Manufacturer's Monthly October 2023

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OCTOBER 2023

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Manufacturers’ Monthly Contents­­­­­­ 6 Editor’s Note

30 Energy Chains

10 Comment

33 Robotics

12 News

36 New Facility

16 Manufacturer Focus

38 Marine Aluminium

20 Online Support

41 Cold Sensors

22 Welding Gases

44 National Manufacturing Summit

24 Safety Automation

46 Events

26 Robotic Gases

49 What’s New

28 Renewable Energy

50 Last Word

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

The opinions expressed in Manufacturers’ Monthly are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2023 Articles All articles submitted for publication become the property of the publisher.

The Editor reserves the right to adjust any article to conform with the magazine format.

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This month’s Manufacturer Focus delves into the world of trailers and the very impressive trailers Sloanebuilt is delivering to the Australian market.

The organisation has continually improved its operations to deliver a quality product with support long after the trailer rolls off the manufacturing line. The company is shrewdly investing in new technology and recently took home an impressive award.

Scan to watch the video for more information and features.

Throughout other sections of the magazine, we delve into the world of marine aluminium supplied by Capral, servicing Western Australia.

We look at the offerings from Treotham and The latest solution for access to all online services from SEW-EURODRIVE. its backup support provided to its customers and on-site mixing at Hilton Manufacturing provided

by Air Liquide which has been solving a range of challenges for a manufacturer that is a critical part of the supply of trucks in Australia.

TRAILERS for Australia

E-Commerce:

> Engineering & Selection > Inquiry & Order > Delivery & Material Flow > Startup & Maintenance

Directly access the functions you want depending on activity or interest.

www.sew-eurodrive.com.au/en_gb/online_support/online_support_startseite.html

Official Industry Partners

INSIDE >> 22

30

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Welding gases mixed on site

Automation support start to finish

Marin aluminium support

>>

Ph: (03) 9794 8337

4 OCTOBER 2023 Manufacturers’ Monthly

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Siemens SENTRON protection devices not only meet these requirements, but also integrate into automation environments and collect energy data to form the ideal solution for safe, efficient power supply.

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Editor’s Note

JOSH FARRELL – Editor, Manufacturers’ Monthly

Global manufacturing stagnating

A

S I settle into the world of manufacturing, I find myself constantly buoyed and excited by some of the announcements from companies and governments.

I have been poring over reports from the Australian institute and the potential for Australia to become a global superpower in the renewable space is one that thrills me.

Thales Australia recently opened new facility in Lithgow, continuing to grow Australia’s defence manufacturing capabilities after months of announcements from defence companies in Victoria and Tasmania.

Quantum technology and computing companies Q-CTRL and Diraq are demonstrating Australia’s advanced manufacturing capabilities on a global scale.

Governments as well are beginning to understand the needs of the industry, with the announcement of

6 OCTOBER 2023 Manufacturers’ Monthly

changes to the NSW TAFE board an exciting one for the industry. Whilst it is an exciting period locally, it is less so on a global scale according to the J.P.Morgan Global Manufacturing PMI. The downturn in the global manufacturing sector continued, with output falling for the third straight month, August PMI data provided signs that the contraction was easing.

Rates of decline for production, total new orders and new export business all slowed and employment edged higher.

August saw manufacturing production decline for the third successive month, as contractions in the intermediate and investment goods subindustries more than offset mild growth in the consumer goods category.

National PMI data signalled that the euro area remained a weak spot, with output contracting at a marked pace.

Mainland China returned to growth,

the US fell back into decline and the downturn in Japan continued.

Underlying the latest scaling back of global manufacturing production was a decrease in new orders.

New business fell for the fourteenth month running, albeit at the slowest pace since May. The euro area, US and Japan all saw new work intakes contract, in contrast to a modest increase in mainland China.

International trade flows declined, extending the current sequence of contraction to one-and a-half years.

August PMI data provided further evidence that manufacturers are responding to the weaker economic backdrop by operating on a leaner footing.

Purchasing activity, stocks of inputs and holdings of finished goods were all reduced during the latest survey month.

Lower demand for raw materials also eased the pressure on supply chains,

leading to a shortening of vendor lead times for the seventh month in a row.

Input costs and output charges increased during August, after both price measures had signalled decreases in each of the prior three months.

It has been an exciting month writing the October edition and it promises to be an enthralling read.

I was able to attend Hilton Manufacturing where I learnt about the mixing gas that is done on site and some of the impressive products they are sending to market.

Our Manufacturer Focus was the impressive Sloanebuilt trailers who recently took home an exciting award.

You may notice the absence of the Engineering Focus this month and in its place is a story from the National Manufacturing Summit where we delve into the report from the Australian institute.

Happy reading!

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GEOFF CRITTENDEN – CEO, Weld Australia

Industry calls for radical national strategy to make Australia’s renewable energy revolution a reality Australia’s manufacturing industry is calling on the Federal Government to take action now and implement a radical national strategy to make Australia’s renewable energy revolution a reality.

M

ANUFACTURING and energy industry leaders—from union representatives, developers and business owners, through to academics, economists and government ministers—gathered in Canberra in early August at the 2023 National Manufacturing Summit.

The message was clear: if Australia is to meet its net zero targets by 2050, our Federal Government must enact transformative national policy that delivers secure supply chains and a diverse renewables and clean energy economy, all of which can be sustained by the manufacturing industry. Australia must take inspiration from the United States, and their Inflation Reduction Act (IRA), which allocated upwards of US$500 billion in new spending and tax breaks that aim to boost clean energy.

The Imperative We are now at the stage where even the most obtuse observer must realise that global warming is real and is coming at us much faster than we imagined it could.

Last year, Australia experienced record floods, with countless people losing their homes. This year, we’re expecting a record bushfire season, with the Northern 10 OCTOBER 2023 Manufacturers’ Monthly

Hemisphere already experiencing some of its hottest temperatures on record.

The climate crisis makes manufacturing the renewable energy revolution an imperative.

In fact, the Australian Government has already legislated emissions reductions targets of 43% (on 2005 levels) by 2030 and net zero by 2050.

Importantly, these targets will necessitate the construction of new infrastructure on a massive scale.

Australia’s existing renewable energy generation of 64GW is forecast to grow to over 218GW by 2050. This will comprise 90GW of wind, 39GW of solar, 18.7GW of water, and 35.9GW of battery storage. For example, it is expected that over 11,000 wind towers will need to be produced, each requiring 500 tonnes of plate steel (for onshore wind towers) or 750 tonnes (for offshore wind towers).

The annual production of plate steel in Australia is currently 400kt.

To connect all this new generation to consumers, AEMO estimates that more than 10,000km of new transmission lines and 25,000 transmission towers (at 30 to 60 tonnes of steel per tower) will need to be constructed around the country.

Australia’s renewable energy industry will need a raft of additional resources to deliver on these ambitious projects, including: manufacturing and fabrication capacity, raw materials (particularly steel), and contracting and contractor resources. Plus, new technologies will need to be developed and deployed.

While our governments can wish, and hope, and make public pledges about Australia’s transition to renewable energy, we simply do not have the sovereign manufacturing capability to make this a reality. The Federal Government and state governments can wish their renewable energy policies into existence, but without a massive investment in local manufacturing, it will not be achievable.

The US Model The Inflation Reduction Act (IRA) came into effect in August 2022 in the United States, with the central goal of reindustrialising and decarbonising the US. It is estimated that the IRA’s provisions will facilitate a 43% reduction in US carbon emissions by 2030.

The United States, through the IRA, has taken shown tremendous leadership, enacting a plan to tackle the challenges

of the renewable energy revolution; a plan with manufacturing at its heart; and a plan that is already delivering unprecedented growth in the sector.

A combination of tax credits, loans and subsidies, the IRA is driving private sector investment in clean electricity and electric vehicle manufacturing. The IRA is an investment in—not a cost to— the US economy.

When announced, the IRA was expected to amount to US$391 billion on energy and climate change provisions.

However, independent research estimates that this may rise to $1.2 trillion. This is estimated to pave the way for some $3 trillion of private capital investment in renewable technology and manufacturing—an investment without which the US economy and society could suffer catastrophic and irreversible damage.

The IRA has already had remarkable beneficial impacts: in its first six months in operation, over 100,000 new clean energy jobs have been created across 90 projects, investment in clean tech and semiconductor manufacturing has doubled, and real spending on manufacturing has also more than doubled. manmonthly.com.au

Weld Australia is encouraging the government to take action on renwable manufacturing possibilities.

The International Context It is little wonder that these bold government-led investment plans have already been echoed in China, Europe, Canada, India, Japan and South Korea.

It is estimated that the Chinese government has invested between eight and ten times more than the US and Europe combined into energy transition technology and development of renewable technology manufacturing capacity. For example, thanks to its fast start and sustained, powerful industrial strategies, China has already secured a dominant position in all downstream segments of EV manufacturing.

The European Union recently announced the Green Deal Industrial Plan, which provides a framework for green technology and critical mineral supply. In addition, in July 2023, approval was confirmed for the European Chips Act, which will support an estimated €43 billion of investment between now and 2030 in measures such as next-generation technologies, and certification procedures for energy-efficient chips.

To achieve national decarbonisation goals, the Japanese government has manmonthly.com.au

formulated the Green Development Strategy through Achieving Carbon Neutrality in 2050. The South Korean government is set to embrace the economic opportunities of decarbonisation through its landmark Korean New Deal. In a landmark March 2023 federal budget, the Canadian government unveiled C$80 billion worth of fiscal programs to accelerate clean energy investments and developments.

The (Lack of) Australian Response Meanwhile, Australia is still considering its response.

In Australia, the task of responding to the IRA seems to have created such an insurmountable challenge that we have ground to a halt. A policy of fiscal conservatism driven by Treasury is obstructing any type of progress. We are defeated before the first shot is fired.

Australia has many advantages in the global race for sustainable manufacturing, including an unmatched endowment of primary renewable energy sources, and ample deposits of critical minerals that are essential to production of renewable energy equipment. However, the painful

legacy of decades of policy neglect for domestic manufacturing has left Australia’s industrial base in poor shape to seize the opportunities being opened up by the global energy transition.

Australia must stop debating the fiscal policy and act. We must become a valued partner within international renewable energy supply chains. We must overcome our traditional ‘dig and ship’ mentality and leverage our critical minerals supply to manufacture complex, value-added renewable energy products onshore.

If Australia is to ever achieve net zero, we must have our own version of the IRA, tailored to our local conditions.

Australia simply has no choice. The alternative is unthinkable. We have half the net debt as a percentage of GDP as the US, so why are we even hesitating?

Adjusted for the scale of the Australian economy, the Australian Government must commit $300 billion—approximately $12 billion a year to 2050—to a program similar in size and scale to the IRA. This sum is equivalent to current carbon subsidies, inconsequential when compared with the anticipated mining royalties from rare earth minerals, and less than

the $368 billion we plan to spend on nuclear submarines.

With an IRA-type program that combines subsidies and incentives, commercially viable procurement procedures and a sensible national strategy, the manufacturing industry will be able to respond and carry its share of the load. Industry will be able to invest in its own facilities and create more high-quality jobs. We will not be able to manufacture everything we need but we will be able to deliver enough to provide a buffer to gaps in the global supply chain and ensure reasonable pricing.

Australia must embrace the golden opportunity that the renewable energy revolution presents. We must become a clean energy manufacturing powerhouse, that exports value-added products to world. In this way, Australia will create thousands of new jobs, reduce our risks to volatile international markets, reduce the cost of living for Australian families, and play an essential role in global decarbonisation.

It is already too late. Australia must act now. We must act bravely and fund our renewable energy revolution properly. Australia’s governments must have the courage to act now.

Manufacturers’ Monthly OCTOBER 2023 11

News @MM TAFE NSW teacher appointed to key advisory board for the first time in eight years For the first time in at least eight years a TAFE NSW teacher has been appointed to join the TAFE NSW board, as it helps guide TAFE NSW through recommendations to the Minister on services, priorities, and operations.

Metal Fabrication and Welding Teacher Stuart McKinder’s appointment to the TAFE Commission Board has been welcomed by Deputy Premier, and Minister for Skills, TAFE and Tertiary Education Prue Car. Mr McKinder has a long affiliation with TAFE NSW after completing a five-year apprenticeship in 1992, and becoming a welding and metal fabrication teacher in 2008. He currently teaches at TAFE NSW in Wetherill Park.

Deputy Premier and Minister for Skills, TAFE and Tertiary Education Prue Car spoke about the appointment.

“The skills crisis in NSW means there’s never been a more important time to

rebuild TAFE NSW. That starts with hearing directly from teachers,” Car said.

“This appointment will ensure TAFE NSW teachers are empowered to shape the future of Australia’s largest vocational education and training provider.

“I want to ensure the NSW Government benefits from advisors who are at the coalface of helping learners, businesses, and communities to thrive,” she said.

While on the board, Mr McKinder will be supported by a panel of teachers who will act as an advisory group, providing a diverse range of perspectives across regional and industry skill areas to ensure all facets of teaching are considered.

Chair of the TAFE Commission Board Danny O’Connor spoke about what this announcement means for TAFE NSW. “This appointment will ensure the advisory board gains a deeper understanding of the things that matter

Bringing the teacher onto the board will bring hands on experience to the organisation.

most to the educational workforce,” he said.

“Mr McKinder’s appointment will round out the professional depth already on the Board.

“Among the Board, we already have a wealth of diversity and industry experience with members coming from critical skills sectors including IT, construction, hospitality, community

services, health, and education,” O’Connor said.

“Hearing directly from teachers will boost the Board’s ability to advocate on behalf of the teaching workforce, ensuring TAFE NSW can deliver skillsbased training that provides individuals with access to meaningful jobs, and which is aligned to the skills needs of industry and communities across NSW.”

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Construction of vanadium electrolyte facility underway Australian Vanadium Limited (AVL) has appointed engineering group Primero Group to construct its vanadium electrolyte manufacturing facility in Western Australia.

AVL was awarded a $3.69 million Federal Government grant in 2021,2 with part of the funding allocated to building and operating a commercial vanadium electrolyte manufacturing facility in Western Australia, to support the commercialisation of VFBs. AVL aims to produce vanadium electrolyte for commercial use in VFBs by November 2023 and is working on off-take agreements for the produced product.

AVL has also appointed experienced operations professional Simon Rough to safely manage the facility through construction and into production.

Rough’s extensive experience in vanadium processing and sulphuric acid production makes him a perfect fit to lead the team to successful production of high-quality electrolyte.

AVL CEO, Graham Arvidson comments, “It is satisfying to see the progress being achieved by the team as AVL’s vanadium electrolyte manufacturing plant starts to take shape. Using USV’s proven electrolyte manufacturing technology, AVL aims to become a trusted supplier of vanadium electrolyte within Australia and beyond.

“We are pleased to have welcomed Simon onboard to manage the facility

and work with the existing team, utilising in-house electrolyte knowledge and relationships that have been built with companies such as USV and VFB manufacturers.

The implementation of the electrolyte plant provides an ideal opportunity for AVL to put into practice, test and further mature its systems, processes and management systems that will ultimately underpin the larger Australian Vanadium Project.”

Rough has 20 years of processing and operational experience. He has safely led high performing teams in hydro and pyrometallurgical operations, vanadium processing and sulphuric acid production.

AVL holds the exclusive licence of USV’s process technology for manufacturing vanadium electrolyte for Australia and New Zealand. This technology has been used for the design of the vanadium electrolyte manufacturing facility which is being built in the northern Perth suburb of Wangara.

Partnering with Primero Group, AVL has developed the facility design to comply with Australian standards and requirements.

Until production of vanadium oxides from AVL’s Midwest Processing Hub commences, vanadium oxide feedstock for the electrolyte facility will be sourced through AVL’s agreement with USV and third-party sources.

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Manufacturers’ Monthly OCTOBER 2023 13

News @MM Australian shipbuilder Incat Tasmania to deliver the world’s largest battery electric ship Incat Tasmania is leading the world in producing pure-electric lightweight zeroemission ferries and has nearly completed a ship for an international customer.

Australian shipbuilder Incat Tasmania has under construction the largest lightweight battery electric ship, coming in at 130 metres in length, and is being constructed for delivery to its South American customer, Buquebus.

This ship, the world’s largest batteryelectric Ro-Pax ferry, will be 100 per cent battery electric. The energy storage system will be four times larger than

any battery installation that has been constructed and installed anywhere in the world for the marine transport environment. The batteries power a series of E-motors which drive the water jet propulsion system. The electrical system integration is by Wärtsilä and ESS

by Corvus Energy.

The interest in these battery electric ships is very positive and Incat is now working toward the construction of its second but smaller battery-electric vehicle/passenger ferry.

Incat Founder Robert Clifford spoke

Incat is supplying battery powered boats to the global market.

about what the ship means for the maritime industry.

“We are proud to be building in Tasmania this first in class ship for Buquebus who like us share a vision to be at the leading edge of low emission shipping in the world,” he said.

“Incat has always been an innovator and once again we are leading the world and the world is taking notice.

“This worldwide interest in Incat’s capabilities to deliver electric ships is a great opportunity for Tasmania and we expect this interest to magnify.

“We are already increasing our workforce and have just finalised plans for the recruitment of at least another 200 employees over the next 12 months with the expectation that our workforce will more than double in coming years,” Clifford said.

Incat Managing Director Craig Clifford further detailed the ship.

“The build of the Buquebus ship is leading the world in this type of ship construction and will have leading edge technology in terms of zero emissions propulsion and storage systems,” he said.

“Once in operation the shore-side

charging systems will have 50 per cent more capacity than any current installation world-wide.

“The world first Incat Hull 096 will have a capacity for 2100 passengers and crew, 225 cars and will also include a Duty Free Shop of over 2000 square metres on the one level.”

Clifford explained that feedback has been positive from customers and the prospects for more jobs in Tasmania.

“The opportunities for jobs and investment here in Tasmania are exceptional.

“The Australian Federal Government has a clear plan for decarbonising the economy and with 100 per cent renewable energy and already net zero emissions having been achieved here in Tasmania we are ideally placed to build zero emission ships for the world right here,” he said.

“In fact due to Tasmania already having achieved overall net zero emissions we are the only location on the planet that is able to construct zeroemission, battery electric ships in an already net zero emissions environment for our customers.”

CSIRO awarded Boeing’s Supplier of the Year Boeing, the world’s largest aerospace company, has named CSIRO, Australia’s national science agency, a Supplier of the Year for the fifth time since 2010.

The ‘Pathfinder Award’ recognises the substantial value CSIRO has created for Boeing through technological breakthroughs across space, advanced materials, data analytics, energy, manufacturing, robotics and autonomy.

CSIRO has partnered with Boeing to develop new lightweight and sustainable materials for both aircraft and possible space applications.

The companies have also invested over $200 million across a wide range of projects to advance production systems, improve safety, reduce waste and increase environmental sustainability in aviation.

“We are absolutely delighted to receive Boeing’s Supplier of the Year 14 OCTOBER 2023 Manufacturers’ Monthly

award,” Kirsten Rose, acting CSIRO chief executive said.

“Congratulations to all of our amazing scientists and engineers who continue to raise the bar and have global impact.

“We look forward to continuing to grow CSIRO and Australia’s global profile as a research and development leader driving innovation across manufacturing, space, technology and sustainability,” she said.

Rose shared that the 34-year strategic relationship with Boeing demonstrates the impact the CSIRO can create for industry through collaboration, science and innovation.

Maria Fernandez, president of Boeing Australia, New Zealand and South Pacific spoke about the partnership between the two organisations.

“Together, Boeing and CSIRO continue to tackle issues of great importance to the global aerospace industry through

The strong partnership between Boeing and CSIRO continues in 2023.

innovation and investment here in Australia,” Fernandez said.

Boeing’s Supplier of the Year Award program is an industry-leading recognition program that highlights the accomplishments of the company’s topperforming suppliers.

CSIRO was previously named a Boeing Supplier of the Year in 2018, 2017, 2016 and 2010.

Earlier this month, CSIRO and Boeing jointly released the Sustainable Aviation Fuel Roadmap, which charts a path for the decarbonisation of the aviation industry. manmonthly.com.au

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Manufacturer Focus Proud to be Australian In the bustling world of heavy vehicle manufacturing, where innovation and quality are paramount, there’s one company that stands out as a shining beacon of excellence. Sloanebuilt Trailers, an Australian-owned and family-operated business, has earned the prestigious title of Australian Owned Business of the Year 2023, marking a significant milestone in its remarkable journey.

O

RIGINALLY founded in the mid 1970’s by Ken Sloane in Camden, New South Wales, the company serviced the rapidly expanding coal industry. A decade on and Sloanebuilt underwent a transformative change in ownership in 1986 led by Fred and Helen Marano. Since their acquisition, Sloanebuilt has been at the forefront of manufacturing trailer and tipper bodies retaining an 80 per cent customer retention rate for the past 35 years of operation to continually push the boundaries of innovation. Being awarded Australian Owned Business of the Year for 2023 reaffirms its dedication to Australian manufacturing and its relentless pursuit of excellence in the Heavy Vehicle Manufacturing industry.

Manufacturers’ Monthly recently met with the senior management team at Sloanebuilt to understand

16 OCTOBER 2023 Manufacturers’ Monthly

the contributing factors attributed to the company’s unwavering industry success. managing director, Fred Marano spearheaded the conversation providing comprehensive insights from his extensive experience and knowledge gained over the decades being at the helm of the organisation. He was joined by his son Tim Marano, the director of business development, and Mythili Sarathy, head of strategy and senior management advisor who contributed to this meaningful conversation with the expertise and leadership focused on its manufacturing excellence as well as fostering the next generation and future of Sloanebuilt.

A trailer for every need Sloanebuilt’s journey to becoming Australian owned business of the year has been marked by innovation and diversification. The company’s focus lies

in crafting aluminium tipping bodies and semi-trailers. With over 100 meticulously designed product variants, Sloanebuilt caters to a wide spectrum of customers from varied industries, including mining, construction, civil, farming, grain, and quarries, demonstrating its adaptability and commitment to serving the evolving needs of its customers.

The company proudly sells its products directly to the Australian market, adhering to the highest standards and compliance with Australian regulations. Sloanebuilt has a fully integrated manufacturing facility that houses an extensive range of machinery and equipment. Located in Smeaton Grange, the state-of-the-art nine-acre facility boasts seven overhead cranes, drive through bays, a wash bay, grit blasting, specialised heated spray booth with a paint mixing room, water jet

cutting machine, aluminium mill, large and small press machines, plasma cutter, weighbridge, a spare parts store, repairs bay and much more.

Sloanebuilt’s distinguishing feature in manufacturing trailers is their holistic approach to retaining customer-centricity across all facets of operations. From the beginning to the end, customers are a primary focus of the company.

Sloanebuilt’s management team said the company aims to build trailers as if they were building for themselves. Treating customers as if they are one of their own to deliver the highest quality.

Among manufacturers, Sloanebuilt is in a unique position in that it sells directly to market, allowing follow ups with clients, providing after-sales support such as service and repairs, spare parts for its trailers. “The customers that run parallel to us want a company that is not simply

manmonthly.com.au

Manufacturer Focus

sending them a product but working closely with them throughout their journey,” Fred noted.

Sloanebuilt has the capacity to perform repairs, maintenance and refurbishments on a range of trailers and equipment including a wide variety of truck and trailer makes and models. Servicing its own trailers means Sloanebuilt understands the common issues that can arise with the use of heavy vehicle equipment and can action preventative measures in the production line.

Maximising Australian vendors One of the key pillars of Sloanebuilt’s success lies in its commitment to sourcing from Australian vendors.. By prioritising local suppliers and materials, Sloanebuilt not only contributes to the growth of the Australian manufacturing sector but also ensures the highest quality for

its products.

Sarathy explained that Sloanebuilt source from local suppliers for parts when they cannot be produced in-house to ensure it can maximise quality. “What we do is we focus on the local market to source some of the best calibre products because it can give us greater control on the supply chain,” she said. “The local vendors also understand the regulations better which helps us deliver impeccable products,” Sarathy explained.

By keeping manufacturing within Australia, Sloanebuilt bolsters local communities, supports Australian workers, and safeguards the integrity of its products, all while embodying the essence of Australian craftsmanship and innovation. In an era of extensive competition, Sloanebuilt’s dedication to remaining Australian-made not only sets it apart but also serves as a shining

example of how Australian manufacturing can thrive on a foundation of quality, reliability, and unwavering commitment to local industry.

The Sloanebuilt way What truly sets Sloanebuilt apart is its enduring status as a family-owned and operated business. The Marano family’s dedication and determination have been instrumental in shaping the company’s values and culture. While the essential ethos remains constant, the Sloanebuilt team continually strives for excellence, pushing boundaries, and providing innovative solutions for their customers.

Fred Marano expresses the company’s ethos clearly: “We want that culture of what we do to run through the whole business, all the way down to the last person working on the trailers.”

Alongside the extensive Australian

supply chain, Sloanebuilt engrains strict quality management procedures in the company culture to ensure that their customers receive best quality trailers. “We have a strict quality management system that is totally integrated, every manager has a clear understanding of what the expectations are and delivers those goals as a team,” Fred said.

These procedures begin all the way at the hiring stage Sarathy detailed.

“Every employee that we hire is of the highest quality,” she said. “Being a family run business, team leaders have an understanding of what each employee needs to be doing, they look at their skills, their qualities and what training they need to do.”

It is by creating this culture, that Sloanebuilt can streamline production processes, enable better innovation and deliver high quality products that meets standards and exceed all expectations.

The Sloanebuilt team continues to grow.

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Manufacturers’ Monthly OCTOBER 2023 17

Manufacturer Focus

Bringing the right people in is imperative to Sloanebuilt’s success

Sloanebuilt’s people Sloanebuilt’s success story is fundamentally tied to its investment in people. The company places great importance on hiring and nurturing talent within its ranks. From the experienced engineers who meticulously design the trailers to the skilled fabricators, mechanics, painters and welders who craft them with precision, it’s the people behind the scenes who breathe life into every product. The leadership team’s vision, the trainers who nurture talent, and the support staff who ensure seamless operations all play pivotal roles in shaping Sloanebuilt’s success.

Tim Marano, director of business development, has a very hands-on relationship with the workers and explained in even greater detail the team dynamics. “By investing in our people with the training and support they need, we are able to minimise downtime, errors and deliver quality products,” he said.

Sloanebuilt, according to Sarathy, is always searching for ‘diamonds’ that will become an asset to the company once they are brought into the fold.

“The question is whether to build talent or buy talent,” she said. “We are a fast-growing manufacturer, so this is a decision we have to make all the time. We will always have to hire externally, but the plan is always to build from within in the long run, identify key roles and use our talent internally to fill those.

“By utilising existing team members, 18 OCTOBER 2023 Manufacturers’ Monthly

The company has created an end to end site in NSW.

they understand our culture and our processes, we have a clear strategy for the growth of our team, and we will continue to follow that,” she said.

In addition to rigorous training, Sloanebuilt actively engages in apprenticeship programs, ensuring that new entrants to the industry receive the support and guidance needed to thrive.

“Even when an apprentice finishes after four years, they may not be 100 per cent ready. But once they find their strength, we can encourage growth and development from there,” Tim noted.

The power of automation in manufacturing In a world where automation is at the forefront of manufacturing discussions, Sloanebuilt remains committed to achieving the delicate balance between tradition and technology. Fred Marano acknowledges the potential benefits of robots and cobots while emphasising that these technologies should complement, not replace, the skills and expertise of the company’s workforce.

With a company like Sloanebuilt, so many of the trailers built are customised, making automation challenging and requiring all workers to maintain an ability to adjust accordingly. “Cobots seem to be the way forward, working in tandem with the machine is a way I can see our production line being sped up and benefitting from modern

technology,” Fred explained.

The team at Sloanebuilt does not believe that standalone robots are in the short-term future for the company and expects to use a range of other advance machines and systems to meet the needs of the production line. Tim explained that Sloanebuilt is considering its options and what will work best for its own processes. “Robots and cobots obviously have a range of benefits, but we are bringing them in slowly and cautiously to ensure they work alongside our team and don’t replace jobs,” he said.

Sarathy added, “I think it is all about mindful investment in new technology – we cannot risk making outlandish investments that will not benefit the company.”

Customer centricity remains a primary focus for the company in ensuring the successful implementation of these technologies. “As business leaders we need to understand where the industry is going based on the needs of the customers and not on the want of the technology, we need to always put our clients first and not just blindly follow the direction technology is heading in,” Sarathy said.

Sloanebuilt’s strength and ability to produce custom-made trailers could make complete automation challenging, but the company actively evaluates where technology can enhance their processes without sacrificing the human

touch that sets them apart.

Sloanebuilt expects to utilise automation in its prefabrication space in the near future, as it appears to be a more optimistic area and far more cost effective than investing in robotics on the production line.

Looking forward with purpose Sloanebuilt remains family-owned and determined to celebrate its success by supporting manufacturing in Australia, Fred Marano emphasised. “We’re here not only to support ourselves but also to support manufacturing in Australia collectively,” he said.

“By investing in our people and maintaining our industry-leading quality, we are poised for continued growth,” Fred explained.

As Sloanebuilt propels itself into the future, one thing is clear: its journey of innovation, quality, and dedication to Australia’s heavy vehicle manufacturing industry is far from over.

“We are of course here to support ourselves but also holistically as manufacturers in Australia by supporting each other,” Fred said.

“We bring good people onboard, we train them well and give them that career pathway to remain a critical part of the manufacturing industry.

“We need to celebrate our industry and show that welding is no longer a dirty and dark profession, it has good, clean manmonthly.com.au

Manufacturer Focus

and high-quality equipment that is a pleasure to work on,” he said.

Recognising Australian manufacturing excellence In May 2023, Sloanebuilt was honoured with the prestigious title of Australian Owned Business of the Year. This remarkable achievement marks a significant milestone in the company’s journey highlighting Sloanebuilt’s unwavering commitment to Australian manufacturing and its relentless pursuit of excellence and innovation in the heavy vehicle industry.

The Australian Owned Business of the Year award distinguishes businesses that are advocates of the Australian Owned initiative and have a strong operational focus on Australian-produced and manufactured suppliers. Sloanebuilt was selected as Australian Owned Business of the Year from over 200 entries across industries demonstrating the company’s commitment to local partners, vendor, suppliers, talent and hence its contribution to the local community, heavy vehicle industry, manufacturing sector and the country. Its state-of-the-art facility, which served as the venue for the award ceremony, is a testament to its continued investment in cutting-edge technology, advanced manufacturing manmonthly.com.au

machineries and processes, safety and quality management systems, and skilled tradespeople, engineers, and admin staff.

As a leading player in the heavy vehicle industry, Sloanebuilt Trailers has become synonymous with focusing on generations of product knowledge, quality awareness, customer centricity, safety conscious and manufacturing excellence.

With a commitment to Australian manufacturing and prioritising local suppliers, Sloanebuilt has supported the national economy, created employment opportunities, fostered a talent ecosystem, and contributed to the local community.

Sloanebuilt were presented with this award by Kristy Ponting, the general manager of Australian Owned whose passion and extensive experience in promoting Australian businesses further highlighted the significance of this recognition.

Ponting commended Sloanebuilt’s unparalleled commitment to quality, safety, and comradery in manufacturing. She attested that the Australian Owned judges panel meticulously selected Sloanebuilt out of 200 entries due to its remarkable capabilities, exceptional processes and being sustainable and consistent in executing it. Ponting praised Sloanebuilt’s incredible

facility and growth over the years as well as the company’s pivotal role in advancing the Australian economy.

“We proudly fly the Australian flag out the front of our site because we believe in Australia and are very passionate about seeing it grow.” Fred said, in relation to the company’s achievement. “For us, this award just shows we are on the right track, but it doesn’t mean we have reached the end point, we need to keep striving to be better every single day,” he said.

When you buy from Sloanebuilt, you’re not just acquiring a quality product; you’re supporting Australian communities, workers, and the broader manufacturing industry. While proud to celebrate its success, the company is not resting on its laurels, remaining tightly focused on supporting manufacturing and supplier economy more broadly in Australia.

“We are of course here to support ourselves but also holistically as manufacturers in Australia by supporting each other,” Fred said. “We need to celebrate our industry and show that welding is no longer a dirty and dark profession, it has good, clean and high-quality equipment that is a pleasure to work on.”

Manufacturers’ Monthly OCTOBER 2023 19

OnlineSupport Taking online support to another level In response to the customer demand, SEW-EURODRIVE has expanded its online support portal. Manufacturers’ Monthly spoke with the team to learn more.

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EW-EURODRIVE has been listening closely to its customers and in response have rolled out its new Online Support platform that changes the way existing and prospective customers communicate and receive support from SEW-EURODRIVE. Manufacturers Monthly spoke with Kang Wei Ang who is the National Product Manager – Standard Products division for SEW-EURODRIVE. “We know that globally, everyone is going through a digital transformation, everything we do is going digital and it is no different for SEW-EURODRIVE,” he said. “We are expanding our digital services to growing customer’s expectation and evolving market needs.

The new digital generation is used to being online and not so much on the phone,” he explains.

“We have only begun moving customers across to the E-commerce section in the last few months to give them the ability to get quotations and place orders online. Prior to that we have already seen many of our customers using our other online services that have been available for quite some time. The availability of Drive Selection, Product Configurator, CAD data, Product Manuals and Software downloads with no

The new Online Support portal will revolutionise the way customers work with SEW-EURODRIVE.

20 OCTOBER 2023 Manufacturers’ Monthly

prompting – they have a real desire for the platform,” Kang Wei said.

The Online Support portal is logically divided into sub-sections centred around Engineering & selection, Inquiry & order, Delivery & material flow, Start-up & maintenance, CAD data, Documentation, Product data and Software.

Engineering and selection This section contains useful tools to assist the customer during the engineering and drive selection process for a specific application.

Kang Wei used the example of an engineer designing a new belt conveyor system.

“With the highly intuitive Drive selection tool, the user enters conveyor details and application data such mass of the load and the desired belt speed. In the background the tool instantaneously calculates the motor power and gear ratio required,” he said.

“At the same time the user selects their preferred gearbox type, shaft interface and mounting arrangements. The tool then finds close matching solutions from our digital catalogue,” Kang Wei said.

From this point the customer can choose the drive that best suits their application from a technical and price point. From the real-time generated product image, they can check and

confirm their mounting position. Finally through the automatically created link they can download the CAD data to complete their design.

“These CAD files can be downloaded in 2D or 3D models, it is all dependent on the needs of the client,” Kang Wei explained.

Should there be a design change, they can always go back to their saved project at any time and make a new drive selection.

Another useful tool in this section is the Product configurator.

“This is basically our digital catalogue for all standard SEW products” Kang Wei explains. “Here the user can browse, select and configure products such as gearmotors, servomotors, decentralized drives, frequency inverters, controllers and so on by themselves.”

Once configured, they can automatically get links to technical specifications sheet, CAD data, and all documentations relevant to that product.

Inquiry and order This is the main section of the portal relating to E-commerce. Here the customer can generate an inquiry or place an order directly online.

“They can start from Drive selection or Product configurator. With their selected product(s) they fill their shopping cart.

Once they have everything they need they can click the enquire button. Customer will receive their quotation in a relatively short time frame,” Kang Wei explained.

Additionally the customer can save their template for the project and reuse it later for similar projects. All the selected products, product configurations, CAD and technical data will be saved.

In case of a replacement or spare product, the customer can simply enter the serial number of the original product and they can get a quotation for the exact replacement. It is a phased-out or legacy product, an equivalent replacement will be offered.

In this same section an authorised customer can also place the order online by advancing to the ordering page.

Alternatively they can click to forward the quotation to their colleague responsible for purchasing who has been appropriately set up to order online. An order acknowledgement is sent to the customer once the system has processes the order. manmonthly.com.au

OnlineSupport

Start-up and maintenance “The Startup and maintenance section of the portal has been tailor-made to provide the greatest support possible for commissioning and maintenance staff,” Kang Wei explains.

All newly supplied products from SEW-EURODRIVE have a Product Label on them. This is basically a QR code when scanned with a mobile devices, the customer will be directed to the Online Support page when they can get all critical data relating to this particular product.

“For someone who is doing installation and commissioning of a gearmotor, they can get helpful information such as a picture of the mounting position, unit dimensions, operating instruction manuals, oil type and quantity, and wiring diagram,” he said.

For someone who is commissioning a frequency inverter, they can get technical manuals, wiring diagrams, download the relevant commissioning software, and check & activate software licenses. manmonthly.com.au

With a scan of the Product label maintenance staff can browse and order spare parts or a complete replacement unit by adding it to the shopping cart. If they prefer to work on a larger screen, they can save their scanned data online and continue on a PC later.

“All spare parts relating to that serial number are listed and the customer just needs to add what they need to their shopping cart. The explodedview pictures are displayed to assist the customer to identify the parts. Stock level and pricing of the spare parts are also shown online,” Kang Wei explains.

Once the shopping cart is filled, the maintenance staff can either request a quotation or proceed to placing an order. “”This is a great benefit for maintenance staff who are on after-hour shifts because they do not need to phone or email anyone in the middle of the night,” Kang Wei said.

The complete e-commerce process has been designed to be as seamless and

easy as possible for our customers.

From identifying the required parts, to getting a quotation, and placing an order, there is minimum contact needed, and therefore minimizing response time and potential errors. The orders are automatically processed at the SEW-EURODRIVE warehouse and are despatched at the earliest possible time.

“As the history is stored in Online Support system, the customer can login at any time to view all current and previous quotations, and also check the status of all their orders and deliveries, “ he said.

Meeting the market needs The Online Support portal has a wealth of information and tools to cater for various user needs.

“We understand everyone has different needs depending on their job functions. Our portal has been designed to cater for everyone whether they are in the engineering, estimation,

maintenance and purchasing role, “ Kang Wei said.

For engineers, quick access to CAD files and technical data are important.

For maintenance staff, online support tools for trouble-shooting and ability to source spare parts are critical. For example if a customer know a brake wears out quickly, they can go to the maintenance section to track down and order the brake disc.

“We also know people are working longer hours and so many manufacturers are operating three shifts these days , so we know the importance of having everything available quickly on our website 24/7,” Kang Wei explained.

“We have received really positive feedback. This is what our customers have been asking for and the uptake of it has been fantastic so far,” he said.

With the online support system rolled out internationally, it has been well received and the Australian market is already leaping at the opportunity.

Manufacturers’ Monthly OCTOBER 2023 21

Welding Gases Mixing on-site a no-brainer Manufacturers’ Monthly got the opportunity to tour Hilton Manufacturing’s Dandenong site to learn more about the company and its industrial gas solution provided by Air Liquide.

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ASED in Dandenong and Brisbane on 20,000 m2 and 6000 m2 sites respectively, Hilton Manufacturing is providing fabrication in a range of steel and aluminium products predominantly for the truck, bus, leisure and defence industries.

Started in 1976 by Margo and Tom Hartley, Hilton Manufacturing has set the highest standards in precision engineering and manufacturing quality.

Deon Pateman is the procurement coordinator at Hilton Manufacturing and has detailed some of the clients who turn to Hilton Manufacturing.

“We are a trusted supplier who works with blue chip companies like Kenworth, Volvo, Daimler Chrysler and Rheinmetall Defence,” Pateman explained. “We predominantly support the local market – but we also support global supply chains when international firms cannot source products.”

Hilton Manufacturing has in excess of 350 employees with a range of blanking, forming, pipe bending, welding and machine tool equipment on-site including over 20 automated welding robots and more than 100 pieces of CNC controlled equipment.

“Investing in these pieces of equipment has allowed us to be flexible with our clients.

We see ourselves as a small to medium batch volume company with MOQ’s ranging from one to 1000. We do not carry excessive stock, as part of our challenge is quick tool change over to still be competitive with smaller MOQ’s” Pateman detailed.

“When companies like Kenworth are producing 20 trucks per day. It is critical to have a sophisticated MRP system to help manage the flow of raw material into the shop and finished parts out. Today we are producing approximately 2 million parts per annum”.

Quality gas for quality welds Gas is a critical component for Hilton Manufacturing as 30 per cent of its workforce is related to its welding capability. Whether it be engineers, toolmakers, robot programmers or robot welders, welding is critical.

22 OCTOBER 2023 Manufacturers’ Monthly

30 per cent of Hilton Manufacturing workfroce centres around welding.

Having one third of the team involved in welding along with a large number of forklifts, the supply of gas from Air Liquide is a non negotiable.

“Gas is really essential to everything we do, that is why we have partnered with Air Liquide for as long as we have, we need to ensure our needs are always met,” Pateman explained.

Partnership with Air Liquide When Hilton Manufacturing moved into the LED traffic management space, they identified a chance to break back into the caravan chassis manufacturing market.

As with any new venture, it did not come without challenges as Pateman explained.

“We had some initial weld penetration issues, it was challenging as we did not know whether it was user error, or our equipment was not up to scratch or a gas issue,” he said.

“With these initial challenges we got in contact with Air Liquide to see if they had a solution and Andy came to the fore.

“Andy suggested a gas with a higher CO2 content to assist with our penetration issues and that has been perfect,” Pateman explained.

Partnering with Air Liquide was a

simple choice for Hilton Manufacturing as the company is a world leader in gases, technologies, and services for industry.

Air Liquide is present in 73 countries and serves more than 3.9 million customers.

Since the change was made to the welding system, Hilton Manufacturing has had no issue with its weld penetration and the caravan chassis leaving the Dandenong site matches the company’s high expectations.

Hilton Manufacturing has installed on site mixers to support its flow of gas to a range of machines which has been fantastic for the team.

“We decided to install the onsite mixers as it created a lot less work for our welders, no more down time spent lifting and moving cylinders,” Pateman said.

“We want our welders spending more time welding and less time spent moving cylinders around and by having this mixing system, they are now far more efficient”.

“It eliminates trucks on site as well; the fewer trucks coming through the gate the safer our sites are and that is a major plus.

“We would have to have trucks coming on site almost every day to deliver cylinders without these mixers, it means

we can always be improving our safety,” he said.

The mixer system from Air Liquide is managed remotely by the company, eliminating the need for the management team at Hilton to monitor the supply of gas.

“When the system begins to run low, it automatically triggers a delivery for the site, ensuring gas is always on hand for the welders,” Pateman explained.

“By having the gas directly connected

The team at Air Liquide worked closely with Hilton Manufacturing to rectify weld penetration issues.

manmonthly.com.au

Welding Gases The onsite mixers are an asset and alleviate user error. it also eliminates error – a welder may accidentally grab the wrong cylinders and that can negatively affect the product we are sending to market.”

Pateman explained that by having the gas controlled by Air Liquide it makes the site safer but also makes welding simpler for the team.

“By having this mix directly into our machines and utilising Air Liquide to understand what we need, the welders are not having to decide the right levels,” he said.

“They do not have to adjust the amount of CO2 by five per cent or anything like that, they are purely focussed on the quality of their welds.

“We need to ensure every weld that is completed is to the highest standard, we are competing on quality, not necessarily price so everything must be as close to perfect as possible,” Pateman said.

The challenge for a company like Hilton Manufacturing is to meet a visual quality on truck components as every driver is critical of the appearance of their truck.

Every weld on a bulbar or a fuel tank must be pleasing to the eye, so having a strong focus on weld quality is imperative.

By ensuring the quality of the gas supplied meets its needs, the welds completed are at the highest quality an consistency every time. supplied meets its needs, the welds completed are at the highest quality every time.

manmonthly.com.au

Manufacturers’ Monthly OCTOBER 2023 23

Robotic Safety

Celebrating 25 Years of a Safer Australia

Pilz has been working diligently to improve safety in Australia for the last 25 years, Manufacturers’ Monthly looks back at the journey that delivers Pilz to where it is today.

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VER the past quartercentury, industrial safety and automation in Australia have transitioned from rudimentary beginnings to advanced systems and services. Pilz Australia has been an integral part of this transformation, cites Rosanne Jessop.

It’s a momentous year for Pilz Australia as they celebrate two milestone occasions – Pilz Australia’s 25th anniversary and Pilz GmbH’s 75th Anniversary worldwide. Australia was part of the company’s first venture outside of Europe, along with subsidiaries in Brazil and Japan, back in 1998. Being the pioneer in the Asia Pacific market, Pilz Australia has established itself as a leading provider of safety automation solutions and services, revolutionising industrial safety across many sectors in the country.

24 OCTOBER 2023 Manufacturers’ Monthly

Rudimentary Beginnings Founded in 1948, the family business has continuously transformed itself – from a glass-blowing business to an electronics company, to an automation and digitalisation coampany. In the postwar period, it was the pioneering spirit of Peter Pilz, the son of Hermann Pilz, that drove the transformation from glass apparatus manufacturing to electronics in the 1960s. Peter Pilz did not live long enough to witness most of the company’s breakthroughs in innovation due to a tragic plane crash in 1975. His wife Renate, however, committed herself to continuing his life’s work. As a housewife and mother, not overly familiar with the company and its products, Renate Pilz never even considered selling the company. Instead, she familiarised herself with technology and business and joined the company as

75 years globally and 25 years locally has delivered Pilz to the forefront of safety in Australia.

Chairman of the Advisory Board. In 1995 she became Managing Director. Renate Pilz strengthened the global presence of the company through the establishment of Pilz subsidiaries worldwide.

In 1998, Pilz Australia was founded with a clear vision - to make Australia safer through advanced automation solutions focused on the stringent demands of safety. Backed by Pilz GmbH, its parent company headquartered in Ostfildern, Germany, Pilz Australia set out to provide holistic safety automation solutions along with expert services to

customers in the region.

With Australia being one of the leaders in sectors such as mining, food and beverage, manufacturing for trade, healthcare, and agribusiness, they were the perfect ground zero in the Asia Pacific market. Recognising the potential of advanced safety automation systems and their ability to create safer work environments, Pilz Australia leveraged that along with investing in their employees.

Rosanne Jessop, Managing Director of Pilz Australia and New Zealand spoke manmonthly.com.au

Robotic Safety

Rosanne Jessop, managing director of Pilz Australia and New Zealand.

about those early years.

“We wouldn’t be here without our dedicated team who worked tirelessly to develop tailored solutions for our clients that not only comply with safety regulations but also enhance operational efficiency and productivity.

We’ve been doing this for 25 years, and we’ve been an integral part of the transformation of industrial safety and automation in Australia,” she said .

Collaboration and Partnerships Aside from the constant drive to deliver new solutions, one of the company’s strong points, according to Jessop, is its relationship-centric culture. “Instead of becoming a one-off supplier or service provider, we like to develop relationships, getting to understand the customer and their needs,” she stated. manmonthly.com.au

“The Pilz family really emphasised the importance of this aspect throughout the years, and we’ve embraced it. By working closely with our customers, we have been able to tailor our solutions to meet their specific needs, ensuring maximum safety and reliability.”

Pilz has cultivated strong relationships not only with their customers but also robust partnerships with leading organisations, regulatory bodies, and industry experts. These collaborations allowed Pilz to gain valuable insights, exchange knowledge, and contribute to the development of safety standards and best practices globally. Numerous international approvals and certifications of their products, from sensor technology through to control and drive technology, ensure that its customers are spared costly re-adjustments, so that nothing stands in the way of their project’s success.

Looking Ahead As Pilz Australia celebrates this milestone, the safety automation company is excited about the future of safety innovation. To remain committed to its motto: Safety for human, machine and environment, Pilz continues to invest in research and development, and staying at the forefront of technological advancements.

“Our mission is evolving: With our automation, we make the world more digital, connected, flexible, efficient, more secure, and safe every day.

With the expansion of our portfolios in the security aspect of machinery and automation, expect further developments and launches of new services and training in the industrial security domain. Pilz is also now piloting a SaaS application to tackle digitalisation demands, so watch this space!,” says Jessop.

Pilz Australia’s 25th anniversary is a testament to its unwavering commitment to safety and innovation. Over the past 25 years, Pilz Australia has made a significant impact on workplace safety across industries offering a comprehensive range of solutions. The portfolio of the technology includes identity and access management, relays, controllers, sensors, and systems for industrial communication, diagnostics and visualisation. An international range of services with consultancy, engineering and training completes the offer. “We are proud of the impact we’ve made and the trust our customers have placed in us. As we look back on our journey, we express our gratitude to our loyal customers, dedicated employees, and supportive partners.”

Jessop said. “Together, we will continue to shape a more secure and safe future for Australian industries.”

Manufacturers’ Monthly OCTOBER 2023 25

Robotic Welding Shielding gases optimise robotic welding Manufacturers’ Monthly caught up with BOC’s Peter Kuebler to explore the intersection of robots, cobots, welding technologies, and providing the gases essential to their proper functioning.

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T BOC – a company renowned for its expertise in gas and welding equipment – the focus is always on innovation and technological advancement. Peter Kuebler, Manufacturing Gases Applications Manager at BOC, has had a journey with the company spanning two decades, and today he works at the intersection of gases and modern welding technologies – including robots and cobots.

“You might wonder what cobots and robotics have to do with gases,” Kuebler told Manufacturers’ Monthly.

“Well, we only get involved with those that use gases. BOC doesn’t sell robots or cobots. We provide the welding and plasma cutting systems that are attached to them as well as shielding gases and filler metals.”

The welding space is in a state of flux, with BOC at the forefront of this change.

26 OCTOBER 2023 Manufacturers’ Monthly

It’s not just robots and cobots that are being utilised to great effect by BOC’s customers, its partners, distributors, and integrators. The company – and Kuebler – are very involved in other dynamic subsectors of the manufacturing and welding markets, including additive manufacturing or 3D printing of metals.

But aside from this forwardfacing approach to cutting-edge tech development and deployment, what sets BOC apart in a highly competitive market?

Its client-centric approach, for one, as manifested in their Application Technology Centres, where BOC conducts trials and demonstrations for its clients.

“Testing and tailoring are vital to ensuring successful solutions,” he said.

“We must be adaptable, agile, and responsive to increasingly diverse range of client requirements.”

Cobot welding Although Australia is somewhat lagging in its appetite for modern welding solutions, there is increasing interest in cobots – collaborative robots – as a relatively affordable and easy transition for those welders interested in entering the robotic age, especially with the current skills shortage.

“Increasingly, it’s about robots and cobots,” Kuebler noted. “The appeal of these advanced machines – particularly in a post-COVID environment – has risen, even though we still trail other countries like China in terms of their adoption.”

Kuebler has observed a surge in customers wanting to trial cobots and robots, viewing them as gateways to refine and enhance their operational processes. “Most customers prefer a hands-on trial before purchasing, which is understandable when you’re stepping

into unknown territory,” he said.

He shared an anecdote of a Queensland customer who – eager to capitalise on an instant asset write-off – approached BOC with a sense of urgency, keen to make an immediate purchase.

“For this customer the incentive structure and the decisiveness were there, as they grasped the importance of embracing this new robotic era in welding – but for others it’s a longer process of education.”

And it’s a process BOC is eager to engage in. To ease such apprehensions, BOC offers robust support through its Technology Centres, the first of which opened in Brisbane, followed by centres in Sydney and Melbourne.

“Visitors can come in during our open days or we provide one-on-one sessions and demonstrations,” he said. “We try to underscore the potential of cobots

manmonthly.com.au

Robotic Welding

Inside BOC Application Technology Centre at Rocklea.

for welding applications, particularly in terms of their user-friendliness. You can simply press buttons, position them – and you’re all set to go.”

Cobots, with their ability to be directed with just a tap of the finger, serve as a safe bridge to the future for those wary of diving head-first into automation.

BOC Gas & Metal fabrication specialists work closely with clients on solutions.

Beyond the productivity and efficiency benefits afforded by cobots’ obvious functionalities, Kuebler pointed to other features that give cobots an edge over their traditional industrial robot counterparts.

While the latter typically require enclosures, demanding a separate space and often a new unique programming language, cobots offer an intuitive interface that is as easy to use as an iPad.

The right gas for the job In the same way that welding systems for cobots and robots must be tailored to individual client needs, the provision of gases for such welding technologies is intrinsically application dependent.

Shielding gases are vital in protecting the molten weld pool from air but also play an important role in governing welding speed, weld quality, appearance, spatter and fume.

BOC offer an extensive range of shielding gases optimised for specific welding processes, materials, joint geometry, aesthetic and environmental outcomes. Professional advice is provided for shielding gas selection for optimum welding quality, productivity and safety.

“Generally, we use packs of cylinders,” he said, going on to discuss the different supply methods involved in different applications; always emphasising the importance of specific contexts.

“For high-volume customers, we’ve been mixing gas on site, combining argon with carbon dioxide, oxygen or helium, which is more economical than using cylinders or packs.”

manmonthly.com.au

Cobot welding is an important development for the welding industry. Photo courtesy of Colbotic Automation.

For automated cutting machines, BOC tailors the supply method to the machine’s requirements and production volumes: “Large-scale laser cutting operations typically use bulk tanks of nitrogen or oxygen. We also supply resonator gases – delivered in single cylinders and critical for optimal laser function.”

Safe and sustainable With sustainability considerations an ever present – and ever-increasing – concern, Kuebler highlighted BOC’s proactive approach. He pointed out that since 2018 welding emissions have been formally recognised as carcinogens.

BOC, the Linde group and its partners, have conducted robust research on how to minimise these harmful emissions.

“It’s not only about energy consumption but also about the welding process, the shielding gas, and protecting workers from ultraviolet light and fumes,” he said.

“We’re committed to helping the industry minimise these risks.”

Ensuring excellence Returning to an earlier subject, Kuebler underscored that BOC’s eastern seaboard Application Technology centres are a major part of what separates the company

from its competitors. And it’s not just about the benefits these centres afford to external clients, equally significant is their importance for BOC’s internal operations.

“We don’t just serve customers there; we also train our staff and evaluate new products.”

Although BOC relies on its parent company, the Linde Group, for R&D facilities located mainly in Europe, the US, and China, it’s the testing centres in Australia that ensure these innovations are suited to the local market.

“Many of the products developed abroad cater to specialised industries in markets like Europe, the US, and China,” he said. “However, Australia’s market is smaller and spread over a vast territory, making super-specialised product development less feasible here.”

That’s why BOC invests in testing of new products at its tech centres and then field testing by customers in the real world. This proactive approach to testing is emblematic of BOC’s overall commitment to staying ahead of the technological game while guaranteeing consistency and reliability to end-users.

It’s an approach that has reaped dividends for BOC and its clients thus far, and will doubtless continue to do so.

Manufacturers’ Monthly OCTOBER 2023 27

A M C E E Q W C E E Q W C E E Q W

Renewable Energy

Mapping local hydrogen capability Advanced manufacturing offers significant opportunities for job creation, productivity improvement and capability building in Australia, according to the Industry Capability Network’s (ICN) submission to the inquiry into Developing Advanced Manufacturing in Australia.

I

CN South Australia has completed a Hydrogen Supply Chain Mapping and Gap Analysis study, identifying more than 2000 South Australian suppliers that could provide goods and services to the emerging hydrogen sector.

It comes on the back of the South Australian Government investment in new hydrogen projects and infrastructure, including a world-leading hydrogen power plant near Whyalla by 2025.

The report was prepared using the Perspective by ICN capability tool, from information in ICN’s database. It outlines the number, size and scale of capable businesses across each likely package of work, and whether the business is an Aboriginal Majority Owned Business (AMOB).

In launching the report of the study

28 OCTOBER 2023 Manufacturers’ Monthly

at the TACTIC Conference in Port Augusta, ICN SA’s Manager, Supply Chain Development, Bettina Venner said ICN would work with stakeholders in government and industry to ensure local businesses can maximise participation in the hydrogen industry.

According to the report, South Australia is well advanced in the renewables and hydrogen transformation, with 69 per cent of its 2002 energy generation in 2022 coming from wind and solar PV, and a growing green hydrogen project pipeline.

“The significant existing industrial capability and capacity that supports South Australia’s resources and energy sectors will play a critical role in growing our state’s hydrogen ecosystem,” Venner said.

This capability mapping and gap analysis study examined the existing trades, services and supply capability that could support a local hydrogen industry. It also looked at potential low points or gaps.

“As well as documenting the existing capabilities that can be applied directly to the hydrogen industry, such as civil works and water desalination, the report also highlights potential opportunities for local businesses to diversify their existing capability to this sector,” Venner said.

“It can also be used to attract investment in new capabilities to the state for the manufacture of items which would otherwise be imported.”

Overall, the study found local matches for around 75 per cent of the

hydrogen supply chain capabilities outlined in this report, with particularly high capability in some categories.

“Our findings underline the significant opportunity for future growth and development of the green hydrogen industry in South Australia,” Bettina said.

Read the Hydrogen Supply Chain Mapping and Gap Analysis study.

The Industry Capability Network (ICN) provides Australian businesses with access to a powerful online tool to help connect them with suitable suppliers, project managers and business opportunities across Australia and New Zealand.

For more information on ICN, visit the icn.org.au or call 1300 961 139. manmonthly.com.au

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Energy Chains

Built on partnerships Treotham is a one stop shop for all things automation, supplying the best equipment from across the globe.

T

REOTHAM has more than 30 years’ experience providing highquality components and products to automation and industrial markets from a range of global companies.

As the exclusive distributor for many international product lines, Treotham’s customers gain from its local presence and the extensive knowledge and experience of its staff.

The company’s most diverse and impressive product is its energy chain range supplied by international company igus®.

Energy chains – also called energy supply chains, drag chains, cable guides and e-chains – are used to secure the supply of energy and data to moving industrial equipment have to withstand the most diverse environmental influences.

The decisive fact about energy chain is the symbiosis of the components moving against each other. They include cables, hoses, interior separation elements, strain relief devices and guide troughs.

The materials used have to be optimally matched to each other so that maximum operating times and a long service life are achieved. Thanks to energy chain systems, downtime is avoided wherever energy in the form of electricity, gas, air or fluids is supplied to moving loads.

30 OCTOBER 2023 Manufacturers’ Monthly

Ralph Harpur is the marketing manager at Treotham and he explained to Manufacturers’ Monthly some of the uses for the energy chains and other products from igus®.

“We are seeing igus® energy chains used in a vast array of companies everything from food processing plants, to robotic production lines all the way through to giant gantry cranes on a dock,” he explained.

“Energy chains are incredibly durable and resilient; there is a size capable of fitting on massive mining equipment in the Pilbara down to a micro size designed to fit into small printers.

“There is also a model of energy chains that comes with sensors built in to immediately notify users of breaks or failures to minimise potential downtime and get systems back online quickly,” Harpur explained.

Igus is still privately owned to this day the company has a thirst for success.

Treotham stocks a number of impressive products for automation including a large range of energy chains from Igus and a wide range of cables, connectors, glands and sensors.

technologies, and its award-winning and patented product and system solutions are used in industrial production worldwide. Wenglor’s sensor and image processing systems ensure the highest quality and efficiency in automation.

“The company has some incredible sensors built into its connectors that can measure when a bottle is about to fall for example and then has sensors running through the conveyor belt to ensure everything including labels go correctly onto the product,” Harpur explained.

Split into twelve product categories, Wenglor sensors work according to almost 200 different functional principles, thus

making the industrial landscape safe and efficient today. With the ever-increasing use of learning robots, its products must be able to make decisions themselves and communicate within the process. They are the sensory organs of automation for Industry 4.0 – and thus the most important components for smart machines.

Aftersales service John Sharp is the sales manager at Treotham and detailed the process of supporting customers from starts to finish.

Sharp explained that company’s often come to Treotham with a range of

Wenglor sensors Wenglor is one of the most successful medium-sized family-owned companies for smart sensor and image processing

There’s a Wenglor sensor for every application. manmonthly.com.au

Energy Chains challenges that can vary from existing products through to brand new designs.

“It can be an existing technology or something completely alternative or even a new build and we will come in and work out what configuration works best,” he explained.

Maintenance is critical to the support of these products and Treotham takes a proactive approach to supporting its customers.

“We will usually try to offer a maintenance schedule based on the duty cycle of the machine, it can vary from three to six months,” Sharp said.

“While most people we work with have a fantastic technical knowledge it is still worthwhile having a schedule as they don’t have the understanding of our product, so they are not used to that specific problem and where to look when it comes to common issues.

“The schedule allows us to take the responsibility out of the hands of the user and we can tell them when we will come and maintain their systems,” he said.

Sharp and his team are trained to quickly and efficiently recognise faults or

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items that have been fitted incorrectly.

By way of illustration, he recalled a brand-new piece of mining equipment he inspected.

“I got to the top of the elevator and walked out and within five steps I said to the workers, ‘Don’t run this machine it is not fit for service’,” he said.

“They honestly laughed because they couldn’t believe we could pick up a fault so quickly, particularly on a brand-new machine.

“I pointed to the offending part and explained it was fitted upside down and they quickly rectified it and signed up to our maintenance schedule,” Sharp chuckled.

Sharp went on to detail how much of what Treotham does is a partnership, working in tandem with companies to provide a solution to their challenge.

“We really find ourselves working closely with stakeholders, we spend so much time in this space we have a deep understanding of the product that we can bring to their production,” he said.

“Most of the time we are working with entrepreneurs, and they have a great knowledge of their product so we

Ship loading dock with an Igus energy chain.

just need to educate them on how to maximise our products with their own,” Sharp explained.

Australia wide support Treotham is 100 per cent Australian owned and managed and through a network of warehouses in Sydney, Brisbane, Melbourne and Perth, Treotham stocks over 10,000 high quality products.

Its head office is based out of its 3000 square metre site in Sydney where it can stock 1000s of items for quick response for customers.

The company stocks Amphenol, Chainfelx, Cicoil, Elfin, Elgo electronic, Euchner, Eupen, Hema, Hummel, igus, ILME, ital sensor, Kabeltec, Lapp, Pflitsch, PMA, Thomson, Tst, Wenglor and Wittenstein.

Manufacturers’ Monthly OCTOBER 2023 31

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Warehouse Automation

Creating more space with automation Robotic Automation has a long history of supporting clients with their robotics and automation needs with manufacturers continuing to turn to the company to improve logistics and product storage.

R

ECENTLY RA supported a prominent distributor in the logistics industry, which faced significant operational challenges in their existing warehouse facility.

The manufacturing company – like many others – had been so focussed on perfecting its product that its warehouse management had fallen by the wayside, with costly outsourcing becoming an issue.

The manufacturer had a lack of organisation and a haphazard arrangement of pallets which resulted in inefficiencies, with difficulties in locating stock leading to unnecessary delays and increased manufacturing costs.

When RA viewed the site there were immediate concerns around safety as well, with tall pallet stacks and incidents

manmonthly.com.au

of forklift operators damaging racking structures. To address these issues, the client sought a solution that would streamline warehouse operations, improve stock management, enhance safety, and integrate seamlessly with a new, RA specified Automated Storage and Retrieval System (ASRS) shuttle system.

A major challenge facing RA was integrating the new Automatic Guided Vehicle (AGV) system with the ASMS shuttle system and then transferring the entire warehouse to the new system without interrupting ongoing operations.

System installation RA began with a phased approach for this specific solution, selecting a fleet of

four MAXAGVs. These state-of-the-art vehicles are designed to autonomously navigate the warehouse environment, retrieve, and transport pallets of product with precision.

With the current stock in an extremely disorganised system, RA systematically removed all existing stock and scanned it into the new Warehouse Management System (WMS). This process enabled accurate tracking of each item while ensuring uninterrupted warehouse functionality.

A critical improvement RA made was to the palletising system. Pallets arriving from the manufacturing area were meticulously scanned by forklift operators. The WMS, armed with realtime data, determined the optimal rack location for each piece of stock,

thereby enhancing storage density and accessibility.

Once the storage location was determined, the AGVs seamlessly transported the pallets to the designated rack location. The AGVs also controlled the new ASRS shuttle system, commanding it to store items logically in the up to 22 deep rack positions, maximising warehouse space utilisation.

The AGV system facilitated autonomous order fulfilment. Upon receiving an order, the AGVs efficiently retrieved the required combination of stock types and delivered them to the outfeed area, streamlining the order processing workflow.

The incorporation of a 3D visualisation component within the new Manufacturers’ Monthly OCTOBER 2023 33

Warehouse Automation

WMS enhanced visibility and navigation within the warehouse and can be easily viewed on smart phones, pads and laptops. This visual representation of the warehouse layout enabled efficient stock identification and retrieval.

MAX AGV system Max is a state-of-the-art, dependable AGV Control System that runs on a modern client server Windows environment. It utilises Microsoft products, providing great possibilities for future expansion. Max is userfriendly with well-presented screens and logical functionality.

Max Control System handles everything from transport and warehousing, load tracking, buffering, and order swapping to optimal dynamic route selection, location selection, charge control, priorities and dead lock prevention – all shown in real time 2D & 3D visualisation.

34 OCTOBER 2023 Manufacturers’ Monthly

Max controls the AGV routing making split second decisions along the AGV’s guidance path in order to select optimum routes to specific destinations. In certain applications Max can be supplied with optional Warehouse Management for stock control and inventory. The Max system has embedded optimal dynamic routing and load tracking, so users know where pallets and products are at all times.

Automated benefits The implementation of the AGV system in conjunction with the ASRS shuttle system yielded several significant benefits for the company.

The company was able to transition to 24/7 operations, which significantly improved operational efficiency. Stock management was streamlined with the 3D visualisation tool that made retrieval simple and efficient.

The manufacturer was able to truly

maximise its space with a gain of two to three times the volume pallets using the same footprint. With space restrictions always creating challenges, the company could now maximise warehouse storage through deep rack storage.

Safety on site was drastically improved, too, with tall pallet stacks no longer required and more space available, forklift-related incidents have been reduced.

By effectively integrating a sophisticated AGV system with an ASRS shuttle system, the client transformed a once-chaotic warehouse into a streamlined and efficient operation.

The innovative solution not only resolved the initial challenges but also laid the foundation for improved productivity, safety, and customer satisfaction. This successful case study serves as a testament to the power of advanced automation and integration in modern warehouse management.

35 years of automation Now celebrating its 35th anniversary RA has a vast range of experience when it comes to improving a company’s automation processes and incorporating robotics.

Robotic Automation P/L was established in 1988 and with more than 3500 solutions delivered, installed and supported for a range of clients across the Australasia region.

RA is a leading supplier of turnkey solutions, deploying its core technologies from Motoman Yaskawa Robotics and MAXAGVs and the company says it looks forward to providing the next innovative solution for coming facilities of the future.

Scan the QR code to watch the system in action.

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Power Distribution

APS in partnership with Siemens open innovative new Manufacturing Centre in Adelaide APS Industrial has opened a first of its type Manufacturing Centre in South Australia which has sped up turnaround times and created 150 new jobs for the industry.

A

PS Industrial’s new manufacturing facility in South Australia is set to help the automation specialists manufacture and supply its products to the market in a quicker and more efficient manner.

The Adelaide based Manufacturing Centre is the first non-Siemens facility worldwide to adapt and assemble the Siemens range of Air Circuit Breakers (ACBs).

CEO, Siemens Australia and New ZealandPeter Halliday spoke about the importance of this announcement.

“This is the first time in the world that these Siemens products will be assembled and certified outside of a Siemens factory, giving the same quality assurances,” Halliday said, “This demonstrates the trust and ability of our national distribution

36 OCTOBER 2023 Manufacturers’ Monthly

partners, APS Industrial. APS will adapt and assemble Siemens ACBs and peripheral equipment right here in Adelaide, which is good for jobs, good for industry, and good for the economy,” he said.

Thanks to the innovative new facility, the air circuit breakers will now reach the market 50 per cent quicker than before.

Siemens business manager for Electrical Products Stephen Gough spoke about what this means for the delivery of the air circuit breakers.

“This is a significant investment for our business,” Gough said.

“The opening of this state of the art Manufacturing Centre has always been the vision at our existing site in Adelaide and to see it come to fruition is very exciting for us.

“The facility creates a new world of

opportunity for our company to support our customers,” he said.

It’s estimated more than 150 technology jobs will be created at the site over the coming decade.

“In addition to the ACB adaptation capability, we have bolstered our capability across the entire value add services and advanced manufacturing portfolio,” said Gough.

“As an example we also have a Rittal Perforex machine onsitewhich will enable us to respond to the market quickly, reduce lead times and all with local and Australia built content in our projects,” he said.

The facility will enable APS Industrial

Siemens business manager for Electrical Products, Stephen Gough. to speed up the delivery of ACBs to switchboard builders and electrical contractors who service both the Australian and New Zealand markets.

David Hegarty, CEO, APS Industrial spoke about the thinking behind this large investment in its facility. manmonthly.com.au

Power Distribution

The new facility will allow APS to adapt and customise the circuit breakers it delivers to local industry.

It is expected the facility will create 150 new jobs in South Australia.

“This is a significant investment for all of us, APS, Siemens, and for local industry,” said Hegarty.

“Five years ago, APS was formed as Siemens’ master distributor in Australia and since then we have grown significantly in size and scale as we’ve helped electrify the digitalise industries.”

Gough explains that the APS Manufacturing Centre will also reduce APS’ reliance on global supply chains, mitigating the risks of extended turnaround times.

“We have evolved into something far more effective and efficient,” said Gough.

The creation of more technology jobs, and the capacity for more growth on the new site, is in line with the some of the core values of APS Industrial.

“We are all about jobs and growth, it is pivotal to our approach,” said Gough.“ manmonthly.com.au

Gough explained that an emphasis on manufacturing locally, and with Australian sourced materials, was another key element in speeding up the turnaround time for customers.

“We can do all of the ACB customisation that a customer requires here in Australia, that is exciting for us. We had an aevent in Adelaide with over 60 customers and while speaking to some and they placed an order, and it arrived the next day. That’s what this investment is all about,“ he said.

Gough detailed that another important aspect of the facility was making sure everything was fully compliant.

“Earlier this year we went back to the local test station to test our distribution boards. They performed extremely well and arenow fully compliant,” he said.

Much of the feedback they received at their recent customer open day was centred around the level of local support for the manufacturing industry, indicating APS Industrial was meeting the demands on the market.

“I think it’s easy to say no, but APS says yes, and we find reasons to do it, not reasons not to do it,” he said.

“If we see an opportunityto support a customer, and ultimately the future

of the industry, we commit to it 100 per cent.”

Halliday said Siemens was proud of the relationship the company has built with APS Industrial.

“The decision demonstrates an expansion of Siemens footprint in South Australia and our long-term commitment to the state,” he said.

“We and APS are helping progress Australian industry and economy.

“We can’t expect industries to innovate and continue growth trajectories without access to the right resources.

“This is a significant move that helps address one of the most critical challenges being faced by industry today,” he said.

Gough said he was excited to see APS help with those growth trajectories, while simultaneously having its own.

Manufacturers’ Monthly OCTOBER 2023 37

Marine Aluminium Unique supplier for unique boats Dongara Marine has been improving its output of boats thanks to a new site and has turned to Capral to help meet its needs for aluminium.

The company creates custom boats for Western Australia.

D

ONGARA Marine has continued to develop its boats that are sent to market, transforming the company at regular intervals, it has become a custom boat builder that delivers for the marine industry in Western Australia.

The company recently moved to its new site in Geraldton where it has a range of in-house capabilities including, fabrication, engineering, electrical installation, marine glazing, blasting painting and delivery.

Dongara Marine has specific expertise in high tech composites, manufacturing wheelhouses and other structures for both its own and other boatbuilder’s projects.

Dongara Marine Director John Fitzhardinge began designing, building, and operating commercial fishing boats in Port Denison in the 1960s, before founding Dongara Marine with his wife Beth in 1975.

The main business was to provide vessel support including refit, repair, maintenance and a chandlery store for the local fishing fleet but over the years John designed and built several more 38 OCTOBER 2023 Manufacturers’ Monthly

boats through Dongara Marine.

The company’s diversified business model enabled it to weather the significant contraction in domestic demand for new vessels that characterised the first 15 years of the 2000s. Since that time its capabilities have been increasingly sought out for new vessel construction projects, not only for fishing boats but also for pilot launches, work boats, and passenger vessels.

With highly experienced management, bigger facilities, and a larger, more diverse workforce Dongara Marine now has in-house capabilities to undertake virtually every aspect of new vessel construction, repair and modification, and vessel support for both commercial and government clients.

Boat construction Managing director and part-owner Rohan Warr explained the boat building process for Dongara Marine.

“Every time we are building a boat, we are trying to make it better than the last one, whilst sometimes there’s some backwards steps, we always want to be improving what we are sending to

market,” Warr said.

“I think the other thing that we do, which is very different is that we have all trades in house meaning we’ve got our own fabricators, our own shipwrights and our own spray painters.

“The two boats in the shop at the moment are two pilot boats, which are identical and that’ll be the first time we’ve ever done that, having two boats that are exactly the same side by side.

“I don’t know how we would go with our workforce if we were just pumping out the same machines over and over, they like the challenge of solving new problems each time they build a boat,” Warr explained.

but strong for what it is, which is perfect for remote regions that we are often providing these boats to.

“If you are working in far flung

Partnership with Capral Warr explored the relationship between Dongara Marine and Capral. By working closely with the aluminium supplier, it has greater scope for customisation and continual improvement.

“The aluminium from Capral gives us fantastic customisation which you cannot always get with other materials, it also is extremely durable,” he explained.

“Aluminium is incredibly lightweight manmonthly.com.au

Marine Aluminium

For more crafted with Capral scan the QR code below

Dongara Marine has been constructing boats for some of the harshest environments in Australia.

regions of Western Australia, not many places will have someone who can repair composite materials, but most towns will have a welder who can make quick

repairs, it allows those who purchase from us to minimise down time,” Warr detailed.

Warr explained how the aluminium

The team has been using Capral for the supply of aluminium.

manmonthly.com.au

stands up far better to corrosion than comparable steel. Aluminium boats are expected to remain in service for over 35 years and Warr expects to see some boats that are correctly maintained remaining in service for close to 50 years.

The relationship with Capral extends further than just simply the quality of the aluminium provided as Warr detailed.

“Our relationship with the sales guys is great, we only want to deal with people who make our lives easier and that is what we get with Capral,” he said.

“The Pilot boats that we are just finishing now used probably 30 tonnes of aluminium, Capral has a great price point, and they have the capacity to meet our needs so we stick with them,” Warr said.

Dongara Marine has been working with Capral on and off since 2012 but they have been working with them almost exclusively since 2019.

Capral works closely with Dongara Marine to deliver products that meet its specific needs, Capral delivers exactly what the company needs to minimise waste and keep the costs to a minimum.

New facility Dongara Marine moved into its new facility in the middle of August in 2022 and it has allowed the company to greatly improve its output as Warr explains.

“We have effectively doubled our output at this facility, we have gone from four or five boats to sometimes close to 14 now,” he said.

“This has thrown up a new set of challenges, we really have to be on the pulse with our management and making sure we have enough real estate for each boat.

“We have to have 16 and a half metre clearance under the hook on the crane to get it out so that is challenging,” Warr said.

As he went on to explain, whilst it has thrown out some new challenges for the team, it has been beneficial overall.

“We have been able now to complete our boats indoors whereas we used to to take them out using prime moves but now we can bring a boat lifter into the shed,” Warr explained.

“We used to have a lot of sleepless nights doing that work, but now it is far simpler and we can really see our production ramping up over the coming years.”

Manufacturers’ Monthly OCTOBER 2023 39

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Cold Sensors Sensing the need for more Temperature control is becoming a critical component of many manufacturing processes and transportation; the food industry is one such sector where cold sensors are critical to the supply of products.

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ith the number of perishable food and biopharmaceutical products in the market, maintaining their temperature integrity has never been so important. In 2017 Australia released the cold chain guidelines, providing strict controls for manufacturers and those transport cold good must follow.

Around 2.2 million tonnes of food waste is generated by the Australian commercial and industrial sectors each year.

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Zebra’s portfolio of electronic temperature sensors stands out due to their unique, purpose-built designs.

With mobile connectivity and data-

sharing capabilities, Zebra devices deliver exceptionally versatile and effective monitoring of temperature-sensitive products throughout production, storage, and cold-chain shipping.

They give users greater control and visibility to capture temperature readings and location data to help protect temperature-sensitive products from damaging exposure. By increasing automation and speeding processes, Zebra devices help ensure greater reliability in end-to-end, cold-chain monitoring.

While other devices require USB connections to access data, Zebra’s portable, wireless temperature sensors are Bluetooth enabled, allowing data to be retrieved and recorded through packing materials, containers, vehicles, cold-chain equipment, and temperature-controlled rooms.

This convenience makes it easier for users to quickly view temperature data without opening containers, thereby helping to reduce potential for human errors and limiting products’ exposure, which can cause product loss, deterioration of efficacy, and harmful effects to consumers.

In addition, Zebra’s ZSFinder app and Zebra Cloud to provide immediate, remote access to device data via the cloud. ZSFinder app enables easy setup, monitoring and tracking of sensors using Android mobile devices. Zebra cloud provide wireless, cloud-based data-sharing, storage, and reporting for compliance or analysis.

Zebra’s electronic temperature sensors are also among the most customisable in the market. Other devices which are preconfigured with monitoring settings require users to purchase different

devices for different needs.

Zebra devices, however, can be configured for each cold-chain shipment or storage environment, giving users a wide range of options and controls over settings, including start time, reading intervals and alarm limits.

ZS300 sensors Users can achieve a higher level of continuous visibility into temperature and location data within the supply chain with Zebra ZS300 Electronic Sensor.

Easy to configure, you can use the same sensor to monitor products with different temperature profiles without the need to purchase multiple variations of pre-configured devices.

The ZS300 is tough and high performing. An IP67 rating enables reliable operations in your most challenging applications and Bluetooth Low Energy v5.2 delivers high speed data transmission, cutting the time needed to gather data and move on to the next task.

The sensor has a range of up to 30.5 metres via bridge and mobile devices and a wide temperature range of negative 40°C to plus 85°C and it can store up to 16,000 data readings.

Zebra can deliver the additional level of insight you need to manage shipments efficiently, identify temperature excursions in real time and act upon them without manual intervention to maintain product quality and effective compliance.

Zebra’s no-cost sensor recycling program makes environmental responsibility simple and easy.

ZB200 bridge The ZB200 Bridge is easy to install and set up, with a convenient mounting bracket and single button operation. The high-performance Bluetooth radio enables the bridge to collect reliable manmonthly.com.au

Manufacturers’ Monthly OCTOBER 2023 41

ColdSensors

The Zebra system is a major asset in cold supply.

data from multiple Zebra electronic sensors within range 30.5 metres and automatically deliver it to the Zebra cloud.

The ZB200 Bridge sends back temperature and location data through the cloud to your system, reading through packages, containers, and vehicles, without manual intervention across multiple application cases, for instant temperature and location visibility and effective real-time response.

This streamlines the decision-making process and enables valuable insights across the entire supply chain.

The bridge uses dual band Wi-Fi and ethernet for connectivity with a 110-240v AC, USB power supply in a polycarbonate enclosure to give it maximum protection.

The combined operation of the ZS300 sensor and the ZB200 bridge enables the creation of reports to help maintain quality and regulatory compliance.

Zebra’s electronic sensor ecosystem has 42 OCTOBER 2023 Manufacturers’ Monthly

been designed to ensure data integrity and authenticity to help you defend against security breaches.

Why choose Zebra?

For Developers who have customers with temperature sensitive products looking for a solution to gain visibility into temperature exposure, Zebra’s Cloud-enabled developers solution for electronic temperature sensors offers a high-value addition to their software solutions.

It enables visibility into their customers’ supply chain temperature breakdowns with devices that can be quickly configured and provide automated temperature and location data collection with exposure alerts in near real-time The ZS300, ZB200 are an integral part of managers operations that enables visibility into supply chain temperature

The system communicates easily with a smart device

breakdowns with devices that can be quickly configured and provide automated temperature and location data collection and distribution in near real-time.

The range of sensors from Zebra offers a secure and easily interactable solution that enables temperature visibility across the entire supply chain.

The ZS300, ZB200, and Zebra cloud

has a security layer to ensure data integrity and authenticity providing secure connections to block unauthorised access, prevent data and task parameter manipulation and controlled data exchanges, that also has an SDK to enable custom app development and API’s to easily integrate within existing systems and access to data across the entire supply chain in near real-time. manmonthly.com.au

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Making Australia an energy superpower This article will delve into the report that was released at the National Manufacturing Summit which explores the potential for Australia to become a renewable manufacturing powerhouse.

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T the National Manufacturing Summit held by Weld Australia, Dr Jim Stanford and Charlie Joyce from the centre for Future Work at the Australian institute released a report titled, Manufacturing the Energy Revolution.

The report reviews the new incentives for production of batteries, electric vehicles, renewable energy generation and transition equipment, and other renewable energy products that the US is currently demanding after the implementation of the Inflation Reduction Act. The report provides evidence that the U.S incentives and content requirements are sparking an unprecedented expansion in manufacturing investment in the U.S. Australia has many advantages in the global race for sustainable manufacturing and need to capitalise on its position.

The theory and practice of climate industrial policy A particular focus of climate industrial policy is to use new investments in renewable energy production as a platform for supporting the expansion of related manufacturing activity. Two broad classes of spill-over linkages between renewable energy production and manufacturing are possible; 1. The production of manufactured 44 OCTOBER 2023 Manufacturers’ Monthly

products, materials, and technologies that are utilised in renewable energy generation projects and systems.

2. The use of renewable energy as an input to other manufacturing activities in order to reduce their environmental footprint and make them consistent with climate policy targets.

The report explores the importance of policy and explains that for several decades since the 1980’s, industrial policy became largely unfashionable amongst economic policymakers. Governments were advised to not pick economic ‘winners and losers’ through active measures to favour particular sectors.

Instead supposedly market forces and business decisions were to be placed in charge of determining the sectoral structures of economies.

Australia suffered from the neglect greatly and the manufacturing sector was at the centre of this neglect and its downturn has been severe.

With the growth of renewables in many of Australia’s closest allies, it has an opportunity to grow its manufacturing space once more.

Australia possesses one of the richest endowments of renewable energy capacity and massive reserves of lithium and many other critical minerals that are in increasing demand. Australia currently has over 50 per cent of global

lithium production, but has no capacity for converting that into value-added products.

The current state of climate industrial policy in Australia Professor Ross Garnaut notes in his book superpower that “per person, Australia has natural resources for renewable energy superior to any other developed country.”

The Australian Energy Market Operator has found that Australia has the capacity to generate three time its energy needs through renewable energy generation with the facilities only taking up 0.15 per cent of its land mass.

If Australia remains focussed on simply exporting minerals overseas it would remain vulnerable to the traditional constraints of resource led development which include volatility in terms of trade, dependence on foreign investment and foreign markets and exposure to environmental side effects of expansive resource extraction.

Since 2012 the commonwealth has sponsored two major clean energy technology funding organisations, the Australian Renewable Energy Agency (ARENA) and the Clean Energy Finance Corporation (CEFC).

Since the election of the current federal government, several new

initiatives have been announced to facilitate significantly greater investment in clean technology development. These include the Powering the Regions Fund, the National Reconstruction Fund, the capacity Investment scheme, and the Hydrogen Headstart Program.

In May of 2023, at the G7 conference, Australia and the US signed a significant agreement concerning bilateral climate co-operation. The US-Australia climate, critical minerals and clean energy transformation compact. The compact establishes climate action as a central pillar of the US-Australia relationship.

Rising to the challenge Several senior government ministers have flagged their commitment to adequately responding to the IRA and seizing the opportunities of the renewable energy revolution. Treasurer Jim Chalmers as declared it a priority of the government to make Australia a beneficiary of the IRA investments rather than a victim.

Ed Husic has held discussion with Washington DC to explore a potential link between Australia’s National Reconstruction Fund and the IRA, to build a direct value chain between Australia critical minerals mining and US battery manufacturing.

Joyce and Stamford explain that it is critical for policy makers to appreciate manmonthly.com.au

National Manufacturing Sumit the order of magnitude of domestic fiscal intervention that will be required just to match U.S effort, let alone address the structural disadvantages that have held back Australia’s fully fledged participation in this industrial transformation.

The pair explained that there are several best practices which Australian policymakers should consider closely.

Coordination and planning: A successful climate inudtsiral strategy will have many moving parts involving actions and interventions form various levels of government, private investment decisions, and participation by other stakeholders.

Sovereign Capability in key functions: It is vital for several reasons that Australia achieve the capability to produce some essentials systems and components that will play central roles in the energy transition.

Australia’s abundant endowment of resources and its preferential and trusted trading relationship with the U.S and other allies, gives it a key advantage.

The same logic however, applies to various manufactured components

manmonthly.com.au

that are equally vital to the success of renewable energy developmentsincluding batteries of all sizes, key renewable energy generation equipment, specialised transmission technology, and even final assembly of key sustainable energy based products.

Public equity and accountability: A major focus in the IRA and complementary strategies is to enhance the bottom line incentive for private firms to invest in various aspects of renewable energy expansion, including related manufacturing activities.

Investment in a skilled and inclusive workforce: A potential constraint on the expansion of renewable energy and related jobs is posed by the need for training and skills acquisitions. Such an ambitious skills and training agenda will require a focused and well resourced plan, supported by the commonwealth and state governments, industry and trade unions.

Conclusion The fossil fuels that Australia has become so reliant on and makes up a large and

growing share of those mineral resources have a definite ‘best before’ date that is approaching quickly.

A failure to proactively carve out a more diversified value-adding role in these new global industries is reinforcing Australia’s underdeveloped position in world trade.

The renewable energy transformation opens a generational opportunity for Australia to reimagine its stunted role in the global economy.

Because entire industries are being reinvented from the bottom up, new players can hope to join that new global competition.

Manufacturers’ Monthly OCTOBER 2023 45

Events Sino-Australian collaboration through grinding products This December 4th, the Brisbane Convention and Exhibition Centre will host Australia Hardware Tools & Grinding Expo (ATGE), a groundbreaking exhibition.

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S co-organisers, Abrasivestocks, a China-based digital platform specialising in the grinding industry, is excited and thrilled for the expo. The event aims to foster SinoAustralian business relationships, particularly in the realm of hardware tools and grinding products.

The Underestimated Australian Market Australia, with its modest population of 26 million, is often overlooked by global providers of tool s and hardware.

However, it’s a significant importer of high-quality tools and abrasives from Europe, America, and Asia. The Australian

government’s emphasis on sustainable and eco-friendly manufacturing adds a unique edge to its market and this focus is ushering in new opportunities that Chinese companies should explore.

The Evolution of ‘Made in China’ The phrase ‘Made in China’ once carried a stigma of low quality, especially in hardware and abrasives. This perception is rapidly changing, China’s government is pushing for high-quality manufacturing and technological innovation. Coupled with its cost-effectiveness and robust supply chain, Chinese products are increasingly meeting and exceeding global standards.

Market Differences •

•

•

Consumer Demand: Australians prioritise quality and sustainability, while the Chinese market is more diverse.

Market Size: China offers a vast market, whereas Australia’s is more concentrated.

Regulations: Each country has its own set of product standards, an essential consideration for successful collaboration.

The Imperative of Collaboration ATGE promises to be more than a product showcase; it’s a catalyst for Sino-Australian cooperation. China’s

market, known for its inclusivity, welcomes global partnerships, as Chinese manufacturing strides towards high-quality development, there’s much to learn from Australia’s focus on standardisation and sustainability.

Conversely, China’s efficiency and cost-effectiveness can aid Australia’s burgeoning manufacturing sector.

The potential for Sino-Australian cooperation in hardware tools and grinding products is immense.

ATGE aims to be the platform that accelerates this collaboration.

Abrasivestocks is committed to making this happen, benefiting both nations’ manufacturing landscapes.

The expo will be held December 4th in Brisbane.

46 OCTOBER 2023 Manufacturers’ Monthly

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What’sNew Photonis iNocturn Ultra-Sensitive Intensified Camera The iNocturn from Photonis is an intensified camera combining an image intensifier tube with a sensitive, low-light camera. It features a unique combination of ultra-sensitivity, low SWaP, high frame rate, high-QE photodetectors, and nano-second gating. The intensified camera can detect different wavelength ranges from deep UV to NIR and is suited for applications in fluorescence imaging, electrical discharge detection, microscopy and spectroscopy. The camera’s high-resolution sensor is also equipped with a high frame rate for high-speed moving objects in applications such as industrial monitoring.

Small, compact and lightweight, the iNocturn intensified camera offers 1280 x 1024 pixel resolution, frame rates up to 100 fps at full resolution, spectral range from 200 – 1100 nm, however this is subject to photocathode choice. With either gated or non-gated options the minimum detection capability is up to a single photon. Connection is via PAL/ NTSC, CameraLink, HD-SDI, USB 3.0, LVCMOS, C-mount and operational temperature -10 deg C to +55 deg C. Thanks to the Smart Tube Management, the iNocturn range of camera produces high quality images and videos supporting the ability to perform single photon detection, with an ultra-low read noise reached without the need for any additional cooling.

The High QE image intensifier comes with different range of wavelength spanning from deep UV to Near Infrared enabling the user to focus on a specific range of wavelength for a particular application. For example, spark and electrical discharge detection application is very suitable with the iNocturn SUV, while the iNocturn Blue or Green can be used for other applications that include wafer inspection, spectroscopy and microscopy.

Company: Scitech Pty. Ltd Phone: (03) 9480 4999 Website: www.scitech.com.au

iEi’s PPC2-CW22-EHL 21.5” Fanless Panel PC with Intel® Celeron® Processor J6412 ICP Electronics Australia is proud to introduce iEi’s PPC2-CW22-EHL. With the rise of the Industrial Internet of Things (IIoT), the need for rugged, high-performance panel PCs has never been greater. iEi’s PPC2-CW22EHL, a 21.5” fanless panel PC, stands out in this crowded market with its superior specifications and features.

At its core, the PPC2-CW22-EHL is powered by the Intel® Celeron® J6412 processor. This ensures the system’s capability to deliver high levels of performance at ultra-low power consumption. With a burst speed of up to 2.6 GHz, multitasking becomes smooth and efficient. This is complemented by an impressive 8GB LPDDR4x memory, which offers faster memory speeds and lower power consumption, ensuring stability even in vibration-prone applications.

The PPC2-CW22-EHL isn’t just about power and speed; it’s built to last.

The true flat surface with an industrial-grade TFT LCD is easy to maintain and clean, preventing dust and liquid penetration. Its touchscreen, robust with anti-glare, anti-UV, and scratch-resistant features, supports operations even with gloved or wet hands—a significant benefit in industries like food processing.

Moreover, the panel PC boasts dual 2.5GbE LAN ports for enhanced networking, high-speed 10Gbps USB connections, and a 4K HDMI dual independent display capability, ensuring versatile connectivity options.

And for those concerned about security, the PPC2-CW22-EHL comes equipped with Intel® Platform Trust Technology. iEi’s PPC2-CW22-EHL also promises effortless upgrades. Its mechanical design is compatible with previous models, allowing for easy replacements. Other features like touch-enabled BIOS and customizable I/O interfaces make it adaptable to various industrial needs.

In essence, the PPC2-CW22-EHL is more than just a panel PC; it’s a testament to iEi’s commitment to driving forward the IIoT revolution with manmonthly.com.au

top-tier technology. From CNC machine operator panels to air traffic control systems, this device is set to redefine how industries operate.

Key features: • • • • •

Intel® Elkhart Lake Platform Dual M.2 (M.2 B Key & M.2 M Key) support Anti-glare and Anti-UV PCAP Support Gloved and Wet Hand Operation Newly Designed Panel Mount Kit

Company: icp electronics Australia Phone: (02)94576011 Website: www.icp-australia.com.au Manufacturers’ Monthly OCTOBER 2023 49

The Last Word

DR BEN MUIR – Team Leader, Automated Materials Discovery Team DR SHAUN HOWARD – Digital Lead, Senior Engineer, Automated Materials Discovery Team

Robotics, automation & the new era of materials science

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aterials science has played a pivotal role in advancing technologies and shaping the world in which we live. Over the past decade we’ve seen major breakthroughs in the development and application of new technologies. This has led to significant advances in energy storage materials, flexible electronics, advanced composites, additive manufacturing, and novel biomedical materials for prosthetic implants, drug release and mRNA vaccines just to name a few.

Recently, the integration of automated and robotic tools has supercharged the field even further, transforming how materials scientists and engineers approach our work. This is unlocking new avenues of research and expanding the boundaries of what we can explore.

CSIRO was an early believer in the transformative power of robotics and automation in research laboratories.

In that spirit, we launched the Rapid Automated Materials and Processing (RAMP) Centre in Melbourne in 2014, to demonstrate how these tools could accelerate advanced materials and chemical science research and development (R&D).

The RAMP Centre is a dynamic laboratory where we can create and optimise new materials faster than ever before. Under the direction of our scientists, robots dispense and mix chemicals repeatedly and reproducibly, control the reaction conditions, and take samples long after we’ve switched off the lights and gone home for the night. By using robots and automation to handle repetitive tasks, our researchers can focus on the bigger picture, speeding up the journey from a brilliant idea to real-world physical outcomes and applications.

Whether it’s crafting a more efficient catalyst for chemical processing or developing a new drug delivery method, RAMP takes a lot of the guesswork out of the process.

Since its inception, RAMP has been a springboard for innovation in a wide variety of industries including aerospace, mining, manufacturing, energy, agriculture and health. This has led to projects as varied as generating hundreds of new contact lens formulations, to 50 OCTOBER 2023 Manufacturers’ Monthly

developing novel conductive coatings for the aerospace industry. The robotics laboratory gives our business and industry partners the opportunity to explore the benefits of automation, working alongside our specialists including statisticians, AI experts, chemists, biologists, engineers and materials scientists.

The RAMP team has worked with our partners to re-think experimental workflow approaches and expand the scope of research that is possible. This innovative approach has reduced the discovery and optimisation time to achieve successful results. As we approach the ten-year mark, we reflect on the increasing uptake of automation in advanced materials and chemical research. And we consider what will be important over the coming decade.

One pervasive misconception we have observed is the fear that robots will ‘take our jobs’ – even among trained research staff. In our experience, robotics complements our human expertise and input, rather than replacing it. However, it’s fair to say that the skill sets required are evolving and do differ from those

needed in traditional laboratories. Staff with coding skills, understanding of machine learning methods and strong hands-on engineering competencies are increasingly valued.

Some of the additional benefits of using robotics in R&D we’ve observed include: • Accelerated discovery of advanced materials: The demand for materials with superior properties is seen across many industries, from aerospace to health. Automation, in conjunction with high-throughput experimentation, empowers researchers to swiftly synthesise and evaluate thousands of novel materials. Robotic systems perform these tasks with unmatched precision, slashing the time required for material discovery. In some cases, this has reduced the typical time taken to conduct experiments from weeks or months ‘at the bench’ to only days (or even hours) to achieve the same or better results.

This speeds up development cycles

•

•

enhancing product performance and competitiveness, and enabling new products to get to market quicker.

Customisation and iterative design: Automation allows us to customise and change variables quickly to achieve a specific result. Researchers can modify material compositions or processing conditions to meet requirements and learn the factors which significantly affect a tangible property like viscosity, colour, molecular weight, etc. This agility is valuable in industries like aerospace and additive manufacturing where novel lightweight, high-strength materials are in constant demand.

In medical applications, the ability to systematically alter parameters allows us to tailor properties to suit a specific part of the body or optimise the kinetics of release of a therapeutic compound.

Improved safety in hazardous materials handling: Some materials used in R&D can be hazardous to human health, but using robotics can reduce (or eliminate) manual handling

manmonthly.com.au

in many instances. There is also the clear advantage of reducing the risk of repetitive strain and other workplacerelated injuries by using robotics for repetitive work. This frees up trained scientific staff to focus on the creative and strategic aspects of their roles. This not only protects researchers but also improves the reliability of experiments by minimising human intervention.

Through our interactions with partners across Australia and the international community, we have seen a sizeable increase in the acceptance and adoption of automation in laboratory research, both within academia and industry. No longer are robots limited to ‘typical applications’ like automotive manufacturing plants to weld and cut joints and fittings. Their roles are quickly expanding across all manufacturing sectors – including niche R&D operations. In the decade ahead, facilities like RAMP are going to be the new normal, providing critical infrastructure to further drive innovation via: • Data-driven insights for informed decision making: In the data-driven

•

era, informed decision making is the linchpin of success. Lab automation plays a pivotal role in data collection, and machine learning algorithms exploiting Natural Language Processing and other methods now mine this treasure trove of information for insights. Material behaviours and properties can be interpreted and deciphered with unprecedented depth, enabling businesses to make strategic choices that maximise efficiency and cost-effectiveness, and enable rapid innovation.

Remote research and collaboration: The ability to control experiments and collect data from anywhere in the world is facilitating collaboration and dissolving boundaries among experts. This has become especially important in recent times, as global events like COVID-19 have limited laboratory access and made in-person collaboration more difficult. This potential could be taken further to explore the possibility for in-situ research in extreme or inhospitable

environments, such as underwater or even in space.

CSIRO is currently planning for the next generation of our laboratory facilities, and some of the key elements we believe are ripe for exploration are: • Collaborative robotics: Systems that are inherently designed to work around humans without the need for cumbersome safety systems.

These robots can be modularised to create multi-step processes, or simply deployed for extra capacity alongside research staff to meet demand. Units which can multi-task and be moved around as needed will be cost effective and could turn standard bench-top instrumentation into automated workstations.

• Mobile robotic platforms: These are already being used in warehouses and clinical environments like hospitals. We believe these will play a growing role in the R&D sector to transport chemicals and consumable items from storage, and transport waste to appropriate depots. These are increasingly used in

tandem with collaborative robot arms to allow manipulation and transport in dynamic environments where both people and equipment operate side-byside.

• Improved interactive interfaces: Natural Language Processing is rapidly evolving to providing an intuitive way for humans to interact with technology. Imagine a digital assistant (think Google or Siri for the lab) that can provide technical information on demand, record experimental details automatically, interpret your results, and assist with programming a robot to perform the desired task. Beyond voice control, augmented reality is already offering us new avenues to interact with equipment, retrieve information, and communicate with each other in real-time while having unencumbered use of our hands. That’s particularly useful in a laboratory setting.

The future is exciting and at CSIRO we look forward to helping to develop and demonstrate the new tools and capabilities that will shape the next generation of R&D labs.

CSIRO has been using robots and automation in its facilities for close to a decade.

manmonthly.com.au

Manufacturers’ Monthly OCTOBER 2023 51

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