Manufacturers' Monthly August 2023

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AUGUST 2023

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Exploring the DN range of machine tools

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Manufacturers’ Monthly Contents­­­­­­ 4 Editor’s Note

41 Industry Events

8 Comment

42 Women in Industry

13 News

44 Grinding and Metalwork

22 Manufacturer Focus

46 Predictive Maintenance

26 Machine Tools

49 Events

30 Additive Manufacturing

52 Engineering Focus

32 Aluminium Certification

56 What’s New

34 Additive Manufacturing

58 Last Word

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2 AUGUST 2023 Manufacturers’ Monthly

Technology in industrial sectors has thrived in the post pandemic era with much innovation happening globally. We are pleased to feature in this edition some of our partners’ new technologies that they have announced recently.

In this month’s Manufacturer Focus, the Manufacturers’ Monthly team toured the facilities at ActionLaser in Sydney, who recently completed its project with the Advanced

Future Filters The

Behind the cover Manufacturing Growth Centre (AMGC), learning the ins and outs of the company and what is driving its success both locally and globally, and how it is improving filtration technology.

Also in this edition, additive manufacturing specialist, Markforged, who featured new products at the recent AMW 2023, shares their 10-year milestone journey with us. Read all about it in this edition.

Official Industry Partners

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34

52

Exploring the DN range of machine tools

10 years of Markforged

Using a household item to solve climate change

>>

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Editor’s Note

JOSH FARRELL – Editor, Manufacturers’ Monthly

Industry improving ability to protect against ransomware

W

ITH the headaches that come with end of financial year well behind manufacturers, many are beginning to return to long standing projects and processes that are in need of attention or improvement.

One major focus is cyber security and how businesses can better protect themselves against ransomware attacks.

According to Statista, more than 493 million organisations were affected by ransomware attacks in 2022.

Sophos recently completed its sectoral survey report titled, “The State of Ransomware in Manufacturing and Production 2023”. The report found that 68 per cent of ransomware attacks against our sector saw the adversaries successfully encrypt the data.

While the initial statistic is worrying, the instances of company’s using backup systems to recover this data has grown from 58 per cent to 73 per cent.

Seventy-seven per cent of manufacturing organisations reported lost revenue as a result of these attacks.

Field CTO at Sophos John Shier commented on what manufacturers have been doing to get data back.

“Using backups as a primary recovery mechanism is encouraging, since the use of backups promotes a faster recovery.

While ransom payments cannot always be avoided, we know from our survey response data that paying a ransom doubles the costs of recovery,” he said.

Shier noted that longer recovery times in manufacturing are a concerning development.

“As we saw in the Sophos report, based on incident response cases, the manufacturing sector is consistently at the top of organisations needing assistance recovering from attacks,” Shier said.

“This extended recovery is negatively impacting IT teams, where 69 per cent report that addressing security incidents is consuming too much time and 66 per cent are unable to work on other projects.”

While hearing all of these statistics can be scary, there are numerous ways to protect a business from these attacks.

Sophos experts recommend the following: • Strengthen defensive shields with: • Security tools that defend against the most common attack vectors, including endpoint protection with strong anti-

exploit capabilities to prevent exploitation of vulnerabilities, and Zero Trust Network Access (ZTNA) to thwart the abuse of compromised credentials; • Adaptive technologies that respond automatically to attacks, disrupting adversaries and buying defenders time to respond; and • 24/7 threat detection, investigation, and response, whether delivered in-house or by a specialist Managed Detection and Response (MDR) provider.

• Optimise attack preparation, including making regular backups, practicing recovering data from backups and maintaining an up-todate incident response plan • Maintain good security hygiene, including timely patching and regularly reviewing security tool configurations.

Businesses will need to consistently evolve the IT systems on site and within its team to protect the company from virus and ransomware attacks.

While the threat of ransomware may send fear through an organisation, it

is still an intriguing time to be in the manufacturing space.

The August edition of Manufacturers’ Monthly is an exciting read with a strong focus on additive manufacturing in Australia.

It starts with comments from industry expert Dr Daniel East to give a snapshot of additive manufacturing and what the future may hold locally.

Further into the magazine, the Manufacturer Focus will look at ActionLaser, who is exporting over 80 per cent of its filtration products to international markets.

From there we look at Hare and Forbes Machinery House and the DN range of machine tools, and Titomic’s range of cold spray additive manufacturing systems.

We also look at SEMMA – who is celebrating its 20th year – as well as the recent Women in Industry awards, where we spotlight two winners fromthe manufacturing sector.

Finally, in Engineering Focus, we examine how a common household item is helping to combat climate change.

See you next month.

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C 1 4 AUGUST 2023 Manufacturers’ Monthly

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Industry, government and statutory bodies work together to improve welder safety outcomes nationally

I

Weld along with the government are working hard to improve safety around ingesting of fumes.

8 AUGUST 2023 Manufacturers’ Monthly

NDUSTRY, government and statutory bodies are working together to ensure that appropriate strategies are in place to reduce welder exposure to fumes and prevent long-term health effects.

Established by Weld Australia in early 2019, the Welding Safety Council provides a forum for industry and legislative safety authorities to discuss issues and work collaboratively to identify solutions.

By drawing together key government stakeholders, statutory bodies and industry into a single independent body focused on eradicating welding-related injury, the Australian welding industry continues to take a significant steps forward in protecting both the general public and welders.

Recent media coverage has raised the issue of lowering the limit for exposure to welding fumes. In recent years, the welding industry has become increasingly aware of the hazards posed by metal fume produced during the welding process.

This fume, comprised of microscopic particles of hot metal and gases, poses serious risks when inhaled by welders.

In early 2017, the International Agency for Research on Cancer classed welding fumes as ‘Carcinogenic to Humans’.

However, when appropriate precautions are adhered to, risk of exposure is greatly minimised.

Welding can and should be considered a safe occupation; when proper precautions are taken, welders have no cause to fear accident or injury. But, when safety isn’t taken seriously in the workplace, the risk of a severe incident becomes a real concern.

It is vital that appropriate strategies are in place to reduce welder exposure to fumes and prevent the long-term health

effects that can result from exposure.

All welders should receive training on methods to mitigate the effects of metal fume, including positioning themselves to reduce exposure and investigating less toxic alternatives where possible.

Education is the key to ensuring a safe and productive working environment for everyone. Employers need to invest in thorough and up-to-date training for all their employees to ensure that they understand the risks associated with welding, the mitigation strategies they can use, and the equipment available to prevent accident and injury.

As the Responsible International Institute of Welding (IIW) representative in Australia, Weld Australia is at the forefront of global welder safety best practice. We regularly participate in international research and development programs designed to improve welding fume safety practices.

Local Exhaust Ventilation (LEV) systems capture and extract welding fume at the source and are a proven way of reducing exposure. All workplaces should have fit-for-purpose LEV systems installed and regularly maintained.

Powered air purifying respirators (PAPR) are also a proven method to minimise the welder’s exposure to welding fume in conformance with WHS regulations.

Initiatives to improve welder safety In collaboration with industry, Weld Australia has implemented a range of other initiatives to help improve welder safety.

Weld Australia has published a wide range of welding safety resources, which are available to the public completely free of charge.

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Fume minimisation guidelines: welding, cutting, brazing and soldering This Guide includes all the information required to help protect workers from the hazards associated with welding fumes.

Technical Note 7: Health and safety in welding This Technical Note gives guidance on health and safety practices in welding, cutting and allied processes such as brazing, soldering, pre- and post-weld material treatments, and metal spraying, for the prevention of injury, ill health and discomfort, as well as damage to property, equipment and environment by fire, and explosion.

Various chapters deal with: • Basic principles of safe working

• •

The main hazards and safety measures in welding, cutting and allied processes Precautions required in particular working situations

Technical Note 22: Welding electrical safety Although electric arc welding can be performed perfectly safely, there are circumstances when there is a substantial risk of electric shock. Precautions against this risk include use of properly maintained equipment, correct protective equipment and sound work practices.

With reference to Industry best practice, Technical Note 22 addresses how to safeguard a person against electric shock, reviewing elements such as: equipment, the human body, the workplace Australian Standards.

Weld Australia is currently developing two comprehensive online welder safety training courses. One course is tailored for welders, while the other is aimed at welding engineers and supervisors. These courses cover a raft of activities across a range of welding processes, from electric arc welding and flame cutting, through to topics like welding fume safety, and welding in confined spaces, at heights, or in hot and humid conditions. These courses will be completed towards the end of this year and made freely available via the Weld Australia website.

The Weld Australia website was recently reconfigured to enable the issue of Safety Alerts. These Alerts will draw attention to welding safety incidents, including the known causes of the

incident and what steps can be taken to help prevent similar incidents occurring.

Education is the key to ensuring that anyone who welds is safe. Employers, professional welders and DIY enthusiasts alike must invest in thorough and upto-date training to ensure an in-depth understanding of the risks associated with welding, the mitigation strategies that can be used, and the equipment available to prevent accident and injury. In 2023, Weld Australia’s goal is to help ensure every welder makes it home safely at the end of every day.

If you know someone who is welding without the proper training or experience, be sure to pass along Weld Australia’s free resources.

All of these resources are available via the Resource Centre on our website.

Improving safety is a high priority for Weld Australia.

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Manufacturers’ Monthly AUGUST 2023 9

Comment

DR DANIEL EAST – Group Leader, Advanced Manufacturing and Metals, CSIRO

Additive manufacturing: trends and opportunities

A

S the director of CSIRO’s Lab 22, Australia’s centre for additive innovation, I have witnessed the rapid and impressive growth of the additive manufacturing (AM) industry.

When we established Lab 22 in 2015, our primary goal was to introduce the pioneering technology of 3D printing to Australian companies and demonstrate its potential benefits.

From early inception to deep integration Since then, AM has evolved into a mature and thriving industry, embraced by Australian businesses across diverse sectors for its efficiency and effectiveness in production.

Aerospace companies have used AM to create lightweight and intricate parts, reducing costs and improving fuel

efficiency on the way. In healthcare, AM has been instrumental in producing personalised implants and prosthetics, leading to better patient outcomes.

Automotive businesses have adopted AM for rapid prototyping and parts manufacturing, expediting the design process. And consumer goods companies have leveraged AM to offer unique and customisable products, differentiating themselves in crowded marketplaces.

All these companies have benefited from AM’s ability to fabricate complex geometries, reduce lead times, minimise waste, and enable mass customisation, thereby driving efficiency, fostering innovation, and enhancing customer satisfaction.

These processes also open up the design window for components that may not have been manufacturable or economic through other processes.

A great example of this is metallic AM which has carved out its own market niche producing geometrically complex small parts, such as heat exchangers, biomedical implants, custom sporting goods, mixers, and production dies featuring conformal cooling channels.

Supporting stronger supply chains

CSIRO has been leading the development of additive manufacturing since opening Lab 22.

10 AUGUST 2023 Manufacturers’ Monthly

In the past few years, the growth of AM has accelerated even further, catalysed by disruptions caused by COVID-19 which exposed vulnerabilities in conventional supply chains.

Amidst the chaos, AM emerged as a versatile and modular production system, gaining recognition for its potential in distributed and point-ofuse manufacturing which can eliminate single points of failure. Here, AM offers resilience, reduces dependency on global supply chains and has become increasingly valued as an enabling technology.

This decentralised model of working is especially advantageous for Australian companies, given our remoteness from major manufacturing hubs in Asia and Europe. Remote sectors, such as defence, mining, resources, and agriculture, particularly stand

to benefit. These industries often face logistical challenges in accessing traditional manufacturing resources and spare parts.

Advances in large format printing The growth of AM has been supported by technological improvements and the capabilities of available equipment.

Of note is the expansion in the capabilities of larger format printers – particularly those leveraging robotic techniques. Such advancement has significantly impacted the size and complexity of the parts that can be manufactured, opening up many new applications and benefits.

Larger format printers with robotic armatures equipped with deposition heads allow us to produce much larger components than traditional AM systems.

This enables structures that previously couldn’t be produced in a single piece.

The result is an increase in structural integrity and quicker assembly times.

However, it’s not just about size.

These printers are ideal for creating less geometrically complex parts, which can be beneficial when functionality and structural strength are more important than intricate design.

Solid-state techniques gain prominence We have also seen a notable expansion of solid-state based techniques – or those that transform materials from a solid form into the final part without passing through a liquid phase. Benefits include reduced thermal stresses, less distortion, and the ability to process materials that are hard to melt or mix.

Fused filament printing is a very interesting solid-state process. It works by pushing a thin strand of heated plastic, called a filament, through a nozzle to build objects layer by layer.

This technique is commonly employed to produce intricate models, functional parts, and detailed prototypes.

Another innovative solid-state technique is friction stir AM which combines the principles of friction stir welding and AM to create strong and defect-free metal structures. manmonthly.com.au

Simulation and quality assurance advances engender trust With advancements in AM, we’ve seen a surge in interest in simulation and quality assurance methods. These are critical in ensuring the parts produced via AM meet the required standards of performance and safety, especially in high-stakes industries such as defence and for biomedical applications.

Techniques such as real-time monitoring of the AM process and advanced software tools for simulation are becoming more commonplace, which is promising for the continued growth of AM technologies.

CSIRO continues to drive innovation Here at CSIRO, we played a significant role in the driving the adoption of AM in Australia, and we continue our commitment to innovation in the industry to this day.

On the research front, CSIRO is spearheading various initiatives. Our large-format AM work, for instance, could allow mining companies to manufacture parts on site, unlocking productivity gains through reduced downtime. We’re also working on a range of software tools which could streamline and optimise the AM process.

I’m particularly excited about the software we are developing to generate robotic tool paths for repair and part manufacture. Our work on in-situ measurement is also notable, as this could provide immediate feedback on manmonthly.com.au

CSIRO is researching new ways to utilise AM including in the medical field by printing a sternum. the AM process, enabling real-time adjustments and improvements to ensure the highest quality outputs.

In addition to metallic parts, CSIRO is also exploring the frontier of functionally graded materials. These are parts made from a combination of different alloys or metals and ceramics within the same component. This brings a new world of possibility for AM, as it allows us to create parts with properties that can vary according to the specific requirements of different sections of the part.

Blazing a trail for AM’s future We are thrilled to be a core partner in the federally funded Trailblazer Universities Program an initiative aimed at supporting six Australian universities and their partners in becoming leaders in research commercialisation. Here, CSIRO will play a vital role by providing universities access to specialised AM equipment and expertise essential for their projects.

For instance, for the Resources Technology and Critical Minerals Trailblazer, led by Curtin University, we will acquire Binderjet printers known for their ability to achieve high-resolution

outputs in high-volume production.

These machines boast a faster production rate compared to other AM processes.

The initial Trailblazer project involves manufacturing parts for the SpiroPak technology developed at Curtin. SpiroPak increases the efficiency of chemical processes by using parts with a unique, nature-inspired geometry that improves mass transfer and reduces energy loss. CSIRO will support this work by researching methods to reduce the cost of manufacture of parts that can reliably be produced with the Binderjet process.

Another technology CSIRO will obtain with the Defence Trailblazer – Concept to Sovereign Capability, led by the University of Adelaide in partnership with UNSW, is the robotic laser wire deposition equipment, which can create large structures with higher resolution than wire arc AM, while still using costeffective wire feed instead of expensive metal powders. Laser processes offer greater control over heat input, making for better control of material properties. The initial project will focus on manufacturing aerospace parts from titanium alloys. Our research will explore the production of parts that are

larger than a metre, using materials that are traditionally challenging to fabricate through other techniques.

CSIRO will also acquire a material SLM laser powder bed, for work with The University of Southern Queensland, through the iLAuNCH Trailblazer for space research. This instrument is particularly suited for parts operating at high temperatures, allowing the incorporation of cooling channels within the structure using a copper surface for efficient heat conduction. Structural sections of the part can be joined with a different metal possessing higher strength. The equipment will be used for prototype production for components operating in extreme environments.

These acquisitions, along with other exciting equipment, promise to unlock more complex and diverse applications of AM, pushing the boundaries of what is achievable. We are thrilled to be at the forefront of this effort, driving innovation and propelling the industry into a promising future.

If you’d like to learn more about how additive manufacturing could work for your business, you can contact me at daniel.east@csiro.au.

Manufacturers’ Monthly AUGUST 2023 11

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News @MM Sicona acquisition to advance battery materials manufacturing Sicona CEO and cofounder Christiaan Jordaan announced this week the company had purchased a number of international patents and patent families developed by some of the world’s largest advanced materials companies.

He said these patents would cement Sicona as a “globally significant battery materials champion”.

In collaboration with fellow Australian battery technology company, Gelion, Sicona purchased the patents which have been under development and production

by US-listed, A$90 billion company, 3M, and the London-listed £ 9.2 billion company, Johnson Matthey, since 2005.

Gelion acquired the lithium sulphur patents owned by Johnson Matthey, and Sicona secured 73 patents and 11 patent families relating to silicon-alloy anode materials, electrode design, pre-lithiation

and associated intellectual property.

The original technology was developed at Dalhousie University by some of world’s foremost lithium-ion battery pioneers.

“It’s a major coup for Sicona to acquire this technology,” Mr Jordaan said. “For an Australian battery materials company to acquire what is considered some of the most advanced silicon anode materials technology is quite remarkable really.”

Jordaan said the technology was a “strategic investment” and will be complementary to the current silicon carbon products produced by Sicona.

“Tens of millions of dollars has been invested into this technology and the testing of these materials,” he said.

“This is silicon metal-based technology, which is the core of what we do at Sicona. We are cementing ourselves as the global leaders in silicon metal-

based anode technology.

“The silicon-alloy material is manufactured from the same raw materials we already use and is highly synergistic to us as an additional product in our product portfolio. Our team will now do further work on how to best utilise it.”

3M started work on the silicon anode technology in 2005 at Dalhousie University under the guidance of Professor Dahn and Professor Mark Obrovac.

In 2012, 3M announced a further investment in silicon anode materials in the form of a US$4.6million (matched) grant from the U.S. Department of Energy.

In January 2017, 3M sold its NMC cathode technology to Umicore to focus on silicon anodes but in 2019 completed

an exit from the battery materials sector through the sale of its silicon anode tech to Johnson Matthey.

In November 2021, Johnson Matthey announced it would be exiting its battery materials business.

“We are the beneficiaries of two major global companies electing to exit the battery materials industry at exactly the wrong time,” Mr Jordaan said.

“It’s a further step in our mission to become a globally significant battery materials champion. An Australian company now holds the keys to the castle on cost-effective, scalable silicon anode technologies.”

Recently, Sicona Battery Technology announced it had raised AU$22 million in Series A funding which will be used to further the company’s development plans both in Australia and the United States.

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Manufacturers’ Monthly AUGUST 2023 13

News @MM Government seeks public opinion for $392 million industry fund The Federal Government has taken another step towards launching the new Industry Growth Program (IGP) which will help SMEs get their great ideas to market and overcome barriers to scale.

A discussion paper launched today is asking how the program should be designed and operated to get the best outcomes.

The IGP will support small and medium-sized enterprises (SMEs) and start-ups to turn ideas into real products and businesses, particularly through earlier high-risk and high-cost phases.

The program will target priority areas under the Government’s landmark $15 billion National Reconstruction Fund including: • value-add in agriculture, forestry and fisheries • value-add in resources • transport • medical science • renewables and low emission technologies

defence capability enabling capabilities The program will help transform industry in Australia by providing expert business advice and matched grant funding to support enterprises to increase revenue, grow their workforce and attract investment.

Through the Industry Growth Program Discussion Paper, the Government is encouraging a wide range of views on the design and implementation of the program, such as diversity and inclusion, program governance and the eligibility of applicants and projects.

A new independent committee with expertise in commercialisation and industry growth will also be established to provide program oversight and recommendations to the Department of Industry, Science and Resources on projects to receive grant funding.

The discussion paper is available here and consultations close on 30 July 2023.

Minister for Industry and Science, • •

The Indsutry Growth Program will help SMEs overcome barriers to scale.

Ed Husic, said, “We are laying strong foundations for future economic growth and job creation through our $392 million Industry Growth Program.

“This is about supporting companies to navigate the difficult aspects of getting ideas to market.

“We’re particularly keen to help bridge the ‘valley of death’ – where great ideas, often backed by solid research, are

hamstrung only by a lack of funding and expertise.

“This consultation is about creating the right conditions to ensure brilliant Australian entrepreneurs can grow and thrive here at home.

“By supporting projects in National Reconstruction Fund priority areas, we’re setting up the next wave of Australian businesses to thrive for years to come.

Revitalising national rail manufacturing The Australasian Railway Association’s (ARA) push for a national rail manufacturing plan is a step closer with the Federal Government appointing a rail manufacturing advocate and new council tasked with streamlining practices to drive growth in the industry.

The announcement follows ARAfunded research, released by the Federal Government last year, which showed that a coordinated national approach to rail procurement and manufacturing would have saved $1.85 billion over the past 10 years.

Separate ARA research also confirmed the current uncoordinated approach to type approval processes by procurers is costing the rail industry $230 million per year.

The Rail Industry Innovation Council will be chaired by Jacqui Walters, appointed as the Advocate.

ARA CEO Caroline Wilkie said the ARA has worked closely with the Office of National Rail Industry Coordination since it was formed last year, advocating 14 AUGUST 2023 Manufacturers’ Monthly

strongly for better harmonisation across jurisdictions.

“It is encouraging to see the Federal Government act on the decades-long lack of harmonisation across the country’s rail networks that has hampered competitiveness, significantly increasing costs and constraining investment,” Wilkie said.

“The industry urgently needs a centralised approach to procurement to drive productivity and innovation if we are to meet the challenge of a $154 billion pipeline over the next 15 years.

“The current state-based local content policies are akin to operating in different countries and have led to duplication of facilities and made it hard for some organisations to bid for key contracts.

“A transparent, long-term and coordinated strategy will be critical to support a sustainable industry and enable increased investment through certainty,” Wilkie said.

ARA Chair Danny Broad, who was appointed as a Council member, said the

announcement is the first step towards developing safe, sustainable rail and will foster research and development and boost skills and capabilities in the sector.

“This plan will support more trains being built here in Australia and create local, skilled manufacturing jobs,” Mr Broad said.

“It will improve government supply and export opportunities for local businesses and improve competitiveness overall.

“The ARA looks forward to the delivery of the National Rail Manufacturing Plan to support industry productivity and facilitate opportunities for Australian manufacturers.”

The rail rolling stock manufacturing and repair industry has a revenue of just over $2.4 billion and a direct value-added of $515 million.

The ONRIC is leading a national approach to deliver the Australian Government’s $14.2 million National Rail Manufacturing Plan.

The office is tasked with working

closely with state and territory governments, manufacturers, industry peak bodies, unions and research organisations to implement the Plan.

Federal Assistant Minister for Manufacturing and Trade Senator Tim Ayres announced the appointment of the Council members today at Maryborough Railway Station in Queensland.

The following appointments were made to the Council: • Danny Broad (Chair, Australasian Railway Association), • The Hon Rachel Nolan (former Queensland Transport Minister), • Ravi Ravitharan (Professor, Monash University Institute of Railway Technology), • Katarzyna Stapleton (CEO, Queensland Rail), • Glenn Thompson (Australian Manufacturing Workers’ Union), • Vicki Brown (University of Technology, Sydney) • Graham Bentley (Aurecon) • Samantha McWilliam (WSP) manmonthly.com.au

News @MM ARC funding boosts 57 Australian innovative research projects Australian researchers have received over $28 million under the ARC Linkage Projects scheme to collaborate with industry partners and community organisations to work towards practical solutions in industry settings.

With the announcement of Australian Research Council (ARC) funding, researchers are set to start a range of outstanding research projects including finding innovative ways to develop resilient supply chains to better assist the Australian economy and reconnecting Warlpiri communities with past documentation and recordings of their cultural heritage.

The ARC chief executive officer, Ms Judi Zielke PSM, said the ARC Linkage Projects scheme supports Australian researchers to collaborate with industry partners and community organisations to work towards practical solutions in industry settings.

manmonthly.com.au

“For example, one of the ARC’s Linkage Projects awarded today comprises researchers working with Surf Life Saving Australia to develop a smartphone ripdetection tool and an online education game to help reduce the number of drownings in rips at Australian beaches each year.

“Another is partnering with Qantas Airways, to develop and test strategies to mitigate jetlag to directly inform operations for ultra-long-haul flights, improving travellers’ alertness and sleep, and reducing the risk of fatigue related accidents,” said Ms Zielke.

Awarded ARC Linkage Projects include: Southern Cross University ($303,617): research to raise awareness and increase the number and diversity of people on the Australian Organ Donor Register to assist in the growing demand for organ transplantation in Australia.

The scheme supports Australian researchers to collaborate with industry partners.

The University of Newcastle ($506,031): to encourage broader responsibility for environmental sustainability by expanding the knowledge and awareness of threatened species within Australian local communities.

Macquarie University ($362,322): in partnership with the Australian Broadcasting Corporation (ABC) and the National Archives of Australia, this project will uncover and interpret records relating to listeners and viewers during the broadcaster’s first 50 years. Its purpose is

to deepen understanding in the Australian community of the role the ABC plays in the lives of audience members, and the needs and interests of the community that have shaped it.

Griffith University ($507,466): this project will explore robotic assistance for ultra-precise and pain-free dentistry through units installed at health centres and aged-care facilities, improving the oral healthcare of the Australian community, and facilitating access in regional and remote communities.

Manufacturers’ Monthly AUGUST 2023 15

News @MM Vaxxas opens nation’s first needle-free vaccine manufacturing site Australian biotechnology company Vaxxas, in partnership with the Queensland Government, today announced the opening of its global headquarters and state-of-the-art manufacturing facility in Brisbane.

The custom-built 5,500m squaremetre (60,000 square feet) Vaxxas Biomedical Facility is a first-of-its-kind manufacturing site designed to support the scale-up of Vaxxas’ needle-free vaccine technology platform, the highdensity microarray patch (HD-MAP), for late-stage clinical trials and first commercial products. metre meter The Vaxxas Biomedical Facility is expected to support up to 200 local, skilled jobs and produce millions of vaccine patches per year once fully operational, contributing to Queensland’s local economy.

The Queensland Government provided funding and operational support to Vaxxas in developing the site.

Additional funding has been provided by the Australian Federal Government through its Modern

Manufacturing Initiative to support the installation of specialised manufacturing infrastructure.

Deputy premier, minister for state development, infrastructure, local government and planning and minister assisting the premier on Olympic and Paralympic Games Infrastructure, Dr Steven Miles officiated the opening.

“Queensland is fast shaping up as a global research and innovation hub thanks to the Palaszczuk Government’s investment in state-of-the-art facilities like this one. Economic Development Queensland worked closely with Vaxxas to progress designs and approval for this facility, so it’s fantastic to be here to open it,” Miles said.

“The Palaszczuk Government is committed to supporting homegrown biomedical start-ups to scale up successfully and ensure we keep this innovation and our best and brightest researchers on home soil.

“This world-renowned technology has the potential to play a vital role in pandemic preparedness because it allows

The new facility will improve Australia’s preparedness for pandemics. vaccines to be deployed quickly and easily to our communities.

“Queensland is going from strength to strength as the place to work and invest in science, and Vaxxas is a fantastic example of a home-grown biotech success story that we need to retain here in Queensland. The opening of the Vaxxas Biomedical Facility in Brisbane’s Northshore is taking us one step closer to

achieving that goal,” Miles concluded Vaxxas’ proprietary HD-MAP technology platform has the potential to improve vaccination by creating vaccine products that are easy to use, potentially enable self-administration, and can be stable at room temperature, reducing the complexities and costs associated with refrigerated distribution required for many existing vaccines.

World-leading graphene enhanced cement trials commence Australian manufacturer First Graphene will lead a consortium that commences graphene-enhanced cement and concrete trials, aimed at validating industrial-scale manufacturing.

The trials will use the company’s PureGRAPH product at Breedon Group’s Hope Cement Works in the United Kingdom.

Approximately 2,000 tonnes of graphene-enhanced cement will be produced at the Derbyshire plant, which is the largest in the UK. The volume of cement is thought to be among the highest produced globally by trials using graphene to enhance cement properties.

The trial provides the opportunity to further validate and showcase the CO2 reduction benefits provided by adding 16 AUGUST 2023 Manufacturers’ Monthly

graphene to the cement production process on an industrial scale.

About 1.2 tonnes of PureGRAPH 50 is being used in the trial, testing multiple dispersion methods and dosage rates to determine the most effective and beneficial application process. The graphene will first be formulated into a grinding aid and then introduced into the cement grinding mill feed.

Dispersion into the cement production line will occur over a 24hour period using traditional grinding aid dosage lines, with minimal operational or mechanical change required to the existing plant.

Cement produced will be validated

by Breedon’s Quality team to assess its performance enhancement.

Results from the trial will be used

to build on data obtained from smaller scale trials previously conducted at an accredited concrete processing laboratory in the United Kingdom.

These small- scale trials have generated positive results.

Recent work carried out by the University of Manchester confirmed the potential for PureGRAPH enhanced cement to reduce CO2 emissions and deliver a range of mechanical benefits in concrete- based systems, at very low graphene loading levels.

The graphene enhanced cement produced through the trial will be supplied to leading British construction and regeneration group Morgan Sindall Construction, which will use it in real world construction demonstrations.

The company is renowned for

its cutting-edge approach to carbon reduction, sustainable material use and building methods in the construction sector.

First Graphene managing director and CEO Michael Bell said, “This industry collaboration led by First Graphene is an example of world leading research and a significant jump in trial size to demonstrate the value of graphene in greening the cement and concrete industries.

“To our knowledge the volume of graphene-enhanced cement being produced is among the biggest ever trialed globally.

“We’re aiming to determine a simple, low-cost method of introducing graphene to industrial scale cement production to drive the sustainability and decarbonisation of one of the manmonthly.com.au

News @MM highest emitting industries on the planet.

“Having involvement from leading manufacturer Breedon and sustainability innovator Morgan Sindall adopting this cement into real-world applications gives the trial extreme credibility, showcasing the potential of green cement products powered by First Graphene’s PureGRAPH.” Breedon Cement managing director Jude Lagan said, “We are truly excited to be part of this consortium led by First Graphene. The role graphene can play in helping to decarbonise the cement industry could be significant, and we are keen to contribute to this process by facilitating what is set to be one of the largest global trials of this kind at our Hope Cement plant in Derbyshire.

“The construction industry can play an essential role in the creation of a sustainable built environment, as long as we continue to embrace innovation.

“We look forward to working with Morgan Sindall and the University of Manchester to showcase some brilliant real-world applications for this innovative graphene product.”

manmonthly.com.au

The graphene cement trial will create a more eco-friendly product.

Manufacturers’ Monthly AUGUST 2023 17

News @MM New jobs and skills council announced for manufacturing Today, the Hon Brendan O’Connor, Minister for Skills and Training, announced that the Manufacturing Industry Skills Alliance (Manufacturing Alliance) has been established as the Jobs and Skills Council (JSC) for the manufacturing industry.

Formally IBSA Group, the Manufacturing Alliance is an industryowned and industry-led organisation supporting the development of skilled workforces enabling modern manufacturing and associated industries to succeed. It works with stakeholders across Australia, including employers, unions, educators, learners and governments.

Jobs and Skills Councils have been established by the Australian government to bring industry representatives together, with balanced representation from unions and employers, to identify and deliver the workforce skills that are needed for strong, competitive and sustainable industry.

The Minister commented, “I am excited about the benefit that the Manufacturing Industry Skills Alliance will provide to its industry and workers.

The Manufacturing Alliance will play a key leadership role in shaping the future of manufacturing in Australia. We are providing considerable support to ensure workers have the right skills now, and in the future, and Jobs and Skills Councils are a key part of making this happen.”

“These new JSCs will act as a source

The Manufacturing Alliance will identify and deliver workforce skills for the manufacturing industry.

of intelligence on issues affecting their industries and provide valuable leadership and advice in addressing skills and workforce challenges,” he said.

Sharon Robertson, CEO Manufacturing Industry Skills Alliance said, “Australian manufacturing is experiencing a period of renewed opportunities. As organisations seek to capitalise on future growth, they need a workforce with the right skills to make it happen. We are looking forward to being on the journey with them and providing workforce development solutions.”

She added, “If the collaboration we have seen from governments, unions, employers and training providers while we were establishing the Manufacturing

Alliance is anything to go by, then we are well placed to make a tangible difference to industry and its workforce.”

Industries supported by the Manufacturing Alliance are as broad and diverse as Australia itself. They range from metal fabrication, print, food manufacturing and aerospace through to polymers, pharmaceutical manufacturing and laboratory operations, as well as emerging industries such as space.

Jobs and Skills Councils advocate for industry and work closely with government to create an efficient training system delivering sustainable prosperity for workers, employers and the wider Australian economy. They move beyond a narrow focus on training package

development, which was a feature of the Skills Service Organisation model, to address system-wide barriers from a labour market perspective.

They focus on workforce needs and skills development with a strong emphasis on building partnerships between industry and the vocational education and training sector.

The Manufacturing Alliance’s predecessor, IBSA Group, was part of the vocational education and training sector for 20 years, including being a Skills Service Organisation for the manufacturing industry.

About the Manufacturing Industry Skills Alliance The Manufacturing Industry Skills Alliance (Manufacturing Alliance) is the Jobs and Skills Council (JSC) for the manufacturing industry. Industry owned and industry led, we work with employers, unions, educators, learners and governments across Australia to build the skilled workforce needed for modern manufacturing and associated industries, now and for the future.

Our predecessor, IBSA Group, was part of the vocational education and training sector for 20 years, including being a Skills Service Organisation for the manufacturing industry.

The Manufacturing Industry Skills Alliance is a Jobs and Skills Council funded by the Australian Government Department of Employment and Workplace Relations.

Gemco Rail to manufacture iron ore railcars for Rio Tinto Perth-based Gemco Rail will build 100 iron ore railcar wagons for mining giant Rio Tinto, supported by government investment of $6.9 million through the Local Manufacturing Investment Fund (LMIF).

The LMIF funding will be used by Gemco to upgrade its Forrestfield facility and establish a new facility in Karratha.

The $15 million LMIF is part of an election commitment to support 18 AUGUST 2023 Manufacturers’ Monthly

local companies to enhance their competitiveness and provide an effective service to this important market sector.

The partnership with Rio Tinto will enable Gemco Rail to expand its existing operations to establish the first-ever rail ore car manufacturing and maintenance facility in the Pilbara, creating new jobs, increasing spend with local and Indigenous businesses

and supporting local economic growth.

Rio Tinto expects to invest approximately A$150 million to purchase 100 locally built ore rail cars over six years as well as continued investment in bearing refurbishment over ten years, to support the company’s Pilbara operations.

The first locally-built railcar is expected to be delivered in mid-2024, while the Karratha-based facility is expected to be

established by the end of 2024.

WA premier Roger Cook said, “My Government is absolutely committed to rebuilding our local manufacturing capability, and we’re getting on with the job of delivering on our commitment.

“Not only will the agreement create jobs and diversify the economy, it will help revitalise and future-proof local manufacturing in WA, including in the Pilbara. manmonthly.com.au

News @MM “It will also reduce WA’s reliance on overseas suppliers and helps our State become more self-sufficient.

“It’s a win for jobs, a win for the economy and another step towards a stronger manufacturing sector in WA.” The new Karratha facility will reduce the need to transport iron ore cars and bearings between the Pilbara and Perth, removing an estimated 150 truck journeys from WA roads and 300 tonnes of CO2 each year.

Rio Tinto iron ore chief executive Simon Trott said, “We aim to create enduring partnerships that generate positive impacts in the regions where we operate and are proud to be leading the way in bringing iron ore car manufacturing and maintenance to the Pilbara.

“We’ve taken our original scope to build iron ore cars in Western Australia and enhanced it to see the construction of ore cars in the same region as our operations. This will bring a new industry to the Pilbara, creating jobs and providing more opportunities for local and Indigenous businesses.”

The partnership between Gemco Rail and Rio Tinto will create more opportunities for local businesses.

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Manufacturers’ Monthly AUGUST 2023 19

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News @MM QLD state budget backs local manufacturing and employment An investment of almost $1.35 billion in skills, training, employment and small business support has been allocated in the 2023-24 Queensland State Budget.

The 2023-24 Queensland State Budget also includes the following highlights: • A total of $86 million is being invested to revitalise and upgrade training infrastructure to deliver key projects such as: • the Eagle Farm Robotics and Advanced Manufacturing Centre.

• the expansion of Great Barrier Reef International Marine College in Cairns to deliver world-class maritime training.

• the Bohle Renewable Energy

The Queensland State Budget will invest almost $1.35 billion to strengthen local industry.

manmonthly.com.au

•

•

•

Centre at the TAFE Queensland Trade Training Centre (Bohle) in Townsville.

29.8 million over three years to replace the vocational education and training (VET) information and communication technology systems, this includes $8.8 million in 2023-24. $4.6 million over two years for the Women in Trade Apprenticeships Mentoring Program to support women in trades and increase retention and completion rates. $5 million over two years for cyber security support initiatives for small to medium enterprises, with funding held centrally.

•

Support for the establishment of the Queensland Indigenous Business Network to provide support and advocacy for the growth of First Nations businesses.

• Up to $1 million committed to assist with the development of the Cairns Indigenous Training Centre to provide First Nations people in the Far North with a tailored trade training facility.

Queensland premier Annastacia Palaszczuk said, “Queensland’s economy is going from strength to strength but that also means we have a greater demand on our workforce and that is expected to increase with an extra 280,000 jobs forecast for Queensland by 2024-25.

“To help address the demand, the 2023-24 State Budget will allow for the continued delivery of the Good People.

Good Jobs. Queensland Workforce Strategy 2022-2032.

“The Strategy, which was launched last year, has already delivered or started delivery on 23 key initiatives, and this is set to expand considerably over the next financial year.

Minister for employment and small business, minister for training and skills development and minister for youth Justice Di Farmer said, “Queensland’s economy is diverse and expanding into new industries, requiring the training system to anticipate and deliver a skilled workforce to ensure continued economic growth.

“In the 2022-23 financial year to date, more than 212,000 students have been supported through the Government’s investment in vocational training.

“Fee Free TAFE in 2023, which is delivered by TAFE Queensland and Central Queensland University, will continue to be available for Queenslanders looking for a pathway to their dream career or even a career change.

“To date, 32,000 Queenslanders have been supported in Fee Free TAFE courses across more than 80 qualifications.

“In addition to some of the newly funded programs, we will also continue our unwavering support of the lifeblood of our communities and our economy – small businesses. We will provide a number of programs to support them, including the successful Big Plans for Small Business grants programs.”

Treasurer and minister for trade and investment Cameron Dick said, “The 2023-24 State Budget reflects the strength of our economy, which is great news for Queensland in terms of employment and for our small business sector.

“The Big Build announcement highlights unmatched job opportunities across the State as we embark on a very exciting future.

“To support this Big Build, the Palaszczuk Government is investing in upskilling our workforce and importantly, boosting the ranks of women in trades.”

Manufacturers’ Monthly AUGUST 2023 21

Manufacturer Focus

Lights camera action for filters Manufacturers Monthly got the opportunity to tour the facilities at ActionLaser in Sydney who recently completed its project with the Advanced Manufacturing Growth Centre (AMGC), learning the ins and outs of the company and what is driving its success both locally and globally.

A

CTIONLASER’S laser drilling technology was developed by the CSIRO back in the 1980s to meet the needs of the sugar industry in Australia. The company was then born in 1988, delivering some of the first laser perforated filtration screens globally, and is now exporting close to 80 per cent of its product internationally.

The company was and remains the pioneer in laser drilling technology and manufactures filtration for industries 22 AUGUST 2023 Manufacturers’ Monthly

including sugar, mining, chemical and plastic recycling. The company has recently launched its second-generation replacement MeltFilter discs that are more efficient and longer lasting.

ActionLaser created the MeltFilter discs to fit Erema Plastic, the global industry-leader in polymer and plastic recycling machines. Their R&D has determined the optimal steel type, annealing process, and heat treatment required, and developed a propriety

method of perforating the steel disc, using a laser to drill precise micro-holes in a circular pattern that maximises disc strength.

When developed by the CSIRO in the 1980’s, the original chrome coated stainless steel filtration screens were designed to meet the needs of the sugar industry who were desperate for a more efficient centrifuge screen that was able to provide a longer working life and withstand extreme abrasion.

Head of Sales and Marketing Stephen Greer recently joined the company and explained the company’s growth to where it is today – a key part of the filtration industry.

“Originally the partnership was ActionLaser working closely with the Australian sugar industry,” Greer explained.

“When you are filtering sugar, you have three levels, the first two levels of filtration are relatively simple and low manmonthly.com.au

Manufacturer Focus

The ActionLaser product developed by the CSIRO has been a game changer in the filtration space.

impact but it’s that third level that is the most challenging and that is where our system comes in.”

“That level of filtration has a lot of ‘violence’, it is very abrasive, and it is the pivotal level when it comes to maximising the amount of sugar extracted,” Greer said.

The laser system was created to perforate stainless steel as it was going to last longer than other types of metal, without it companies would be changing manmonthly.com.au

Bevan Rashford is continuing to grow ActionLaser into a powerhouse on the global market.

filters almost daily as opposed to months at a time with the ActionLaser system.

Challenges As with any business – particularly one delivering such a ground-breaking solution – ActionLaser has dealt with numerous challenges over the journey, as Greer explained.

“I think ActionLaser is similar to a lot of Australian businesses, we are good at what we do but we struggle

to communicate that with a wider audience,” Greer said.

“Sometimes it can feel like we are a train running on greased rails and this is the benefit in bringing the AMGC on board, it gave us an opportunity to re-calibrate and even find a new way to think about how we look to the future, it is a great change in culture.”

“We need to stop being the humble little Aussie battler, we should bring more people with STEM backgrounds in

who we can utilise to grow our company and help us to compete on a global stage,” Greer said.

While some businesses were nervous about bringing an Australian supplier like ActionLaser on board, German manufacturer Siebtechnik recognised the quality of an Australian product and sought out the ActionLaser filter.

It was an exciting learning curve for the company and allowed them to set up the business in a way that allowed Manufacturers’ Monthly AUGUST 2023 23

Manufacturer Focus

The team works diligently to deliver a high quality product globally.

it to cater directly to its clients as Greer detailed.

“We had the technology well established but it was about finding a way to make sure it delivered specifically for Siebtechnik,” he said.

“Siebtechnik needed the filter to be steel based which was something new, but it allowed us to test the limits of our system and how far the laser could go,” Greer said.

A further challenge faced by ActionLaser is the supply of its metal for its new product and new market coming from Europe, which can pose numerous challenges as many of the filtration companies are based on the continent.

“Very few manufacturers could make the steel directly to our parameters needed and so the only place we could go to was Europe and the fear always was that we would be left behind when compared to our European counterparts,” Greer explained.

“When looking at the global market we realised we could not go along doing the same as everyone else and we should start to look at ways to differentiate ourselves.”

“It was important to fill any gaps in our knowledge and source more locally 24 AUGUST 2023 Manufacturers’ Monthly

and so we partnered with Heat Treatment Australia, which improved our lead times and onshored our process – which is fantastic,” he said.

International perceptions and growing globally A success for ActionLaser has been its ability to not only deliver locally but really succeed overseas and export a large percentage of what it produces.

“I think the hardest thing for us initially was the idea of customers that we are far away from Europe,” Greer said.

“I remember speaking to a German client and when I showed him an Asian centric map that had us in the middle, he was fascinated by the idea that we are not as far away as he thought,” he said.

Production manager David Pask joined ActionLaser in the last couple of years and discussed how the company has overcome this perception.

“We recently had a Polish company where our contact spent months convincing his superiors to give us a chance,” Pask said.

“Then once they came on board, he contacted us and said, ‘Hey, I sent you the order Thursday and it was here by

Monday’, which we knew was always possible, it was about convincing them that is what we can do.”

“We are good at logistics, it is what we have done for years and having clients in Europe for over 30 years means we have a firm understanding of what we need to do to deliver on time,” he said.

Uses for filters Initially a challenge for ActionLaser was competing with low-cost markets based out of Latin America and Asia but the arrival of COVID-19 and supply chain issues has changed the thinking around products like filters.

The initial development of the filters was to meet the needs of sugar made in the southern hemisphere which is made from sugar cane and far more abrasive than sugar from the northern hemisphere [from sugar beets].

The challenging lead times seen throughout and after the pandemic has seen a shift of thinking away from simply cheap products but a move towards higher quality and longer lasting products such as the filters supplied by ActionLaser.

Creating this strong and highquality product has seen the filter used

for a range of applications, one being aluminium supplier Alcoa in washing its alumina By bringing in a longer lasting filter it removes the instances of replacement and team members having to enter the machines, which could increase the likelihood of injuries.

“Changing from cloth filters to stainless steel has taken the life from two to three months to now close to five years,” Greer explained.

“When I recently travelled to Europe, I was able to learn a lot about our customers and their needs and what I uncovered was, is that we are the critical point for all of these companies, the filter is pivotal to their operations,” he said.

Greer went on to detail how ActionLaser works closely with its clients to deliver a customised product filling the needs of the application.

“We do not just send the product and say here you go good luck; we go into a lot more detail than that,” he said.

“We will develop the product with a client, so we can make sure we meet their needs.”

“We can communicate what our limitations are when it comes to our technology – which is not much – with the plastics industry our limitation was that we could drill but we could not process the melt disk.”

“We have now brought that advanced manufacturing processing in house so we can manage the whole process and give strong repeatability, quality and performance,” Greer said.

Challenges facing Australian manufacturing As often is the case, Australia developed impressive filter systems that were not seen anywhere else in the world, but people continually attempted to copy ActionLaser’s design; unsuccessfully, as Greer explains.

“I think the thing to remember is that when we started this process it was just us, whereas now there are five or six in Europe alone plus countless companies throughout Asia,” he said.

“These third-party companies are attempting to compete on price alone and we need to show our quality when compared to them. It is important for us to take the high road and continue to deliver a high-quality product and show users globally what a quality product from Australia can do,” he said. manmonthly.com.au

Manufacturer Focus Greer went on to discuss what Australian manufacturers need to be doing to compete on a global scale.

“When you look at a company like RØDE Microphones based out of Silverwater they have found a niche and completely dominate the microphone market globally, not just in Australia,” he said.

“ActionLaser has been able to lean in and own a big piece of a small pie by finding a niche and I think that is a strong way for us to compete internationally.

It will be all about finding an area with maybe only two to three competitors.”

The future Greer is excited for the future for ActionLaser and with the arrival of new faces the company is expected to go from strength to strength.

With Bevan Rashford into his role of CEO for 20 years, the company is in a strong position and was able to bring Greer on board recently along with production manager David Pask, the company is looking to maximise its position in the market by bringing in the right people.

ActionLaser has partnered with a company based out of the United Kingdom which has been mutually beneficial for both.

“That company is able to service our filters throughout Europe, it improves our footprint across the continent, it means we now have the product, a service provider in the vicinity and a strong presence in the market,” Greer explained.

“We recently partnered with a Spanish company who will be supplying our MeltFilters to Europe,” Greer said.

“They have been able to go out and speak to our customers and get really positive feedback and having that close

point of contact moving forward will be a massive benefit to us. They have already managed to generate over 40 leads for us.”

While ActionLaser is close to the Asian market, they will also have a partner in Japan who will be selling the filters and supporting them with the backup support.

“We have a partner in Japan who will be presenting at the expo in Japan later this year and we are excited to grow more and more in that market,” Greer explained.

“We are taking a different approach to each region; we have been in Europe throughout June and July, and we will go to Japan in October and then the United States later in the year and we will try to uncover the best way to approach each market.”

“We are taking it market by market, we have Europe up and running and I think the next step is Asia and then the United States after that but that is why these trips are so important,” he said.

It is not just new regions that ActionLaser is moving into, they are continuing to update its processes and making the customer experience far smoother.

“We have updated our website and created a new MeltFilter brand for plastic recycling to make sure as we go to more markets globally, the website reflects the quality of the product that we are sending to market,” Greer said.

“Even on our old website we were getting strong leads from across the globe, so we have updated it now and we hope to see that grow even further,” he said.

Automation is the next step for the company as it looks to find ways to improve the quantity of filters it can send to market as Pask explains.

“At the moment we have to babysit the machines as they work, we have to have

The high quality product is shipped efficiently across the globe.

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With the prospect of automation on the horizon the team will soon be redeployed into other areas.

them manned for the eight hours we are here,” he said.

“By automating that process we can change pour output from eight hours to 24 hours of working time and that will be a game changer.”

“We can then re-deploy those workers out into other areas and that will improve our output even further, it is an exciting prospect,” he explained.

billion in estimated revenue.

AMGC recently announced the Advanced Manufacturing Ecosystem Fund of $7.5 million in which it seeks to build the advanced manufacturing ecosystem in the Northern Territory. The fund aims to grow advanced capabilities and increase investment in and output of advanced manufacturing activity in the Northern Territory and grow jobs.

Tyson Bowen from AMGC explained what the goal for AMGC is when it The AMGC partners with companies like ActionLaser.

The AMGC co-funded the project with “We look for hidden gems like ActionLaser, contributing $558,500 while ActionLaser and the goal is to give them Industry matched it with $741,500. the ability to commercialise and grow, AMGC co-funds industry projects to with the aim to lift other company’s along commercialise innovation. In this way, with them,” he said. approved industry projects demonstrate “A rising tide lifts many boats.” how, and the techniques, Australian “It is about building partnerships manufacturing can become more globally between company’s and giving them competitive.

AMGC projects are expected to add 4288 the ability to grow and that is what we have seen with ActionLaser, they have jobs in Australian manufacturing and has developed this and now they can compete committed $137.2 million currently with an expectation that it will yield a return of $1.62 on a global market.”

Manufacturers’ Monthly AUGUST 2023 25

Machinery Tools All roads lead to Doosan Manufacturers Monthly sat down with Rick Foster, general manager of Hare and Forbes Machinery House, to learn more about the almost 100 year history of the company and its range of Doosan Machine tools.

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ARE AND FORBES Machinery House can trace its way back to the 1930’s where it started under the Hare and Forbes name, and it still remains family owned to this day.

Beginning life as a secondhand machinery and scrap metal dealer, the business has continually – in its near 100 year history – evolved to meet customer requirements as a supplier of new and used workshop equipment across Australia and New Zealand.

Its humble beginnings saw customers rummaging through bins and 44-gallon drums for a required part, with much of the stock made up of World War II army surplus. The company has moved a long way from this but maintains the same support for its customers it always has.

Joining the company 35 years ago, Rick Foster has seen a lot of change during his time at Hare and Forbes Machinery House and in his current role of general manager is proud of where the company is today.

“When I started at the company, we were selling close to 80 per cent second-

air compressors, lathes, and milling equipment. The company was even one of the first to import an angle grinder from Japan that sold for $99, incredibly good value at that time, it later become the well known brand Makita.

Every step of the way was about improving what was available to clients in Australia and bringing fresh products to the local market. The next big step for Hare and Forbes was to expand its base from Sydney and the first step was to head north to Brisbane.

“We started off in a small car yard in Brisbane and we would forklift our machines out into the yard each day and then back inside at the end,” Foster chuckled.

“It was a humble start, but it allowed us to find our way into the Brisbane market and we learnt a lot from each time we expanded and moved forward,” he said.

In 2002 Hare and Forbes acquired Herless Machinery who were based in Melbourne and Perth, allowing the company to expand its footprint to

The company has ventured into the automotive restoration space and used this knowledge to restore one of its original trucks.

“It is still a close-knit family environment; when I started back in the 80’s we had 23 employees and have now grown to over 200, and we know most of each other by name,” Foster said.

“We all work hard for each other and then, in turn, work hard for our customers; it’s a fantastic environment,” he said.

CNC Machines

All of our service technicians are sent to the DN solutions factory in Korea to learn from the engineers on all of the Doosan machines, ensuring they have a firm grasp of the range. hand equipment and 20 per cent new,” Foster explained.

“We were selling second-hand gearboxes, electric motors and water pumps,” Foster said. “But as supply of these began to dry up, we knew our customers wanted more from us – so it was time to expand our horizons and open up new opportunities.”

Hare and Forbes consistently identified areas to support its clients better throughout its history, including building and importing power hacksaws, 26 AUGUST 2023 Manufacturers’ Monthly

Sydney, Brisbane, Perth and Melbourne in the early 2000s.

In 2007 the company was then contacted by a number of employees of a reseller in New Zealand asking to open another branch across the Tasman. Recognising the opportunity to grow further the company leapt at the opportunity in 2008.

While Hare and Forbes Machinery House has grown rapidly, Foster explains how they have maintained the values that have seen its success.

Through its history, Foster and the team at Hare and Forbes Machinery House have grown relationships with a number of suppliers in both Taiwan and Korea and one that has been beneficial for the team is the partnership with Doosan.

Doosan has a strong history dating back to 1976 when it opened its first machine tool factory, and it now has close to 400 different machines available.

Foster explains why the team at Hare and Forbes brought the Doosan range into the fold.

“We always wanted to get into the CNC market, we began bringing in our own range from Taiwan but when we acquired the business in Melbourne, they were stocking what was known as the Daewoo range at the time and they have now rebranded as Doosan or DN Solutions as they are known nowadays ,” he said.

Hare and Forbes Machinery House has a strong backup support network.

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MachineryTools “The brand has become very well trusted in Australia; I think people were initially nervous about buying a product from Korea when we brought it on board, but customers are thrilled with it. After buying one machine we will see people coming back for a second and third; that repeat business is great for us to see,” Foster said.

Foster believed that in the early days the DN solutions range was used as a bargaining tool when companies were sourcing a Japanese machine, but this has long since changed.

“It was disappointing when we saw that, but the tables have turned now and we have a strong position in the market and the machines are very well respected in the manufacturing space,” he explained.

“We have probably close to 1000 machines out in the Australian market and what has been imperative for us throughout the process is providing the backup support needed to make sure down time is minimised for users,” Foster said.

The machines are so well respected in Australia Hare and Forbes recently sold

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into Brad Jones Racing and will help the Chevrolet team with its machining.

Backup support Each of the Hare and Forbes branches has several technicians trained by DN solutions who can quickly mobilise to support customers.

“All of our service technicians are sent to the DN solutions factory in Korea to learn from the engineers on all of the DN solutions machines, ensuring they have a firm grasp of the range,” Foster said.

“The factory supplies the machines, the training and warranty parts, but it is up to us here at Hare and Forbes to make sure we deliver on our end and that is something we take very seriously,” he explained.

With each branch maintaining a crew of technicians, much of the country is covered, and with plans to open a branch in Adelaide the support will only grow from there. While the backup support was pivotal, it was also important to maintain strict quality controls for the machines they imported, as Foster explains.

The company stocks the DN range of machine tool systems.

Manufacturers’ Monthly AUGUST 2023 27

Machinery Tools

Its long and illustrious history has seen it consistently find new ways to better support its clients “I think the thing people do not realise is that we have strict quality control on all of our products. Each and every time a machine shipment comes in from overseas one of each type of machine is taken out of the packaging and put into our workshop to be diligently checked by our technicians,” he said.

“This can be from the smallest milling machine for hobby use all the way through to our biggest CNC machines.

“We will take them out of the box and a report is completed on them in which we will pay close attention to the safety features on the machines. We will then also add any extra safety features someone may require like emergency stop buttons and other things they may need for their specific business,” Foster explained.

For Hare and Forbes Machinery House, DN solutions is not merely a supplier but a true partner; they work closely with the Korean based company.

“It is fantastic for the team that 28 AUGUST 2023 Manufacturers’ Monthly

there is only a two-hour time difference between us, allowing technicians to quickly communicate with the head office. We can ask them a pressing question and we can have a response within business hours, again supporting us with the backup support we provide,” Foster explained, “Once a shipment arrives, we can go back to the factory with something that we want to get fixed or adjusted to improve the product. When the next one comes in, we will check the changes and the process continues again after that.”

“We are working with the factories to make the product better,” Foster said.

Foster explained how value for money is a big part is of why people look into the DN solutions machines – but there is more to the DN solutions range than just that.

“While they originally find them good value for money, they also stand up well to the needs of the user; they are coming back again and again,” Foster said.

“We sold a DN solutions sliding head

lathe to a local manufacturer, he bought his first and has since bought six in four years.”

“He had used Swiss machines in the past, but now prefers the DN solutions as they have better backup support and the value for money is better,” Foster said.

Sourcing the correct machine When it comes to finding the right machine for the user, Hare and Forbes Machinery House takes a partnership approach to sourcing machines for customers.

“We will look at the work a manufacturer is doing or the work that they have coming when it comes to deciding what they need. They may have also just won a contract and that will help us in deciding what their needs will be,” Foster explained.

“The thing that is important to consider is future proofing your machines, so we make those considerations as well.”

“We will go out to someone who is

considering a machine and we will discuss their options and make a suggestion to help them decide what machine is best.”

“We did a similar process recently, recommending a machine for Qantas to repair the wheels on its planes, so they can make repairs quickly as opposed to relying on the product to come from a supplier,” Foster said.

Hare and Forbes’ long and varied history has delivered it to the position now where it is setting itself up as a one stop shop for equipment. The company stocks a range of CNC cutting systems, CNC Metal Machines, welding equipment, machine tools and accessories A range of lifting and handling equipment, hand tools, meat processing equipment, workshop equipment and wood working machines are also offered

by Hare and Forbes. The company has even branched into the automotive restoration space, an area that is growing quickly in Australia. manmonthly.com.au

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ESSENTIAL SMALL MOLECULES FOR MATTER

Additive Manufacturing Going cold is hotting up Manufacturers’ Monthly sat down with Ben Andrews and Dominic Parsonson from Titomic to learn more about its cold spray technology and how it can be used in the additive manufacturing space.

Titomic works in conjunction with its clients to deliver a strong product to market.

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DDITIVE Manufacturing is one of the fastest growing sectors in manufacturing, with new developments constantly appearing on the global market. These have included selective laser melting, laser power bed fusion, and filament metal – but an exciting development made by Titomic is its cold spray additive manufacturing system.

High-pressure cold spray technology makes it quicker, easier, safer, and more sustainable to manufacture with metals. This process rapidly deposits strong metals, alloys, and other specialty materials at low temperatures – so they retain their intrinsic properties without needing to be melted.

Dominic Parsonson is the head of sales at Titomic and Ben Andrews is the global marketing manager. The pair explained how additive manufacturing has developed to become what we know today.

30 AUGUST 2023 Manufacturers’ Monthly

“A lot of people say additive manufacturing is an overnight success; this is simply not true – it has spent 30 years in the wings waiting for its opportunity to thrive and has finally reached that point,” Parsonson said.

“What separates our version of additive manufacturing from others is that other versions are melt based whereas Titomic is a cold spray system,” he explained.

The Titomic cold spray system accelerates the powdered metal by using a high pressure nitrogen gas stream into which the metal particles are injected, propelling them at supersonic speeds to a surface, where they impact and deform turning into a dense strong metal.

“What makes the cold spray system stand out is it is incredibly fast, it can deposit 5 to 7 kilograms per hour depending on the metal, which is far faster than any other version of additive manufacturing,” Parsonson said.

The Titomic cold spray system gives users greater flexibility in what they produce and even allows a manufacturer to combine metals to make a stronger product, something which may not be possible with standard manufacturing techniques.

“By using a cold spray system, you can use high temperature metals like Inconel 718 which are more challenging for melt based processes, which can be used, for example, in large scale barrels for artillery or even pressure vessels,” Parsonson explained. “They can reduce the weight as well by combining metals, allowing users to make a product that can withstand greater rigours.”

“In the Ukrainian war, we are seeing the conflict using an incredible number of barrels, something not seen for close to 60 years. Companies in the United Kingdom and other parts of Europe cannot keep up and Australia has realised it can support them.

Stronger metals for stronger defence “Our technology really lends itself to an application like that, using standard methods of manufacturing you cannot combine metals like you can with cold spray. Because you’re not heating the metal, it can be stronger than metal forged utilising standard methods.”

“By combining the metals to create a stronger product you can minimise the instances of having to replace barrels, something that is so pivotal in a conflict such as this,” Parsonson explained.

As Australia continues to ramp up its defence manufacturing, finding new ways to compete on a global scale will be imperative for its success.

While the potential for Titomic’s system to be used in large scale manufacturing like that of barrels is immense, Andrews and Parsonson believes misconceptions around the technology are holding it back. manmonthly.com.au

Additive Manufacturing The pair believe the preconception that additive manufacturing is reserved mostly for fine or complex pieces is holding back Australian manufacturers ability to truly capitalise on the manufacturing style.

“Titomic’s technology does not lend itself to those highly detailed and intricate parts that are so often associated with additive manufacturing, but in high-performance, largescale metals manufactured quickly” Andrews explained.

“The cold spray system works fantastically in conjunction with the machining industry,” he said. “Cold spray can make near-net shapes, or in other words, parts that are 95 per cent complete. Then, machine tools complete the final, fine stages to make a highquality product.”

Andrews and Parsonson spoke about Invar tooling, which is often used to produce carbon fibre aerospace components. The process lends itself to tooling, as industrial dies and moulds are often very large. The cold spray process manufactures these large parts to near-shape, leaving only 5-10 per cent of machining needed, as opposed to machining tens or hundreds of kilograms of material away from a billet to produce a tool. “They would contact their supplier and ask for a piece of Invar

and the response would be you would have to wait 18 months for that to arrive,” Parsonson said.

“Either the team waits 18 months, or they have to stock huge amounts of the material in their warehouse, sending costs through the roof,” he said. “Instead, they can come to us and say we need Invar in this rough shape, and we can get it to them in close to four weeks.”

Titomic, originally developed in collaboration with CSIRO, maintains its collaborative ethos. As Parsonson put it, “We are problem solvers.” Clients can approach them with a challenge, and Titomic can provide a tailored solution, ranging from selling the necessary machinery to entering a joint venture or manufacturing the part themselves.

“People can come to us in a range of ways but often they will approach us with a challenge they are facing, and we will help them to find a solution.”

“After they have come to us with the problem, we can sell them the machine they need, or we can enter into a joint venture with them, or we can even manufacture the part ourselves,” he explained.

A joint venture between Titomic and a manufacturer is mutually beneficial for both parties, utilising Titomic’s skills and materials to produce a strong product and then leveraging the manufacturer’s

The cold spray product is a slight deviation from standard additive manufacturing.

market access to send a successful product to market.

Parsonson explained that often they will develop capabilities themselves by completing research and sending it to organisations, who will then come on board. After developing a new product – thanks to a government grant – one customer joined Titomic to deliver the project to a wider audience.

Dispelling myths Parsonson went on to explain some of the misunderstandings around additive manufacturing in Australia and how

The Titomic product is an exciting development in the additive manufacturing space.

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cold spray manufacturing can benefit manufacturing locally.

“Metal additive manufacturing suffers from the vision that it is going to be the best thing since sliced bread and will destroy manufacturing as you know it – and that is simply not true,” he said.

“Our process works alongside traditional manufacturing. We are there to add to the traditional manufacturing network and find ways to do things faster, smarter, and better than we ever have before.”

The uptake of additive manufacturing has been impressive at tertiary institutions over the last decade or so, but Parsonson worries that as the technology deteriorates the next generation coming through will fail to reap the benefits of metal additive manufacturing.

“One of the challenges in Australia is getting universities to collaborate on investments in large metal additive manufacturing systems to open up new opportunities,’ Parsonson detailed.

“Not enough focus is put around vocational training,” he added. “Being used for research papers at universities is great, but those completing vocational training will be the ones using it, so we need to make sure they are learning how to use those machines.

“These guys might just end up buying a cheap plastic printing machine online and that satisfies no one, so we need to make sure we bring metal additive manufacturing into the vocational space so Australia can reap the benefits of this great homegrown system.”

Manufacturers’ Monthly AUGUST 2023 31

Aluminium certification

Capral is the first in Australia to achieve the certifications.

More than a piece of paper Capral has continued its push to improve the quality of the aluminium it is sending to market, announcing it has received certification from the Aluminium Stewardship Initiative (ASI) for the manufacturing of aluminium extruded products.

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NVIRONMENTAL concerns and Chain of Custody considerations are front of mind for the manufacturing sector and Capral has been working overtime to meet the best in industry standards.

Recently it achieved ASI performance standard V3 (2022) and Chain of Custody (CoC) standard V2 (2022) certification.

These certifications recognise Capral’s commitment to responsible production, sourcing, and management of aluminium products.

The ASI Certification program was developed through an extensive multistakeholder consultation process and is the only comprehensive voluntary sustainability standard initiative for the aluminium value chain. The ASI Performance Standard V3 and ASI CoC Standard V2 were launched in May 2022

32 AUGUST 2023 Manufacturers’ Monthly

following a multi-year revision process.

Capral’s CEO Tony Dragicevich spoke about the importance of achieving ASI’s certification for Capral and, by extension, its customers.

“As buyers become increasingly conscious of the environmental impact of products, Capral’s ASI certification is a significant achievement and reinforces our position as a responsible and sustainable business,” he commented.

“It has been a difficult journey; these standards set high benchmarks and are assessed rigorously by third-party auditors,” Dragicevich said. We can proudly hang our hat on the fact that we are the first Australasian aluminium extruder to achieve certification under the ASI Performance and Chain of Custody standards. Our management systems developed over many years

helped us achieve this in less than twelve months – a phenomenal effort by our team.”

The ASI Performance Standard centres around 11 principles assessed using 62 criteria with a focus on three sustainability pillars which include environment, social and governance standards. The aim of the voluntary program is to address pressing sustainability issues in the aluminium value chain.

The Performance Standard creates more accountability for users around biodiversity, indigenous people’s rights, circularity, and greenhouse gas emissions.

The ASI CoC Standard sets out requirements for the creation of a Chain of Custody for material that is produced and processed through the value chain

The announcement from Capral follows on from the recent release of the LocAl range.

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Aluminiumcertification into diverse downstream sectors.

The implementation of ASI’s CoC Standard links verified practices at successive steps of the supply chain – certified under the ASI Performance Standard – to the products produced by ASI Certified Entities. The CoC Standard also confirms that appropriate policies and due diligence processes are in place to identify and address critical issues, such as corruption, human rights abuses, materials originating from conflictaffected and high-risk areas in the supply chain, and support responsible sourcing.

The certifications apply to all of Capral’s 26 facilities, composed of mills, distribution centres and trade centres, across Australia. Capral Aluminium is the first extruded product manufacturer in Australasia to achieve ASI Certification.

ASI’s Standards apply throughout the supply chain, from bauxite mining through to downstream sectors that use Capral’s aluminium in their products.

After the release of Capral’s LocAl low carbon option for Australian Manufacturers, Capral can now provide ASI Chain of Custody association with these products allowing Manufacturers transparency and a clear process to show the quality of the aluminium used in products.

The general manager of industrial and procurement Luke Hawkins spoke about what the ASI certification will mean for Capral’s manufacturing clients.

“We view our ASI certification as an opportunity for our customers; it makes

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The certification from ASI will apply to all 26 Capral facilities.

it possible for them to communicate with confidence to their clients about the origins of the aluminium they are purchasing,” he said. “It allows them to choose certified material for their projects supporting their business sustainability initiatives.”

Fiona Solomon is the CEO at ASI and she delved further into the certificate and what it means for Capral and

aluminium suppliers globally.

“For companies like Capral that are in the downstream part of the aluminium value chain, traceability is critical for identification of potential environmental and social risks, which enhances accountability and helps to identify any non-compliance or unethical practices associated with the upstream supply chain,” Solomon said.

“Capral’s ASI Certifications demonstrate that it supports responsible sourcing, transparency, and accountability in its own operations along the entire aluminium value chain.”

The certification is just another step for Capral along the process of becoming a greener and more environmentally conscious company.

In early 2022 Capral committed to net zero by 2050 and then shortly after Capral joined the ASI initiative. The end of 2022 saw the arrival of Capral’s low carbon option.

The company has implemented various sustainability initiatives, including energy efficiency measures, waste reduction programs, and material recycling. Capral also works closely with its suppliers to ensure they meet the same high standards for sustainability.

These initiatives have allowed Capral to

reduce its environmental impact and improve its operational efficiency.

As the demand for sustainable products continues to grow, the ASI certification is likely to become increasingly important for companies across the aluminium value chain.

Capral’s certification is just the beginning of a new era of responsible and sustainable aluminium production.

Marc Banks, group ESG and risk manager, added that it is important to recognise the scale of this achievement.

“We certainly won’t stop here; we have set ambitious targets to reduce our greenhouse gas emissions by 30 per cent by 2030 and source 50 per cent of our electricity from renewable sources by 2025. and we are committed to making more lower carbon aluminium products available to the Australian market.”

ASI has more than290 members, include leading civil society organisations; companies with activities in bauxite mining, alumina refining, aluminium smelting, semi-fabrication, product and component manufacturing, as well as consumer and commercial goods, including the automotive, construction and packaging industries; industry associations and other supporters.

Manufacturers’ Monthly AUGUST 2023 33

Additive Manufacturing

Markforged has been empowering manufacturers for 10 years.

Celebrating a decade of additive manufacturing excellence Markforged has been at the forefront of additive manufacturing for the past 10 years, helping manufacturers revolutionise the industrial production landscape by bringing 3D printing right to the factory floor.

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ARKFORGED’S journey has been marked by groundbreaking innovations that have strengthened manufacturing resiliency, enabled industrial production at the point of need, and empowered manufacturers worldwide to create strong, accurate parts in both metal and advanced composites.

The Markforged story began in 2013 with years of research and development, culminating in a milestone achievement in 2014 when the company unveiled the world’s first 3D printer capable of printing in continuous carbon fibre.

This advancement opened new possibilities for manufacturing stronger and more resilient parts. A year later, the company launched Eiger, its cloudbased 3D printing software. With Eiger, Markforged offered a user-friendly platform that merged the advancements 34 AUGUST 2023 Manufacturers’ Monthly

of its printers, materials, and software into one cohesive ecosystem – the Digital Forge.

Empowering modern manufacturers The Digital Forge is Markforged’s intuitive additive manufacturing platform and has become the go-to solution for modern manufacturers seeking to optimise their production processes. With over 10,000 customers in over 70 countries, the company has brought on-demand industrial production to the point of need.

By utilising both metal and advanced composites, manufacturers can create strong, accurate parts with exceptional durability. This capability has become increasingly important, especially in times of supply chain disruptions, as it reduces lead times and ensures uninterrupted production.

Headquartered in Waltham, Massachusetts, Markforged continues to design reliable and user-friendly hardware, software, and advanced materials to empower Digital Forge. Today, Markforged generates yearly revenues of around US $100 million, which is no small feat in the additive manufacturing industry.

Shai Terem, the President and CEO of Markforged, left a successful career in the finance industry to pursue disruptive technologies that could make a positive impact on the world.

“I believe Digital Forge is one of the most reliable platforms out there because it is very intelligent, gets better over time and is very easy to use,” Terem said.

“When adoption of a platform like this for mission-critical parts happens, you will see more and more parts go from physical inventory to digital inventory, which means more cost savings and efficiency in

the entire ecosystem.”

Speaking about Markforged’s vision, Terem emphasised the importance of creating high-value, end-use manufacturing applications that solve supply chain challenges. He highlighted the growing adoption of additive manufacturing, driven by the need for local production and reduced dependency on external suppliers.

Making strides in Australia Numerous Australian companies in industries including manufacturing, food and beverage, mining, automotive, defence, aerospace, machine shops, construction, and medical, have embraced Markforged’s additive manufacturing technology, paving the way for innovative solutions and cost savings without compromising on quality.

“I think there’s an internal driver in manmonthly.com.au

Additive Manufacturing Australia which combines innovation culture with real manufacturing capabilities,” Terem said. “For Markforged, we are manufacturing-focused and in Australia, there is a real need and real adoption.”

Richard Elving, Senior Director for Australia at Markforged, said the company’s strategic partnerships, along with the prioritisation of same-day service and support, have played a crucial role in the company’s success in the region.

Over the past five years, Markforged has rapidly expanded its presence in the country, establishing demonstration centres in major cities such as Melbourne, Perth, Sydney, Adelaide, and Brisbane.

By partnering with local businesses, the company has enabled Australian manufacturers to enhance in-house manufacturing efficiency and reduce reliance on external suppliers.

WA-based medical device equipment manufacturer Avicena was quick to recognise the contribution 3D printing could make to the manufacture and ongoing operation of its ground-breaking Sentinel Biosecurity Platform, an accurate, rapid and scalable molecular diagnostic instrument capable of detecting diverse pathogens, including COVID-19.

According to Avicena’s CEO, Tony Fitzgerald, the two industrial Markforged 3D printers in the company’s Perth office play a “small but significant” role in the company’s operations. Components of the Sentinel system are designed – and are now produced – in-house on the two printers.

“In the early iterations of Sentinel, most small components were made of aluminium, and many were sourced as ready-made items. As we progressed, we redesigned many of the parts to improve functionality, and in many cases upgraded the materials we used to increase component strength,” said Fitzgerald. “This is just one of the reasons we regard our 3D printers as an important part of our supply chain.”

Elving added, “Avicena has leveraged 3D printers to customise and produce complex end-use components, enabling faster time-to-market and improved customer outcomes. Over 100 components are now produced in-house, by 3D printing carbon fibre composites, rather than casting overseas.”

SQP Engineering, a familyowned business providing industrial manufacturing solutions, represents manmonthly.com.au

Richard Elving is the Senior Director for Markforged Australia.

another successful adoption story. The implementation of Markforged’s FX20 and Metal X systems has enabled SQP to deliver better solutions to its customers and explore new markets, including medical, aviation, and agriculture.

SQP Engineering needed to produce a wireline counter cover for mining equipment systems, but their existing equipment and 3D printer couldn’t meet the requirements. Markforged’s FX20 3D printer proved to be the perfect fit. It reduced the printing time for the wireline counter cover from nine hours to two and a half hours and improved the surface finish of the printed parts, impressing customers.

In addition to the FX20, SQP Engineering acquired the Markforged Metal X system to enhance its additive manufacturing capabilities. With these technologies, they can now manufacture a wide range of production-grade parts that are difficult to machine, offering better pricing and faster turnaround times.

Moving forward, SQP Engineering plans to leverage the FX20 and Metal X system to expand into industries like medical, aviation, and agriculture.

Markforged’s impact goes beyond commercial applications, extending into the defence industry as well. Secure Bits, a completely veteran-owned Australian business, has been working with Markforged to provide critical solutions to the defence sector.

By providing 3D printers and collaborating on special projects,

Markforged has enabled Secure Bits to enhance its manufacturing capabilities and generate new leads. Moreover, Markforged’s comprehensive data security measures align with Secure Bits’ focus on security and confidential operations. Markforged’s Digital Forge platform ensures that data remains secure, enabling Secure Bits to use the printers on-premise without compromising sensitive information.

Additionally, Markforged’s printers produce high-quality parts, making them suitable for various defence applications.

For instance, Secure Bits utilises Markforged printers to demonstrate an Air Force simulation system that requires rapid production of lifelike components.

Additive manufacturing is gaining prominence in defence, both strategically and in deployable environments, due to its ability to quickly solve problems and fabricate replacement parts.

Looking ahead, Markforged remains committed to pushing the boundaries of additive manufacturing, both globally and locally in Australia.

“I really hope to collaborate with Australian innovation and to have millions of parts printed here for the products that are being innovated and produced in Australia,” Terem said.

As Markforged celebrates its tenyear anniversary, Elving encourages businesses to consider bringing additive manufacturing into their supply chains.

“As Australian manufacturers navigate the challenges of the evolving global economy, the adoption of 3D printing technology emerges as a compelling solution. By embracing automation, digital transformation, and additive manufacturing, businesses can reshape their operations, overcome traditional constraints, and unlock new opportunities for growth,” he said.

“With successful case studies of local manufacturers leveraging 3D Printing technology, the path to a thriving and resilient manufacturing sector in Australia becomes clearer than ever before.”

The Markforged 3D printers are having a major impact on Australian manufacturing.

Manufacturers’ Monthly AUGUST 2023 35

Greener Infrastructure Conference 2023 18–20 September 2023 Melbourne Convention & Exhibition Centre

Registration is now open.

Victoria’s infrastructure industry is joining forces to create a greener future and deliver purposely greener projects. Be part of the change.

Scan code to register ecologiq.vic.gov.au/conference-2023

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The three-day conference will feature industryleading speakers, expert panels, networking events and a trade hall that’s bigger and better than ever.

Hoisting Equipment Turning to Australian made The Portalift vehicle hoists from Endurequip were recently featured throughout the Australian Made Campaign. Manufacturers’ Monthly delves into the Portalift range and how it can benefit the automotive service industry.

The Endurequip Portalift hoists can be used indoors or outdoors and are simple to move.

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NDUREQUIP Hoists is an Australian Heavy Vehicle Hoist brand with a history of more than 30 years of delivering workshop lifting and handling solutions to the heavy vehicle industry, public transport, logistics, mining and rail industries.

Endurequip Hoists has been part of RUD Australia since 2015 and all Endurequip manmonthly.com.au

products are manufactured at the RUD facility in Brisbane at its state-of-the-art 6000 square-metre factory.

Featuring the Australian Made logo, the Endurequip Portalift is a portable hoist system that can lift up to 7.5 tonnes per post or 30, 40 or 60 tonnes when used in a combination of four, six, or eight hoists. Portalift hoists can also be

customised for railway workshops, fire brigades and local authority workshops.

Endurequip offers a structural manufacturer’s lifetime warranty with onsite service and authorised service centres Australia-wide.

Endurequip also offers a complete range of workshop lifting and handling solutions such as:

• • • • • • • •

Drive On/Off Ramps Vehicle Stands A-Frame Trailer Adaptors Mobile Gantry and Transport Frames Safe Work Platforms Workshop Trestles Tyre Stillages Workshop and Transit Trolleys Manufacturers’ Monthly AAUGUST 2023 37

Hoisting Equipment Gemilang (Nexport) Australia Established in 2009 and headquartered in Mitchell Park, Ballarat, Gemilang Australia (currently Nexport P/L ) is a designer, manufacturer, and distributor of aluminium buses for the Australian and New Zealand markets. The company has 16 employees and has produced more than 300 buses. It turned to the Portalift system for its manufacturing process.

Nexport was commissioned to fabricate new buses for the Victorian government.

In order to fulfil the manufacturing requirements, Nexport needed heavy vehicle hoists and stands that would provide full underbody access to the buses’ ‘bird cages’ during assembly. They needed the equipment to be durable, high-quality, and safe to facilitate efficient bus assembly work and ensure workplace safety.

Nexport approached Endurequip upon the recommendation of the Victorian family-owned bus operator Dysons Group.

Dysons’ Sam Distefano, Group Manager of Fleet Services, advised Nexport to turn to the Endurequip range as it would suit the needs of the company.

Supporting an Australian Made brand was a major positive for Nexport and bringing RUD and Endurequip on board

The Portalift system has been built to withstand wear and tear.

with four Portalift heavy vehicle hoists was a simple decision.

The Portalift system chosen by Nexport is rated up to 30 tonnes, well exceeding the weight requirements they needed but ensuring the team could work well within safe limits.

The Endurequip vehicle stands

enabled Nexport to simultaneously access and work on various vehicles and machinery. With the ability to be easily adjusted they had the added advantage of being easily moved around the workshop to suit the needs of the team.

Another company turning to the Endurequip range was Queensland

Users have been impressed with the system and the customer service from RUD.

38 AUGUST 2023 Manufacturers’ Monthly

small business Dan’s Truck Detailing.

Dan required a safe solution for his hoisting needs and turned to the Endurequip range.

“Through working in the truck game for a while, I have seen a lot of truck hoists and Endurequip’s Portalifts are the most convenient and portable for a oneperson job,” Dan said.

“I have seen other brands in my time in trucking, but we find the Endurequip offers the most safety. Obviously, there’s a risk working under there all day, so we want the best for our employees.

It really is a small price to pay for a lot of security.”

“The high-quality design makes these hoists super durable – they’ve been up and down thousands of times and they do their job every time,” he said.

Dan went on to explain how fantastic the service has been from the Endurequip team and the peace of mind he has working with the hoists.

“The customer service from the Endurequip team has been outstanding,” Dan acknowledged.

“A specialist came out to set up the hoists and took the time to train us in the use of the machine; he continues to visit the site to maintain the hoists which is a major plus for us,” he said.

“Being locally manufactured was a major plus for us too. It is a lot less stressful knowing that you have the Endurequip team on your doorstep ready to help.” manmonthly.com.au

Melbourne Convention and Exhibition Centre

REIMAGINING THE SUPPLY CHAIN

MEGATRANS returning 18-19 September 2024 BOOK YOUR STAND TODAY

megatrans.com.au MEGATRANS is Australia’s largest integrated conference and exhibition dedicated to the logistics industry. MEGATRANS will showcase the latest in artificial Intelligence (AI), robotics, automated racking, telematics and route optimisation, warehouse automation, intelligent fleet systems, blockchain, Internet ofThings, big data and advanced analytics.

Industry Events SEMMA celebrates 20 years Manufacturers’ Monthly was in attendance at SEMMA’s gala dinner in which the organisation celebrated its 20th year serving the South East of Melbourne.

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HE South East Melbourne Manufacturers Alliance (SEMMA) got its start 20 years ago and the story has taken on a life of its own in the years after. Whilst many of its founding members disagree whether it was over a breakfast or a dinner, they do know it was born from the South East Business Network (SEBN) after identifying a need to better support local manufacturers and protecting rail manufacturing.

Sandra George is the Manager at the SEBN and is the Secretary at SEMMA and she spoke about how SEMMA was born over 20 years ago.

“At the annual dinner in 2002 for SEBN, discussions were had on protecting the rolling stock industry that was under threat at the time and how we could better protect it,” she said.

“Taking on board the concerns raised, then CEO of Greater Dandenong Council, Warwick Heine (through SEBN) sought interest in creating a local Manufacturing Association to be the ‘voice of local SME manufacturers’.”

The manufacturing interest in this initiative was strong, with a small group of businesses, facilitated and supported by council, taking the lead on designing and creating the South East Melbourne Manufacturing Alliance (SEMMA), becoming incorporated in early 2003.

The organisation has now grown to more than 200 members with a combined total of employees exceeding 16,000 across those companies.

SEMMA CEO Honi Walker opened the event outlining the humble beginnings of the alliance and celebrated what it has become.

“If we look at the Victorian manufacturing landscape back in 2003, there was every chance it was thought of as dirty, dumb, and dangerous,” she said.

“Due to earlier government decisions, we’d lost our tech schools and, as the recruiting ground for manufacturers – this also affected our supply of qualified tradespeople, engineers, welders and general factory staff as students were directed to universities, retail or hospitality.”

40 AUGUST 2023 Manufacturers’ Monthly

“Major Australian manufacturing sectors (footwear, fashion, light consumer goods) went offshore for financial reasons and the age of mass consumerism and the internet changed our buying habits,” she said.

Walker went on to detail how manufacturing in the South East of Melbourne bounced back from this.

“After surviving a global pandemic and breaks in our international supply chains, the Australian Federal Government realised we needed to bring back manufacturing,” she explained.

“Our ‘Sovereign Capabilities’ were suddenly a feature of Minister’s statements and departmental directives,” Walker said She went on to explain how SEMMA has become a voice for South East Melbourne and changed the thinking behind modern manufacturing.

“Manufacturing is now smart, secure and sustainable,” Walker said.

“The next twenty years for SEMMA will be focused on assisting our members to be part of the new technology growth areas of Ai, robotics, automation and assist them to connect and collaborate with their peers and government while ensuring a pipeline of qualified staff is developed.”

“SEMMA will assist our members to seek new avenues in defence and space, transport, health technologies, digital and advanced technologies, and food manufacturing as well as import replacement and export markets and the burgeoning sector of renewable energy. ” SEMMA took the opportunity at the event to honour its founding members with each receiving a trophy commemorating the commitment they had made to the alliance.

“The members and the team at SEMMA wishes to express our gratitude and appreciation for the founding members who established this remarkable alliance back in 2003,” Walker said.

“Their collaborative spirit and commitment to advancing the manufacturing industry in our region have helped shape SEMMA into the influential organisation it is today and

The Hon Ben Carroll MP opened the gala speaking to the importance of the organisation and its support for the industry.

Manufacturing is now smart, secure and sustainable setting a foundation that continues to benefit the entire manufacturing community,” she said.

SEMMA president Peter Angelico from ABECK Group spoke of what manufacturing will look like moving froward.

“Manufacturing holds immense significance for the Australian economy, it contributes significantly to employment, exports, and innovation,” he said.

“The manufacturing sector employs a substantial workforce, providing skilled and stable jobs to thousands of Australians. It also drives economic growth through its supply chains, creating opportunities for various sectors, such as logistics, technology, and services.”

“Moreover, manufacturing plays a

pivotal role in Australia’s export industry.

The sector produces high-quality goods that are in demand globally, generating substantial export revenue and fostering international trade relationships.”

“Australian-made products are recognised for their excellence, reliability, and adherence to stringent quality standards, giving the country a competitive edge in the global marketplace,” Angelico said.

Angelico went on to explain how SEMMA supports manufacturers in the south east.

“The founding members of SEMMA recognised the crucial aspects of manufacturing and understood the need for a collaborative approach to address the challenges faced by the industry,” he said.

“Through their efforts, SEMMA has manmonthly.com.au

Semma Update

Victorian Rail Advocate & Founding Member, Jill Walsh spoke about SEMMA’s proud history and its support for the rail sector. become a driving force, advocating for the manufacturing sector’s interests, facilitating networking and knowledge sharing, and offering support to businesses,” Angelico said.

manmonthly.com.au

The event was an opportunity to celebrate SEMMA’s founding members.

He went on to praise the organisation for its hard work and dedication.

“SEMMA owes its success to the dedication and vision of its founding members. Their recognition of the

importance of manufacturing to the Australian economy has paved the way for SEMMA’s crucial role in supporting the sector’s growth and development.”

“Manufacturing continues to be a

vital industry in Australia, providing employment, driving exports, and fostering innovation, making it an integral part of the nation’s economic landscape.”

Manufacturers’ Monthly AUGUST 2023 41

Women in Industry Awards Phillips takes out top award

Giselle Phillips took home the sfaety advocacy award before winning the woman of the year.

Giselle Phillips from Fredon Queensland took out the safety advocacy award before winning the woman of the year award at the Women in Industry awards.

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HILLIPS originally started her career working in the hospitality space before moving into events management in her home country of South Africa. Coming across to Australia she worked in hotels before realising the work life balance did not suit her.

Phillips’ eye for detail saw her make the move to Origin Energy, first organising meeting rooms and – as the company grew – her job expanded to managing that over five buildings as a team lead before a knock came on her door..

“The company approached me and said that I had a really good eye for detail and worked well with stakeholders and subcontractors, they asked if I had considered workplace health and safety,” Phillips said.

“After a period working for them across sites in Queensland I took some time off to be with my family and I came back to work for Fredon in the health and safety space.”

Phillips went on to explain her passion for workplace health and safety and what she is doing that might be a little outside the norm.

“I think there is a misconception around health and safety that it is all about policing or that it is very data driven,” Phillips said.

“For me it is a collaboration, I am

educating people and taking them on a journey, and I am bringing ideas from a range of different sources,” she said.

Coming on board at Fredon gave Phillips the opportunity to work on a blank canvas and bring a new approach to safety for the company.

“I had to do a lot of relationship building when I first arrived and it was important to speak with stakeholders to understand the processes in place,” she said.

“I wanted to bring my creative flair to the role and take the bull by the horns and roll out exciting programs and work collaboratively.”

“It was all about getting buy in and understanding around what people wanted from me and by doing that, I was able to cultivate a safe space in which trust has been built,” Phillips explained.

A range of programs have been implemented at Fredon. Phillips explained what she has been most proud of: “When I started each project was running like silos, I wanted to create a smoother process that made information easier to share and onboarding even simpler for new starters,” she said.

“Another project I have been supremely proud of is our well-being initiatives.

Some people may feel mental health and well-being is outside the remit of workplace health and safety, but I completely disagree.”

Phillips was extremely proud to take out the top award.

42 AUGUST 2023 Manufacturers’ Monthly

“I came to realise very quickly the construction industry has struggled with suicide and depression and there is a stigma around that,” Phillips explained.

Bringing strong mental health support to Fredon was a big part of her goals for the role.

“I worked closely with other companies who had implemented strong ideas around mental health support and bring them into what we are doing here,” she said.

“We did things like Funky Friday Hi-Vis Shirts and scarves to bring awareness to mental health on the jobs.”

“We brought advocates in as well to discuss what we can be doing better to support one another and showing that people should not be afraid to speak up if they are struggling,” she said.

Phillips went on to explain why as a company it was important for Fredon to focus on mental health.

“If someone’s mental health is suffering their work will absolutely suffer as well so supporting mental health is vitally important,” she said.

“At the end of the day, if someone’s not feeling good, they might risk not only their life, but somebody else around them because of negligence or them not being able to focus on the tasks they are working on.”

“Then once we know someone is struggling, we can make rotations and maybe bring them into the office for the day, just to make sure our team is looked after” Phillips said.

Phillips discussed what it meant winning both the safety advocacy award and the woman of the year award at the event.

“I had my CEO with me at the event and it was so fantastic to have his support, he could see my passion for the role and what it meant for me,” she said.

“I did not see myself winning the woman of the year award, I was surrounded by incredible women, so it was an absolute honour,” she said.

“I just wanted to say when I was up there that women need to support each other as much as we can, winning that award was not just for me but for women everywhere who are fighting for change and improvements.” manmonthly.com.au

Women in Industry Awards Kurianski a rising star Sophia Kurianski is the founder of 3D file sharing company Jinolo and recently took out the rising star award at the Women in Industry awards night.

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HE Jinolo product was developed

by Kurianski after identifying a shortcoming in current models of data and file sharing between engineers.

Kurianski had recognised that engineers were sharing files and designs by manually handing each other flash drives and wondered if there was a better way for this to happen.

“It came from the idea that it was extremely challenging to share 3D designs as it stood, Dropbox and Google docs simply could not keep up with the requirements for sharing 3D CAD,” she said.

The growth of Jinolo is an exciting prospect for Kurianski.

manmonthly.com.au

“So, we began a consultation process with people to understand what they needed.”

“COVID was the real catalyst for the business taking off as organisations realised, they could not share information in the way they had anymore and they needed to go more digital with what they were doing,” Kurianski explained.

The Jinolo program allows the CAD file to be uploaded to the cloud-based system and in turn can allow users to make adjustments and comments. It can be used like a whiteboard but in a 3D model.

Kurianski was surprised to take out the award ahead of so many impressive women.

Kurianski explained what the program is being used for.

“You will see people mostly using it for clients, the way it is built is for people who may not understand engineering speak to use it clearly,” she said.

“When you first open a regular CAD file it can be incredibly confusing to look at, so Jinolo is all about making it simple and allowing various areas to make comments and suggest changes.”

“This program will allow greater collaboration throughout industry, and we are seeing a range of manufacturers turning to it. We recently sold it to single freelancers, and we will also sell to bigger design houses, so it really has a use for varying spaces,” Kurianski said.

Winning the rising star award is not a sign that Kurianski will be stopping anytime soon, and she has big plans for the future.

“As it stands it is all about honing what we have and making it the best product we can for our customers right now, we can see potential in the future to incorporate AI and exciting things like that but at the moment it is about delivering on the product we have,” she said.

“We are very happy with how the company has been progressing since we started it, the growth has been great, and the feedback has been positive, but it is about listening to customers and ensuring we are delivering,” Kurianski said.

Kurianski spoke about the rising star award and what it meant for her.

“I honestly did not expect to win the award, we had our networking event before and there were so many impressive women there and I was just happy to be nominated alongside them,” she said.

“I didn’t expect to win something like this five years ago, I was only just beginning my engineering journey at university, and I never expected to have my own start-up five years later and winning an award like this,” Kurianski explained.

Kurianski had some encouraging words for women who were considering moving into the manufacturing and engineering spaces.

“I think for women going into the manufacturing and engineering space it is about finding your passion and that will help with maybe the intimidation around it being a male dominated space,” she said.

“Once you find the area you are passionate about, you can find the people who want to tinker and build things alongside you and by doing this you can get over the fears associated with joining these industries.”

“I always found when you found your niche people did not care what your gender was, they just wanted to work in that space with people who shared their interest.”

Manufacturers’ Monthly AUGUST 2023 43

CONGRATULATIONS! For the past 7 years, Atlas Copco Australia have been a proud sponsor of the Women in Industry awards, namely, the Rising Star of the Year award.

These awards are a special way in which we can show our commitment to advancing gender balance in industry. As a global company, we recognise the link between diversity and as we say, “there is always a better way.” Contributing to these awards is just another way that we can show that we recognise the talents and achievements of females across our industry. Congratulations to all of the finalists and this year’s winner, Sophia Kurianski! www.atlascopco.com 1800 023 469

0823_AtlasCopco_WININ_FP.indd 1

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10:52 PM

Abrasives Event ATGE Brings New Opportunities to Australian Manufacturing The Australia Hardware Tools & Grinding Expo (ATGE), will open at the Brisbane Convention and Exhibition Centre on December 4th this year.

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BRASIVESTOCKS has worked closely with the China Hardware Association to open the International Hardware Tool Grinding Expo in Brisbane, to inject vitality into the Australian tool and grinding field. This international show is also supported by the Australian Hardware Association.

Dever Yang is the CEO of Abrasivestocks and he spoke about what the expo means for Australia and the history of Abrasivestocks.

“Seven months ago, we established the Australian branch in Brisbane,” he said.

“In the past five years, Abrasivestocks established itself in Zhengzhou, the capital of grinding in China, and is a wellknown factory to business platform for the grinding industry chain in China.

“In the past five years, we have provided services for the Chinese supply chain, serving more than 30,000 abrasives companies, handling millions of tonnes of

abrasive inventory, and playing a unique role in facilitating global communication between abrasive producers and buyers,” Yang said Dever Yang spoke about the motivation for setting up a subsidiary in Australia.

“By setting up a subsidiary here, we have the opportunity to introduce the best Chinese grinding tool brands and its supply chain capabilities into the Australian market and support Australian manufacturing and promote in-depth cooperation and exchanges between China and Australia,” he said.

Yang further explained why Australia was chosen as the location for the expansion, and the goals he set after forming the company.

“We know that Queensland’s resources and material base are world-renowned.”

“The state government is vigorously attracting new materials, new energy, and innovative manufacturing companies to support Queensland’s manufacturing industry,” he said.

“Brisbane, as the capital of

ATGE will be held at the Brisbane Convention and Exhibition Centre.

Queensland, is a fast developing city, especially with the Olympic Games coming, we hope to be a participant in the growth of Brisbane and to help more enterprises in the industrial chain, show the development of Brisbane to the world, and attract more entrepreneurs to contribute to the progress of Queensland and contribute to the Made in Australia campaign,” Yang explained.

In recent years, the Australian government has recognised the need to move beyond the stereotype of an agricultural and mining powerhouse to make Australian manufacturing a global

The event will encourage collaboration between China and Australia. manmonthly.com.au

player Yang explained.

“Australian biomedicine, CNC, additive manufacturing, and the high energy efficiency of solar energy also play a pivotal role in the world,” Yang said.

“Australia already has sufficient basic conditions, which will greatly promote the growth of industrial demand.”

“I firmly believe that the introduction of Chinese high-quality grinding products and automated grinding production equipment to Australia will provide more choices and opportunities for local manufacturers and investors.” Yang said.

“This will strengthen the economic cooperation between China and Australia and achieve mutual benefit and winwin results. Embracing globalisation is the general trend. Of course, we welcome more Australian manufacturing entrepreneurs to come to China, to my hometown, Zhengzhou, the grinding capital,” he said.

During the exhibition in December, many tool and grinding manufacturers will gather in Brisbane.

In 2024, ATGE will also select 10 to 20 companies from among the Australian exhibitors who participated in the exhibition this year. The whole process is free, and a group will go to China to investigate the increasingly excellent Chinese grinding manufacturing.

ATGE will be another international hardware and tools fair in the southern hemisphere and the fifth largest grinding exhibition in the world.

Manufacturers’ Monthly AUGUST 2023 45

Predictive Maintenance What does a successful predictive maintenance program look like?

To protect your assets, you need to predict. Manufacturers’ Monthly explores the distinction between predictive maintenance and condition monitoring, as well as the key components of a successful predictive maintenance program.

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ONDITION monitoring is a maintenance approach that involves monitoring the performance and health of machines or equipment continuously to identify signs of potential issues or deviations from normal operation. Predictive maintenance is a proactive approach that utilises data analysis to predict when maintenance will be needed, allowing manufacturing companies to reduce

downtime and minimise maintenance costs.

While both approaches hold value, predictive maintenance stands out as a proactive strategy that leverages data analysis to predict maintenance needs.

Freddie Coertze, the national business manager for ifm Australia, explains, “If I were to summarise the key differences it would be to say that condition monitoring is a reactive approach to maintenance

management that focuses on identifying problems as they occur, while predictive maintenance is a proactive approach that uses data analysis to predict when maintenance will be needed.

“Both approaches can be valuable, but predictive maintenance is defined by the word ‘predict’. It has the potential to provide greater benefits by reducing downtime and minimising maintenance costs.”

According to Coertze, there are three components that are crucial to ensure the success of a predictive maintenance program an Internet of Things (IoT) platform, condition-monitoring hardware, and –predictive formulas provided by artificial intelligence.

“To have visibility of assets, you need the connectivity and integration that digitalisation provides,” Coertze remarks.

“To help our customers simplify this

Predictive maintenance can help manufacturers reduce maintenance costs.

46 AUGUST 2023 Manufacturers’ Monthly

manmonthly.com.au

Predictive Maintenance integration, ifm created moneo – a selfservice software platform that acts as a middleware to existing systems such as SCADA.” The moneo solution by ifm combines operating and information technology to bring the power back into the engineer’s hands. It has an inbuilt DataScience Toolbox that enables operators and engineers to leverage their knowledge of equipment with the benefits of AIassisted predictive analytics and machine learning.

“Successful predictive maintenance is about detecting anomalies to machine performance early and automating the actions surrounding that deviation so that not only are notifications sent, but actions are prescribed to fix the issue,” explains Coertze. “It’s having full integration from the shop floor to the top floor.”

Currently, while condition monitoring is widely used, there is a disconnect between the data collected by sensors and the workflow, says Coertze.

“Many industrial businesses still rely on manual processes in terms of how their sensor data is analysed and maintenance is performed. Many businesses are still using a preventative or scheduled maintenance approach – they might look at vibration on componentry but it’s not going to give them the insight or ability to solve real equipment issues in advance,” he explains.

“I am of the opinion that this type of condition monitoring – where it is applied within a manual context of action – provides information too late to make a significant difference.”

The moneo solution supports successful predictive maintenance by

providing the platform, the sensor hardware, and the software that supports AI-assisted predictive formulas.

“To explain simply how it works, we would first connect the sensors to the equipment, then we would collect data from the sensors and the moneo software will identify baselines and set parameters and limits as to how the assets should be performing,” he says.

“If the system detects an anomaly, a ticket will be sent to staff to investigate with a prescribed action to first check and then rectify the problem. This same predictive maintenance workflow is then applied to everything within the operation or plant.”

There are many benefits that come with implementing successful predictive maintenance – namely better longevity of equipment, improved productivity onsite,

and improved efficiency, particularly in the use of energy. Predictive maintenance will do more than prevent downtime, it will help keep equipment always running optimally.

“Condition monitoring with vibration analysis is simply not enough – by the time vibration has started, it’s often already too late to intervene and save the machine. To protect your assets, you need to predict. That’s why having a predictive maintenance program is important and moneo can ensure that this program is implemented with success,” Coertze concludes.

By adopting a predictive maintenance program supported by tools like ifm’s moneo, manufacturers can achieve optimal equipment performance, prevent downtime, and ensure efficient operations.

ifm Australia’s moneo puts the power back into the engineer’s hands.

manmonthly.com.au

Manufacturers’ Monthly AUGUST 2023 47

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Events

The robotics event will showcase some of the most advanced machines available on the market.

A roadmap for robotics to enhance Australia’s modern manufacturing capabilities CEO of the International Exhibition & Conference Group Marie Kinsiella spoke with Manufacturers’ Monthly about the state of robotics in Australia in the lead up to the 2023 Modern Manufacturing Expo.

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S industries that have always prioritised innovation as a way to make processes more efficient and cost-effective, manufacturing and robotics have a long and illustrious history together.

The manufacturing sector was the first to recognise the potential of robotics, with industrial robots appearing on the factory floor of automotive manufacturer, General Motors, as early as 1961.

Fast forward to the present day and the controlled manufacturing environment is seen as the ideal testing ground for new robotics and automation systems.

Here, highly skilled workers are on hand to oversee these systems and ensure their high performance.

CEO of the International Exhibition & Conference (IEC) Group Marie Kinsella explained the relationship between robotics and manufacturing.

“Robotics represents the peak of new technologies and is hugely valued by manufacturers for its ability to incorporate both automation and Artificial Intelligence,” explains Kinsella.

“That’s why we’re thrilled to

manmonthly.com.au

have the prestigious industry body, Robotics Australia Group, onboard as a Supporting Partner of the 2023 Modern Manufacturing Expo.”

The free-to-attend Modern Manufacturing Expo takes place from 20th to the 21st of September 2023 at the Sydney Showground in Sydney Olympic Park. It will showcase the latest in manufacturing processes and technologies needed to power up operations and boost the speed at which new concepts and products are brought to market.

Much like the collaboration-focused Modern Manufacturing Expo, Robotics Australia Group is designed to instil a focused, collaborative approach between industry, research, government, startups, investment, and education to build a robust and world-class robotics ecosystem within Australia.

in Australia, and to identify the challenges and opportunities available for robotics in the country.

It includes a detailed analysis of the role of robotics in 13 of Australia’s most essential industries, including manufacturing, and the sector-specific challenges and opportunities needed to develop robotic capabilities.

“Reshoring manufacturing has long been a priority for both Australia’s public and private sectors but high operational costs and an over reliance on overseas imports have proven to be a difficult challenge to overcome,” Kinsella explained.

“Increased adoption of robotic technologies may be what’s needed to compete on a global scale and strengthen our sovereign capabilities, and this will be a prominent topic of discussion at the Modern Manufacturing Expo in September,” she said.

A clear roadmap for developing Australia’s robotics ecosystem

‘Simply not enough robots’

In 2022, Robotics Australia Group released a detailed Robotics Roadmap for Australia publication to raise the profile of robotics

Unfortunately, while the manufacturing sector has been quick to embrace the potential of robotics, Australia

as a whole has lagged behind other developed countries.

The roadmap observes that not only does Australia not develop its own industrial robots, but that the number of installed industrial robots has declined since 2014 by 14 per cent, compared to an increase of 60 per cent worldwide. This has caused Australia to drop from a ranking of 18th to 35th out of 37 in the world in robot density in the manufacturing industry.

Another factor contributing to low robot population density is the lack of uptake from SMEs who find that large-scale automation solutions are either unsuitable for their operations or too costly.

“This trend is not limited to robotics, as we have heard time and time again that while small manufacturers are enthusiastic about the potential of Industry 4.0 technologies, they simply cannot afford the upfront investment,” Kinsella said.

“That’s why a core purpose of the Expo is to connect manufacturers with industry advocacy groups like the Robotics Australia Group.”

“We want to make manufacturers Manufacturers’ Monthly AUGUST 2023 49

Events Marie Kinsella is the CEO of the International Exhibition & Conference (IEC) Group.

aware of the resources and financial grants available through government-backed schemes like the National Reconstruction Fund (NRF), which has made a substantial provision for increasing the uptake of robotics in Australia,” she added.

What lies ahead The manufacturing section of the roadmap concludes with the finding that Australia has a specific need for robotics to act as a force multiplier - augmenting and extending world-class, skilled human capability while reducing human exposure to dirty, dull and dangerous processes.

To achieve this, the roadmap outlines the following achievable five-year goals: • Educate local suppliers in ‘skill multiplying’ cobotics or robotics, so they can best allocate human, robotic or shared operations in the completion of tasks.

Enhance automation simulation capabilities (humans and machines) allowing for the application of synthetic data to ensure successful and sustained process improvement.

• Development of more capable cobots.

• Design and prototype a $2,000 “skillmultiplying” robot through modern sustainable technologies.

“It is clear that intelligent robotic systems which can easily and rapidly adapt to new product lines based on demands and realtime needs, are key to removing Australia’s reliance on global supply chains and overcoming our skilled labour shortage,” Kinsella said.

“We look forward to the thoughtprovoking discussions and innovative solutions that will be showcased at the 2023 Modern Manufacturing Expo through our exciting partnership with Robotics Australia Group.”

•

The event will be held from 20-21 September at the Sydney Showground.

50 AUGUST 2023 Manufacturers’ Monthly

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Engineering Focus Fighting climate change with a household ingredient Researchers have unlocked an industrial process that harnesses excess atmospheric carbon dioxide to produce acetic acid. Lead researcher Akshat Tanksale sat down with Manufacturers’ Monthly to discuss details of this cutting-edge development and its implications for the wider industry.

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S the world grapples with the growing threat of climate change, scientists and researchers are exploring innovative solutions to combat rising carbon dioxide levels. In a remarkable breakthrough, a team of chemical engineers at Monash University has developed an industrial process to produce acetic acid that not only utilises excess carbon dioxide from the atmosphere but also has the potential to create negative carbon emissions. This ground-breaking discovery showcases how sustainable technology can transform a greenhouse gas into a valuable resource.

Carbon dioxide, a greenhouse gas primarily produced from burning fossil fuels, accounts for a significant portion of the world’s greenhouse gas emissions, which contribute to global warming.

L-R Rajan Lakshman, Prof Akshat Tanksale, Dr. Swarit Dwivedi, a postdoctoral research fellow in the group and one of the co-authors.

Importance of carbon capture and utilisation The pressing need to combat the current climate crisis and reduce carbon dioxide (CO2) emissions has driven researchers to explore carbon capture and utilisation.

The challenge of carbon capture has loomed large, with various attempts to store excess carbon dioxide underground yielding limited success.

“Carbon capture and storage is important and has been researched and trialled for decades now. It is important to sequester carbon dioxide so that it does not go back into the atmosphere. Carbon sequestration has yielded limited success so far, including at the Gorgon Carbon Capture and Storage (CCS) project,” said lead researcher Professor Akshat Tanksale.

The Gorgon project is one of the world’s largest carbon storage endeavours by gas giant Chevron and is located on Barrow Island in Western Australia.

Traditional approaches to carbon capture and storage involve capturing CO2 at the emission sources and storing it in underground sites, with specific 52 AUGUST 2023 Manufacturers’ Monthly

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Engineering Focus

The MOF is a highly crystalline substance made of repeating units of iron atoms connected with organic bridges.

MIL-101, a type of Metal Organic Framework used in this study.

geological requirements.

“Once the CO2 is captured, the question was could we do something useful with it? As part of our research, we were exploring products or chemicals that can be made from that carbon dioxide, but with a process that does not emit CO2 back into the atmosphere.

The product would also need to be commercially useful, where sales from the products would also offset the cost of capturing the carbon dioxide.”

Akshat Tanksale’s journey in this research space began in 2019. A chemical engineer by trade, he has been studying sustainable chemicals and fuel production for several years, which eventually led him to narrow down on acetic acid as a focal point of the research. Acetic acid is a vital chemical with various household and industrial applications and is an ingredient in vinegar, vinyl paints and some glues.

Global demand for acetic acid is currently estimated at six and a half million tonnes per year. There are also significant carbon emissions associated with its production from natural gas.

“If we could successfully use carbon dioxide to make acetic acid, which is then used to make polymers used in vinyl paints for instance, the polymers essentially lock away the CO2 for a long manmonthly.com.au

time,” Tanksale explained.

The power of solid catalysts While current processes have explored the conversion of CO2 to acetic acid, it predominantly relied on conventional commercial processes that used liquidbased catalysts.

“We wanted to come up with a new sustainable and cost-effective catalyst and there was not a lot of literature where solid catalysts were used to make acetic acid,” Tanksale said.

Determined to break away from expensive metals like rhodium or iridium, the team created a novel metal organic framework (MOF) – a highly crystalline substance comprising repeating units of iron atoms linked with organic bridges.

Through controlled heating, these MOFs transformed into iron nanoparticles embedded in a porous carbon layer, forming a unique and efficient solid catalyst. The solid iron catalyst represents a significant leap forward in acetic acid manufacturing. It boasts several advantages, with Tanksale emphasising its economic viability.

“We really wanted to move away from expensive metals because when you’re attempting to solve one problem,

you don’t want to create a new one – in this case, the new problem would be extracting those metals. Iron, on the other hand, is found close to the surface of the earth and is available abundantly currently and would be easy to source,” he said.

Moreover, the solid catalyst can be employed in a fixed-bed reactor, eliminating the need for a separate purification step, thus streamlining the production process and reducing energy consumption.

This also presents an opportunity to significantly improve current manufacturing processes that pollute the environment as well as a solution to slow down or potentially reverse climate change while providing economic benefits to the industry from the sales of acetic acid products.

Collaboration and the path to commercialisation After the research team discovered the catalyst and its properties, the next step was to understand how it worked.

Tanksale explained that while Monash University had world-class facilities, they did not have all the necessary tools and needed further expertise from other stakeholders. Two of the team’s

key collaborators came from Hokkaido University in Japan and The Pennsylvania State University in the United States.

“Assistant Prof Abhijit Shrotri from Hokkaido University, who was also my first PhD graduate, supported us with materials testing to understand the properties of this catalyst,” Tanksale said.

“At Penn State, I worked with Prof Adri van Duin, who invented a computational program over 15 years ago that can predict the properties of materials in difficult circumstances. Some things happen at an atomic scale or molecular scale, and within a very short timeframe, hence making it impossible to observe experimentally.”

“In such cases, we use computer simulations to observe minute changes in the properties of materials. Prof van Duin’s software helped us simulate the behaviour of our material, and how the material evolves with thermal treatment,” he said.

Tanksale’s research project was supported by Monash University’s Engineering Researcher Accelerator Award. The project will also receive future support from the Industry Transformation Research Hub by the Australian Research Council (ARC).

Announced in July last year, Monash Manufacturers’ Monthly AUGUST 2023 53

Engineering Focus Therma transformation process of the metal organic framework (MOF) which makes the catalyst.

University will receive $5 million for the ARC Research Hub for Carbon Utilisation and Recycling to develop technology that harvests CO2 emissions and creates pathways to recycle that CO2 into new valuable products.

The research team’s vision extends beyond academia, as they actively collaborate with industry partners with plans to send the development to market.

When asked about challenges he anticipated, Tanksale said there would always be challenges when boundaries are pushed, and the team is currently working towards understanding these challenges. The immediate goal for the research team is to de-risk the technology by understanding and overcoming potential challenges of industrial implementation. Over the next two years, they aim to scale up the process to take the technology to commercial success.

“Given the scale of this process, requiring tons and tons of material, carbon capture and conversion, it needs to be demonstrated millions of times not just thousands of times,’ Tanksale said.

“That is beyond the scope of the university. Therefore, it will eventually have to go out of the laboratory and be implemented on an industrial scale.”

“We’ll either have a spinoff from Monash University or license it to an established company and then, it will be the task for the companies to scale that beyond the laboratory,” he said.

Achieving true net negative emissions To achieve truly net negative carbon emissions, Tanksale recognises the importance of integrating the innovative process with green hydrogen production.

“Acetic acid is currently made from 54 AUGUST 2023 Manufacturers’ Monthly

Rajan Lakshman, a PhD student in Prof Tanksale’s research group and co-author of the paper with reactor used for the CO2 . conversion to acetic acid.

natural gas . Natural gas is first converted into what is known as synthesis gas – which is carbon monoxide and hydrogen – and then you react a part of the same gas with methanol to make acetic acid; this is a long sequence of processes as it stands currently,” Tanksale said.

This process can be simplified by using just carbon dioxide and hydrogen.

Currently, hydrogen is derived from natural gas, but with advancements in green hydrogen technology, which relies on renewable electricity to split water into hydrogen and oxygen, a completely carbon-free source of hydrogen could be used in tandem with the carbon dioxide capture from the air.

“This process is still being researched and hasn’t reached its full potential for commercialisation yet,” Tanksale said.

“To really achieve the net negative carbon emissions that we are aiming for, you need carbon dioxide capture from the air as well as green hydrogen,

and both these technologies are in their nascent stage.” “In the future, when the commercial potential has been developed for both these enabling technologies, we can complete the

sustainable cycle,” he said.

Tanksale added that their research was always ongoing and would constantly look to optimise existing processes.

“There are scientific questions that always come from research. Research doesn’t give solutions; it throws new questions as well,” he said.

“For instance, one of the questions we want to answer with this is how can we increase the rate further?”

“Currently, the reaction takes a few hours to finish but can we reduce that to a few minutes? We are also attempting to work on the size of the reactor. If we can potentially increase the rate of reaction and have smaller reactors, this would mean lower capital cost and lower energy consumption,” Tanksale said.

Speaking about his personal vision for the future, Professor Tanksale said he would like to explore what the project could further to do achieve true negative carbon emissions.

“We’re trying to reduce carbon dioxide emissions in the first place from all the energy production and chemical industries. But reduction alone will not be enough, we need to actively remove carbon dioxide from the atmosphere so that we can reduce the effect of global warming faster,” he said.

“By capturing carbon dioxide from the air and converting that carbon dioxide into materials that do not emit carbon dioxide back into the atmosphere – I’m hoping that one day we can achieve true net negative emissions.”

Acetic acid is an important chemical used in several industrial processes and is an ingredient in household vinegar.

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info@atge.com.au

What’sNew Vortex HDV PAPR System Protecting the respiratory health of welding operators on the mine site is crucial in ensuring a safe and healthy work environment.

In recent years, there has been a growing demand for respiratory protection that not only offers increased protection but also enhances comfort and visibility.

Welding Industries of Australia, has addressed this need with its latest innovation, the Miller Vortex HDV PAPR System.

Designed to take respiratory protection to the next level, the Miller Vortex HDV PAPR System offers a range of features and exclusive technologies that set it apart from other systems.

The standout feature of the Vortex HDV PAPR System is the HDV Technology that provides high-definition clarity, giving welders a sharp and detailed view with minimal distortion. This feature makes it easier for welders to see their work with greater accuracy and efficiency.

ClearLight 2.0 technology minimises glare and optimises the light spectrum, providing a

clearer, brighter and more realistic weld view.

InfoTrack technology features a memory function and allows the operator to store two favourite settings and track weld time and arc counts.

X-Mode technology is another exclusive feature and major benefit to welding operators. Designed for outdoor usage, it eliminates sunlight interference, and the lens only darkens when the welding operator strikes an arc, making it ideal for low amp TIG and out-of-position welding.

The system’s lightweight blower unit weighs only 1362 grams, providing long-term comfort, allowing welders to wear it for extended periods without causing strain. The Vortex HDV PAPR System provides protection against welding fumes, making it an ideal choice for welders working in confined spaces.

The six air distribution points ensure that the air is evenly distributed, providing maximum cooling and comfort, while the three air speeds allow the operator to control the volume of air to meet their work conditions.

The audible and vibrating alarm increases safety by notifying the user in noisy environments of low battery.

Included in the package are two lithium-ion batteries, one to use and another for charging, eliminating downtime when it’s time for a recharge.

Usage of the Vortex HDV PAPR System is easy, thanks to the LCD display that provides an easy-to-read screen for viewing fan speed, current time, and battery level, and a filter timer to remind

the welder when it’s time for it to be replaced.

With all of these features and technologies combined, the Miller Vortex HDV PAPR System provides the ultimate respiratory protection for welders, ensuring greater clarity, comfort, and safety.

Company: Welding Industries of Australia Phone: 1300 300 884 Web:www.welding.com.au

iBase’s SE-603-N 11th gen Intel Core/Celeron U-Series fanless signage player Backplane Systems Technology is presents iBase SE-603-N. iBase’s SE-603-N is a cutting-edge fanless digital signage player equipped with 11th Gen Intel Core/ Celeron U-Series Processors. With dual-channel DDR4-3200 SO-DIMM supporting up to 64GB, it promises high performance. The integrated Intel graphics enable fluid 4K content playback across three independent displays using HDMI 2.0, DVI-D, and DP connections.

The SE-603-N excels in connectivity with options for M.2 E-Key and M.2 B-Key slots that facilitate Wi-Fi, Bluetooth, capture cards, and 5G. This ensures that the player can be integrated into various network configurations, making it incredibly versatile.

One of the defining features of this device is its robust build. The fanless and all solid-state design not only reduces noise but also increases the device’s durability.

Coupled with a wide operating temperature range of -20°C to 70°C, this ruggedized player is ideal for demanding environments.

Adding to the attractiveness of the SE-603-N are the iSMART intelligent energysaving and Observer remote monitoring technologies. These features facilitate efficient power management and allow for remote device management, significantly reducing maintenance efforts and costs. Furthermore, with TPM 2.0, vPro, and a watchdog timer, it ensures maximum security and reliability in deployment.

Key Features: • • • •

iSMART intelligent energy-saving & Observer remote monitoring technologies 11th Gen Intel Core/Celeron U-Series Processors 2x DDR4-3200 SO-DIMM, dual channel, Max. 64GB Intel Processor integrated graphics device

56 AUGUST 2023 Manufacturers’ Monthly

• • • • • • •

Supports OOB (Out-of-Band) and PDPC (Peripheral Device Power Control) functions 1x HDMI 2.0, 1x DVI-D, 1x DP (supports DP++) 1x M.2 E-Key (2230) for Wi-Fi, Bluetooth or capture card options 1x M.2 B-Key (3052) for 5G options TPM 2.0, vPro and watchdog timer Wide-range operating temperature: -20°C ~ 70°C Ruggedized, fanless and all solid state design

Company: Backplane Systems Technology Phone: (02) 94576400 Website: www.backplane.com.au

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What’sNew Lauris Technologies FF1225 Series Ultrasonic Flare Gas Flow meter The Lauris Technologies FF1225 Series Ultrasonic Flare Gas Flow meter, designed and manufactured for accurate flare gas metering.

Lesser meter technologies, not “Fit For Purpose” are at times selected in a cost cutting effort. These inferior solutions can result in inaccurate flow measurements and higher maintenance costs.

The FF1225 delivers accurate flare gas measurement over a wide range with minimal maintenance intervention. The flow meter is offered with several options including local or remote mount transmitter, temperature and pressure transducers, and a multi-path version that provides flow uncertainty of better than one per cent.

Both the local or remote LCD display shows velocity, flow rate, total flow, temperature and pressure. The onboard memory of the transmitter/display allows for storage of up to 250,000 data points.

Total data stored is defined by the sample rate programmed by the user.

The FF1225 is based on proprietary ultrasonic transit-time measurement with minimum detectable gas velocity of lower than 0.01 m/s (0.03 ft/sec). The maximum velocity measurement capability of 100 m/ sec (330 ft/sec) standard and 150 m/sec (·500 fUsec) optional provides turndowns of 10,000:1 through to 15,000: 1

Key features: • • • • •

Lowest minimum detectable velocity No pressure drop Totalised flow, flow rate Wide range of metallurgy Variety of pressure rating Qs

Company: AMS Instrumentation & Calibration Pty Ltd Phone: 03-9017 8225 Website: www.ams-ic.com.au

ICP’s robust and high capacity ICP DAS DL-110S-E ICP Electronics Australia presents the ICP DAS DL-110S-E. The DL-110S-E is a robust and high-capacity data logger module developed by ICP DAS. Equipped with IP67 protection approval, it can efficiently measure and record illumination, temperature, humidity, and dew point data. Its broad measurement ranges for illumination (0 to 100,000 Lux), temperature (-20 to +60°C), and humidity (0 to 100% RH) make it a versatile choice for diverse environments.

The device can store up to 600,000 records, each embedded with a date and time stamp, ensuring an accurate log of environmental conditions. Users can access real-time data remotely from the device using the free Windows software, the iOS App, or the Android App. Supporting industrial protocols including DCON, Modbus RTU, Modbus TCP, and MQTT, the DL-110S-E offers seamless integration with existing systems. Its Ethernet and RS-485 communication interfaces further enhance its interoperability.

With a built-in web server, users can easily configure the module and monitor data. The DL300 Utility offers enhanced features such as run chart display, log alarm events, and data export to .CSV files. Additionally, the device supports IoT applications through the MQTT protocol and offers real-time data accessibility with the iAir App. manmonthly.com.au

In applications like greenhouse automation, the DL-110S-E proves invaluable, providing environmental monitoring to optimize plant growth conditions, increase crop yield, and ensure product traceability.

Key features: • • • •

• • • • •

Illumination Measurement Range: 0 to 100,000 Lux Temperature Measurement Range: -20 to +60°C Humidity Measurement Range: 0 to 100% RH Able to store up to 600,000 records with date and time stamps Free Software Utility, iOS APP and Android App Included Supports the DCON, Modbus RTU, Modbus TCP and MQTT Protocols Includes RS-485/Ethernet Communication Interfaces Includes redundant power inputs: PoE (IEEE 802.3af, Class 1) and DC input Supports Web Confi guration and Firmware Update via Ethernet IP67 Protection Approval

Company: ICP Electronics Australia Phone: (02) 9457 6011 Website: www.ipc-australia.com.au Manufacturers’ Monthly AUGUST 2023 57

The Last Word

TIM ODOKEYCHUK – President, AME Australia

Building manufacturing excellence: Following a proven framework

M

ANUFACTURING excellence encompasses the continuous pursuit of improvement in all areas of the enterprise.

It involves learning to adapt to market needs, innovating the business and operating model, and eliminating unnecessary effort, burden, and unevenness across the value chain.

This pursuit is a crucial aspect of any enterprise’s success, requiring the entire team to adopt a comprehensive approach that encompasses both technical and cultural advancement to yield resilience and sustainable growth.

For decades, the Association for Manufacturing Excellence has been supporting its members in that pursuit by sharing better practices across its network of manufacturers – covering 18 sectors across our ANZ region – which runs from family-owned SMEs to multi-National firms – all of whom have incredible success to share and lessons learned.

58 AUGUST 2023 Manufacturers’ Monthly

Globally, we have been fortunate to have been exposed to such an array of companies striving to be their best – so leveraging these insights to excellence for our Members’ benefit was a natural step in our journey and has led the Association to develop what we call the AME Lean Sensei framework.

First released in 2016, the AME Lean Sensei has enabled our members to take stock of where they are on their excellence journey and inform them on where their greatest opportunities for improvement (and investment) can be found.

The framework provides a structured roadmap that encompass five levels of maturity that organisations can use to gauge their performance and identify areas for improvement.

My intent is that those reading this article can gain a basic appreciation for what these levels of maturity are and can understand how this framework may be leveraged in your organisation to guide

you along your pathway.

Let’s take a closer look together.

to actively participate in continuous improvement initiatives.

Level 1: Beginning the excellence journey

Level 2: Building a foundation for excellence

At this initial level, organisations are starting to embrace lean principles and methodologies. They have recognised the importance of waste reduction, process efficiency, and employee involvement.

However, their implementation may be fragmented and lacking a unified approach. The focus is primarily on isolated improvement projects, rather than a holistic transformation of the entire organisation.

To advance to the next level, organisations need to establish a strong foundation by creating a shared vision for the transformation and developing a culture of excellence throughout the organisation. They must invest in training and practice to equip employees with the necessary skills and knowledge

At this stage, emphasis is on creating stability and consistency in operations, as well as fostering a mindset of problem solving.

The organisation has begun to integrate lean principles into their core business processes. They are beginning to establish cross-functional teams, implementing visual management tools, and standardised work processes.

To progress further, organisations must focus on streamlining value streams, reducing lead times, and implementing pull systems. They are empowering employees to identify and eliminate waste, promote effective communication across departments, ensure the daily/weekly/ monthly ‘must-do’ activities are completed while developing a robust measurement

manmonthly.com.au

system to track key performance indicators (KPIs) related to safety, people development, cost-effectiveness, quality, and customer satisfaction.

Level 3: Advancing excellence competency At level 3, organisations have developed a deep understanding of lean principles and methodologies. They have achieved significant improvements in their processes, quality, and overall performance.

Continuous improvement is ingrained in the organisational culture, and employees at all levels actively participate in problem-solving and kaizen activities.

To advance to the next level, organisations need to focus on further expanding their lean knowledge and capabilities. They should encourage a broader adoption of lean across all functions of the business and develop a system for benchmarking and sharing

The AME Lean Sensei framework enables members to better understand where they are – and where they’re going – on their excellence journeys.

best practices. It is crucial to foster a spirit of innovation and empower employees to experiment with new ideas and technologies that can enhance productivity and competitiveness.

Level 4: Sustaining excellence Organisations at level 4 have attained a high level of maturity in lean thinking and methods. These principles are deeply ingrained in their DNA, and the entire organisation is aligned towards a common goal of continuous improvement.

They have developed a robust management system that enables them to sustain their gains and respond to changing market dynamics.

To reach level 5, organisations must focus on nurturing leadership excellence.

They need leaders who can inspire and motivate employees, create a culture of trust and transparency, and drive the organisation towards continuous learning and innovation.

Additionally, organisations should seek opportunities for collaboration and partnership with other industry leaders to gain insights and stay at the forefront of manufacturing practices.

Level 5: Evolving enterprise excellence At the pinnacle of the AME Lean Sensei maturity framework, organisations have attained a sustained level of enterprise excellence. These organisations have successfully integrated lean principles beyond their own operations and into their supplier and customer architecture.

Ultimately, they are recognised as industry leaders and benchmarks for manufacturing best practice.

To continue evolving their approach to enterprise excellence, organisations must continuously challenge themselves to explore new frontiers and adapt to emerging trends in technologies, seeking to anticipate unmet market needs (or new markets themselves).

With the capacity gained from a stable and capable enterprise, they can invest in growth activities and maintain their competitive edge in an ever-evolving landscape. manmonthly.com.au

The pursuit of excellence – Practicality, Persistence and Patience Those reading this article know that an excellence journey is a step-bystep endeavour.

Knowing where or how to progress on your own pathway can be an overwhelming challenge for Leaders attempting to go it alone.

A great way to get started is to just understand where you are today.

That’s where the AME Lean Sensei assessment tool covering 65 elements of effective business practice (ranging from the development and deployment of Management Systems, People Centric Leadership, Improvement Methods) links leaders to resources such as videos, articles, books, and ideas where you need it the most.

As a regular practice, every year we invite our members to submit a detailed self-assessment grading their progress from a previous baseline to their current level of maturity and performance.

This evidence-based approach allows our members to dive deeply into areas of focus in their organisation and challenge their leaders and process owners to demonstrate and together celebrate their efforts to develop excellence maturity.

This process also prepares the assessment participants to share their story

across other areas of the organisation so that best practices are rapidly understood and easily adopted through a ‘community of practice’.

Many of our members openly showcase their progress and welcome peer review because of the value and insight it gives them in return. One of the best ways to test our knowledge and continue our learning towards mastery is to teach or share.

Whether it be through any of our AME activities – such as our executive roundtable, site tours, conferences or networking functions – Leaders can take the opportunity to share their aspirations and efforts in a safe environment and ‘borrow with pride’ from other members who’ve overcome similar challenges or can help see the next step from a different perspective.

Those keen to challenge themselves further can opt for an onsite AME Excellence Award assessment where, over the years our 100-plus certified assessors have helped validate and challenge Members to improve and further augment their efforts and even leverage unique insights to overcome strategic barriers.

We invite you to connect with our community and take advantage of our collective knowledge across our Membership while leveraging the AME Lean Sensei framework along your own pathway to excellence.

Manufacturers’ Monthly AUGUST 2023 59

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220.10 076.23

Cleaner, Greener.

Lower-carbon aluminium for your projects.

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FOR MORE INFORMATION VISIT:

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* When compared with global average CO2e for primary aluminium production, Scope 1 and Scope 2 ex smelter.

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