients to proceed to sample production without any financial commitment. This not only simplifies the process but also reduces the risks associated with importing.”

GSS works closely with the client manmonthly.com.au

to resolve any issues with the sample until it meets their requirements. Upon approval, GSS takes charge of the entire mass production process, providing endto-end management.

Engaging in DIY importing or working with overseas agents directly can pose significant risks for manufacturers.

Unforeseen quality issues, port charges, customs clearance issues, and logistics costs can result in unexpected expenses, which manufacturers cannot afford.

Moreover, overseas agents may not

be held accountable for their actions, leaving businesses without any recourse, Crundall explains.

“It’s relatively easy for local businesses to find a factory in some cases, but are they reliable?” he remarked. “Lacking the support of extensive experience and long-term relationships with factories, it can be difficult to address any issues that arise if products fail to meet standards.

At GSS, we take responsibility for the quality of the products we manufacture for our clients. Thanks to our strong relationships and buying power with factories, we have the capability to effectively resolve any issues that may arise.”

Crundall explained the benefits of GSS’s strong relationships with its manufacturing partners.

“Having good working relationships is critical for doing business in Asia. We have been working with some of our core factories for over 15 years and visit them regularly. Our relationships mean that we can negotiate more effectively, implement our own quality control procedures, and run smaller quantities than typically accepted,” he said.

“Factories typically have high minimum order requirements. However, we do so much work with our partners that they

are happy to make smaller quantities. We can then put these smaller orders into our consolidated shipments, increasing the cost-effectiveness of shipping for our clients.”

GSS recognises the importance of maintaining existing supply chain relationships while also prioritising the need for diversified supply chains post-pandemic. To address this, GSS established an office in Vietnam, which is now responsible for handling a significant portion of factory vetting and production management in the Southeast Asia region, offering diversification opportunities to clients.

“As we navigate today’s rapidly changing global market, it has become evident that having a diversified supply chain is no longer just an option, but a necessity,” he said. “At GSS, we understand this need and have taken a significant step to address it by establishing our office in Vietnam.

While we have always sourced products from India and Taiwan, our clients can now benefit from our new office’s capabilities to manufacture high-quality products in Vietnam. By doing so, we can provide our clients with a more diversified supply chain, giving them peace of mind and greater flexibility to navigate the challenges of an ever-changing market.”

Daniel Crundall has personally visited factory floors in China more than 50 times.

Manufacturers’ Monthly JUNE 2023 39

Compressors Longevity and reliability in compressed air solutions Pilot Air has been providing customised industrial compressed air solutions across Australia for over 40 years. During that time, the company has built a reputation for reliability, quality and premium service that has seen it rise to be one of the country’s most trusted brands in industrial solutions for large-scale enterprises.

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HE Pilot Air team is one of longevity and relationship building. Knowing its clients and working closely with the business to customise compressed air solutions that solve the immediate problems whilst delivering long-term advantages is what separates Pilot Air from its competitors.

Pilot Air’s work in the industrial space crosses various sectors. The company has delivered solutions to large agricultural cattle farming businesses, providing customised compressed air solutions for cattle yards that manage the largest herds in the country. The remote location and harsh environmental conditions demand the highest reliance on integrity and uncompromising product quality.

Material handling and large distribution centres (DCs) rely on Pilot Air’s full cycle customised approach to solving complex, multifaceted operations. Large distribution centres require performance equipment that delivers during times of high demand and can power down during low demand periods. Energy efficiency and low carbon emissions are high priorities, along with systems that are digitally

Pilot Air has a long history working in the pharmaceutical space.

40 JUNE 2023 Manufacturers’ Monthly

integrated into the DC demand model.

Pilot Air runs a complete and detailed diagnostic of the DC capacity and delivers a customised compressed air solution that future proofs the operational demands with superior performance, digital compatibility and energy savings that enable the DC to plan with complete confidence.

Shopping centre developments and refurbishments, hospitals and universities benefit from Pilot Air’s expertise in industrial grade air compressor systems.

Large spaces with high traffic require robust delivery of compressed air infrastructure that has the power and performance standards to ensure full time capability with minimal disruption.

Pilot Air’s maintenance and servicing schedules work hand in hand with project and site managers to ensure the compressed air infrastructure is working at its optimum without jeopardising the workings of the facility.

Industrial manufacturing, automotive, water treatment plants, theme parks, food and beverage manufacturing, and medical and pharmaceutical clients across Australia continue to choose Pilot Air for

Compressed air solutions are vital for crop spraying and many other agricultural processes. their compressed air solutions.

CEO of Pilot Air Martin Wyllie spoke of the commitment to delivering custom solutions to its clients.

“Pilot Air has been delivering customised industrial compressed air solutions to the market for decades.

Offering the best hardware and digital integration is a big piece of the puzzle for many of our clients; however, it is the personalised service, diagnostic evaluation and ongoing support that our team delivers that make all the difference.

Many clients come to us when they have a problem. We solve that problem and ensure the solution is future-proofed with ongoing support. As a family-owned Australian company, we can be much more nimble in delivering solutions that purposely fit the needs for industrial businesses,” Wyllie said.

“Our ethos is longevity; we want the capital purchase to be maximised over the product’s lifespan. That starts with offering a robust product, maintaining it and keeping parts so that the investment remains current for two decades or more.

For that reason, service and spares are an integral part of the business,” Martin said.

With manufacturing and servicing hubs in Sydney and Brisbane and a

network of compressed air specialists, Pilot Air’s reach extends across the country. The company has over 45 staff members who are focused on air.

The company is a full cycle provider of industrial compressed air solutions for large-scale operations. Australian and family-owned, Pilot Air knows Australian conditions and knows that off the shelf products do not always meet a customer’s needs. Working directly with the customer, understanding their needs and future growth plans and building sustainable relationships that put the customer first are critical elements to its success.

“We comprehensively assess the scope of what the customer needs. We’ve been doing this a long time and intrinsically partner with supply chain partners who have a similar ethos to us,” says Martin.

When you need a large-scale compressed air solution for agriculture, materials handling, a distribution centre, hospital, water treatment plant, shopping centre or office tower, manufacturing enterprise or any other high demand environment, Pilot Air is Australianowned and family-owned, and has been servicing industrial customers for over 40 years. manmonthly.com.au

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Australia

Additive Manufacturing Forging the future for additive manufacturing in Defence Markforged is combing innovation culture with real manufacturing capabilities to make an impact on Australia’s Defence industry. Manufacturers’ Monthly speaks with one of the company’s partners to learn why additive manufacturing is being adopted by defence on land and sea.

Additive manufacturing is being used by Defence on land and at sea.

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ICK Owen has been an Army Defence Reservist for 20 years.

It’s what pushed him in the direction to start Secure Bits, a completely veteran-owned, Australian business which helps Defence via its two divisions: critical infrastructure and advanced manufacturing.

Critical Infrastructure Division was born to fill a need firstly in the critical power space – within secure facilities, data centres, airports, seaports etc. – because traditional contractors didn’t understand technology, and those supplying the technology didn’t understand the engineering.

The advanced manufacturing division of the business was born in a similar vein.

“We were typically unable to find contractors that could build what we needed, either in a secure way,a timely way, or both,” Owen said. “We built an advanced manufacturing division for internal use, to secure an in-house manmonthly.com.au

capability to build things. It basically means we can build things that are secret, we have staff with clearance (up to Top Secret) and have the facility and manufacturing processes which are secret.”

Secure Bits acts as a ‘one stop shop’ for defence projects, sitting across composites, metals and rapid prototyping, but also CNC machining, sheet metal, plastics and electronics all in house. With its secure facility, it is able to build from start to finish rather than just a case or just the electronics, meaning an idea enters and leaves as a finished product. Owen explained that additive manufacturing has been on the rise in Defence across the world over the last few years.

“Defence innovation has been heavily adopted in recent years,” he said. “There’s a number of bases around Australia now with additive manufacturing, available to soldiers to innovate and solve problems.

At a higher level, defence is adopting

Group Captain Mike Burgess-Orton, director of Jericho Disruptive Innovation with Nick Owen. additive manufacturing or testing out additive manufacturing in deployable and strategic capabilities, and we are part of that.”

Part of this journey, in a big way, is Markforged. Earlier this year, the company launched its biggest, most capable printer yet – the FX20 – which brings its software platform Digital Forge

and Continuous Fibre Reinforcement designed for high-strength end-use parts in aerospace and defence.

In Australia, Sydney’s Garden Island Naval base has both composite and metal Markforged printers. Supporting local business is a pillar of Markforged’s recent growth in Australia, such as its work with Australia’s homeland security specialist Manufacturers’ Monthly JUNE 2023 43

Additive Manufacturing XTEK with the development of composite curing techniques.

Thanks to Markforged printers, XTEK has been able to “bridge the gap” between its Adelaide research and manufacturing facility and prototypes made at its Canberra office.

Owen explained how Markforged has helped Secure Bits branch out to reach more customers.

“We are primarily orientated to Defence, Government and the intelligence community,” he explained.

“We’re used to everything being word of mouth and people coming to us because we’re the only ones that do it.

Markforged have been essential in that lead generation and helping industry find us.”

On top of this, Markforged works with Secure Bits’ manufacturing division, providing 3D printers for special projects.

Markforged has prioritised security from its beginning, bringing comprehensive data security to additive manufacturing by keeping data safe across its Digital Forge platform and enabling on premise slicing.

“Markforged understand our world,” Owen said. “Things like the on-prem tools, for a while were removed from the market and we had to really push to get support in doing that in a secure way, which Markforged understood and worked with us to continue delivery.”

Markforged has more than 10,000 connected printers globally. All these systems, including both composites and metal solutions, are connected through the company’s Digital Forge, a digital manufacturing workflow composed of software, printers, and materials working seamlessly on a unified platform. The system is purpose-built to integrate into an existing manufacturing ecosystem, eliminating barriers between design and functionality and helping to generate and analyse data about real usage. It gives Secure Bits the ability to use Markforged printers on premise without any security concerns.

The software is critical, but the quality of parts produced by Markforged printers is where the company continues to make its name. With Secure Bits, Markforged printers are being used for demonstrating a simulation system for Air Force, for instance. Additive manufacturing is important to this particular project because speed is key in 44 JUNE 2023 Manufacturers’ Monthly

The Secure Bits stand with Markforged printers, including the Metal X and FX20. order to make the simulator as lifelike as possible.

As for the future, Owen sees additive manufacturing playing a bigger part in Defence for both strategic and deployable environments.

“The speed that they can solve problems, but also the speed to fabricate replacement parts or battle worthy replacement parts (short term replacements while they wait for the typical industrial answer), that’s the direction it’s pushing,” he said. “And the same is happening at sea. The US has additive devices on both surface and subsurface and I hope to help Australia follow in those footsteps.”

The US is heavily adopting 3D composite and metal printers on forces vessels to create spare parts on demand, as part of US Navy Command’s NAVSEA plan to transform digital capacity.

Markforged is playing a role in this shift of focus from the US to help sailors think outside the box. Naval Sea Systems Command (NAVSEA) has installed Markforged additive manufacturing equipment aboard nine surface ships, including three aircraft carriers, and aboard four submarines. Enabling crews to creatively and quickly repair items enhancing their self-sustainment abilities, sailors can manufacture components, perform maintenance, and develop quality of life products with ease, without the need for extensive training or

equipment.

Markforged says it was selected after extensive testing due to their ability to remain reliable and identified to address a variety of needs, including standard or preventative maintenance, temporary replacements, quality of life products, drill props, tools, and fixturing.

A Markforged X7 field printer – a polymer-based additive manufacturing system capable of printing high-durability carbon fiber reinforced nylon – was installed on USS New Hampshire in July 2022, and has received tremendous reviews.

Capt. Bennett Christman, the commanding officer of USS New Hampshire, said 3D printers provide the opportunity for creative problem solving.

“These devices lower the barrier for component manufacturing, empowering sailors to take ownership of their repairs, and to think outside the box,” he explained. “Ingenuity and creative problem solving are core to our history as a submarine force. Fostering these values will pay dividends in the way Sailors approach all aspects of their jobs.”

The Markforged X7 3D printer was chosen due to its ability to remain reliable in a simulated shipboard environment. It is a product of the NAVSEA Additive Manufacturing Research and Development Program (NAVSEA 05T) with support from Naval Surface Warfare Center (NSWC) Philadelphia, NSWC

Carderock, and Naval Undersea Warfare Center (NUWC) Newport.

“This system can be used to produce most of the currently approved Technical Data Packages that are available for Sailors on the Joint Technical Data Integration site,” said NAVSEA Additive Manufacturing Assistant Program manager Lewis Shattuck. “These parts have been identified by NAVSEA engineers and the fleet to address a variety of needs including standard or preventative maintenance, temporary replacements, quality of life products, drill props, tools and fixturing.”

Behind all of this innovation and technology in Defence, however, is often a passion to serve and protect one’s country. I gauged this passion for work and country when speaking with Nick Owen from Secure Bits.

“Australia, sovereign manufacturing, sovereign capability and Defence are all things we are passionate about,” he said.

“With almost 50 per cent of our team being veterans, it’s well ingrained that we are those sorts of people – we believe in what we do and who we do it for. We are a little selective with customers, we want to work with people who are passionate about an end goal rather than just making widgets.”

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Events Gearing up for EMO Hannover 2023

The world’s largest trade fair for production technology is back with a bang for 2023.

Manufacturers’ Monthly finds out what is shaping and moving industry and the latest trends in technology for manufacturers.

E

MO Hannover 2023 will welcome over 1600 exhibiting companies and more than 116,000 professional attendees both in Hannover and digitally. The show is moving towards the theme of “innovate manufacturing,” reflected by a new format focused on cross-sector communication.

In September this year, production experts will learn about the latest in industry technology, with four joint booths focusing on additive manufacturing, connectivity, open space cobot solutions, and sustainability.

Martin Göbel, Director Exhibitions at the EMO organiser VDW (Verein Deutscher Werkzeugmaschinenfabriken, or German Machine Tool Builders’ Association) in Frankfurt am Main, knows the value of a visit.

“Nowhere else can production specialists experience the sector’s innovations so close up – presented in

thematic packages over the entire process chain, and up to date at all times,” he said.

“So, if you’re coming to EMO Hannover 2023 in September, you shouldn’t miss out on the joint booths.”

Innovative 3D printing as a fixed constituent Whether in aircraft construction, medical engineering, or the hydrogen economy – additive manufacturing methods are becoming more important to production.

And the business prospects are good.

A survey among around 200 member companies of the Additive Manufacturing Working Group within the VDMA (Verband Deutscher Maschinen- und Anlagenbau, or German Engineering Federation), found almost three quarters of companies are expecting an upward tren in the next 24 months.

However, the technology can only utilise its full potential when it

is integrated successfully in highly automated industrial process chains.

This will be demonstrated in the Additive Manufacturing Area, where companies will be presenting pioneering concepts from the whole bandwidth of the additive process chain, whether direct and indirect 3D printing technologies, engineering materials, or rapid product development (RPD).

Connectivity of production processes at a glance In digital production, machines must be able to communicate with each other, irrespective of their make, age, or controller. The Future of Connectivity Area focuses on these processes. Here, visitors will encounter new applications, automation processes, smart production, Industry 4.0, machine learning, predictive maintenance, IIoT (Industrial Internet of Things), as well as many other

aspects of connectivity. The editorial series Future of Connectivity will also be reporting on these subjects in the run-up to EMO Hannover.

Humans and robots working hand in hand More and more companies are investing heavily in automation to maintain their productivity and competitive strength, to augment their resilience and versatility and to keep pace with growing demand.

For instance, the number of new industrial robots installed in 2021 exceeded the 500,000 mark for the first time. Cobots, or collaborative robots, are particularly in high demand, already making up 7.5 percent of all installed industrial robots.

The Open Space Cobot Solutions Area is fully dedicated to the interactions between humans and industrial robots and their actual and potential applications. Manufacturers will present to an international trade public their automation solutions based on cobots and their innovative use: grippers, image processing, measuring systems, software, industrial electronics, feed systems, and much more can be experienced up close.

Sustainability to underlie tomorrow’s production

Image credit: Trumpf Artificial intelligence can be harnessed for efficient production.

46 JUNE 2023 Manufacturers’ Monthly

The declared goal of the 2015 Paris Agreement is to limit the rise in the mean global temperature to a maximum of two degrees Celsius. Since that announcement it has become clear that the subject of sustainability is seen as a challenge of global imports affecting society as a whole.

Among other intentions, the European Union has resolved as a result to render its economy and society carbon-neutral by 2050. The manufacturing industry too is feeling the considerable effects, and sees itself faced with equally imposing challenges and opportunities.

At EMO Hannover 2023, the Future of Sustainability in Production Area provides the ideal environment for experiencing the latest solutions for tomorrow’s production. Here visitors can learn about the current trends in energy efficiency, manmonthly.com.au

Events EMO Hannover and the German Machine Tool Builders’ Association explaining the concept of the Trade Show in Toronto, Canada.

Overcoming skepticism among SMEs Image credit: Deutsche Messe AG

the integration of renewable energies, circular economy, and lifecycle concepts.

The exhibit reveals plans for climate protection and reduced production costs in times of persistently scarce energy and raw materials.

From the research lab straight to the shop floor Artificial intelligence (AI) for efficient production – An important technology is moving from the research lab into daily use. Not fast enough, perhaps, in the view of those hoping to gain a significant competitive edge from AI. Rather sinisterly in the view of others who currently only have a vague idea of how self-thinking machines could change

their everyday working lives. In the “Future of Business” focus topic at EMO Hannover 2023, experts will be answering urgent questions about new business and working methods. Meanwhile, German universities are supporting AI by convincing local companies to implement AI applications, and by preparing employees to perform new tasks.

ProKI (ProAI), is playing a crucial role here. This is the name of an initiative launched by the WGP (German Academic Association for Production Technology) at the end of last year. Backed by 17 million euros of funding provided by the BMBF (Federal Ministry of Education and Research), a nationwide demonstration and transfer network is being set up

Image credit: Deutsche Messe AG

The world of metalworking meets at EMO Hannover.

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at a total of eight locations to provide practical support for the implementation of AI solutions in industry. The initiative is coordinated by the WZL (Laboratory for Machine Tools and Production Engineering) at RWTH Aachen University.

Taking part are institutes in Berlin, Darmstadt, Dresden, Hannover, Ilmenau, Karlsruhe and Nuremberg. In line with their respective research focuses, they are providing demonstrators and test environments for manufacturing companies in the fields of joining, forming, machining and coating.

A wide range of services provided free of charge to companies “Each individual site is basically autonomous,” explained Christian Fimmers, coordinator of the ProKI network. “But they are in constant touch with each other.” A common brand will be set up with the same training formats, and there will be a website and social media activities aimed at achieving the greatest possible reach and maximum awareness. The services offered range from information events, personalised consultations, workshops and seminars through to practical support for companyspecific projects. Participation is free of charge for companies. The overriding goal is to provide a point of contact for as many companies as possible with an interest in AI – especially small and medium-sized enterprises (SMEs).

The institutes involved in this event include the PtU (Institute for Production Engineering and Forming Machines) at TU Darmstadt. Christian Kubik, head of the Process Chains and Plants department, serves as the Centre’s managing director and said more than 80 companies registered to take part in the first ProKI InfoPoint in Darmstadt. “The interest is there,” Kubik noted.

However, there is a certain amount of apprehension, especially among SMEs. This is reflected in scepticism about the technology, fears of losing control, a lack of expertise, and the fact that the ROI (return on investment) is not always easy to determine. The ProKI InfoPoints now take place online once a month.

They last one hour and are divided into three 15-minute keynote presentations from academia and industry. The topics illuminate different angles of how the use of AI technologies can improve companies’ internal KPIs. Once interest has been aroused, a personal consultation is arranged. Opportunities for AI solutions are then explored. Finally, a visit is paid to the company. “Our motto is: Less talk and more action,” Kubik emphasized.

For many SMEs, the topic of artificial intelligence not only opens up new possibilities, but also brings new problems, at least initially. This applies to the development of a digital infrastructure for the factory as well as to employee training. “This, of course, raises the question of whether it makes sense to give a key production worker half a day off for training,” Kubik admitted.

The time factor, he said, is a major hurdle, especially nowadays with the increasing shortage of skilled workers. Here, it is important for the initiative to show the necessary sensitivity, to determine the exact cost-benefit ratio and also to show how it is possible to take small steps in adopting the new technology. “The companies which are convinced and are really keen are already sending us their staff,” Kubik said. Enhancing employees’ skills is the order of the day.

Visitors to the event can purchase ticket on EMO’s website: visitors.emo-hannover.de/en/for-visitors/tickets/ Manufacturers’ Monthly JUNE 2023 47

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Compressors

An Atlas Copco GA 180-315 VSD+.

Thriving under pressure Atlas Copco’s GA range of oil-injected rotary screw compressors is breathing life into a variety of industries.

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LTIMATELY, contaminated air creates more cost for manufacturers. Product spoilage, maintenance and replacing pipe work or leakages can have disastrous consequences to a businesses’ hip pocket, which is one of the reasons why Atlas Copco product manager Dillon Smith calls compressed air the fourth utility after water, electricity and gas.

Just as companies scrutinise their choice of electricity provider, it’s essential to be choosy when it comes to finding the right air compressor system.

Enter Atas Copco’s premium range of GA oil-injected rotary screw compressors.

“With up to 80 per cent of a compressor lifecycle cost coming from the

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energy it consumes, this is a clear focus area of ours – and the mining industry,” Smith told Manufacturers’ Monthly.

“The GA range of compressors include highly efficient oil-cooled iE4 and iE5 motors, providing energy savings compared to less efficient motors.”

The GA VSDs has a 21 per cent higher Free Air Delivery than its fixed-speed counterparts. This means that for the same power you get 21 per cent more air, which saves on investment and operational costs.

The GA range has several smart features which allow it to adapt and optimise its performance to each customer’s applications, requirements, and conditions. An important example

is the Smart Temperature Control (STC) system, which ensures that the compressor operates with an optimal oil temperature at all times. As a result, it eliminates the risk of condensation in the oil while ensuring maximum compression efficiency.

“With a VSDs, customers can save on investment and operational costs,” said Smith. “Many can buy a lower kW model and still get the air they need. And they can save on service costs thanks to its intelligent features.”

The unit introduces several smart features that allow it to adapt and optimise its performance to each customer’s applications, requirements, and conditions. The most important

example is the Smart Temperature Control (STC) system, which ensures that the compressor operates with an optimal oil temperature at all times. As a result, it eliminates the risk of condensation in the oil while ensuring maximum compression efficiency.

“This first time you can call a compressor smart, and Atlas Copco is all about being the first in innovation – the product not only adapts to the circumstances which the customers operate,” he noted “They don’t always have the same use for compressed air – the VSDs adapts to the air demand profile of the customer, it also adapts its oil injection temperature to the optimum point not only changing the speed of the Manufacturers’ Monthly JUNE 2023 49

Compressors GA compressors lead the changing efficiency needs of different industries.

cooling fan but using the STC system. And it is constantly monitoring the condensate in the air produced by the compressor in the smart drain. When you put all those features together that is what that makes it unique.”

The GA range of compressors owes its flexibility in part to the attention Atlas Copco gives its customers.

“We work with the customer to first of all understand their application needs,” Smith said. “From there we work backwards to understand how much compressed air and what pressure is required for the application.

“We then look at our range of compressors. Each compressor, depending on its kilowatt size, will give you a flow of compressed air at a certain pressure so we ensure that we match the correct compressor with the correct application.”

Atlas Copco is also helping clients hit their environmental, social and governance (ESG) targets. By working with its customers to determine the best type and number of air compressors, manufacturers can optimise energy usage and lower emissions.

Compressors account for one-tenth of industrial electricity consumption worldwide. Atlas Copco has a powerful role in reducing energy use and the associated pollution. Customers worldwide who use Atlas Copco’s advanced, energy-efficient compressors are significantly shrinking 50 JUNE 2023 Manufacturers’ Monthly

their carbon footprint. Many have slashed their CO2 emissions by more than half using innovative Atlas Copco technologies such as: • 100 per cent energy recovery compressors • Variable speed drive compressors (VSD) – saving up to 60 per cent on total energy costs Regardless of the industry, Atlas Copco has effective and efficient solutions for compressed air, oxygen and nitrogen generation applications.

Innovation and technological progress are key to finding lasting solutions to both environmental and economic challenges.

Companies are re-imagining how to create and capture value in this new environment, and Atlas Copco is leading the way. With 150 years of history, Atlas Copco knows the industry’s needs through and through.

“Generally, air compressors require infrastructure such as fixed services, concrete pads, or buildings, but you don’t always have that luxury in more isolated environments such as mining,” Smith said.

“Applications shift in location, and so does the need for compressed air.”

To address this issue, Atlas Copco offers a purpose-built 1000-volt air compressor mounted on a heavy-duty skid frame, making it both durable and mobile.

Tough conditions represent another equipment challenge for manufacturers and engineers. Dust build-up and

temperature can take a toll on the best of motors, which is why Atlas Copco’s GA range of compressors are built strong.

“The GA range comes with IP66 protection on the oil-cooled motor and screw element, so unlike a lot of standard electrical motors – which are cooled via air – Atlas Copco’s GA compressors have an oil cooled motor which keeps the temperature lower in hot ambient conditions,” Smith said.

“That means they are perfectly suited to our harsh, dusty and hot conditions, as they prevent dust or moisture ingress which can prevent early failure.

“Atlas Copco’s premium range of GA compressors can also operate 24–7 in temperatures up to 55°C.” Being an original equipment manufacturer (OEM) means Atlas Copco has the correct solution for each application so the company can tailor its compressors to suit varying needs. It also means the company has a dedicated research and development division to ensure its products are efficient and reliable.

“We’ve worked very hard on producing these GA compressors to ensure that their service downtime is minimal. One example of that is the filter type cartridges we use within the machine for the oil and air separator,” Smith said.

“Replacing this part would usually take a full day depending on the size of

the compressor, but now we can reduce maintenance downtime substantially, meaning greater uptime for the site and operation.”

Atlas Copco compressors also come with the option of a remote energy and maintenance monitoring system called SMARTLINK. “SMARTLINK allows the customer to view how the compressor is operating in real time and provide information via various sensors such as operating temperature,” Smith said.

“This also gives us at data we need on our end to provide updates to our customers, which helps us schedule maintenance.”

And when it comes to maintenance, Atlas Copco has a nation-wide network of factory-trained technicians ready to help at a moment’s notice.

“Being an OEM, our technicians understand our products fully and have the capabilities to service and maintain all products in Atlas Copco’s range,” Smith said.

“A strong local stock of our genuine parts ensures reliability compared to after-market spares. We also locally stock a range of compressors and equipment to support our customers ensuring minimal disruption to our customers operations.

“If customers have a catastrophic failure, we’re able to act very quickly to supply a replacement compressor or item of equipment to quickly and efficiently get the site back into production.” manmonthly.com.au

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What’sNew Xxx Neousys Releases a Market-leading Intel® 13th/ 12th-Gen Edge AI Platform Supporting an 130W NVIDIA® RTX™ GPU Neousys Technology announced its Nuvo-9160GC, a wide-temperature edge AI platform

with superior CPU and GPU performance by leveraging Intel’s 13th/ 12th-Gen platform and an Xxx 130W NVIDIA® RTX™ GPU card.

Benefiting from the cutting-edge Intel® 7 photolithography, Intel’s 13th/12th-Gen processors can offer up to 24 cores/ 32 threads with 2x the performance improvement compared to previous Intel 11th/10th-Gen platforms, and the latest 130W NVIDIA® RTX™ GPU contributes up to 9 TFLOPS of FP32 performance to fuel real-time AI inference analytics applications for multiple cameras.

Nuvo-9160GC inherits a tested and proven thermal design to guarantee reliable system operation from -25°C to 60°C. The passive-cooling design is coupled with an in-house designed motherboard circuit that strategically disperses heat-generating components, and a patented Cassette module to segregate and ventilate the 130W NVIDIA® RTX™ GPU card. The system has six onboard GbE ports and six USB 3 ports. With the patented MezIO® expansion, Nuvo-9160GC can support up to ten GigE or USB 3 cameras in a compact architecture, making it ideal for consolidating and miniaturizing multiple camera visionbased platforms.

Featuring true wide-temperature operation, rich camera connectivity, and flexible expansion, Nuvo-9160GC is ideal for robotic guidance, autonomous mobile robot (AMR), intelligent video analytics or teleoperation in forestry and construction industries.

Company: Neousys Technology Phone: +886-2- 2223-6182 Website: www.neousys-tech.com/en/

SecurityBridge industrial firewall The SecurityBridge industrial firewall by Pilz is a product that offers industrial security that protects industrial automation networks from manipulation and unauthorised access. sector. The firewall guarantees the safety of your staff and the availability of your machine by protecting it against cyberespionage and manipulation.

The SecurityBridge firewall now provides complete protection for industrial automation networks thanks to its updated firmware. In addition to safeguarding the automation system PSS 4000 and the adjustable safe small controllers PNOZmulti, it now permits control over data transmission between any additional subscribers outside of the Pilz range. The SecurityBridge was created in compliance with the secure development methodology as outlined in IEC 62443-4-1 and follows the principle of “Zones and Conduits”.

The extensive diagnostic features now include “packet recording”. This can be used to capture data transmissions between subscribers on the unsecured network and the protected controller network. Recording can be restricted to specific communication interactions to enable you to analyse data more efficiently. That saves you valuable time during diagnostics!

The SecurityBridge industrial firewall also ensures that only authorised persons have access to the plant via the network. As a firewall, it keeps an eye on correspondence with the controller and manages data flow. Moreover, SecurityBridge can be used to hold user permissions, which specify which employees have access to which types of information.

How it works: The PNOZmulti base unit, the PSSuniversal PLC controller, and any other subscribers outside of the Pilz range can all be linked upstream to the SecurityBridge. As a result, the connection between the PC and the device is secure. Changes to a project’s configuration can only be made by users with relevant permissions which prevents unauthorised access to the secured network. This protects the data transmission between Client PC’s and SecurityBridge’s from tampering and manipulation.

Additionally, the SecurityBridge controls the process data traffic and monitors the integrity of the safety system. Changes to the checksum provide information about changes to the projects in the controller project.

Benefits at a glance: • •

Developed in accordance with the standard IEC 62443-4-1 Simple to install, no need to adjust the network parameters

52 JUNE 2023 Manufacturers’ Monthly

• • • • • • • •

VPN connection with role-based user management Configuration changes can only be carried out by authorised users Increased availability, as only data from permitted communication relationships is approved Process data is forwarded in wire speed with low latency for time-critical applications Detects unauthorised changes to the project by verifying the check sum (CRC) Comprehensive diagnostic functions Simple to configure via a web-based user interface Continuous updates are functionally feedback-free for the protected control system

Company: Pilz Australia Phone: 1300 723 334 Website: www.pilz.com/en-AU manmonthly.com.au

What’sNew BOXER-6645-ADS Fanless Embedded Box PC with 12th Gen Intel® Core™ i3/i5/i7/i9 Processor Interworld Electronics is excited to introduce the BOXER-6645-ADS rugged fanless Embedded Box PC from AAEON. The BOXER-6645-ADS contains exceptional processing capabilities of up to 16 cores and 24 threads with 12th Generation Intel® Core™ i3/i5/i7/i9 Processor platforms, providing limitless potential for applications that demand high-performance computing, alongside a rich I/O featuring four independent display interfaces and multiple LAN ports within a rugged, fanless chassis.

The BOXER-6645-ADS is built to withstand harsh environments, including extreme temperatures (-20°C ~ 60°C), shock, vibration, and humidity. The system is housed in a durable aluminium fanless chassis that protects it from dust and other environmental factors. Along with its wide 12~24V power input range, the BOXER-6645-ADS is ideal for continuous operation in the most extreme deployment environments.

The BOXER-6645-ADS is one of the most well-equipped Embedded Box PCs available, with up to eight 10Gbps USB 3.2 Gen 2 slots for high-speed peripherals, four LAN ports for camera and sensor connectivity, and four independent display outputs, making the BOXER-6645ADS conducive to applications such as traffic management control rooms. Additionally, it is equipped with the latest M.2 expansion capability, housing M.2 2230 and M.2 2252 slots to facilitate both Wi-Fi and 5G modules. This abundance of I/O support makes the BOXER-6645ADS stand out from the competition, and makes it an ideal option for industry 4.0 applications.

The BOXER-6645-ADS also comes with a tapestry of integrated peripheral technologies, including Intel® DL Boost, Time Coordinated Computing, Enhanced SpeedStep® Technology and Intel® Iris® Xe Graphics to enable elite AI inferencing performance.

Complementing its power and ruggedness, the BOXER-6645-ADS also offers incredible speed via a dual-channel SODIMM slot supporting DDR5 4800MHz, providing a 50% increase in bandwidth and data rate transfer speed. This low-latency transmittance capability alongside display interfaces, such as HDMI 1.4b and DP1.4a ports, make the BOXER-6645-ADS an excellent candidate for deployment as an edge-server for IoT Gateway use.

Key Features: • • • • • • • •

Intel 12th Gen Desktop Processor Built-in high-performance Intel Iris Xe Graphic Engine Dual-Channel DDR5 SODIMM, Total max. 64GB Support Quadruple Independent Display (HDMI x 2, DP x 2) Support SuperSpeed+ USB3.2 Gen2 10Gbps x 8 (A2) Support M.2 3052 for 5G Module Support Quadruple LAN (GbE x 3, 2.5GbE x 1), vPRO and iAMT Onboard TPM 2.0 For more information contact Interworld Electronics.

Company: Interworld Electronics Phone: 03 9593 7555 Email: ieci@ieci.com.au

moneo: the IIoT platform for industry and production Has your business unlocked the value of predictive maintenance? Are you harnessing the benefits that come with live stream analytics? The modern plant needs more than condition monitoring to ensure assets are healthy and meeting production demands. To protect, you need to predict. The IoT moneo platform from ifm is a self-service tool that enables successful predictive maintenance programs through the help of artificial intelligence.

Moneo comprises a package of both software and hardware so that you can start monitoring equipment straight away. Its modular structure means it can be tailored and easily built upon to suit your plant’s individual requirements and ‘grow as you know’. As an IIoT platform, ifm moneo combines the level of operation technology with the level of information technology. The sensor data generated in the production plants can be read and processed easily and used as a basis for sustainable corporate decisions. Moneo also analyses the sensor data and detects deviations. If a machine isn’t running how it is supposed to, this may indicate that there is wear or changes that could lead to failure.

Moneo will be able to pick up this deviation and alert you before it’s too late.

Moneo’s modular concept provides a selection of different, easy-to-handle applications that can be linked together. From sensor parameter setting to condition monitoring, moneo offers all the features of a future-proof IIoT software. For over 50 years, ifm has been supporting our customers as a leading supplier of automation solutions. We have now combined our experience in sensor technology with the expert knowledge of our software subsidiaries – this is moneo, “simply made for you”.

Company: ifm Phone: 1300 365 088 Website: www.ifm.com/au/en

manmonthly.com.au

Manufacturers’ Monthly JUNE 2023 53

The Last Word

TIM ODOKEYCHUK – President, AME Australia

Total Productive Maintenance holistically addresses equipment and maintenance management.

Making The Most of It: Reactiveness to Reliability

O

NE of the most common barriers to optimising your manufacturing facility’s productivity is the effective design, use and reliability of your equipment.

Many of the operations I am invited to visit have obvious challenges towards keeping their plant and equipment safe and in the best possible condition to produce the best possible quality (let alone increasing its lifespan and throughput with deliberate improvements).

The evidence of less-than-desirable performance does not take a trained sleuth to uncover: volumes of idle workin-process inventory are sprawled across the facility, team members are acting as triage staff and fire-fighters, and ‘Leaders’ invest more time in continual rework of the production schedule and appeasing disappointed customers than solving problems and developing their teams.

Traditionally, you can categorise the losses resulting from breakdowns, issues with setup and adjustments, minor equipment stoppages, speed reductions, reworking of defectives and losses at startup and shutdown.

Having reliability in your equipment

54 JUNE 2023 Manufacturers’ Monthly

resources is essential along your pathway to growth, not to mention a means to create stability for your team to invest their time in value-adding activities – which is what they’ve been engaged to do in the first place.

In other words, it’s not an option. If you find yourself in a reactive situation, it certainly doesn’t have to be or stay that way.

This vicious cycle can be avoided or broken if there is a deliberate effort made to address the root causes of the unplanned downtime, critical failures and lost capacity by diverting efforts from reactiveness to instead developing and protecting a disciplined process while resourcing the necessary focused improvements.

Back to Basics – A Need for a Total Productive Maintenance Perspective Many of you reading this would’ve heard the terms “proactive”, “preventative” or “predictive” maintenance.

These are of concepts and methods contained in the systematic approach of Total Productive Maintenance (TPM), which is a framework that holistically addresses equipment and maintenance

management yielding several benefits.

The systematic approach of a TPM program promotes a culture of safety in the workplace by engaging operators to identify and addressing potential safety hazards associated with their equipment which they’re intimately familiar with and work with engineering and OEM resources to reduce their risk, if not eliminate them altogether.

Further to this, TPM helps to identify and eliminate equipment problems before they become major issues. By implementing maintenance routines, identifying & removing potential failure points found from deliberate audits, leveraging visual management disciplines for schedule adherence and issue resolution, equipment reliability can vastly improve impacting overall equipment effectiveness (Availability, Productivity, Quality). With greater uptime and reduced loss, more time is spent on meeting customer needs increasing throughput resulting in higher profitability. In addition to mitigating start-up, shut-down and changeover loss through effective TPM practices, routine & preventative maintenance activities will cost significantly less than

major breakdowns. Also, with equipment available and operating at peak efficiency, energy costs are reduced.

From the 1960s, TPM has evolved to include a framework of eight pillars developed by the Japan Institute of Plant Maintenance (JIPM), each designed to address a specific aspect of equipment and maintenance management and ultimately providing a framework for improving equipment reliability, reducing downtime, and increasing employee engagement.

So, what are the pillars and what is the aim behind each of them?

1. Training and Education (TE): Involves the development of employee skills and knowledge. By providing training and education to employees, they can better understand the equipment they are working with and take a more proactive role in maintenance and quality improvement. This often requires support from the Original Equipment Manufacturer or Subject Matter Experts who have deep experience with the technology being used.

2. Autonomous Maintenance (AM): Involves empowering operators manmonthly.com.au

to perform routine maintenance tasks on their equipment to prevent breakdowns and reduce the need for specialised maintenance personnel.

3. Planned Maintenance (PM): Involves developing a maintenance plan based on the actual and/or expected condition of the equipment. Activities are scheduled in advance and performed according to a plan that minimises downtime and maximises equipment reliability. This often requires its own production system to ensure part availability just-in-time.

4. Quality Maintenance (QM): Involves the prevention of defects and quality issues through root cause analysis and the elimination of those causes through planned containments and countermeasures. This effort of continuous improvement to ensure quality from the perspective of the customer is essential for any manufacturer competing for growth.

5. Early Equipment Management (EEM): Involves the design and development of new equipment to ensure that it is easy to maintain, reliable, and cost-effective. The goal is to minimize the need for maintenance by designing equipment that is less prone to failure.

6. Safety, Health, and Environment (SHE): Involves ensuring a safe and healthy workplace for employees, as well as minimizing the impact of manufacturing operations on the environment. By prioritizing safety and environmental concerns, businesses can improve their reputation and reduce their risk of liability.

7. TPM in Administration (TPM in Admin): Involves applying TPM principles to the administrative functions of the business. By streamlining administrative processes and reducing waste, businesses can improve their efficiency and reduce costs.

8. TPM in Engineering (TPM in Eng): Involves integrating TPM principles into the design and development of new products and processes.

By considering maintenance and reliability during the design phase, businesses can create products that are easier and more cost- effective to maintain.

For anyone, there’s a lot to absorb manmonthly.com.au

across this entire domain but you shouldn’t be overwhelmed as with most journeys, the walk before your run mindset is needed to take the initial incremental steps to build a foundation then expertise is needed.

Subheader Building Up to Effective Total Productive Maintenance In an early career transformation journey, a few years into our efforts after settling some system-wide improvements into practice, we saw that adopting a holistic TPM approach as principles of engagement and improvement across our facility would be the next phase to raise our plant performance and flexibility.

An essential prerequisite of introducing TPM was stabilising our production system and investing in an improved layout for better material flow.

In the early days, ceasing mass firefighting gave us capacity to make a commitment to workplace organisation or 5S – ensuring that we had a system to engage everyone, everywhere, every day to ensure they had what they needed, when they needed it to perform their best and maintain standards that were foundational for their enjoyment in work.

When we were confident that this was maturing, we chose to take the next step with the introduction of TPM in a simple form – we provided basic training to create awareness of what it was, why it was important for us and was inclusive of everyone from the Senior Leadership Team, Line Managers and every Operator in the plant.

Theory does not yield benefit without practice however, so a small-scale learning-through-doing activity was done to gain an appreciation for where our actual equipment performance was as well as to develop an initial TPM introduction process that worked for us.

While doing this, we reinforced the commitment we were making by having site leadership involvement from the outset - imagine the sight of having a General Manager taking part in a planned machine tear down over a scheduled break to inspect, regreasing essential components and generating improvement ideas with operators in a plant of 500+ Team Members!

The early adopters in these smallscale activities became promoters of TPM because they simplified their work and improved their personal safety.

As it created an area where the ‘next

Designing and implementing a TPM program must be tailored to the needs of a business. majority’ can come to learn from, this was a strategy that played out well to then expand adoption of TPM across the plant.

Peer accountability played an enormous role in evolving the maturity of our TPM effectiveness. To continue the momentum, cross-area audits and sisterplant visits assisted in raising standards and sharing best practice across the broader organisation. It also helped with ensuring commitments were made and kept towards what progress would be on display the next time we came together.

From here, trusting that our team members knew their process and equipment the best, we ensured the “process owners owned their process” while we maintained the role of coaching and support and were able to spend more time on other pillars of TPM including improved equipment design and administrative improvements.

But this is one example and like most methods, concepts or frameworks, it is important to keep in mind that implementing a TPM program is not a one-size-fits-all solution.

Each manufacturing facility is unique, and the approach to designing, resourcing and building discipline for a TPM program should be tailored to the specific needs of the business and its context.

For example, a facility that operates 24/7 will have different maintenance requirements than a facility that operates Monday to Friday. A food & beverage business will have significantly

different requirements to a metal parts manufacturer and again to those producing pharmaceuticals or medical devices.

Adopting TPM – Prepare the Process, Resource the Activity, Build in Discipline Creating TPM maturity also requires a long-term commitment and ongoing effort to maintain and improve equipment reliability. It is not a quick fix however the benefits of TPM far outweigh the time and effort required to implement and maintain the progress.

If you’re seeking to improve your plant reliability through TPM, Management must be committed to the program and provide the necessary resources, including time, funding, and personnel.

All areas and levels of the organisation need to be involved and there must be a shared reason for investing their focus and time into the journey – they must be trained and engaged in the program and the TPM team must be empowered to make decisions and implement changes as needed with clear guidelines that are set out in a project charter.

With your long-term commitment, the right knowledge and support, your team can successfully to work out of a reactive situation by stabilising its systems and augment its reliability, safety and team engagement through a holistic TPM approach giving you the edge to succeed on your pathway to excellence.

“The busier you are, the more you need TPM.” – TPM for Every Operator, Productivity Press / JIPM Manufacturers’ Monthly JUNE 2023 55

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