AMT SEPT 2014 by AMTIL

sep14 Australian Manufacturing Technology

Your Industry. Your Magazine.

From the idea to the ﬁnished product. 21,5”

ERGOline control with Multi-Touch monitor

Inﬁnitely variable adjustment of the screen and keyboard

Transport & Logistics: Going places PAGE 34 SMARTkey: Customised user authorisation

.transport & logistics .Composites .Material Removal .Software .Quality & Inspection

) n V o i t a t (Imi

No Time for Don't Settle for Less. Use IS

The Only Double-Ended Parting and Grooving Insert Unlimited Depth of Cut

Unbeatable Tool Life in Interrupted Cuts

Excellent for High Temperature and Stainless Steel

Excellent for High Temperature Alloys and Exotic Materials

Machining Intelligently

ISCAR HIGH Q LINES

Look Alikes! SCAR's Innovative Products

No Time for Downtime! ICP/ICK-2M

ICF-CFRP

ICP/ICM/ICK

Double Margin Drilling Heads for Premium Surface Finish

Drilling Heads for CFRP and Titanium CFRP Laminates

Exchangeable DCN Drilling Heads for General Applications

FCP

NEW

HCP-IQ

Flat Bottom, Enhanced Self-centering Ability, Self-centering Heads, Premium Surface Quality for ISO P/K Materials for ISO P/K Materials

ISCAR AUSTRALIA PTY. LTD Tel+61 (0) 2 8848 3500, Fax+61 (0) 2 8848 3511, iscaraus@iscar.com.au

www.iscar.com.au

Volume 14 Number 08 September 2014 ISSN 1832-6080

contents

TRANSPORT & LOGISTICS Fraunhofer researches unmanned ships concept Opportunities ahead for Australasian rail sector Enerpac ensures crane safety at Tauranga Iveco – to Australian truck manufacturing

38 40 42 43

COMPOSITES Setting the stage for composites work Aerospace engineering flies ahead at UQ Composite ‘top hat’ protects Silent ANZAC submarine Machining composites like cutting butter

48 50 50 51

MATERIAL REMOVAL Masport’s new Okuma “a step up” Milling down to the micron

52 54

SOFTWARE Celos – From idea to finished product Five trends that will shape the future of ERP FEA: Saving time and costs Managing increasing complexity Met Optix opens for business

56 57 58 59 60

QUALITY & INSPECTION Aerospace manufacturer gains edge with AIFM PolyWorks 2014 – Metrology-grade laser scanning 3D measurement arm technology

62 63 64

From the CEO From the Industry From the AMWU

10 12 14

INDUSTRY NEWS Current news from the industry

PRODUCT NEWS Our selection of new and interesting products

ONE ON ONE Douglas K Woods (US) Association for Manufacturing Technology

COMPANY FOCUS Multi Slide Industries

AMTIL FORUMS Forum HR: Changes to superannuation guarantee Forum Import/Export: Australian export challenge Forum Law: Directors’ duties – are you at risk? Forum OHS: Directors now charged for WHS issues

68 69 70 71

Manufacturing History – A look back in time

AMTIL INSIDE The latest news from AMTIL

sep14 AustrAliAn MAnufActuring technology

your industry. your Magazine.

Transport & Logistics: Going places

.transport & logistics

6 |

Transport & Logistics – Moving Australia forward Australia’s logistics industry accounts for 8.6% of GDP, adding $131.6bn to the economy in 2013. Manufacturers and innovators in this sector are helping to keep Australia moving forward safely and efficiently, while also sourcing the bulk of their suppliers from the domestic market, keeping opportunities and jobs in this country.

Carbon Nexus – Gaining material advantage Carbon Nexus is a brand new, $34m research facility that aims to harness the enormous potential of carbonfibre and composite materials, and set a new path for local manufacturing. The freedom to move seamlessly between laboratory and pilot production means there is nothing like it in the world.

Cover Australia’s logistics industry makes an enormous contribution to Australia’s GDP and employs approximately 1.2m Australians. Australia has the sixth-largest freight and passenger network in the world – with our rail network covering almost 45,000km of track. Page 34

PAGE 34

.Software .Quality .Composites .Material Removal

& Inspection

AMT september 2014

Multi Slide Industries – Hard-wired for success South Australian company - Multi Slide Industries- was hit hard by the decline in the local car-making industry. But due to its ethos of total commitment to “buy Australian”, its reinvention in order to access other sectors , and its reputation for quality - the company is fuelled for growth.

We have an app for that... CoroKey

Insert Identifier

Start Values

Machining Calculator

Select the best insert for the job using basic information. â&#x20AC;&#x153;Easy to choose, Easy to useâ&#x20AC;?.

The guide to all grades and geometries for turning, milling and drilling.

Get start recommendations for machining different materials.

Calculate your optimal cutting settings based on your job parameters.

Milling Calculator

Turning Calculator

Drilling & Tapping Calculator

Product News

Get the right cutting data for your milling operations.

Get the right cutting data for your turning operations.

Get the right cutting data for drilling and tapping operations.

Find out whatâ&#x20AC;&#x2122;s new in metal cutting technology in a new dimension.

Manufacturing Economics

Turning Multi-materials

Metalworking World

Publications

Maximize your production resources. See the connection between profitability and metal cutting solutions.

Define your own material mix and conditions to receive a suggested selection of turning inserts.

Award winning global business and technology magazine for cutting edge developments.

Thousands of pages in one app, up-to-date printed ordering information digital.

Your next app... Stay updated, more apps are under development.

For more information about our app offer, please visit our web:

www.sandvik.coromant.com/apps

FROM THE

Editor

Editor WIlliam Poole wpoole@amtil.com.au Contributors Carole Goldsmith

William Poole

Construction on the move We’ve got a Construction & Infrastructure feature scheduled for November, so last month I embarked on a bit of early fact-finding, and headed along to PrefabAUS 2014, the inaugural conference for PrefabAUS, the peak body for Australia’s off-site construction industry. It was an impressive event, with an impressive turn-out. What was notable for me was that, while there was the expected presence of architects, engineers, property developers and the like, plus the usual roll-call of universities and government agencies, manufacturing was also represented in force, both on the speaker program and among those attending. There is something of a gulf between the worlds of construction and manufacturing. One is undertaken out among the elements on a building site, the other in the closed environment of the factory. The materials, the processes and the types of expertise used in each field are in many cases radically different. However, prefrabricated construction bridges that gap. Advances in manufacturing techniques and materials mean prefab buildings have come a long way from the shabby old portable cabins that once characterised the sector. Meanwhile, the ability to work in the controlled, centralised conditions of a factory represent a powerful advantage for a construction industry juggling a burgeoning array of challenges: economic, regulatory, environmental, logistical, and so on. In other words, you can build a house, brick by brick, out on a building site in blazing sun or driving rain, all the while disrupting the surrounding neighbourhood for months or even years. Alternatively, you can stay in your heated, air-conditioned workshop, and manufacture the house in precise, quality-controlled modules, then load them onto trucks, and assemble them on site, in a fraction of the time and with minimal disruption. This is a sector in a period of radical expansion and innovation. Australia in particular offers enormous growth potential, with prefab accounting for around 3% of housing, compared with 50% in places like Scandinavia. And it is a major area of opportunity for manufacturers. One company already thriving in the sector is Hickory Group, an AMTIL member profiled in this magazine earlier this year. The company utilises manufacturing techniques drawn from the automotive sector, sources a lot of components from former auto-suppliers, and indeed employs a significant number of staff who previously worked in the car industry. A founding member of PrefabAUS, Hickory was one of a number of manufacturing companies that figured prominently at PrefabAUS 2014. The conference offered an interesting snapshot of the current state of play for the sector, and where it’s heading. There were case studies from across Australia, as well as from as far afield as Japan, South Korea and The Netherlands. There were presentations on some of the technical innovations that could drive the sector forward, and there were insights from other sectors, including manufacturing. But there was also recognition of the obstacles. One complaint that recurred was the issue of finance, and the difficulty attracting investment for what are often long-term projects using new technology. Damningly, when one speaker asked how many representatives from the banks were present in the audience, only one hand went up (take a bow, Bank of Melbourne). The speaker put it very succinctly: “They’re just very thick.”

Sales Manager Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed using FSC mix of paper from responsible sources FSC© C007821 Contact Details AMT Magazine AMTIL Suite 1, 673 Boronia Rd Wantirna VIC 3152 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright © Australian Manufacturing Technology (AMT). All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher. Contained specifications and claims are those supplied by the manufacturer (contributor)

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes. AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published monthly. Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $165 (inc GST) per annum. Contact AMTIL on 03 9800 3666 for further information.

But the difficulties of securing upfront backing for innovative new projects are common to any industry, and manufacturing perhaps more than most.

RAPID PROTOTYPING

Contact 3D Systems’ Quickparts® Solutions at +61 3 9819 4422 to discuss your next prototype design or manufacturing project. Get an instant, online quote at www.quickparts.com/ap.

CMY

8 |

AMT September 2014

SHORT-RUN PRODUCTION

PRODUCTION & TOOLING

WHY

Over 100 years Of innOvatiOn, endurance, and perfOrmance. Since their founding in the late 1890’s as The Cincinnati Shaper Company, CINCINNATI Incorporated has built its reputation on three principles: innovation, performance and endurance. From their modern plant and technical centre on a 700-acre site near Cincinnati, Ohio, Cincinnati Inc design and build machines to the standard of ruggedness required by industry - with premium engineering features that stand up to years of rigorous use in demanding environments. This philosophy is evident in their range of laser cutting machines and material handling systems. For further insight in how Cincinnati can benefit your business, contact us at Industrial Laser.

CL400 series CO2 laser machines for full range cutting to 30mm

CL900 series Fibre laser machines for ultra high-speed cutting

Cincinnati choose PRC lasers for their CO2 models, but you don’t need to buy a new machine to reap the benefits of PRC’s innovations: + Low Gas Consumption (via GEM Filter Technology) + Lifetime Electrodes and Glassware + No Turbine Rebuilds + Remote Diagnosis + 2 Year Warranty We can replace your tired laser with a 2.5kW PRC for as little as $135k; 4kW for only $175k. Rental plans are available.

Sole Australasian Distributor: industrial laser sales & service Factory 8, 17 Keppel Drive, Hallam VIC 3803 AUSTRALIA T: (03) 9796 3055 E: sales@industriallaser.com.au www.industriallaser.com.au AUG2104

FROM THE

CEO Shane Infanti – Chief Executive Officer AMTIL

Patriotism – it’s a big word in manufacturing Why are we not more patriotic when it comes to our buying power? I was recently in Adelaide watching the mighty Tigers beat the Crows (no comments please!) and the question came up over the lunch table with my group – Are you patriotic? It was interesting because we all felt we were, but for varying reasons. One of the group has served for our armed forces and had the belief that the strongest show of somebody’s patriotism is to fight for your country. Another cares passionately about the environment and has strong beliefs that we need to do more to protect our land. Another simply “loves our country” and wouldn’t want to live anywhere else. All of these are good measures of being patriotic to one’s country but it wasn’t until I raised the question of “What we buy has a big influence on our ability to function as an economy” that the conversation focused on our purchasing decisions and its impact. We bemoan the fact that the Government has let our automotive industry disappear. It seems that they cop the bulk of the blame for our manufacturing sector being in decline and whilst I agree they have a very important role to play in securing our future (see below), they are not entirely at fault. I was at a function recently and I asked the audience to put their hand up if they were driving a locally built car. 1 in 10 raised their hand. I asked them when they go to the supermarket do they really look at where the product comes from. Same answer. Buying clothes or shoes? Same answer. The simple fact is our population levels don’t allow us the luxury of only 10% caring about local manufacturing. We need this to be much higher. At 30%, we would have had a secure future for our automobile manufacturers. The three car companies consistently said, if we could produce 300,000 cars in Australia of the million sold each year they wouldn’t have contemplated leaving. Why don’t 50% of us buy footwear made here? Of course, I know the answer to this question already. Our purchasing decisions are made on the basis of “value for money for that product”. We do not take the bigger picture into account. We don’t think, if I buy the local product it may support a local

10 |

AMT September 2014

supply chain and small companies that employ people and pay taxes and earn money that buys other locally produced goods and that makes the economy go around. We treat it as a one-off purchase and go home none the wiser. I fear the Government has a similar mentality and this is where most people have an issue with government’s purchasing decisions. We cannot keep making decisions with tax payers’ money that has a negative long-term effect on our manufacturing industry. Somehow, just like all of us, governments need to take into account the future impact of the decision. Whether it is the “whole of life” argument, ongoing maintenance work, an Economic Value Add statement or simply the ongoing ability for local manufacturers to employ and pay people – all of these issues should be considered in the decision-making process. All of us SHOULD take these issues into account but governments MUST take them into account. Maybe it’s time for a stronger show of patriotism from our State and Federal Governments.

The bIgger pIcTure In A sMALLer pAcKAge For further information call Anne Samuelsson on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

AMTIL1163

AMTIL DIgITAL MeDIA KIT

We bemoan the fact that the Government has let our automotive industry disappear. It seems that they cop the bulk of the blame for our manufacturing sector being in decline. Whilst I agree they have a very important role to play in securing our future, they are not entirely at fault.

Watch trailer:

MORE FORCE, MORE STAMINA, MORE BITE. Tiger·tec® Silver turning inserts for ISO P, ISO K and ISO M materials New cutting materials and new geometries – coming together to increase performance by up to 75 %. Based on the unique wear resistance and toughness, it is possible to predict what these cutting materials can endure. This is made possible by a new, patented aluminium oxide coating, which, in conjunction with the Tiger·tec® Silver procedure that is recognised worldwide, adds a whole new dimension to machining.

wintergerst & faiss

Tiger·tec® Silver – because process reliability deserves more bite.

www.walter-tools.com service.au@walter-tools.com

FROM THE

Industry Innes Willox – Chief Executive Australian Industry Group

Going digital: a manufacturer’s guide Following the former Government’s announcement in May 2013 that ten peak industry bodies would be funded to develop and promote a series of ‘Digital Business Kits’, Ai Group was successful in tendering for the manufacturing sector project. Now we have finally launched our Kit, and manufacturers have a valuable new resource available online to guide their efforts in deriving real benefits from digital technologies. Ai Group’s Digital Business Kit for Manufacturers can be accessed at www.digitalbusinesskits.com.au. Our brief was to design, build and maintain an online resource to assist manufacturing SMEs and not-for-profits in their use of highspeed broadband and digital solutions to improve productivity and competitiveness. Drawing on research including our Business End of Broadband report issued last October, together with further consultation with our members though workshops and stakeholder groups, a suite of modules has been developed within an interactive learning environment. This includes diagnostic tools to identify the challenges and opportunities specific to your business, and pathways to further information and learning materials. The project’s emphasis is on the possibilities available to business in the here and now, rather than what might come in the years following the rollout of the National Broadband Network (NBN). Many businesses are being held back by a lack of knowledge about how to get started, how to develop a digital strategy and how to add value to existing business processes. The time to act, we believe, is now. The Government’s launch of the Digital Business Kits initiative, back in July 2013, was held at the premises of an Ai Group member, Ogis Engineering. Ogis is a good example of an Australian manufacturing enterprise that prides itself on maintaining state-of-the-art technology. At its Rosebery plant in Sydney where the launch was held, computer-operated machinery including CNC tube and pipe bending machines and precision plasma cutters greatly impressed me, together with the then-Deputy Prime Minister, Anthony Albanese, who was also present. But when it came to the potential of highspeed broadband, Ogis’ Managing Director Kevin Adler said he thought he probably had a lot to learn. “As members, we’re keen to see what the Digital Business Kit for manufacturers can teach us, in terms of the opportunities the NBN can provide,” he said at the time. “At the moment, from our perspective, it’s

12 |

AMT September 2014

simply a matter of faster download speeds for all the CAD files we get coming in to the business.” That said, Adler did see other benefits that a better broadband connection will provide. “Some of our machines are from overseas,” he said. “If one breaks down, a highspeed broadband connection would allow us to get a video link back to the supplier overseas. We could even carry a laptop out to the machine and show them the problem live.” Another major opportunity he saw concerned the ability to take work offsite. “I find it very frustrating, because I often work from home but my internet connection is shocking,” he said. “If I try to access our system from home it’s so slow I actually end up shutting down and just making do with working offline. I think the NBN will make a huge difference to working remotely.” The opportunity to host the launch of the Digital Business Kits initiative was certainly something Ogis appreciated, if only for the impact it had in prompting the business to further consider the impact of high-speed broadband. “A lot of people think it’s a long way away, because it’s taking so long to roll out,” Adler said. “But you can’t just ignore it and say I’m happy with my speed at the moment and it’s not going to make any difference to me. It’s like anything with technology – if you don’t get up to speed with it you’re going to be left behind.”

With the Digital Business Kit now here, businesses like Ogis can now make use of a very user-friendly collection of information, tips, case studies and advice on how digital technologies can create real benefits for the small-to-medium enterprises within the manufacturing industry. Designed as an introduction to the possibilities that digital technologies offer businesses, the kit also contains useful information and tips from companies who have found real success in integrating new digital technology within the operations and management of their businesses. An example is FMP – Bendix Brakes, an automotive supplier based in Ballarat. They developed an app that uses face recognition technology that enables a customer to take an image of the brake pad, the app recognises the part, automatically searches an online catalogue and identifies the right replacement. The company attributes this and their social media marketing strategy as key in their survival in the very competitive automotive aftermarket. Digital technology and the internet are creating disruptive changes that bring major opportunities and challenges in product and production innovation. With the correct approach and responding positively to the inherent challenges and opportunities, Australian manufacturing firms who are not only technologically sophisticated, but also agile, adaptive and efficient, will be most likely to excel.

FROM THE

AMWU Paul Bastian – National Secretary Australian Manufacturing Workers Union

Business gives Hockey a reality check Treasurer Joe Hockey should know that, no matter how hard you try to sell a dodgy concept, you’ll be found out quickly if it doesn’t stack up. The Budget is unravelling beyond community disgust at the harshness of devaluing the aged pension and making disadvantaged people pay extra for GP visits. The Coalition’s own business constituency is being stung by the impracticality of policies such as requiring dole recipients to file 40 job applications a month, likely to cost firms $700m in wasted time. But their deeper concern is the abrogation of Government’s role in helping business meet the challenges of growing competitive in a digital, global economy.

Yet this Government rips away tool allowances for apprentices who are our manufacturing hope for the future and saddles them with debt. The burden is even worse for young people contemplating university courses, the would-be scientists and engineers needed to power a knowledge economy. Where is the sense in deterring middle- and working-class Australian kids from trying to realise their dreams, with debts their parents only faced when buying the family home?

The ideological obsession with small government and the free market drives the Coalition furphy of a “budget emergency”, but it misses the big 21st century picture for Australia. We urgently need large, strategic public investment in research, education and industry sectors of comparative advantage if we are not to fall far behind overseas competitors. Meanwhile, Mr Hockey is like the man worried about burning the bread in the toaster while the house burns down around him.

This is where the Government fails Australia’s future, as it does by hacking away at the collaborative business-research links that our nation so badly trails on. A $140m cut to the CSIRO and other scientific organisations, hacking into renewable energy research, cutting the $80m funding round from what remains of the Cooperative Research Centres, handicapping ANSTO, and ripping $79m from the Australian Research Council are the opposite of the McKinsey report’s recommendations. These are dumb cuts.

There is not much common ground between my views and those of the Business Council of Australia (BCA). Usually, it’s about zero. But BCA President Catherine Livingstone made some salient points in a recent speech, chiefly that in the real world, business can’t do it all alone. It never could. She drew on a McKinsey study, which found that we rank a lowly 15th on collaboration between business, researchers and Government, far behind our competitors. We’re good at research and invention, but substandard in translating that into practical business production and broader economic gains.

The Prime Minister’s Science, Engineering and Innovation Committee is yet to hold its inaugural meeting, industry research grants have been suspended for the year, and progress on the new industry investment strategy is moving at a glacial pace. The new plan for industry-academic collaboration that Industry Minister Ian Macfarlane spruiks is still secret at time of writing, and will need a funding miracle to be anything more than an empty shell.

The research also emphasised the need for Australia to work much harder on the manufacturing of intermediate products, which make up 70% of world sector trade, rather than final products, something that is an immediate challenge for our car components makers. A lament for not investing more in auto componentry for export in the past illustrates Australia’s overt reliance on its tiny domestic market, though it’s all too easy to be wise in hindsight. Firms such as ANCA, which produces tool-making machines for global companies, are a prime example of the way forward for Australian manufacturing. For a manufacturing sector of our size, finding niche markets on a global scale would be sufficient to sustain thriving enterprises to replace much of the employment lost in older manufacturing areas. The McKinsey report identifies advanced manufacturing, as well as food & beverage processing, as among areas of potential comparative advantage, though the AMWU believes this misses areas of existing manufacturing that have a potential for adaptation. What the Government, particularly Mr Hockey and Finance Minister Mathias Cormann, must understand is that it does control key inputs into growth and wealth creation, as Ms Livingstone said. Infrastructure is more than physical roads; it includes knowledge infrastructure like universities, and research institutions like the CSIRO and ANSTO, which need adequate funds. It is the formal and informal links to industry that will be a deciding factor on whether Australia grows its prosperity in future. And it includes skill development through TAFEs and universities to give our young people the knowledge to drive innovation.

14 |

AMT September 2014

The truth is that industry investment under Minister Macfarlane has fallen foul of the fictitious budget emergency, which doesn’t pass the “pub test” for common sense. While the budget deficit must be handled carefully, a country with a solid triple-A credit rating and a 14% debt-to-GDP ratio (near the best in the OECD) is nowhere near a “debt crisis”. Australians won’t be played for mugs. It’s fair that employers emphasise Government failure to understand their essential needs, but we in the trade union movement also understand that investing in skilled and productive employees means proper remuneration and decent conditions. The BCA and AiGroup have their company tax cuts and the Carbon Tax repeal. But they can’t also expect better funding for research and knowledge infrastructure while leaving ordinary taxpayers, pensioners, students and the vulnerable in our society to carry all the pain. Employers can’t have the PAYE taxpayers’ cake and eat it all too. That’s why we fully support the ACTU putting employers on notice that unions will claw back the unfair costs imposed by a Government backed so heavily and heartily by business in 2013. The AMWU will continue to pursue productivity-based wage outcomes above CPI, we will stand strong to protect penalty rates, and look at 0.5% yearly compensation for a Superannuation Guarantee freeze at 9.5% or four years. If the current childcare rebate is frozen or reduced, we’ll look at a working parents’ allowance, and will consider expecting the employer to reimburse the $7 GP co-payment if a sick note is required when a worker visits the doctor. Business groups are justifiably worried at the Cabinet’s ultra-dry, unrealistic direction. Yes, we are saying we told you so.

industry news

Forgacs announces Broens acquisition Newcastle-based Forgacs has acquired Broens, a precision engineering company operating in defence, aerospace, mining, oil & gas, and other sectors. Speaking about the initiative, Forgacs Chief Executive Lindsay Stratton said: “The acquisition is the first step in our diversification strategy and creates a unique and very marketable mix of capabilities.” In addition to providing significant collaboration and greater opportunities, the acquisition will maintain and build capability for the New South Wales (NSW) and South Australia (SA) defence industries. Forgacs has traditionally focused on heavy engineering and shipbuilding but Broens’ strength is in high-tech precision engineering and aerospace. By bringing the two organisations together, customers will be able to access high value solutions that draw on the spread of capabilities on offer from Forgacs and Broens. “In addition to creating diversification and greater opportunities the acquisition will facilitate the extension of Forgacs’ defence offering to include land and air,” added Stratton. “We are widely recognised for our maritime offering through naval shipbuilding and our through life support operations. Now we will also be involved with the land and air aspects of defence. This is an exciting and undoubtedly challenging opportunity but we are very much looking forward to making it work.” The partnership will also see both companies benefit from access to a wide range of customers, and new market sectors both in Australia and overseas. In the increasingly competitive and demanding defence sector, the acquisition of Broens ensures the company’s future and the ongoing employment of many highly specialised employees. The sustainability and future success of the combined

organisations will add to the capability and strength of Australia’s defence industry. “Forgacs’ defence work has clearly laid solid foundations for us in this area and the addition of Broens will give us added momentum in this critical industry’, Stratton concluded. Forgacs is Australia’s largest privatelyowned engineering and shipbuilding company, servicing the country’s defence, mining, infrastructure and energy sectors. It has been in business for more than 50 years and currently has a workforce of approximately 900 employees – the majority being high skilled tradesmen. It is headquartered in Newcastle, and operates five sites in NSW and Queensland. The company’s shipbuilding business is part of the team building the $8bn Hobart Class Air Warfare Destroyers (AWD) for the Royal Australian Navy and is manufacturing 37 of 93 AWD hull blocks. Forgacs’ heavy engineering business at Hexham in Newcastle focuses on the build and refurbishment of mining, rail, utilities, infrastructure and industrial equipment. Broens is an innovative engineering solutions provider supplying precision engineered products and services to both Australian and international companies. It was established in 1979, operates sites at Ingleburn in NSW and at Elizabeth in SA, and employs approximately 100 people. Broens is engaged in the Joint Strike Fighter (JSF) global supply chain and is supplying specialised tooling to major JSF contractors.

Auto CRC selected to provide Malaysia advocate The Automotive Supplier Excellence Australia (ASEA) Division of AutoCRC is to play a critical role in identifying and pursuing overseas business opportunities for Victorian companies, after it was selected to fill a full-time in-market automotive advocate position aimed at maximising business outcomes for Victoria and Malaysia. The move, announced by Victorian Manufacturing Minister David Hodgett and Malaysia’s Minister for International Trade and Industry, Dato’ Sri Mustapa Mohamed, represents a positive step forward for Australian companies identifying how they can engage with overseas companies and markets. The project will provide mutual benefits to both the Victorian and Malaysian sectors, helping the Malaysian automotive industry to increase its technical capabilities, while giving Victorian automotive suppliers access to the rapidly growing Malaysian and South-East Asian automotive industry. The role will be carried out by ASEA Director Linsey Siede and ASEA Program Manager Peter Taylor, who have been assisting Australian component suppliers to achieve their business goals since 2007 through their ASEA activities. “The project builds on the AutoCRC‘s strong understanding of the Malaysian automotive industry through its existing engagement with the Malaysian Automotive Institute (MAI) and Malaysian OEMs,” said Hodgett. “Both Mr Siede and Mr Taylor are also well

16 |

AMT September 2014

known to the Victorian automotive industry through their roles in the ASEA program. It is envisaged that they will alternate their time between Malaysia and Melbourne on a fortnightly basis to undertake the project.” Siede says of the project: “This outstanding initiative presents Victorian automotive suppliers with direct linkages to the automotive industry sector in Malaysia, to work closely together in identifying new business opportunities for their mutual benefit.” Ian Christensen, AutoCRC’s CEO, added: “The South-East Asian automotive industry is expanding dramatically and this creates numerous opportunities for engagement between countries. AutoCRC has been working in this space for some years now introducing Australian companies and research institutions to partners and opportunities in Malaysia. We are excited to be able to use our expertise in business excellence and knowledge of the Malaysian markets to deliver further benefits to both Victoria and Malaysia.” The in-market advocate role commences immediately.

1 SETUP 5 SIDES 1/2 THE COST WITH MORE STANDARD FEATURES . . .

The Haas UMC-750 5-Axis Universal Machining Center Standard Features Include: • Full 5-axis machining • 8100-rpm, 30 hp spindle • 40+1 SMTC

The choice is simple.

• Wireless probing with routines for center of rotation measurement • Dynamic work offsets and tool center point control

Haas Factory Outlet Australia:

1300

201

www.HaasCNC.com

230

New

Haas. The Lowest Cost of Ownership.

Zealand:

525

6907

industry news

Australian manufacturing must look outwards The manufacturing sector in Australia suffers from a cautious attitude, in terms of focusing on existing product lines rather than taking a transformational approach, a KPMG study has found. The survey of 460 manufacturers across the globe, including 14 large Australian companies, showed many similarities in terms of strategic priorities between local and overseas firms. The highest imperative was enhancing sales growth, followed by improving speed to market and increasing cash flow from operations. Intended strategies were also similar – seeking better insights to find sources of growth; collaborating to innovate and integrating supply chains. But there were notable differences between local and overseas companies on other issues, and findings which raised ‘red flags’ over the future of Australian manufacturing. These included: • Australian firms intended to spend a maximum of 9% of company revenue on new innovation and product introductions, while some overseas companies planned 1015% spend in this area. • 71% of Australian companies’ primary strategy for improving innovation was to enhance existing product lines with only 29% aiming for ‘breakthrough’ innovation. • Over 70% of Australian companies claimed only a moderate or low level of confidence in the reliability of information available to assess customer profitability – yet only 36% had plans to invest substantially in enhancing systems to improve this. • 57% of Australian companies saw increased regulation in their industry as a major challenge over the next one to two years compared with only 31% overseas. Mal Ramsay, National Sector Leader, Industrial Manufacturing, KPMG Australia, said: “While there are some encouraging findings from this study – notably, Australian companies’ plans to more than double R&D spend in the next two years compared to the previous two – overall it shows our firms are comparatively cautious in their outlook, compared to their counterparts overseas. The greater focus on the domestic market here and the desire for incremental rather than transformational innovation raises a few concerns about the growth potential for manufacturers in Australia.

“Even the increased R&D spend is lower than elsewhere. By way of comparison, if you look at Cochlear, it has obtained 65% global market share in its field and invests more than 15% of its sales revenue on R&D. Focusing on breakthrough innovation, finding a niche in high value-add contexts where you have intellectual property, and being ambitious has to be the goal for Australian manufacturing.” Ramsay noted that, while Australia’s geographic distance can lessen foreign competition and create better margins for some manufacturers, the domestic market remains quite small, placing a ceiling on growth potential. “It is good to see an increase in partnering and collaborating with others through joint ventures and alliances to achieve innovation,” added Ramsay. “This is important, as is the indication that in three to five years, most companies will have genuinely integrated supply chains. But more clearly needs to be done to improve the use of data sources to understand product cost and customer profitability. Data analytics still needs to be embraced fully by many companies.” The Global Manufacturing Outlook2014: Australian Perspective paper can be found at: bit.ly/1ofdZuw.

Australian PMI: Manufacturing expands slightly in July The latest Australian Industry Group Australian Performance of Manufacturing Index (Australian PMI) edged into positive territory in July, following eight months of contraction. The latest Australian PMI for July showed the first expansion since October 2013, increasing by 1.7 points to 50.7 (readings above 50 indicate an expansion in activity). Across the eight manufacturing sub-sectors, only food, beverages & tobacco (51.7 points) and the smaller wood and paper products (67.2 points) expanded in July. New orders (51.9) grew for the third consecutive month, while manufacturing employment increased by 4.7 points to 50.2. The large metal products, machinery and equipment, and petroleum, coal, chemicals and rubber products sub-sectors all contracted this month.

half of the calendar year. Nevertheless, respondents expressed renewed concern about the strong Australian dollar.”

“Despite very tough conditions continuing in July, the manufacturing sector showed resilience in the face of strong headwinds with its first shift into growth territory this year,” said Industry Group Chief Executive Innes Willox. “Production, new orders and employment were all higher, providing welcome reward for manufacturers’ ongoing efforts after a very disappointing first

“The high currency is maintaining intense pressure on exporters and import-competing businesses facing weak demand and low prices for locally made products,” Willox added. “Further, with wages and input costs continuing to edge higher, there were very few signs that manufacturers’ margins are recovering sufficiently to attract much-needed investment into the sector.”

18 |

AMT September 2014

Four of the five activity sub-indexes were above 50 points: new orders expanded for the third consecutive month (51.9); and manufacturing employment increased by 4.7 points to 50.2, following seven months of contraction. On the negative side exports contracted, falling 3.5 points to 48.8. Both the stocks and sales sub-indexes remained in contraction, albeit at decelerating rates. Wages and input costs continued to grow – the average wages sub-index climbed 13.1 points to 69.6 (unadjusted).

Industrial Door Solutions

r a e l C

t s e b e h t ly

Contact our team today to find a solution for you

M.T.I. Qualos Pty. Ltd. are leaders in the manufacturing and service of Industrial Transparent Flexible Doors, Insulated Traffic Doors, and Roll-Fast Doors. We produce to the highest quality standard within a full range of industrial doors to suit any door application.

NEW 36pp brochure now available. Contact us to get your FREE copy.

M.T.I. Qualos Pty. Ltd. 55 Northern Road, West Heidelberg, Vic. 3081 Tel: 1300 135 539 Email: sales@mtiqualos.com.au Website: www.mtiqualos.com.au

industry news

Bosch redevelopment to create 89 jobs Robert Bosch Australia will create 89 new jobs with the $40m redevelopment of the company’s Clayton facility in Melbourne’s south-east. Victorian Premier Denis Napthine announced that the State Government is supporting the redevelopment, stating that the upgrade would also secure 842 existing jobs and ensure that Bosch’s head office remained in Melbourne. “This is the single largest investment by Bosch in Australia since the local subsidiary was established in 1954,” said Napthine. “The project – which includes the construction of new offices, workshops, testing facilities and training rooms – is a huge vote of confidence by the Victorian manufacturer. This investment will enable Bosch to diversify its operations and focus on developing and selling high-tech products into growing markets. Bosch Australia employs 1144 staff nationwide, with 842 in Victoria. The redevelopment of its Clayton manufacturing plant is due to be completed by early 2016. Minister for Manufacturing David Hodgett said the Victorian Government had worked closely with Bosch Australia on its plans to redevelop its Clayton site and capture new opportunities. “This major upgrade will help Bosch Australia further diversify from automotive

original equipment to key strategic growth areas such as the automotive aftermarket, consumer goods, industrial and building technologies and energy technologies and services, which it expects to account for up to 90% of its business in the near future,” said Hodgett. “It will enable the company to progress new and emerging opportunities in vehicle servicing, niche electronics, component remanufacturing, and energy storage solutions. It will also further strengthen its co-operation with the global Bosch corporate research organisation.”

Rugby legend opens OneSteel Metalcentre Australian rugby league legend Steve Mortimer OAM opened the new Wagga OneSteel Metalcentre store last month, together with local and state politicians and OneSteel Metalcentre customers. Located in Wagga’s Bomen Industrial Park, OneSteel Metalcentre is the result of the consolidation of the Leeton and Wagga Metaland stores and is designed to fulfil the steel supply and processing needs for Wagga and the surrounding Riverina region. Speaking at the opening, former NSW Blues and CanterburyBulldogs captain Mortimer said this new OneSteel Metalcentre store was just what a city like Wagga needed. “It’s great to see an Australian company like OneSteel support rural and regional Australia,” said Mortimer. “OneSteel Metalcentre has over 50 stores across the nation, 40 of which are in rural and regional centres, which says a lot about their continuing commitment to the bush. As a proud Wagga boy, I think this is a great day for the city where I grew up.” Michael McCormack MP, Parliamentary Secretary to the Minister for Finance

20 |

AMT September 2014

Bosch Australia President Gavin Smith said the planned investment was a clear signal by the company’s German parent that they remained confident about the business outlook in Australia. “In the wake of negative announcements across the Australian automotive Industry we are pleased to be able to share some good news,” Smith said. “This investment is essential to ensure we provide an appropriately modern and collaborative working environment for our employees, and provide facilities that better suit our activities now and into the future.”

VPTN set for showcase Registrations are open for ‘Discover. Connect. Grow’, a showcase event being held by the Victorian Platform Technologies Network (VPTN) in Melbourne on 11 September.

Discover. Connect. Grow brings together platform technology experts from Victoria’s publicly funded research organisations to meet with companies who may benefit by using the state-of-the-art facilities available in Victoria.

and the Federal Member for Riverina, congratulated OneSteel Metalcentre on its investment and vision in developing this new site. “OneSteel has serviced the Riverina in one form or another since 1981 – a proud record,” said McCormack. “This new site will see the company growing even further, providing more opportunities and giving the local economy a real shot in the arm.”

VPTN platform technologies specialise in a range of areas: from antibodies to additive manufacturing, from gene sequencing to sleep science, from medical imaging to materials characterisation. Last year the VPTN Showcase attracted over 140 registrants from across the VPTN, industry and research sectors. This year’s showcase will be held at the National Centre for Synchrotron Science in Clayton, from 9amto 12pm on 11 September. Further details are available at www.platformtechnologies.org/event/ vptn-discover-connect-grow.

Industry news

Inaugural EMTE-EASTPO ends on positive note The first EMTE-EASTPO 2014 concluded successfully on 17 July at the Shanghai New International Expo Centre (SNIEC). Some 650 international manufacturers from 24 countries showcased their innovative machinery to buyers from 54 economies. The four-day exhibition attracted a visitorship of 47,654. Local visitors from 32 cities made up majority of the participants. The biggest group of domestic visitors were from south-eastern China namely, Anhui, Jiangsu, Shanghai and Zhejiang. Buyers from India, Japan, Korea and Southeast Asia made up the majority of international visitors. EMTE-EASTPO is a strategic east-west partnership of two established machine tool show-owners from Europe and China, namely the European Association of the Machine Tool Industries (CECIMO) and Shanghai EASTPO Culture Development. Dr Frank Brinken, Chairman, Economic Committee of CECIMO remarked at the opening of the joint exhibition: “We are very pleased with the outcome of our maiden efforts to stage the first EMTE-EASTPO exhibition, a high-quality showcase of innovative technology and practical solutions presented by leading names from around the world.” EMTE-EASTPO 2014 featured a total of eight country pavilions and national groups from Czech Republic, France, Germany, Italy, Korea, Spain, Switzerland and Taiwan region. The exhibition brought together some of the world’s leading machine tool manufacturers eyeing the vast market opportunities in China. The joint exhibition also saw the successful staging of several knowledge-sharing activities and technical seminars. The EMTEEASTPO CEO Summit was one of the key activities held in

conjunction with the exhibition, attracting some 100 participants to learn and exchange ideas with a panel of distinguished speakers led by keynote presenter, Dr Fritz Klocke, Professor and Director of Laboratory for Machine Tools and Production Engineering of RWTH Aachen University (Germany). Filip Geerts, Director-General of CECIMO, said: “We are privileged to have the presence of many machine tool experts and leading industry end-users from both East and West in one place to discuss important issues under the theme ‘Profitable Growth Through Stateof-the-Art Manufacturing’. We hope that the discussions that had been initiated at the summit will spur greater cooperation between machine tool makers and users.”

MAPAL Australia - Supporting local industry and businesses. Providing general and special tooling and Australian made Advantage metal working fluids. www.mapal.com.au | sales@au.mapal.com | 1300 825267

AMT September 2014

| 21

Industry news

AMCRC – seven years of achievements The Advanced Manufacturing Cooperative Research Centre (AMCRC) will be finally wound up over the next month, after seven years of successful operations. Collaboration has been the key to success for the AMCRC and its industry partners since its foundation in 2008, according to its CEO Andrew McLellan. Significant achievements have been made as a result of intellectual property developed via collaborative efforts led by the AMCRC. “Our focus over seven years has been on facilitating success for Australian SMEs working in the advanced manufacturing sector,” said McLellan. “We’ve invested in bringing together the best minds and the greatest ideas with the aim of building a viable future for Australian manufacturing – and we’re proud of what we have achieved in the period.” One highlight came in May, when the research was recognised at the CRCA Awards with the Polycrystalline Diamond Machining project receiving an Excellence in Innovation award at the 2014 CRC Association Conference held in Perth. The advanced technology, which makes use of sophisticated electric arc control methods, integrated with a complex, fiveaxis computer-controlled machine, to form the sharp cutting edges of the PCD tools, is already being sold by ANCA to global aerospace manufacturers. An AMCRC additive manufacturing project was recognised at the 2014 Safran Innovation Awards in Paris in May. The project industry partner, Microturbo, received the award for the manufacture of hot section components of a gas turbine, using laser fusion on powder bed. The award was recognition of the quality and success of the AMCRC project with Microturbo, with significant work undertaken at Monash

HARD Technologies, working with Deakin University and VCAMM, continued to progress the commercialisation of the hardening technology for tool steels with a patent application in the USA and jointventure partnering with a local manufacturer and the creation of DSTHARD Duplex Surface Treatments, LLC in Canton Michigan, North America, by HARD Technologies Pty Ltd and Dynamic Surface Technologies (US).

AMCRC CEO Andrew McLellan.

University. The project has also led to the launch of a commercial spin-off, Amaero Engineering. A major project, with MIL-Systems, Creative Power Technologies (CPT) and RMIT University, involved the development of reactive power control (RPC) inverters for solar photovoltaic (PV) applications. This inverter design enables the solar PV renewable energy that can be fed into the grid to be maximised and the quality of the grid voltage to better meet the goals of the consumer and the community. In conjunction with Quickstep and Deakin University, the AMCRC developed a process to enable rapid construction of carbon fibre composite components. The project gained traction when Quickstep moved into new premises in Bankstown, NSW, securing initial orders for the Quickstep equipment from international organisations.

The AMCRC was also involved in the development, with MBD Energy and James Cook University, of technologies to produce high-value products including biofuels, nutraceuticals and high-value polymers. Pilot plants have been constructed in Queensland – at Tarong Power Station and Pacific Reef Fisheries – to allow technology development and commercialisation, with downstream products evaluated by potential domestic and international endcustomers worth hundreds of millions of dollars. The last few months have seen the AMCRC team working together with the Manufacturing Industry Innovation CRC (MIICRC ) as part of a bid development team on a new proposal for an Innovative Manufacturing CRC (IMCRC ). As the AMCRC is formally wound up, its legacy will continue through the cooperative community it established, the researchers it trained and the IP it created. “We understand that the Federal government is committed to the future of CRCs and the benefits they bring,’ added McLellan. “We hope the collaborative approach will continue in the new IMCRC.”

The Future is Here, at Design Hub Visitors to The Future is Here exhibition, at the RMIT University Design Hub till 11 October, will get a chance to witness the future of manufacturing, in The Factory. The Factory is a space equipped with a range of working machines including 3D printers, robots and a CNC milling machine, staffed by RMIT technicians and Industrial Design students. The machines will be at Design Hub for the duration of The Future is Here exhibition: creating, testing and experimenting. Visitors are welcome to explore, discuss and participate in one of the many programs offered throughout the exhibition. The Future is Here is a touring exhibition created by the Design Museum in London. Manufacturing is currently facing a transformation in the way we design, make and consume the objects that we depend upon. New techniques, technologies and relationships mean that the boundaries between designer, manufacturer and user are becoming increasingly blurred – The Future is Here asks what that means for all of us. As part of this exhibition, The Factory reflects the idea that today’s fabrication tools are small enough to put on a desktop, simple and

22 |

AMT September 2014

affordable enough to use at home and more widely available than ever before. A single individual working in a spare room can now achieve what once needed a whole chain of designers, developers, technicians, machinists and distributors. For its Melbourne iteration, The Future is Here will also profile new thinking drawn from the RMIT Design Hub research community. Displayed alongside internationally-sourced works from the Design Museum in London will be a series of speculative projects from Melbourne where ideas and new technologies meet at the forefront of innovation. designhub.rmit.edu.au

Acra Machinery Pty Ltd 20 Fowler Road Dandenong, Victoria, 3175

Supplying your solutions Today, Tomorrow, Forever

FOR ALL YOUR SHEETMETAL MACHINERY SERVICING NEEDS ALL MAKES AND MODELS! AUSTRALIA WIDE!

ACRA MACHINERY SPECIALISE IN: - BREAKDOWN REPAIRS - OPERATOR AND PERSONNEL TRAINING - RECONDITIONING - PREVENTATIVE MAINTENANCE - PLANNED MAINTENANCE SCHEDULES

Acra Machinery employ all our own highly qualified and specialised staff and don't subcontract out work, so you can be rest assured that you are receiving the very best service possible. Our fleet of fully equipped service vans travel Australia wide, so talk to us us today to enquire about your machinery servicing requirements or find out when one of our team will be in your local area.

www.acra.com.au PROUD SUPPLIERS OF

Phone: 03 9794 6675

Fax:03 9794 6655 www.acra.com.au

Keep up with our products and promotions

Email: info@acra.com.au

Government news

SA loan program to boost businesses and jobs Financial guarantees will be offered by the South Australian Government in partnership with the major banks to stimulate business growth and create jobs. Premier Jay Weatherill unveiled the program as part of an announcement of ten economic priorities that which will form the basis for the Government’s reform agenda. Weatherill said businesses had strongly advocated that one of the biggest barriers to growth was access to capital.

for the State’s economic transformation. “South Australia faces some significant economic challenges,” said the Premier. “The case for change is clear – our largest industry by value – manufacturing - is in decline and our car industry is disappearing. Our defence sector is also now in doubt. The economic vision that I have set out will guide our reform agenda for this term of Government and meet these challenges.”

“The Unlocking Capital for Jobs Program will make it easier for business to secure commercially viable loans where companies would otherwise not have the balance sheet strength to access finance,” he said. “This is the first in a series of reforms that are aimed at accelerating industry growth in this State and creating jobs. “As a first step in this policy, the Government will offer financial guarantees to the value of $50m. This offer will allow up to $250m to be leveraged in funding to secure and accelerate new job creation here in South Australia over the next few years. We anticipate that by partnering with business through this process we may even be able to strengthen individual business cases in a way to make this loan program unnecessary.” Over the next month the Deputy Chair of the Economic Development Board, Rob Chapman, will work with the banks and relevant Government departments to formulate a process that will best service

Weatherill said that a broad cross section of academia, business representatives and the community in their work on Shaping the Future of South Australia as well as the Economic Development Cabinet Committee and the EDB had helped shape the priorities.

the objectives of the program. Weatherill said the Unlocking Capital for Jobs Program was based on successful schemes in the UK, New Zealand and Canada. All of the major banks have agreed to participate as part of the program. Weatherill also unveiled a broad new vision

“At a time of significant change and challenge, South Australians will naturally be looking for direction, something that can provide them with a basis to frame their choices about their education, their jobs and their investments,” said Weatherill. “At the last election we promised we would take a lead in the modernisation and transformation of the South Australian economy. These priorities will guide that transformation and the reforms we will undertake.” www.premier.sa.gov.au

Investment milestone for Geelong’s innovative manufacturing The Victorian Coalition Government’s $500,000 investment in a world-first short nanofibre manufacturing plant has reached a key milestone, with construction of the facility at Deakin University in Geelong now complete. Speaking at Deakin University, Minister for Higher Education and Skills Nick Wakeling said the world-first plant demonstrated the importance of effective collaborations between training providers, industry and government. The Geelong Future Industry Project (GFIP), a part of the Coalition Government’s $11m Skilling the Bay Initiative, allowed local biotechnology company Cytomatrix, Geelong-based engineering firm Austeng and Deakin University to construct the facility. “The short nanofibre technology has enormous potential to create jobs in a range of innovative areas, including medical sciences and biotechnology,” said Wakeling. “Cytomatrix will be working with students from Deakin University, while Austeng engages vocational training students from The Gordon and engineering students from Deakin to develop vital skills within Geelong’s transforming manufacturing sector.” Member for South Barwon Andrew Katos joined Liberal candidate for Geelong Paula Kontelj at the tour, and said the

24 |

AMT September 2014

plant’s completion would create significant opportunities for students at The Gordon and Deakin University. “This world-first plant provides a huge boost to Geelong and to the training our local institutes can offer students wishing to study in the region,” Katos said. Wakeling said the Skilling the Bay initiative was engaging young people in training and employment, enabling industries to adopt new technologies and improving the skills of adults at risk of long-term unemployment. “This commitment is on top of the Napthine Government’s record $1.2bn a year investment to build a better vocational training system for all Victorians,” said Wakeling. Skilling the Bay is being led by The Gordon in partnership with Deakin University, local industry and community organisations in Geelong. www.thegordon.edu.au

Government news

Helping automotive suppliers adapt Applications have opened for the Federal Government’s $20m Automotive Diversification Programme, which offers assistance for Australian automotive suppliers seeking to diversify into other sectors. The Automotive Diversification Programme is one part of the Government’s $155m Growth Fund to drive development in new industries before the end of local car manufacturing in 2017. The Government is also preparing a National Industry Investment and Competitiveness Agenda, to focus on long-term issues relating to competitiveness, productivity and job opportunities in the industries of the future. Industry Minister Ian Macfarlane said the Australian Government is determined to ensure a strong, long-term future for Australian manufacturing. “With the Victorian and South Australian Governments, we are maximising opportunities for automotive supply chain firms affected by the closure of local automotive manufacturing,” said Macfarlane. “Supply chain firms can access the Automotive Diversification Programme to shift their focus towards the high growth industries of the future. This initiative will help to ensure that these firms continue to operate in Australia beyond 2017.” Victorian Minister for Manufacturing David Hodgett added that the automotive supply chain is an important part of the Victorian economy, with the majority of the supply chain based in the state. “This sector has significant capabilities, knowledge and proficiency in advanced and precision manufacturing techniques that are both relevant and transferable to other industries,” said Hodgett. “This programme is about transitioning firms away from their dependence on automotive manufacturing before local car making finishes at the end of 2017.

“This programme also complements existing Victorian Government initiatives aimed at connecting the automotive supply chain to business opportunities in other markets and industry sectors such as defence, construction, mining and medical technology.” South Australian Minister for Automotive Transformation, Manufacturing and Innovation, Susan Close, said automotive suppliers in Australia faced significant challenges in the years ahead. “The Automotive Diversification Programme will help them to transform to remain competitive and cope with change,” said Ms Close. “This programme will enable firms to take advantage of their considerable capabilities and adapt to different industries. It will help firms diversify by supporting R&D, re-tooling, commercialising new ideas, expanding their businesses, or to develop export capabilities by matching business contributions on a one-to-one basis.” The Automotive Diversification Programme is open to applications and will run over four years, ending in 2017-18, with at least one application round per year. More information, including Ministerial Programme Guidelines and application forms, is available from: www.business.gov.au

HIGH VOLUME PRODUCTION Achieving accurate holes with long tool life requires a very stable cutting action. The solution is to design a drill with optimised tool geometry, tool coating and low thrust. Sutton Tools’ carbide drills offer maximum tool life, due to the micro carbide material, the latest surface coating and cutting edge conditioning that contributes to optimal chip control. Sutton Tools’ carbide drills are the best solution for reliable production of high volume hole making in CNC machining centres and lathes. To find out more contact Sutton Tools 1800 335 350 cservice@sutton.com.au

AMT September 2014

| 25

Tech news

USA: Printing the metals of the future

Austria: New material for ultra-thin solar cells

Researchers are implementing a 3D printing process that transitions from one metal or alloy to another in a single object, allowing the continuous transition from alloy to alloy to alloy, and the studying of a wide range of potential alloys.. “We think it’s going to change materials research in the future” said R. Peter Dillon from the JPL. Although gradient alloys have been created in the past in R&D, this is the first time these composite materials have been used to make objects, In the new technique, layers of metal are deposited on a rotating rod, thus transitioning metals from the inside out, rather than adding layers from bottom to top, as in the more traditional 3D printing technique.

Extremely thin, semi-transparent, flexible solar cells could soon become a reality. Scientists have combined two semiconductor materials, consisting of only three atomic layers each, holding great promise for a new kinds of solar cell.. The team was the first to combine two different ultra-thin semiconductor layers (Tungsten diselenide and molybdenium disulphide).One of the greatest challenges was to stack the two materials. If there are any molecules between the two layers, so that there is no direct contact, the solar cell will not work. Eventually, this feat was accomplished. Part of the incoming light passes right through the material. The rest is absorbed and converted into electric energy. It is extremely light weight (300sq.m weighs only one gram) and very flexible.

NASA/Jet Propulsion Laboratory

US: Robot folds itself up and walks away A team of engineers has built an autonomous robot that starts as a single composite sheet programmed to fold itself into a complex shape and crawl away without any human intervention. A full electromechanical system was created that was embedded into one flat sheet - a composite of paper and polystyrene - and a single flexible circuit board. Hinges were programmed to fold at specific angles. Each hinge contained embedded circuits that produce heat on command from the microcontroller. The heat triggers the composite to self-fold in a series of steps. When the hinges cool, the polystyrene hardens — making the robot stiff — and the microncontroller then signals the robot to crawl away. The process consumed approximately the energy in one AA battery. “This changes the way we think about manufacturing, in that the machine fabricates itself”. Wyss Institute for Biologically Inspired Engineering at Harvard

Vienna University of Technology

US: Metal wear in sliding parts discovery Researchers have discovered a previously unknown mechanism for wear in metals: a swirling, fluid-like microscopic behavior in a solid piece of metal sliding over another. The findings could be used to improve the durability of metal parts in numerous applications. The team observed what happens when a wedge-shaped piece of steel slides over a flat piece of aluminum or copper. A single sliding pass is sufficient to damage the surface, and subsequent passes result in the generation of platelet-like wear particles. The defects also occur in surfaces created by manufacturing processes like grinding, polishing, burnishing, etc. Ongoing research will explore potential routes to reduce wear arising from this type of mechanism. Future work will study how a material’s grain size and ductility influence this type of wear and how these types of defects can be eliminated through the modified design of tools and dies. The researchers also have developed a theory and simulation for the mechanism. Purdue University

Germany: Crash-testing rivets

Germany: Customised surface inspection The quality control of component surfaces is complex. Researchers have engineered a high-precision modular inspection system that can be adapted on a customer-specific basis and integrated into the production process. Dubbed MASC: “Modular Algorithms for Surface InspeCtion”, this modular inspection system can be modified to customer-defined specifications. The system is suited for the most diverse materials and covers a size range from tiny components for medical technology through to entire sheets of rawhide or ceiling panels. One particular challenge includes those inspection procedures that require very high resolution. Because no surface is quite homogenous, the consequence is that components that are actually free of defects are identified as defective. This advantage of this procedure is that the analysis can be refined to such an extent that incorrectly identified flaws become virtually eliminated, Fraunhofer

For combining steel with aluminium, or steel with plastic materials, conventional welding techniques are entirely unsuited. Automakers therefore resort to mechanical connections instead, such as rivets. Often, connections are the weak points: in a crash and they are typically the first thing to fail. Automakers use simulations to verify if the various connection points sustain these stresses in an accident. However simulations are quite often off the mark (ie such computations could ascribe a greater load capacity than the rivets can actually bear under real emergency conditions). A more advanced model now delivers realistic projections - allowing the forecasting of rivet performance more reliably – both with slow and fast bending loads, as well as with pull and shear forces that emerge when the joined components become shifted, relative to each other Fraunhofer

Switzerland/USA : Spinning 3D-printed objects Researchers have given objects a new spin with an algorithm that makes them easier to design, so that they have asymmetric shapes. The algorithm can take a 3D model of an object and, within less than a minute, calculate how mass can be distributed within the object to enable a stable spin around a desired axis. Sometimes, adding voids within the object is sufficient to provide stability; or the object’s shape might need to be altered or a heavier material might be added inside. This has applications beyond fanciful and customised designs for spinning toys and can be adapted to the design of non-spinning, statically balanced objects. Disney Research

26 |

AMT September 2014

Product news

SICK – preventing collisions at Dubai port In expanding its flagship facility - Jebel Ali in Dubai - ports operator DP World committed to making the new Terminal 3 a fresh benchmark for safe and efficient operation. To meet this commitment to its customers, it used safety technology from SICK. Jebel Ali is a technologically advanced facility, employing stateof-the-art port handling equipment. In a bid to offer its customers uninterrupted operations and improve on an already high levels of service, DP World decided to equip the expansion of its Jebel Ali Terminal 3 facility in Dubai with SICK’s latest collision prevention systems. The new Terminal 3 is equipped with 19 remotely controlled ship-to-shore (STS) cranes and 50 automated stacking cranes (ASCs). All 69 cranes will be equipped with SICK’s new AOS Advanced Object Detection System, for boom collision prevention on the STS cranes, and pathway collision prevention on all STS cranes and ASCs. In order to maximise efficiency, the Terminal 3 also uses LMS511 laser measurement scanners for truck/ vehicle positioning, and POMUX KH53 linear encoders for precise, automated positioning of the trolleys. The AOS system uses cutting-edge LMS511 and LMS111 laser measuring sensors. The advanced laser scanning technology allows it to be used 24/7 in virtually any weather conditions – coping with the high levels of dust, rain and other environmental conditions encountered in Jebel Ali. In combination with a Flexi Soft high-performance, modular safety controller, the AOS system provides a sophisticated self-testing function to check at any time the availability of the laser scanner system regarding all configured field sets and installation position. This combination of cutting-edge laser scanner technology and the Flexi Soft controller provides high diagnostic coverage and maximum reliability. The AOS from SICK surpasses therefore the highest safety requirements specified for the collision prevention feature. However, outstanding technology was not the only reason for DP World to opt for SICK. The company’s track record, decades of solid industry know-how and engineering expertise mean that SICK can readily respond to industry-specific requirements for complete solutions with virtually all sensor technologies. The Jebel Ali project was an example of global co-operation in action: experts from SICK based in Dubai, Sweden, China and Germany successfully liaised with DP World, the system integrator from Sweden, and the main manufacturers from China and Abu Dhabi. “Round the clock availability is paramount in container terminal operations,” says Nabil Qayed, Director, Technical Department, UAE Region for DP World. “The collision prevention solutions from SICK play a key role in our new Jebel Ali terminal to ensure this happens and will help us to continue providing world class customer service.” www.sick.com.au

CMT Advertisement 13.01.14.indd 1

13/01/2014 4:04:30 PM

AMT September 2014

| 27

product news

Kaeser SXC – efficient performance Kaeser Compressors has launched its next-generation SXC series all-in-one rotary screw compressor packages. Ideal for light industrial compressed air users, these ‘plug-and-play’ systems deliver maximum performance in a compact, quiet and energy-efficient package. Each SXC series compressed air package includes a rotary screw compressor, refrigeration dryer and air receiver, making them the ideal solution for workshops and smaller production facilities requiring an all-in-one compressed air system solution. This compact design further ensures a small footprint presenting the perfect solution where space is at a premium. These high-performance compressor packages boast a number of energyefficient characteristics. At the heart of each package is a Kaeser rotary screw compressor featuring a specially designed air-end with flow-optimised Sigma Profile rotors. This enhanced airend design delivers more compressed air per kilowatt of input power for less energy consumption, contributing significantly to the impressive overall efficiency of these powerhouses.In addition, each SXC series compressor package includes the basic Sigma compressor control system as standard. With its efficient start-stop control, the basic Sigma control ensures optimised compressed air system

performance at all times by constantly monitoring the entire SXC series package. Extraordinarily quiet in operation, the SXC series all-in-one rotary screw compressor packages emits sound levels as low as 65dB(A). This makes them ideal at point of use. The SXC packages are maintenancefriendly with all service and maintenance

points easily accessible. Ready for operation, fully automatic, super-silenced and vibration damped, the SXC series of rotary screw compressor packages from Kaeser Compressors are available with motor power 2.2kW to 5.5kW, standard working pressures of 7.5, 10 or 13 bar, and FAD of 0.26-0.80m3/min. www.kaeser.com.au

Titan – handheld XRF analysis Amid much uncertainty about the quality of imported alloys in today’s market, it is vital to assess the standard of materials being imported, and equally important that fabrication items are checked against alloy mixes. The second-generation S1 Titan handheld XRF analyser from Bruker Elemental quickly and accurately analyses elemental composition and identifies the alloys of your sample. Possible applications include: aerospace, automotive, metalsprocessing, refineries, power plants, mining, recycling, scrap sorting and consumer-product testing. The S1 Titan is capable of analysing an impressive list of materials and can be configured specifically to analyse precious metals. Enhancements of the new S1 Titan include a weatherproof, IP54-rated housing, optional integrated camera and/or small spot collimator. The protective Titan Detector Shield has been made standard on all models. Enhanced SharpBeam technology improves precision measurement and

28 |

AMT September 2014

reduces power requirements, resulting in increased battery life. The new S1 Titan is available in four configurations: 800, 600, 300, and 200. The 800 and 600 models use a thin film window and FAST SDD detector for fast analysis of up to 37 elements, including light elements. Light Elements models now have SMART Grade, which automatically shuts off exposure when the instrument has sufficient data for an accurate identification. The 200 and 300 models are good-value analysers with SiPIN detectors. If equipped with an aluminised Kapton window, the S1 Titan is also able to measure in-process samples at temperatures up to 500 degrees Celsius. www.rfsales.com.au

Product news

Headland announces Studer partnership Headland Machinery has announced a new partnership with Studer Cylindrical Grinding. Established in Switzerland in 1912, Studer is a market and technology leader in universal, external and internal cylindrical grinding, and form grinding machinery. With more than 20,000 delivered systems worldwide, Studer enjoys a longstanding reputation for precision, quality and durability. Ideal for grinding precise, medium-sized work pieces in individual and batch production, Studer’s range of conventional electrical and hydraulic universal cylindrical grinding equipment encompassing everything from smaller, easy-to-handle machines to complex grinding systems. For large-series production, Studer supplies tailored solutions with optimised grinding cycles and high machine availability.

THE MITSUBISHI CUTS EVERYTHING, EVEN YOUR COSTS.

As the latest addition to Headland’s portfolio of precision CNC machinery and high-end technological products, Studer joins leading CNC suppliers such as Makino, Nakamura Tome and Breton. By combining Studer’s experience in manufacturing Swiss precision, and Headland’s 60 years of experience and knowledge of the Australian market, this new partnership guarantees world-class machine tool innovation, supported by a highly trained network of service engineers. www.headland.com.au www.studer.com

LVD expands ToolCell options Due to increasing demand, LVD is now offering a 220-ton, three-metre model of its unique ToolCell press brake system.

ToolCell houses all tooling inside the machine and automatically performs tooling set-ups. A large selection of top and bottom tooling is stored in a tooling stadium/ warehouse under the back gauge. An innovative gripper design built into the machine’s back gauge finger serves as the tool changer mechanism. When a job is complete, the press brake automatically changes the top and bottom tooling as required for the next job. All tool stations are precisely positioned, eliminating the need for manual adjustments. LVD’s patented Easy-Form Laser in process angle monitoring and correction technology ensures firstpart, good-part bending accuracy. A 19-inch touch-screen display makes operation easy and intuitive. Along with the new 220-ton, three-metre model, LVD offers a 220-ton, four-metre model and a 135-ton, three-metre model. www.gwbtools.com.au

NOW THAT’S APPLIED THINKING.

All Mitsubishi lasers feature next generation cross-flow resonators. This exciting, new technology results in outstanding savings on maintenance and running costs, whilst still delivering the class leading performance that you expect from Mitsubishi. Laser gas usage can be as low as 3L/h, and a staggering 90% energy saving can be achieved in standby mode. Mitsubishi lasers are also surprisingly affordable, so there are savings all round. Featuring laser power up to 6kW and sheet capacities up to 6000 x 3000mm, there’s a Mitsubishi laser for practically all applications.

For more information: Call: 03 9706 8066 Email: sales@appliedmachinery.com.au Visit: www.appliedmachinery.com.au

YOUTUBE LOGO SPECS

PRINT main red

gradient bottom

C0 M96 Y90 K2

C13 M96 Y81 K54

white

black

C0 M0 Y0 K0

C100 M100 Y100 K100

PMS 1795C

WHITE

on light backgrounds

on dark ba

standard

no gradients

no gradie

watermark

watermar

stacked logo (for sharing only)

stacked l

PMS 1815C

BLACK

Connect with us socially

AMT September 2014

| 29

product news

More grades for TaeguTec’s Life+ line TaeguTec has expanded the range of its Life+ line with the addition of the TT8105 grade for high-speed turning on steel machining applications. Because of its special coating technology, the new addition to the Life+ line enables excellent wear resistance while also guarantying stable and long tool life. The TT8105 gets an extra boost with the addition of the GoldRush treatment, a special coating that enables better surface roughness and high durability. TaeguTec has expanded the Life+ line in order to offer customers a wider range of application solutions and selection. The TT8105 is the current addition to the Life+ line that includes the TT8115, TT8125 and the TT8135. During tests of the new TT8105 Life+ coating, TaeguTec found that tool life improved as well as wear resistance. One example involved the machining test of a guide cover made from alloy steel. With

all cutting conditions the same, TaeguTec recorded an increase of tool life by as much as 54% over a similar offering by a leading competitor. The new Life+ grades have excellent wear resistance, are stable in high-feed and

speed machining conditions, and are an ideal choice for professional and amateur machinists who aim to achieve excellent surface roughness while minimising buildup-edges. www.taegutec.com

Schunk: precision igus – world’s first 3D-printable machining as standard bearings igus has introduced the world’s first plastic filament for 3D printers enhanced with lowfriction, tribological properties. The material, 50 times more resistant to wear and abrasion than conventional 3D printer materials, is ideally suited for creating custom bearings.

igus has been researching filaments for 3D printers to provide customers with more flexibility in their design ideas. Now, customers can design custom parts or manufacture prototypes that still offer the tested service life of igus plastic materials. The new product, which has undergone extensive tests in the igus test lab, is the first filament for 3D printers specifically developed for motion-control applications. The new filament will give customers more flexibility for the design of their application’s bearings and even prototypes can be produced quickly and cost-effectively. igus also offers access to 3D models of igus products in STL format, which can easily be downloaded and used directly as input data for 3D printing. This technology will help to reduce the high tooling costs of part production, while eliminating waste for additional production savings. www.treotham.com.au

To achieve precision in the sub-micron range during ultra-precision machining, tool-holders need features such as balancing grade extremes. This is now being offered by Schunk with its Tribos-Mini and Tribos RM series of polygonal tool holders. Now available from Schunk, the new tool holders are offered with HSK-E 25, HSK-E 32, and HSK-F 32 interfaces that start with a clamping diameter from 0.5mm. As an additional option, Schunk is also providing ultra-fine balanced tool holders with a balancing grade of G0.3 at 60,000rpm. Consequently, demanding requirements in terms of dimensional accuracy and surface quality when micromould making can now be provided for precision sectors like the optical, medical, watch and jewellery industries. Compared to conventional balanced tool holders for micromachining, the tool life is significantly longer while delivering precision and surface finishes beyond alternate systems. In micro-machining it is commonplace for extremely small, intricate and expensive tools to be used; so employing such precision tool holders will pay dividends for the end user in a short period of time. The Tribos polygonal tool holder technology that has been developed and patented by SCHUNK is the ideal choice for micro machining. Even the standard mountings deliver convincing performance levels with a run-out and repeat accuracy of less than 0.003mm at a clamping length of 2.5xD and a balancing grade of G2.5 at 25,000rpm. The Tribos is suitable for every tool shank of h6 quality and depending on the type, it has been tested up to 205,000rpm. Since the mountings have no movable parts, they are mechanically resolute and ensure an almost maintenance and wear-free service life. Even after several thousand clamping cycles, there are no signs of material fatigue. Additionally, the tool change of the Tribos is reliably done via a hydraulic clamping device within a few seconds. www.schunk.com

30 |

AMT September 2014

MTIQualos_July2012:Layout 1

15/6/12 12:39 PM Product

Page 1 news

VersaCube: versatile, durable sensors Rockwell Automation has introduced the new Allen-Bradley 871P VersaCube inductive proximity sensor. These new 4-Wire DC sensors integrate both standard and specialty features into a redesigned 40mm rectangular housing suited for an even wider range of general purpose and welding applications. “The VersaCube combines all of the ‘best in class’ features such as Factor 1 sensing, high IP67, IP68 and IP69K ratings, extended sensing ranges, weld-field immunity (WFI), slag resistance, complimentary outputs and high visibility LEDs into the one economical package,” said Paul Costantin, Business Manager (components - South Pacific) at Rockwell. “The new VersaCube simplifies the selection process for customers and is an obvious choice for standardisation in the food and beverage, automotive, materials handling and general manufacturing industries.” The new 871P WFI VersaCube models provide a level of performance far beyond that of similar products. The VersaCube offers extended range, complementary (NO + NC) outputs and equal sensing distance for all metals. The VersaCube features a new high-visibility status indicator that can be seen from a long distance at 360 degrees. When coupled with the unique mounting flexibility of the VersaCube, installation, alignment and troubleshooting are greatly simplified. For the most demanding applications, the 871P VersaCube can be ordered with ToughCoat, Rockwell’s patented weld-slag resistant coating on the sensing face. ToughCoat prevents the adhesion and accumulation of weld splatter, as well as associated problems including physical damage or “burnthrough” to the internal components. The result is a sensor that lasts considerably longer than its standard WFI counterparts. Featuring reverse polarity, short circuit, false pulse noise and overlay protections the new 871P WFI VersaCube models provide a costeffective solution for a range of general purpose, welding and hygienic applications. Additional capabilities include an enhanced feature set with increased performance, adding mounting features and options for new and drop-in retrofit applications and easy viewing with large indicators for status and diagnostics. “The Factor 1 sensing means that the VersaCube can sense different materials such as iron, stainless steel, brass, aluminium and copper without having to consider de-rating factors, they are all detected at 20mm in a flush mount or 40mm in a no-flush mount,” says Costantin. The VersaCube also features quick installation with variable position-sensing face and mounting options. www.rockwellautomation.com

M.T.I. Qualos Pty. Ltd. are proud to provide the next generation of CNC Co-Ordinate Measuring Machines, the

With increased measuring speed and higher accuracy/resolution the Crysta-Apex S brings a new dimension to the Quality Control process.

To see the future of High-Speed Measurement please contact:

M.T.I. QUALOS PTY. LTD. MELBOURNE 55 Northern Road, West Heidelberg, Vic. 3081. Phone (03) 9450 1900 Fax (03) 9458 3217 Web: www.mtiqualos.com.au e-mail: sales@mtiqualos.com.au

AMT September 2014

| 31

product news

BTX Profiler – Comprehensive analysis To provide affordable yet comprehensive compositional materials analysis at the structural and elemental level, Olympus has developed the BTX Profiler. This functional benchtop unit combines X-ray Diffraction (XRD) and X-ray Fluorescence (XRF) analysis in a single instrument. The combination delivers savings in operational costs, space, and time along with seamless integration of data and results. Olympus continues to be at the forefront of the development of X-ray analysis technology which provides fast, non-destructive qualitative and quantitative characterisation of materials. Instruments developed by Olympus can be used for detection, identification and analysis of elements at a range of concentrations. The BTX Profiler utilises the revolutionary XRD technology developed for the NASA Mars Science Laboratory program, where it is being deployed with great success aboard the Martian rover, “Curiosity.” Building on Olympus and NASA patents, the BTX Profiler also incorporates the highly acclaimed, award-winning, earthbound technology employed in Olympus’ analytical X-ray instruments. According to Andrew Taylor, Regional Sales Manager with Olympus, the BTX Profiler can be used in a wide range of applications. These include energy exploration; mineral identification; ore grade control; counterfeit drug screening; fire and explosives forensics; and corrosion monitoring. “The BTX Profiler can take the drudgery

out of routine analysis,” Taylor said. “With full mineralogical and elemental analysis capabilities, it can be used for single sample measurement or for unattended multi-sample measurements when combined with an integrated autosampler.” The BTX Profiler is more efficient than conventional powder diffraction systems. The closecoupled transmission geometry means that the device only requires a low powered X-ray source and a small amount of sample. The sophisticated sample handling technology incorporates a patented vibration system that enables random crystal orientation in a fixed sample cell. The CCD detector with its smart energy discrimination provides graphical 2-D diffraction patterns, or Ring Patterns, and acquires more data more rapidly than conventional XRD detectors. According to Taylor, development engineers are continually investigating different detectors, filtering techniques and analysis algorithms to improve the unit’s sensitivity and accuracy. The Energy Dispersive XRF technology in the BTX Profiler integrates selectable optimised beam paths of a miniature X-ray tube and specialised filters; a large area silicon drift detector (SDD) for

optimised resolution and detection limits; and close coupled geometry with the sample, allowing for a wide elemental and concentration measurement range. The BTX Profiler’s non-destructive capability is of particular significance for several industrial sectors including energy, geochemistry, pharmaceuticals, catalysts, forensics and education. Early analytical X-ray instruments were large, floor-mounted devices that required lots of power. The cost of such devices was also prohibitive for all but the largest analysis laboratories. Today, the BTX profiler provides the advantages of XRD and XRF testing in a fast, attractive unit that won’t break the bank. www.olympus-ims.com

KURT – linear values over entire stroke For quality control and quality checks, the KURTSmart Probe is an easy way to verify part measurement accurately and economically. Kurt’s new KURTSmart Probe combines the advantages of a linear variable differential transformer (LVDT) with the accuracy of a linear scale, at a fraction of the cost. Kurt’s new generation of pencil probes provides two type of actuation (spring extend and pneumatic extend) for today’s gauging requirements. The KURTSmart Probe features an LVDT pencil probe design that outputs a linear value over the entire stroke of the probe. The probe requires just five volts of power for measurement operation and can run stand-alone measuring and sorting parts based on feature size very quickly. An onboard input and output port supports the triggering of the measurement and action to be taken based on the measurement result. It provides a measurement result without connection to a computer. With a set of five small LEDs on each side, the device can be programmed to visually

32 |

AMT September 2014

show the operator if a part is good (green), trending bad (yellow) or bad (red). The KURTSmart Probe can also be used in computer stations or other devices that support a USB interface to provide complete and accurate measurement results to computer-based data collection systems. Probe results can be mixed to provide complex GD&T data results. The probe is factory calibrated over the entire working range of the probe. This allows user programming for any specific operation range by using Kurt’s KURTSmart PROBE configuration software. This application software is available on-line as a free download from Kurt’s website. Additional KURTSmart Probe features include: 14-bit precision accuracy to 12 bits; pre-calibration to ensure all devices measure identically over the full stroke; on-board dynamic scans (MAX, MIN, TIR, AVG); LED indicators was a

programmable scale to fit a tolerance range; indicators visible from top or side mounted on both sides; on board I/O for stand-alone operation; and USB to COM port interface. The device is nameable for consistent identification by the software, and is compatible with standard USB hubs, allowing multiple probes per system. LVDT stroke lengths available include 2.0mm, 5.0mm, 10mm, 20mm spring and pneumatic extend models. The KURTSmart Probe is part of a complete line of precision custom gauging systems, SPC software and data collection technology available from Kurt Engineered Systems. The company designs and builds precision gage systems from simple bench top stations to multi-featured measuring machines to fit customer needs. www.kurtengineeredsystems.com

Product news

Rugged doors, smooth operation MTI Qualosâ&#x20AC;&#x2122; range of rugged Insulated Traffic Doors operate smoothly, require little maintenance and are built to survive in even the toughest applications. Like all of MTIâ&#x20AC;&#x2122;s manufactured door products, the Insulated Traffic Doors are engineered to perform at a high standard, and have been installed in everything from supermarkets and restaurants, to hospitals, laboratories even cool rooms, as well as in manufacturing facilities. The doors are fully insulated to ensure there is no loss of cool air within refrigerated applications. To reduce any air loss, the doors are also supplied with a complete full perimeter gasket made from a semi-rigid rubber strip. The doors offer long-term access solutions in manufacturing facilities, warehouses, walk-in coolers or separating the sales floor from the back of house area. Insulated Traffic Doors are manufactured from a rigid

PVC internal framework coupled with high-impact ABS plastic outer skins, and have an overall thickness of 44mm. The doors can be manufactured in both single or pair depending on the application. Standard outer skin panel colours available include black, dark grey, light grey or beige, while other colours can be supplied upon request. Standard window sizes include 740mm high by 235mm wide or 540mm high by 540mm wide. To prolong the life of the doors, they are supplied with spring impact bumpers or flat impact panels, which help cushion the impact of motorised or hand traffic. www.mtiqualos.com.au

Lantek â&#x20AC;&#x201C; shipbuilding solutions Lantek has incorporated various specific functions for sheet metal design, nesting and machining in the shipbuilding industry into its range of manufacturing software solutions. By adapting to the specific needs of any metal company, Lantek has consolidated its presence in various metal-related sectors, with more than 14,000 customers in over 100 countries. In the shipbuilding industry, Lantek has invested years in the research and development of specific software solutions to optimise the processes of sheet metal design, nesting and machining, making them more costeffective for the construction of ships and other vessels. Leading shipbuilding companies such as Hyundai, Navantia, Astilleros de Murueta and Ravestein BV have used Lantek technology for years. Lantek provides naval companies with geometry importers that are compatible with the top ship-design systems on the market. Additionally, it offers technology options for machining management, including loops and chamfers that help program the cutting machines and rotating triple torch, and clamps that allow very long pieces to be cut, for results that are 100% faithful to the generated design. Specific options include the ability to manage cutting with multiple torches to increase the production of each machine, continuous cutting to eliminate drilling times and increase the wear life of the cutting nozzles, or the ability to manage any marking, engraving or puncturing process available on the machine.

Lantek solutions also includes nesting software for cutting applications, offering automatic and semi-automatic nesting algorithms or nesting for multiple torches that, among other benefits, allow optimisation of the material and reduced machining time. In addition, Lantek technology enables nesting and automatic machining of double and symmetrical sheets, a comprehensive control of the remnants, and pre-nesting to select the sheet format with the best performance. Other functionalities that Lantek has adapted to the naval sector include timeand-cost calculation, machine loads preview, traceability or integration with any existing management system. www.lanteksms.com AMT September 2014

| 33

Transport & logistics

Transport industry manufacturers and innovators are helping to move Australia forward safely and efficiently, while also sourcing the bulk of their suppliers from the domestic market, keeping opportunities and jobs in this country. By Carole Goldsmith.

Australia’s logistics industry accounts for 8.6% of GDP, adding $131.6bn to the economy in 2013. The industry also employs around 1.2m people. The Australian Logistics Council’s report The Economic Significance of the Australian Logistics Industry, released this July, revealed that the domestic freight task totalled almost 600bn tonne kilometres in 2011-12, or about 26,000 tonne kilometres for every person in Australia, based on estimates by the Bureau of Infrastructure, Transport and Regional Economics. The rail industry wants more of this freight business. According to figures from the Australasian Railway Association (ARA), Australia’s rail network covers almost 45,000km of track, 1800 locomotives and 32,000 wagons and carriages. Australia’s rail network moves almost one billion tonnes of freight annually, and the industry is keen to transport substantially more of the nation’s goods across the country. “Australia has the sixth-largest freight and passenger network in the world,” says Bryan Nye OAM, CEO of ARA. “We are carrying almost a billion tonnes of freight each year, moving goods such as iron ore, coal, sugar, wheat, cotton, right through to Weeties and beer. The UK, in comparison, is moving around 100m tonnes of rail freight annually.

34 |

AMT September 2014

“Currently, however, only 5% of Australian freight goes by rail along the eastern seaboard. It is a safer, cheaper and greener transport medium than road freight, so we are constantly promoting the rail alternative to business and the public.” While freight represents an area of potential opportunity, Nye speaks excitedly about the growth in rail passengers, revealing that 784.2m people travelled on the network in 2013, a rise of more than 80m passengers over the previous four-year period. ARA is a member-based association representing the rail industry in Australia and New Zealand. Its 170 members, of which around 70% are SMEs, include rail operators, track owners and managers, manufacturers, construction companies and other firms, contributing to the rail sector. ARA, along with the Rail Supplier Advocate, Rail Suppliers Network Australasia, the Industry Capability Network and Austrade, are leading a delegation to InnoTrans, to be held in Berlin on 23-26 September. Around 30 Australian rail suppliers have already registered to join the Australian pavilion at what will be the largest rail show on Earth. When asked what Australia needs to keep rail suppliers manufacturing in Australia, Nye called for a collaborative approach. “Australia needs to partner with Chinese firms, so the basic parts can be built overseas,” he said. “The more technical rail components such as system integration should continue to be made in Australia. We also have a lot of old locomotives, which need new engines plus better fuel and communication systems. SMEs across the country need to be involved in upgrading these older machines”.

Transport & logistics

Nye is keen to see the high speed rail network between Sydney and Melbourne built and operating: “Both sides of the government have agreed to preserve the corridor to avoid building over the planned route. This rail link will not only create increased opportunities and employment for rail suppliers, it will also provide a much-needed fast link between the two cities.”

Trackside signalling, Australian-made An active ARA member, Siemens is the only major multinational technology organisation to provide trackside signalling products that are manufactured in Australia. Last September, Siemens was awarded the Australian Made registered trademark for six of its rail automation products, in a ceremony at its Port Melbourne manufacturing facility. The products receiving the trademark included point machines, a train stop, plug boards, signals, a slide detector, and level-crossing flashers. “The point machines M3, M23 and 84M are all different versions of a safety-critical device that allows trains to automatically change tracks where required,” explains Jamie McDyre, Siemens’ Vice-President – Freight and Products for Asean Pacific. “The train stop is a safety stopping device attached to a rail signal that protects against a train passing a signal at danger. Signals are similar to traffic lights for trains, while plug boards, slide detectors and level crossing flashers are components within larger systems.

Every Australian state has its own rail infrastructure, with different gauge systems, and different operating rules and standards, so Siemens needs to design and build products for each state’s requirements. Rail signals in Queensland, for example, have red, amber and green lights similar to road traffic lights, while their Victorian equivalents have multiple colours that tell the driver how fast to travel. Siemens’ customers include every state rail organisation’s suburban and regional rail networks, such as V/Line and Metro trains in Victoria, NSW Trains and Sydney Trains in New South Wales, and Aurizon and Queensland Rail in the north of Australia. Siemens also supplies private companies that own their own rail lines, such as BHP Billiton, Rio Tinto and Fortescue Metals. “We deliver the complete turnkey solution to our customers,” says McDyre. “First we design the system, produce the equipment, then install and commission the signalling and control systems.” Siemens has over 480 staff dedicated to rail here in Australia, including 60 engaged in R&D. As well as the Port Melbourne facility, the company has warehouse and manufacturing sites in Perth and Rockhampton. During AMT’s tour of the Port Melbourne site, McDyre points out a map on the wall showing Australia’s extensive rail network, with a super-imposed image of all the EU countries fitting neatly inside its coastline. He refers international visitors to this map whenever they ask why the company has sites in the west and north of Australia. The three sites mainly do final assembly, with the majority of products made at Port Melbourne. Continued next page

AMT September 2014

| 35

Transport & logistics

Continued from previous page

“We have suppliers of components for our products all around Australia and 90% of our supply chain for products comes out of this country,” says McDyre. “Most of our products are sold to the Australian market, but we are exporting around 10-15% to Asia, mainly to Indonesia, Malaysia and Thailand”. During AMT’s tour of Siemens’ research laboratory, an operator assembles part of a rail control system. McDyre points to the wallbased 386 computer, a relic from the mid-1980s still used today in testing specific interlocking cards. Similar older computer systems are used for testing in other advanced nations like Germany. “Equipment in the rail industry is expected to be supported for a minimum of 20 years, and this poses challenges to OEM suppliers, particularly with electronic equipment and part obsolescence,” he explains. “Test systems like the 386 computer are an essential part of the overall safety assurance of the product and demonstrate why having local support is so critical to customers. Some of the point machines operating on the network are nearly 40 years old. With this facility and our experience of the original equipment we are able to restore this legacy equipment to new through our remanufacture process.” Where some suppliers offer overhaul of equipment to make it operational, Siemens completely strips the equipment of all rust and wear and tear, before replacing every engineering component with new versions. This offers a new life to the equipment, which slots back into the maintenance schedule as a full lifecycle overhaul with the same maintenance requirements as new equipment delivered more recently. McDyre describes the M23 point machine being assembled and tested by operators: “These are large pieces of equipment, around one metre in length and a quarter of a metre in width, and can weigh up to 350kg. They are designed to last for 20 to 30 years handling some of the heaviest trains in the world.” Siemens’ products are all tested for exposure to Australia’s extreme weather in the site’s heating and cooling chamber. Temperatures range from minus 20 degrees to plus 70 degrees Celsius. When asked if the rail automation business is growing, McDyre is optimistic. “The whole rail industry has been affected by the decline in the mining industry. There has been a flow-on effect over the past 12 months, but long-term market drivers remain strong. One of the major problems for the Australian railway industry is the copper theft from the signals. Railway companies are constantly looking at ways to prevent this.”

36 |

AMT September 2014

Siemens is designing, manufacturing, installing, testing and commissioning the rail automation technology to optimise productivity of the rail line between Dingo and Bluff in Queensland. Siemens will deliver rail automation interlocking technology worth $19m to increase the capacity of the new line, which will help to deliver 27mn tonnes of coal each year from the surrounding mines to the Wiggins Island Coal Export Terminal. The project was awarded in June 2013 and will be completed in mid-2015.

MaxiTRANS – jobs for regional communities Leading Australasian semi-trailer and transport equipment manufacturer MaxiTRANS supplies a diverse range of industries, including transport and logistics, food and beverage, construction, agriculture and natural resources. With its head office in Derrimut, west of Melbourne, and manufacturing sites in Ballarat in Victoria, Brisbane and Bundaberg in Queensland, it uses local suppliers from the surrounding areas, whenever possible, and provides jobs for regional communities. MaxiTRANS also has company-owned dealerships around Australia and New Zealand. “As we grow, we help local suppliers grow too,” says MaxiTRANS Group General Manager Manufacturing, Andrew Wibberley. “Part of our company’s philosophy is to support regional communities. We use local suppliers as much as we can, ensuring that they are price-competitive”. Having managed the Ballarat site for six years, Wibberley is now on the road for 2-3 weeks a months, working between and managing all of the company’s different manufacturing sites. “We manufacture leading trailer brands, polyurethane foam and fibreglass body panels, while we also service and repair trailers as well as supply and distribute parts,” says Wibberley. “Our company designs and custombuilds trailers according to our customer’s requirements. We construct innovative solutions to assist our transport clients to maximise their weight per volume load”. Wibberley gives an example of client customisation: “We have designed some trailers for waste management clients so that their

Bryan Nye, CEO of the Australasian Railway Association (ARA).

Transport & logistics

MaxiTRANS Group General Manager Manufacturing, Andrew Wibberley

drivers don’t need to get out of their truck at the tip to remove the waste, with all controls in the truck cab. This is a safer option for the driver and the client. Occupational health and safety considerations are very important in all our trailer designs.” MaxiTRANS’ largest manufacturing site in Ballarat had a $5m site expansion in 2002 to service the growth in the business and today employs around 370 people. MaxiTRANS has continued to review operations since the upgrade and uses continuous improvement programs as a method to remain efficient. When the company acquired the side tipper brand AZMEB in 2012, all of AZMEB’s existing Bundaberg employees were retained, highlighting MaxiTRANS’ focus on supporting regional communities. In total, MaxiTRANS employs over 900 people in Australia, including many engineers and design professionals. Each of the different production sites are set up to concentrate on building specific MaxiTRANS brands. “The Ballarat site mainly produces Hamelex White, Freighter and MaxiCUBE brands,” says Wibberley. “The Brisbane site manufactures Lusty EMS trailers, while AZMEB site tippers are produced at our Bundaberg site. One of our strengths, however, is to use any of our sites to fill large contract orders. Each site is supported by a number of technical qualified engineers and service staff to assist in this goal.” MaxiTRANS has a strategy of constant innovation. In July, the company’s Maxi-CUBE brand delivered a 26-pallet refrigerated trailer into Queensland that was the first of its kind to receive Performance Based Standards (PBS) approval in the state. The trailer was purchased by specialist fruit and vegetable carrier Fruithaul, who placed the order after learning of the productivity benefits of the PBS scheme. PBS are design standards that enable certain designs of truck and trailer combinations to carry larger-than-normal payloads. The type of design depends on the route travelled, the type of cargo and the objectives of the transport operator. In most cases it means operators are able to drive truck and trailer combinations that are outside the standard legal dimensions, improving road transport efficiency and vehicle safety. Each new PBS combination design needs to be designed from scratch based on customer requirements. That MaxiTRANS has more PBS-approved designs than any other manufacturer speaks volumes of its commitment to customisation.

One of MaxiTRANS’ state-of-the-art paint booths.

bespoke products in a relatively short lead time. It is this combined customer requirement for customisation and speed of production which minimises the opportunities for imported trailers coming into Australia. “To bring in a finished trailer from overseas comes at an expensive cost due to a trailer’s dimensions,” Wibberley adds. “Produced from high-grade steel, semi-trailers measure 8-13m long, 2.5m wide and 4-6m high. Imports also tend to be mass-produced, not custom-made like most customers require.” With a firm footing as Australia’s largest semi-trailer manufacturer, MaxiTRANS has one eye on the future. “Part of our future strategy is to grow our current brands and develop new products to diversify the company’s market,” says Wibberley. “With our many trailer brands and backed by our service and parts divisions, we believe MaxiTRANS is able to provide a localised full service offering to our Australian customers, and we’ll continue to strive to improve that offering where possible”. www.austlogistics.com.au www.ara.net.au www.siemens.com.au www.maxitrans.com The ground-breaking 26-pallet refrigerated trailer (right) delivered to FruitHaul, compared to a standard 24-pallet trailer (left).

As MaxiTRANS’ customers have specific requirements, trailers are mainly custom-designed and built. Consequently there is not a lot of mass production done at MaxiTRANS. Wibberley believes this is one of the main reasons why Australian trailer manufacturers continue to succeed. “Designing each of our trailer brands to Australian Standards and to the specific requirements of our customers provides a value proposition. Local production also means we are able to supply AMT September 2014

| 37

Transport & logistics

Fraunhofer researches unmanned ships concept Scientists from the Fraunhofer Society in Germany are engaged in an ambitious project to develop autonomous ships, capable of navigating the world’s oceans without a crew. By Frank Grotelüschen Hans-Christoph Burmeister casts his eye over the instrument panel, taking in the electronic nautical chart, the depth-sounding screen and the radar monitor beside it. Then he grabs the helm and steers his 220m-long bulk carrier in a new direction. “We’re now headed on a course of 290 degrees, at a speed of 12 knots,” he explains. If you didn’t know better, you’d think Burmeister was standing on the bridge of a real ship. But in actual fact he is at the Fraunhofer Center for Maritime Logistics and Services (CML) in Hamburg, Germany, standing in the middle of a room that houses a shiphandling simulator. The steering controls and instrument gauges may be just like those on a real cargo ship, but the view of the horizon out the window is just an image displayed on three screens, showing a seascape complete with whitecaps, simulated twilight and the silhouettes of other ships. The simulator is helping to progress an ambitious undertaking: the development of an autonomous ship. Fraunhofer scientists are working on the idea together with partners from five countries as part of the EU-sponsored Maritime Unmanned Navigation through Intelligence and Networks (MUNIN) project. Burmeister, who co-ordinates the project, explains that, like many other industries, the shipping industry will face a growing demographic challenge in the near-future. In our globalised, networked world characterised by strict timetables, Burmeister says the “exotic charm that the maritime industry had 50 years ago is faded away”. Going to sea often means being away for months at a time, which puts strain on family life. On top of that, the journeys from continent to continent tend to be fairly uneventful, with administrative burdens instead dominating the work of the navigators on board. Some of the technology required to operate an autonomous ship is already available and in use on the bridges of modern ships. Captains today are assisted by autopilots that use GPS to follow a Image courtesy Maersk Line

38 |

AMT September 2014

predetermined course, and cruise-control systems able to maintain a constant speed. Modern ships also feature radar devices and ship identification systems that scan the surrounding environment and automatically raise the alarm when the vessel is in danger. In addition to these technologies, autonomous ships would be fitted with extra sensor devices such as optical and infrared cameras to monitor the surface of the ocean and spot other vessels, flotsam or shipwreck victims. Unmanned cargo ships are designed around a central software system. An autonomous control module evaluates all the data collected from the sensors and makes decisions such as whether the ship should change course to avoid colliding with a container floating free in the water. Nevertheless, a crewless ship would never sail completely unsupervised. An operator would oversee everything that happens via satellite, and intervene if necessary by taking remote action. “It’s conceivable that some situations might arise that go beyond what the autonomous on-board systems are able to cope with, such as when several ships are on a simultaneous collision course or when technical failures occur,” explains Burmeister. In such cases, a land-based station ready to intervene via satellite communication is able to step in and steer the ship remotely.

Circumnavigating danger with a few mouse-clicks Burmeister fires up his simulator to show us what this intervention looks like in practice. On the screen we watch as a container vessel approaches on the port side. Despite Burmeister’s freighter having right of way, the other ship seems determined not to take evasive action. To prevent a collision, the engineer takes over the control of the autonomous ship: “I deactivate the autopilot, set a change of course to starboard, drop our speed and wait until the other ship has passed.” A few remote mouse clicks were all it took to avert the danger.

Transport & logistics

Ship without a crew The Maritime Unmanned Navigation through Intelligence and Networks (MUNIN) is an EU project that was launched in September 2012 and will run for three years. Eight institutions from Germany, Norway, Sweden, Iceland and Ireland are involved in the project, among them the Fraunhofer Center for Maritime Logistics and Services CML in Hamburg. The total budget is €3.8m, of which €2.9m is provided by the EU.

IMO 123486 COG 080° SOG 14.0kn

Control of the vessel will also be in human hands when ships dock and undock. Ships will have a crew on board when leaving port and will remain crewed until the freighter reaches open seas, at which point the crew will disembark in pilot boats or by helicopter and leave the automated systems to take over. When a ship reaches its destination, the same thing happens in reverse: a crew will join the ship before it reaches the harbor entrance to steer it safely into port.

Due to be completed in late 2015, the aim of the EU project is to create a computer simulation that experts can use to put their ideas to the test in a virtual environment. After that, they would be ready to fit out a real ship for full automation. Meanwhile, some of the components the MUNIN experts are working on would be an enormous help on the bridge of any modern ship: automatic lookout systems would help relieve the crew, while improved warning systems would help prevent collisions.

The MUNIN project started in 2012. Designing an autonomous ship means accommodating a range of incredibly diverse requirements, so the experts have been puzzling over all sorts of different details. One of these is how to ensure the ship’s engine can continue to run reliably for weeks at a time without an engineer checking it. As it stands, current machines are designed to function for 24 hours without supervision.

“We’re still a long way from autonomous freighters,” says Burmeister. “But our results could benefit the crewed shipping industry long before then.” Reprinted courtesy of the Fraunhofer Society. www.fraunhofer.de

“For journeys lasting two to three weeks, we would need to take extra steps to ensure the engine doesn’t cut out in the middle of the Pacific,” Burmeister explains. “It would make sense to include more than one of each of the most important components.” Sprinkler systems would have to come on automatically in the event of a fire on board, perhaps caused by a short circuit. Critical areas could be flooded with CO2 as a preventive measure that would make it impossible for a fire to start there in the first place. In heavy seas, the autopilot would need to turn the hull to minimise the effect of the waves, and as a general rule the ship should try to avoid sailing into severe weather systems in the first place by circumnavigating them as the storms draw near. In theory, an uncrewed vessel could even recognise people floating in the water. Burmeister believes that an automatic radar and camera surveillance system might even be better at spotting people than the crew on the bridge, who are often distracted by other duties and so are less reliable. Rescue boats could then be automatically launched to assist the person in the water – though this is an idea that goes beyond the scope of the MUNIN project. However, these vessels could well get into legal hot water. Without a captain on board, who takes responsibility in the event of an accident? “A project partner in Ireland is dealing with issues of this sort and drafting a legal framework for unmanned ships,” says Burmeister. “It looks as though several existing regulations might have to be changed.”

FREDDY TAKES THE NIGHTMARE OUT OF CLEANING COOLANT. Make your coolant last longer, lower your operating costs and extend the life of your equipment with a Freddy vacuum and recycling cleaner.

Freddy rapidly removes coolant, swarf and oil, separates the particulates, then returns the filtered coolant for re-use. Streamlining workflow, he works while your machine is in operation. Help protect your employees from WHS issues such as dermatitis, bronchitis and asthma; let Freddy safely recycle your coolant. To take the nightmare out of coolant management, visit dimac.com.au

MADE IN THE UK

AMT September 2014

| 39

Transport & logistics

Opportunities ahead in rail sector With increased globalisation and tough competition from overseas, there is no denying that the Australasian rail industry is currently facing many challenges. According to Tony Carney, the National Sector Manager - Rail, for the Industry Capability Network, this strong international competition is why the Australian rail manufacturing industry needs to become globally competitive, to secure both domestic and international projects, and to access global supply chains. “The sector is at a crucial junction, where the challenge of global competition can only be faced by openness to the opportunities that globalisation brings,” says Carney. As a recent example of this global competition, Carney cites the fact that the Queensland New Generation Rolling Stock (NGR) Project, recently awarded to Bombardier Transportation, will be manufactured via a joint venture between their Australian and Indian operations. “My role is to actively promote competent, capable, qualified and competitive Australian and New Zealand suppliers into all of the principal contractors, primes and original equipment manufacturers (OEMs) associated with all major rail projects domestically and internationally,” adds Carney. “Via the ICN Rail Directory (www.rail.icn.org.au) we inform SMEs of potential projects, business opportunities, industry forums, trade missions and other initiatives associated with local and international opportunities. “The rail industry needs a national and international focus on business opportunities, which ICN facilitates and supports though the establishment and implementation of industry activities related to the Australian rail industry development strategy – a set of improvement activities and initiatives being undertaken to help improve competitiveness and access to global opportunities.” Carney works closely with individual ICN rail business consultants across Australia and New Zealand, and the ICN Rail team has been intimately involved in many rail projects during the planning, tender, procurement and delivery phases, helping Australian suppliers secure contracts that may otherwise have gone overseas. “The Australian rail industry is doing some very innovative work, especially in the areas of infrastructure, information systems, condition monitoring and fuel,” adds Carney. “To stay globally competitive, innovation is imperative to the survival and growth of the Australian rail industry. There are a number of innovative companies with niche products, across a broad range of areas, who are now supplying internationally. And to stay relevant and in demand, we need to ensure that the rail sector can meet the future needs of the global market.” “With the advent of the Cranbourne Pakenham Rail Corridor Project in VIC, the industry is also seeing some changes in government procurement practices, which will see the shortening of tender and evaluation processes which will help reduce tender costs for companies.” ICN has been involved in many success stories in the rail industry, such as Melbourne E-Class Trams, NSW Waratah Passenger Trains, the Auburn Maintenance Centre, Victorian Regional Rail Link Project, and Adelaide Electric Passenger Trains. ICN continues to work on many rail projects, and has consultants embedded in many major rail projects underway in Australia, including Queensland NGR, North-West Rail Link, and Queensland Coal projects, Cranbourne Pakenham Rail Corridor Project, Sydney Light Rail CBD and South-East Light Rail. ICN also continues to look for opportunities for local suppliers in major international projects. For example, the collaboration between the ICN Rail team and Bombardier Transportation Australia on the Queensland NGR project. Meanwhile, the newly formed Rail Manufacturers’ Co-operative Research Centre (CRC) will develop products, technologies and supply chain networks to increase capability and increase

40 |

AMT September 2014

the capability and global competitiveness of Australian rail manufacturers, particularly in innovations associated with: Materials and Manufacturing; and Power and Propulsion. “ICN is engaged in a number of activities to assist and promote companies to the global market, including trade missions to the Asia Pacific, mainland China and Europe,” adds Carney. “And I will be among delegates from the Australasian Railway Association (ARA) and Austrade at the largest rail industry trade show in the Tony Carney, National Sector world, InnoTrans 2014, in Berlin Manager - Rail, the Industry on 23-26 September, which will Capability Network. incorporate a pre-InnoTrans trade mission to the Middle East, France and Bombardier in Germany to meet accredited railway operators (AROs) and strategic buyers from global rail primes.” Carney recently joined with the ARA, the Department of Industry, Austrade and the CSIRO, to co-ordinate rail industry briefing sessions in Sydney, Melbourne and Brisbane to present on opportunities within the Australian rail sector. “These sessions were attended by well over 600 people to hear about the vast range of activities that are available for suppliers within the industry today and ongoing well into the future, a panel discussion and networking opportunities,” says Carney. “Some of the key messages were that there were a number of major projects underway or recently announced in Victoria, NSW, Queensland and Western Australia, that will create opportunities for local suppliers in the manufacturing, maintenance and infrastructure areas. “As a sector we need to create a robust supply chain, driven by continuous improvement and provide innovative solutions, suppliers must embrace change and drive continuous improvement.” Major recently announced projects include: • Cranbourne Pakenham Rail Corridor (CPRC) – ~ $2.5bn, Vic. • CBD and South East Light Rail (CSELR) project – ~ $1.6bn, NSW. • 65 New Intercity Trains Project – c$2.8bn, NSW. • Melbourne Rail Link, including Airport Link – ~ $11.0bn, Vic. • Forrestfield-Airport Link Project – ~ $2.0bn, WA. • Bus and Train (BaT) Project – ~ $5.0bn, QLD. To support these projects, ICN anticipates providing localisation support services via the ICN Group embedment model, with dedicated individual team members from the ICN National Rail Team in accordance with established probity best practice. Future plans for the ICN Group and the ICN National Rail Team include the creation of individual ICN Gateway (www.icngateway.com.au) project portals, industry and supplier forums, further trade missions, industry visits, conferences and exhibitions, collaboration with all relevant stakeholders. This is all driven by the need for Australian suppliers to position themselves as innovative developers and integrators of technology, with world-class standards of safety, reliability, performance and efficiency. www.rail.icn.org.au www.icnvic.org.au

Transport & logistics

Enerpac ensures crane safety at Tauranga A new-generation synchronous lifting system from Enerpac has been successfully deployed to precisely lift and weigh an 800-ton container crane during its installation at the rapidly expanding New Zealand port of Tauranga, ensuring its optimum weight distribution and reliability in service. The Enerpac Integrated Solutions EVO-12 system, selected by New Zealand heavy lift and shift specialist Rich Rigging, replaced manual control of hydraulic heavy lifting and weighing. The EVO system – examples of which are also being applied across diverse mining and energy, construction, civil engineering and infrastructure projects throughout Australasia – uses PLC control of multiple cylinders from a single point to optimise accuracy, safety and productivity.

The new crane installed at Tauranga using the Enerpac EVO system.

“We used the EVO system to achieve the best safety and efficiency during the lifting and weighing process, to ensure that the new crane was ideally and exactly positioned on its rails so as to achieve outstanding weight distribution,” said Murray Rich, Director of Rich Rigging. Precise positioning and ensuring ideal weight distribution is fundamental to the safety and ongoing reliability of the crane structure, including the legs on which it is supported, and of the rail system on which it moves to load and unload two TEU (twenty-foot-equivalent-units) containers at a time. The new crane on which the EVO-12 was deployed is the latest addition to Port of Tauranga’s crane fleet, with a below-thehook capacity of 80 tons. The Liebherr Super-Post-Panamax ship-to-shore twinlift gantry crane brings the total number of cranes at Tauranga Container Terminal to seven, which are collectively capable of handling the largest ships anticipated to trade with New Zealand in the medium term. Rich Rigging used multiple Enerpac RACL 100-6 aluminium cylinders to lift the 800ton crane, choosing the aluminium types to minimise loads on the structure and for compact power. With a 150mm stroke, the RACL 100-6 cylinders pack their lifting power into a high-pressure (700 bar), highreliability design, achieving 100 tons of lifting capacity in a cylinder with a collapsed height of only 321mm and weighing just 21.9kg. RACL cylinders are members of the broader Enerpac RC cylinder range, including steel types that have been used in Integrated Solutions synchronous lifts of thousands and tens of thousands of tons, on structures as diverse as mining and energy industry ball mills and generators, through to the launching of entire oil and gas industry floating production platforms. The EVO system from which the cylinders were controlled is the evolutionary result of Enerpac’s 25 years of experience in specialised hydraulic engineering and

42 |

AMT September 2014

lifting technology, using digitally controlled hydraulics to accurately and safely lift some of the largest and most challenging structures on Earth.

The Evo-12 Synchronous Lifting System control centre.

Instead of whole teams of lifting personnel trying to manually co-ordinate with each other lifts by hydraulic cylinders dispersed around a job, the EVO Series Synchronous Lifting System integrates the high-pressure hydraulic cylinders involved with a PLC system to monitor and control precise movement and positioning of heavy loads. Through an integrated human machine interface (HMI), all movements are managed from a central control position that displays live operation with real-time status updates for each lifting position, according to Enerpac New Zealand Territory Manager Neville Stuart. Stuart worked with Richard Verhoeff, Australasian Integrated Solutions Manager for Enerpac, in specifying the EVO 12 system for Rich Rigging, which specialises in heavy lifting to 1400 tons working to heights of 100 metres plus. The team at Rich Rigging are acknowledged experts in the assembly, erection, disassembly, relocation and maintenance of port container cranes. “Rich Rigging was particularly impressed with the accuracy of the EVO system in weighing and the ease of use of the system,” said Stuart. “The EVO system is a huge advance of old methods of lifting and weighing, which could involve entire teams of engineering staff spread around a job each trying to co-ordinate their lift with the next person. The time savings and safety with the EVO system are outstanding.” Previous methods of lifting port cranes typically involved a standard pump without

stroke control and no weighing capabilities. Such methods are less accurate in lifting and do not provide any input concerning weight distribution. Murray Rich said the EVO system was simply controlled and provided all the inputs needed. “The Tauranga lifting and weighing operation was an exceptional success in terms of precision, safety and efficiency,” he added. “This is the way of the future, that’s for sure, and we will be deploying the system again on our next project, at the major South Island port of Lyttleton.” www.enerpac.com/en-au

Transport & logistics

Iveco â&#x20AC;&#x201C; A pillar of Australian truck manufacturing When the Italy-based Industrial Vehicle Corporation (Iveco) acquired the International Trucks brand and manufacturing facilities in Australia in 1992, it also took on the stewardship of more than a century of transport and truck manufacturing heritage in this country. Ivecoâ&#x20AC;&#x2122;s manufacturing plant in Dandenong has been a pillar of Australiaâ&#x20AC;&#x2122;s transport industry for over 60 years, producing the iconic ACCO truck for 40 of those years. But the story goes back even further, to the early 1900s, when the International Harvester Company of Australia (IHCA) was formed in Melbourne to manage the Australian distribution and sales of International Harvester products imported from the USA. As Australia developed and expanded, so did the number of motor vehicles on Australian roads, and trucks gradually replaced riverboats as the primary means of moving freight around the country. This prompted IHCA to establish its own Australian manufacturing operations in 1937. Land was purchased on the shores of Corio Bay outside Geelong in Victoria, and an assembly plant and foundry constructed. At the start of the Second World War, IHCA switched from producing farm machinery to manufacturing and assembling military items. In addition to trucks, they supplied gas masks, torpedo bombers, service rifles, Howitzers, Bren guns and machine gun carriers. After the war, IHCA realised that Australia would rapidly develop, with the natural resources to support a vast manufacturing potential. The country was heavily reliant on road transport, but climatic extremes, poor road surfaces, long distances and large loads meant that many imported trucks were inadequate for the task they were expected to perform. The first International Trucks were assembled on an assembly line in a temporary manufacturing plant in South Melbourne. As demand increased, IHCA established the Dandenong manufacturing plant in Victoria, which opened in 1952 and further expanded in 1955. A feature of the expansion programme was the construction of the truck cab plant, which transformed sheet metal into truck cabins using the most modern assembly line methods of the day. The updated facilities also incorporated new machine tools and fixtures, permitting almost twice the previous output. Also in the 1950s, the IHCA truck group joined forces with the Australian Government to develop a 4x4 vehicle for use by the Australian Army. This army truck would be the first commercial road transport to be completely designed and manufactured in Australia, and the popular range of world-standard civilian vehicles that descended from it became known as

the International Australian C-Line CabOver (ACCO) series. The ACCO continues to evolve and keep pace with the latest developments in technology, with a new model due to be released by the end of the year. A unique feature of the ACCO is that since the first prototype, every part of its cab-chassis has been engineered and assembled at the Dandenong plant. Today, the design is a widely used platform in vocational markets, such as concrete mixing and waste collection, throughout Australia. One of the advantages of the vehicles being fully manufactured in the one facility is that Iveco can work closely with the companies producing the machinery and bodywork that will be attached to the chassis to ensure the correct positioning of bolt holes and other fastening points. To assist in the development of products specifically for Australian markets, IHCA also established a proving ground for vehicle testing. Approximately 1161 hectares were purchased at Wormbete, near Anglesea, Victoria, in 1961. This automotive proving ground, now owned and operated by Linfox, is the largest facility of its type in Australia, containing rigorous test areas including a truck chassis twist course, a truck test loop, and a loader test area.

Committed to Australian transport In 1992, International Trucks Australia and the Dandenong factory were acquired by Iveco, a major player throughout the global transport industry and now part of CNH Industrial. With manufacturing plants around the globe, Iveco is an international leader in the development, design and manufacture of passenger transport vehicles, off-road trucks, buses and coaches, and special vehicles for applications such as fire-fighting and defence. The company continues to locally manufacture and supply vehicles designed to meet the tough economic, physical and environmental demands of the Australian market. In Australia today, CNH Industrial employs over 900 staff, with more than 550 people employed by Iveco at the Dandenong facility in manufacturing, engineering, research and development, parts, service and administration, as well as at offices and branches across Australia. The Dandenong plant represents a major investment in the local truck and bus industry, producing several hundred truck and bus chassis per year, and creates employment in Australia for thousands of people in related industries, from retailing operations to component suppliers. www.iveco.com

The Dandenong facility in the 1950s.

The Dandenong plant today.

AMT September 2014

| 43

One on one

Douglas K Woods is the President of the Association for Manufacturing Technology (AMT), which represents and promotes manufacturing technology in the US. The Association owns and manages IMTS (the International Manufacturing Technology Show), which will be held from 8-13 September in Chicago. By William Poole. AMT: What can exhibitors and visitors expect from this year’s IMTS? Douglas K Woods: At this year’s IMTS, visitors and exhibitors alike will experience the excitement and energy befitting a worldclass event. Our Emerging Technology Center (ETC) will feature a live build of a 3D-printed electrical vehicle from Local Motors in partnership with the Oak Ridge National Laboratory. Additionally, the ETC will feature a display about the Institutes for Manufacturing Innovation, a regional hub system of public-private institutes that focus on developing and rapidly commercialising breakthrough technologies. As AMT is also active in promoting workforce development to address growing skills gaps, IMTS will again feature the Smartforce Student Summit, which will attract thousands of students, educators and parents. We want to give students a first-hand look at advanced manufacturing technology and a good understanding about industry careers and the opportunities they offer. Students will sit in on keynote presentations, take part in hands-on exhibits, and meet young manufacturing professionals to get a first-hand account of what their careers are like. For exhibitors, IMTS offers a sales opportunity unlike any other. It’s a rare opportunity to get in front of more than 100,000 customers at the same time! There’s no other show that comes close in North America, and nothing that carries the brand recognition of IMTS. Attendees come year after year because they know they’ll see the latest technologies, catch up with industry contacts, and meet new contacts as well. With over 1900 exhibitors showing off the latest technologies, everyone who comes is guaranteed to walk away seeing or knowing something they didn’t before their visit. AMT: Tell us about the Association for Manufacturing Technology and its role. DKW: The Association represents US-based manufacturing technology builders and distributors. Our members design, build, support and sell a broad array of technologies, from machining systems and tooling, to software and automated systems, to metrology and workholding. Our members create some of the world’s most advanced technology for the shop floor. AMT has managed and produced IMTS since the show’s inception in 1927. We build the show from the ground up each time, and every department within AMT has a role. Our Exhibitions department manages all of the show operations, from designing floor plans to handling operational and logistical details, to finding appropriate vendors, partners and sponsors for our conference programs and other co-located events. Our Communications team takes the lead in marketing and promotion. The Industry Engagement team works with hotel partners to house exhibitors and attendees, and co-ordinates space and logistics for on-site meetings. Meanwhile, our Manufacturing Technology team provides input for things such as the ETC and other technology-focused aspects. Our MTInsight team has been developing and promoting the IMTS

44 |

AMT September 2014

app for exhibitors, which allows exhibitors to find their best sales targets and build relationships with them before they even arrive in Chicago. Global Services helps with bringing in international VIPs and connecting them with AMT members. Smartforce Development produces the Smartforce Student Summit. Advocacy invites federal, state and local government officials and arranges visits and tours to drive home the importance of manufacturing to a growing economy and job market. Strategic Analytics handles post-show surveys and other attendee and exhibitor data. Further support comes from our Finance & HR and Membership teams. Truly, every person at AMT is somehow involved with the massive effort behind each edition of IMTS. AMT: What projects is the organisation working on at the moment? DKW: A lot of AMT’s focus right now is around the use of big data and information. We think what’s happening with digital technology and digital manufacturing is very important to the future of US manufacturing. One of the keys to unlocking big data is open standards, and AMT is the primary supporting organisation for MTConnect, an industry-wide interoperability standard that’s opensource, free, and available to users around the world. MTConnect provides seamless communication between manufacturing devices and equipment, allowing for improved monitoring and collection of shop floor data. It can be used for monitoring things like spindle performance and energy usage on individual machines, as well as tool wear and vibrations during machining. It’s invaluable in helping manufacturers determine if they are getting maximum efficiency and productivity from their operations. To ensure our members were positioned to leverage data we created MTInsight, a manufacturing-specific business intelligence and analytics tool. AMT offers a free seat to its members, who are then offered apps on a subscription basis that will help them leverage the market data and information most relevant to enhancing their businesses. This can help them identify markets, potential customers, and business opportunities on the horizon. We have developers and a sales and marketing team devoted to building and promoting MTInsight to give users the best possible experience. Internationally, we have a Global Services network to promote our members’ expansion into new markets. This year we opened a new tech centre outside São Paulo (Brazil), joining other centres in China (Shanghai), India (Chennai), and Mexico (Monterrey). These tech centres act as an “incubator” for our members’ entry into these markets, providing office and showroom space as well as service capabilities for their products. The tech centres are staffed by experts on their respective markets who can provide the guidance necessary for members to succeed. We also provide networking opportunities through our four-yearly events – the MFG Meeting, the Automation In Manufacturing (AIM) Conference, the MTConnect-focused MC2 conference, and the Global Forecasting and Marketing Conference.

AMT: Tell us a little bit about your background and how you came to your current position. DKW: I’ve been in this industry my entire life. My grandfather had a tool-and-die shop, and I served as an apprentice before moving into various engineering and management positions. I was fortunate to be asked to run an automation operation in Europe and gained in-depth knowledge of the industry from an international perspective. I came back to the US to run my own company focused on automation and flexible machining systems, and that’s when I got involved with AMT. I was active in committees and on its board of directors from 2000-2008, and served as its chairman in 2005-2006 before the opportunity came up to take on the president’s role, which I’ve been in since 2009. AMT: What might an ordinary working day entail? DKW: There are no ordinary days at AMT! We’re involved in so many key technologies, products and services, and the US market is so dynamic, we have many areas of interest and focus. In addition, we spend a lot of time staying connected to our international locations and of course our members so we can be aware of their needs. We’re also engaged with activities on Capitol Hill to ensure the industry’s voice is heard in our nation’s capital. I personally take part in many speaking opportunities to spread the word about innovations happening in manufacturing technology and the immense value the industry adds to the economy. All this helps raise awareness about AMT, our industry and what we stand for – creating a favourable environment for a strong US manufacturing industry. AMT: US manufacturing has undergone something of a revival lately. What’s been the main driver of that? DKW: Multiple factors are converging right now to drive the US manufacturing resurgence. Energy costs are low due to increased exploration and mining, particularly in natural gas. Interest rates are also low, allowing for favourable financing terms in purchasing new equipment. Add to that the fact that US labour costs have remained stable compared to other “low-cost” markets, which have seen skyrocketing labour costs in recent times. And of course manufacturers want to be close to their customers; the US market certainly provides that! All this is driving domestic companies to reshore or onshore at an increasing rate, while foreign direct investment in manufacturing is at an all-time high.

along with it. This plants the seeds for entrepreneurship and an attractive market for business growth. All this leads to stronger innovation and a better ability to export new technologies. AMT: What do you see as the biggest opportunities and challenges for global manufacturing over the next few years? DKW: From an opportunity standpoint, we couldn’t be more excited about big data and digital manufacturing. Moving into this digital realm is going to improve productivity and enhance capital utilisation in ways we’ve not yet even imagined. It’s also going to have an immense impact on design, as designers and engineers will more quickly be able to understand how their designs will perform before they even create their first prototype. Even education and training for workers will change, as technology becomes more accessible but also develops at a more rapid pace – in effect, education will need to adapt to become as agile and flexible as the technology. In terms of challenges, another reason why education will need to move quickly is to address the immense need for skilled workers. To maintain productivity, let alone improve it, companies need skilled workers to come online as quickly as possible. We also need to make sure we’re getting people interested in manufacturing careers and creating a good image for the industry. Those careers have to be promoted to students, educators and parents. We will also see challenges in striking a balance for global competitiveness. Naturally, every country is competing for global market share. It’s ideal if we can strive for collaborative partnerships rather than antagonistic relationships. That means creating a level playing field in terms of IP protection, currency valuation and so on. Our industry will do well to create symbiotic relationships in the spirit of healthy competition. www.amtonline.org www.imts.com

Additionally, the US has long been known for its innovation culture and entrepreneurial spirit. We have one of the best education systems in the world, and have been fortunate to attract and retain some of the best and brightest. All this has helped propel US manufacturing, and from current forecasts it looks like it will continue doing so for the foreseeable future. AMT: What can Australia’s manufacturing industry learn from the experience in the US? DKW: I’m not sure we’re in the best position to be giving advice to Australia as we still have a number of areas where we need to improve ourselves, such as extremely high taxes, onerous regulations and restrictive export controls. But there are several aspects that are important to building a strong manufacturing economy that we could point out. First, it’s essential to promote manufacturing’s value to the local economy – a strong multiplier effect that goes beyond just jobs in factories. Those workers are going to buy homes in the area, become customers at local businesses, and support the local community through sales and property taxes. It’s important that government and the general public become educated on why it’s desirable to have a strong local manufacturing base. It’s also important to foster a good environment for innovation – having the right infrastructure and incentive system in place for creating new technologies, products and services. Businesses are drawn to innovation centres, and then the supply base comes

AMT September 2014

| 45

Composites

Carbon Nexus – Gaining material advantage Situated just outside Geelong (Victoria), Carbon Nexus is a brand new, $34m research facility that aims to harness the enormous potential of carbon-fibre and composite materials, and set a new path for local manufacturing. The facility is part of a broader $103m investment under the Australian Future Fibres Research & Innovation Centre (AFFRIC), a collaborative relationship between Deakin University, CSIRO and the Victorian Centre for Advanced Materials Manufacturing (VCAMM) and supported by both the Victorian and Australian Governments. Based on Deakin’s Geelong Waurn Ponds Campus, Carbon Nexus was officially launched in May to considerable media fanfare, and touring the site it’s clear what all the excitement was about. Walking through the doors there’s an immediate sense of an environment designed with a clear idea of its objectives and how to achieve them. A large, lightfilled office space, with hot-desking for industry collaborators, flows into a series of state-of-the-art laboratories, fully equipped for research and analysis of every aspect of carbon-fibre and composite materials. But it is across the central hallway where you find what might be Carbon Nexus’s trump card: the carbon-fibre production lines. Situated in a cavernous room running the length of the building, the lines provide the capability to produce carbon-fibre entirely on-site. Spools of polyacrylonitrile (PAN – the precursor for carbon-fibre) are fed through ovens, furnaces, surface treatment and numerous other processes, emerging at the other end as super-fine strands of carbon-fibre. The lines allow the researchers at Carbon Nexus to alter any variable or configuration across the production process, manipulating the properties of the resultant fibres. “We would say there is nothing like this facility globally,” says AFFRIC’s Program Director, Ian Kett. “To have research capabilities sitting next to pilotscale production line capacity, with the capabilities, the state-of-the-art equipment and the researchers that we have here... there’s nothing like Carbon Nexus in the world. This is a real change that’s been driven through Deakin with support from our collaborators.” The freedom to move so seamlessly between laboratory and pilot production represents a huge advantage, and Carbon Nexus has an ambitious research program that addresses the fundamental challenges associated with manufacturing using carbon-fibre, in particular cost and time. Increasing the speed of the manufacturing of composite parts to meet production demands and compete with existing materials, such as aluminium, is a major challenge. Moreover, carbon-fibre production remains a costly business, both

46 |

AMT September 2014

in terms of power consumption, and in inputs such as nitrogen, needed within the furnaces. “We’ve got to look at reducing the costs of manufacturing,” says Kett. “Initial research on the innovative lines at Carbon Nexus is already indicating a substantial reduction in energy consumption, which accounts for around 30% of standard carbon-fibre production costs. This research will be vital for informing the design and operation of more efficient, full scale manufacturing plants.” “We also know the precursor itself accounts for about 50% of carbon-fibre production costs. We want to look into that more carefully in the future: Are there alternative precursors? Are there more cost-effective ways of producing precursor that will give us the same outputs?” There’s also a range of areas where Carbon Nexus is looking at how the material’s properties can be improved – to make it stronger, for example, or to make the fibres bond better with the resins with which composites are formed. Resin chemistry itself is a whole additional field of investigation that, according to Kett, requires further advancement to match the current capabilities of carbon-fibre. There are questions to be answered regarding how the supply of carbon-fibre and composites will meet demand if – as anticipated – its mainstream adoption continues. Manufacturing processes and technology are coming under close examination right through the entire production chain.

“We have the capacity at Carbon Nexus to assist industry to meet the challenges of the future and we want to push the boundaries. For every step of the process, there are research projects that can be developed and are being developed at Deakin to support local, national and international advancement.”

Engaging industry A key aspect of Carbon Nexus’ work is that it will be driven by industry, and the needs of industry. There will be an element of bluesky research, but the principal thrust of the facility’s research will be aimed at solving real-world problems and developing realworld applications, devised in consultation and collaboration with industry partners. “Deakin prides itself on its engagement with industry and being industry-relevant,” says Kett. “Particularly for Carbon Nexus, what we do here has to be applied directly to industry, so it will be industry research that will drive this facility. We have industry partners that are now working with us – and that’s building – to solve real issues that can assist them to expand their operations.” According to Kett, more or less anyone in the world can work with Carbon Nexus and Deakin to advance the carbonfibre composites industry. Again, this is indicative of how unusual Carbon Nexus is. Most of the carbonisation lines in the world are manufacturing lines, and therefore fully occupied trying to meet demand for production of carbon-fibres. The few with capacity for research do not extend the same open-access invitation to industry

Composites as Carbon Nexus. The open, collaborative nature of the venture also represents a break from the way in which carbon-fibre technology has developed, where a diffuse field of individual companies and research entities have generally been reluctant to share information, each undertaking R&D in relative isolation, protecting their own IP. “It really is quite revolutionary,” adds Kett. “In terms of being able to say to industry: ‘Here is a place that you could come and work with us to assist you to move forward’.”

A re-emerging hub Fibres of one sort or other have long been woven into Geelong’s history. The city’s first phase of growth came in the 1840s, when it emerged as a key processing hub and export port for the burgeoning wool trade in south-west Victoria. The boom years of the Gold Rush preceded the city’s transition into a major industrial centre. However, a protracted decline in manufacturing has accelerated in recent years, with the Alcoa and Ford plant closures casting long shadows over the local economy. Now, the hope is that Carbon Nexus will help to usher in a new chapter in Geelong’s evolution as a manufacturing hub. “What we’ve always intended is that this facility will be a catalyst for broader industry development. The vision is about this being part of a new wave of manufacturing development in Australia,” says Kett. “The dilemma for us, with the changes in the industry here with Ford and Alcoa and so on, is the lag time for this industry to develop. I wish we were five or ten years further down the track. The speed of development is the big thing for us. An issue which concerns us is how fast we can grow this industry.” Deakin has indeed moved quickly in establishing Carbon Nexus. Contracts with the Federal and State Governments were only signed in 2010 agreeing to the development, and going from that

to having a fully operational facility in the space of four years is undeniably impressive. This is particularly the case since the carbonisation lines comprise an array of highly specialised equipment that has hardly been bought off the shelf.

itself, is Carbon Revolution. A private company formed from an R&D joint venture with Deakin, Carbon Revolution has been making headlines with its award-winning ‘one-piece’ carbon-fibre car wheels, and is hoping to create 150 jobs by 2016.

“Industry can’t believe that,” says Kett. “We’ve had global, significant players coming in and they’ve just been blown away: that we’ve succeeded and built the facility, but also that we’ve installed and fully operationalised two carbon-fibre lines in the timeframe. They’re astounded because this rate of development is pretty unique. Our credibility with industry has gone from ‘That’s good. We’ll see how you go’ to ‘We want to work with you because we’re impressed at what you’re doing’ It’s an example of Australian ingenuity.”

Meanwhile, DowAksa, a joint venture between Dow Chemical and Aksa, a fibre producer in Turkey, has had discussions with Carbon Nexus regarding a collaboration around research and increasing the supply of carbon-fibre. DowAksa is interested in establishing carbon-fibre manufacturing plants in strategic locations around the world, and serious talks are in progress regarding a plant in Geelong that could take advantage of being in proximity to such a world-class research facility.

The challenge now is ensuring that industry utilises the facility. Kett reports that interest is strong, with a number of projects already underway. The initial objective is to move quickly on ensuring that the facility is fully utilised with no down-time, allowing Carbon Nexus to begin building a track record and asserting its credibility with the industry. Carbon-fibre and composites are already having a huge impact in aerospace, and are now being embraced by automotive manufacturers such as BMW and Volkswagen. With possible applications ranging from wind turbines to computer keyboards, the potential is enormous. “We’re already seeing a substantial amount of interest from industry globally,” adds Kett. “Both about how they can work with us in research projects that might assist them in broader manufacturing, but also how Australian industry can develop in the carbon-fibre and composites domain.” Early indications are already looking good, with promising signs that Geelong may be poised to benefit from a new wave of innovation. Also based on the Waurn Ponds campus, not far from Carbon Nexus

If DowAksa, or another company, were to go ahead and set up a plant here, it would provide a further boost to the development of the carbon-fibre and composites industry in Australia. To help justify the establishment of a manufacturing plant, Carbon Nexus is focusing its efforts on building local demand and involvement in carbon-fibre composite development. Following an extensive global search, Deakin has now appointed a Director of Carbon Nexus, Derek Buckmaster, to ensure the new facility realises its full potential. “A carbon-fibre manufacturer setting up in Australia, hopefully in Geelong, would be another major step forward in terms of building that industry,” says Kett. “If you’ve got a supply base here, that will automatically support a range of other companies and industries. “Certainly for Australia, we have an opportunity here. We’re at the forefront in terms of international development with this research facility, and we need to ensure that we build the carbon-fibre composite industry around that. It is a new wave.” www.carbonnexus.com.au

AMT September 2014

| 47

Composites

Setting the stage for composites work By adding a five-axis waterjet/milling machine, its biggest autoclave and a more expansive lay-up room, US company Royal Engineered Composites (REC) has positioned itself to win larger-scale aerospace work. By Derek Korn. Based in Minden, Nebraska, REC has impressive composite production capabilities and has recently made significant strides to process larger-scale parts. Tim O’Dey, Engineering Manager, says the company was spurred to expand its capacity for this type of work a few years ago, sensing an upcoming need for suppliers of big composite aerospace components such as engine cowling sections and thrust-reverser systems. While the company had a wealth of experience manufacturing smaller composite components, its existing production capabilities simply couldn’t accommodate work of that magnitude. Given its vertically integrated approach, scaling up its process would require a considerable investment in a number of areas to keep complete composite manufacturing capabilities in-house. In a bold move, REC has now completed the first of three planned facility expansions. This first expansion increased its total floor space to 7620 sq.m with a high-bay building addition that includes a larger composite lay-up clean room, its sixth and biggest autoclave, and a combined five-axis waterjet/milling machine for final trimming and drilling operations. What’s particularly impressive is that the company made these investments without having orders in hand for the type of large-sized production work it believes will come.

Large additions REC began as Royal Plastic in 1949, specialising in plastics thermoforming. It changed its name in 2010 because its focus has shifted to structural composite components, primarily for aerospace parts such as thrust-reverser doors, sandwich panel components, fairings and radomes. Typically, the manufacturing process for a composite component starts by CNC-cutting individual composite plies that are kitted and delivered to a clean room for hand lay-up in moulds. Some of REC’s clean rooms have laser projectors installed in their ceilings that precisely project a laser outline onto lay-up moulds to show workers where individual plies are to be positioned. Once lay-up is complete, the component is placed in a Mylar bag and delivered to an autoclave, which applies heat and pressure in a nitrogen-filled environment to cure the component. Once curing is complete, the component is removed from the bag, its periphery is trimmed, and holes might be drilled, depending on the application. Some customers ask REC to perform component assembly while others prefer to assemble components themselves. Every element of this manufacturing process needed to be supersized in order for the company to accommodate the larger work it envisions. For instance, its new autoclave from ASC Process Systems is significantly bigger than the shop’s five other autoclaves. Installed in late 2013, the unit is 3.6m in diameter and 9m long. O’Dey says it is the largest ASC autoclave that can be installed in a facility without needing to be built on site. REC’s formerly largest autoclave measured 2.4m x 4.8m. Not only will the new autoclave be used to cure larger parts, but it will be able to handle a greater number of smaller parts per curing cycle than the shop’s other units. It has many more vacuum and thermocouple ports to enable that, as well as a safety system that completely purges the nitrogen from the unit before the door can be opened. Otherwise, the significant volume of nitrogen that would escape could cause anyone standing nearby to pass out. In the past, REC performed trimming, drilling and countersinking work on CNC routers or conventional machine tools. To accommodate larger parts, the company added a composites machining centre (CMC) from Flow Aerospace Systems that

48 |

AMT September 2014

The composites machining centre (CMC) from Flow Aerospace Systems features both five-axis waterjet and milling capabilities.

performs both five-axis waterjet cutting and conventional milling, and offers XYZ travels measuring 6.4m x 2.5m x 1m Based on a design that originated in 1991, this CMC is a gantrystyle machine with dual five-axis waterjet and milling spindle heads. Mark Saberton, Chief Engineer for Flow, says this unit is the first of its Size B models to be installed in the US, boasting a number of design improvements over past models. For instance, Flow used advanced finite element analysis capabilities to remove weight from the structure while maintaining rigidity and increasing speed. Digital servos on machine axes have helped increase speed as well as positioning accuracy, while the refined, Catia-based FlowTrim programming software enables offline simulation to detect possible collisions prior to cutting. The Size B version also features a modular design that enables additional X-axis rails to be added to extend longitudinal travel. The foundation REC created for the CMC allows for those additions to be made without additional excavation if the company chooses to do so in the future. The CMC is also set up to easily add Flow’s Flexible Header System. This reconfigurable fixturing system has multiple actuators that can be raised to different Z-axis heights to accommodate contoured components, each using vacuum cups to secure components during machining. This system could replace or minimise the need for traditional vacuum fixtures.

Waterjet or conventional cutting? O’Dey says REC was drawn to high-pressure abrasive waterjet cutting because it offers specific advantages for machining composite materials such as carbon-fibre reinforced plastic (CFRP), Kevlar and quartz-epoxy composite. Garnet-abrasive media serve as a waterjet stream’s ‘cutting edges’. Because fresh media is continually introduced into the stream, its cutting edges are always sharp, whereas conventional routing and drill bits can wear, possibly resulting in delamination or burred edge finishes. Worn tools can also introduce heat into the part, which is problematic because composite materials are particularly poor at dissipating heat. No sizeable chip is generated to carry the heat away from the low-thermal-conductive material, so heat build-up poses the danger of burning the resin. In addition, the cutting forces for waterjet machining are onetenth or less than conventional machining meaning fixtures for components machined via waterjet need not be as bulky as those required for conventional milling. Managing dust isn’t an issue with waterjet, unlike conventional milling operations for composites.

Composites

Phillip Gill, REC’s president, observes a waterjet trimming process.

The autoclave from ASC Process Systems.

The CMC’s waterjet head differs from those used on typical waterjet equipment. Conventional machines have a tank of water under their cutting bed grates to absorb the waterjet stream after it pierces through a workpiece. Conversely, the CMC has no water tank, but a solid steel bed that’s flush with the shop floor. Its waterjet head includes a C-shaped “catcher cup” to receive the jet after it shoots through a workpiece. The catcher cup collects machining waste and vacuums it into a separating filter. It also prevents the jet from unintentionally cutting through other areas of the workpiece or injuring shopfloor personnel. The catcher cup must be taken into consideration when designing waterjet fixturing, which must provide access on the rear of the workpiece to leave room for it. That said, there are applications in which only a portion of the workpiece can be machined via waterjet due to interference with the cup. In those cases, work must be completed using the CMC’s milling head. High power and torque is generally not needed for machining composite materials, so REC’s CMC milling head features an 8hp, 25,000rpm spindle. The company has found running between 7,500rpm and 8,000 rpm particularly effective for routing/trimming operations on most composites. Balanced, HSK 40A shrink-fit toolholders are used to minimise tool run-out. REC initially used balanced, collet-style toolholders, but the cutters would wear nonuniformly. The company has eliminated that problem by switching to shrink-fit toolholders. REC has had success using tools such as ten-flute CVD-diamondcoated routing bits from Crystallume for trimming operations. Sharp cutting edges combined with an abrasion-resistant diamond coating enable these tools to effectively shear through composite fibres to leave behind a quality edge finish while achieving long life. Because most composite workpieces are relatively thin, the company will routinely alter the depth that a tool reaches through a workpiece to get the most out of the available flute length. The CMC also includes a 12-station toolchanger. During tool changes, filtered air blasts through the spindle and out of the toolchanger to keep contaminants out of the spindle. A new system Flow developed helps manage the dust created during milling. Rather than using a vacuum-based evacuation system, the new design combines cool air and mist delivery to contain the dust. The proprietary system generates a collimated stream of cold air

The CMC’s milling spindle uses balanced, HSK 40A shrink-fit toolholders to minimise tool run-out.

that is delivered to the tool (not through it). Unlike coolant alone, the cold-air stream is able to penetrate what is effectively an air barrier that surrounds tools running at high rpms. This enables the plume of mist to knock down the dust to subsequently be hosed off the machine bed. The system also cools the tool and the workpiece.

Future plans REC still faces a learning curve with the CMC in terms of optimising fixture design. The company might also upgrade the machine’s probing capability. The current probing package is used to accurately locate fixtures on the machine’s bed during set-ups. This is done by probing various locating balls that are machined into fixtures. However, REC might upgrade the package to enable in-process measurement. This would be particularly helpful to verify that countersinking operations for rivet-assembly holes reach their specified depth and don’t protrude above a component’s surface, causing drag during flight. O’Dey envisions adding a crane in the new building addition to more easily transport and install large fixtures onto the CMC. The company may also soon begin using iPads or other tablets on the shop floor in an effort to go paperless and ensure that necessary job information is readily available to shopfloor personnel. www.royalcomposites.com Reprinted courtesy of MMSOnline.

ALUMINIUM ROLLED & EXTRUDED PRODUCTS For enquires please call (02) 9757 7777

Plate – Round, Square & Flat Bars – Sheet – Tread Plate

WATER JET CUTTING & CUT TO SIZE AMT September 2014

| 49

Composites

Aerospace engineering flies ahead at UQ Australian breakthroughs in techniques for welding composite materials are changing the future of aerospace engineering by cutting time and costs. University of Queensland PhD student Luigi Vandi has worked on a new process that allows carbon-epoxy composite materials to be welded by incorporating a thin layer of weldable material during the manufacturing process.

composite materials – and consequently the cost,” adds Vandi. “Using this process, welding composite materials takes only 15 minutes, compared to a typical two-hour process for conventional adhesive bonding methods.”

“Composite materials have become the material of choice for modern aircraft structures,” says Vandi. “More than 50% of the new Airbus A350XWB structure, including the fuselage and wings, is made from composite materials.”

According to Vandi, his research involved unravelling the molecular mechanisms at the interface between the composite and the weldable material. Understanding the molecular process ensured the technology could be safely implemented in aircraft engineering and construction.

Airbus is one of the partners in the CoOperative Research Centre for Advanced Composite Structures (CRC-ACS), which developed and patented the ‘Thermoset Composite Welding’ technique for implementation in aircraft construction. Vandi, whose work is refining the technique, says that unlike metals, carbon-epoxy materials normally could not be welded, making assembly ‘challenging’. “This new process can significantly reduce the assembly time for aircraft made from

“Aircraft manufacturers increasingly are using composites to help make their planes lighter, more fuel efficient and more comfortable for passengers,” he says. “Composites offer significant advantages over metal, as they are not susceptible to fatigue and corrosion, and because they are reinforced with fibre, they rarely develop large cracks.” Vandi believes the new welding technique had the potential to save billions of dollars in

coming decades for airline manufacturers, which could then make new aircraft cheaper to buy, and reduce air travel costs for passengers. The CRC-ACS, the UQ Composites Group’s research partner, is a company funded by industry partners and the Australian Government, and works to advance composites technology in Australia and around the world. Over its 22-year history, the CRC-ACS has been recognised worldwide as Australia’s foremost research and development centre in advanced composites. It has won awards for its success in technology development and implementation across market sectors – ranging from aerospace to oil and gas. The 24 participants in the CRC-ACS include leading universities, major international businesses and smallto-medium enterprises from Australia and six other countries. www.uq.edu.au www.crc-acs.com.au

Composite ‘top hat’ protects Silent ANZAC submarine The conning tower hatch of the World War I Australian submarine HMAS AE2 (the “Silent ANZAC”) was opened for the first time in 100 years in June, thanks to a special composite ‘top hat’ developed by Australian advanced composites specialist RPC Technologies. The wreck of the Silent ANZAC is intact, sitting upright in 73m of water in the Sea of Marmara, where it was sunk in battle on 30 April 1915. Advanced composite manufacturer RPC lent its expertise to develop the secure top hat that was placed over the open conning tower hatch, as part of an initiative of the AE2 Commemorative Foundation. RPC undertook the work on pro bono, with the design, specialist fabrication and manufacturing undertaken at its facility in Corio, Victoria. The top hat, designed by RPC and manufactured in glass reinforced plastic (GRP), fits over the open conning tower hatch to prevent unauthorised entry to the submarine. The hatch had to be strong, light and securable to prevent unauthorised entry. It also had to have exceptional anticorrosion properties to contend with both the rigours and sensitivities of the marine environment. RPC Executive John O’Brien points to the “impressive strength-to-weight characteristics of composite materials” that made GRP a natural choice for the hatch. GRP also offered the lifelong corrosion resistance needed in an underwater

50 |

AMT September 2014

The ‘top hat’ before it was put into place

The ‘top hat’ in place on the submarine

environment as well the strength to properly secure the vessel from unauthorised entry.

creatures. O’Brien co-ordinated the project on behalf of RPC, with Zegir designing the hatch. It was crafted by RPC employees Floro Cabanban with support from Dave Byrnes and Bill Jones at the Corio facility. RPC’s 40 years’ experience in advanced manufacturing for water infrastructure, passenger rail and the Australian defence industries were also drawn upon to develop a simple yet effective design.

“Composite materials like GRP give us the ability to produce complex shapes to enable multiple components to be moulded into one part, which also helps to save on weight and helps reduce manufacturing costs”, says RPC’s Technical Manager James Zegir. “We are fortunate as a company to have some of the world’s leading composite engineers to draw upon when faced with design challenges like the top hat.” There were also special design requirements to shape and provide slots within the new hatch to allow for normal water current flow and to provide unimpeded access for marine

The Silent ANZAC project has been an extraordinarily successful collaboration of experts, all of whom were volunteers drawn from Australia, the US and Turkey. www.rpctechnologies.com

Composites

Machining composites like cutting butter Researchers at Loughborough University in the UK have developed a device that could revolutionise the cutting, drilling and milling of composites. The tool makes working on difficult-to-cut materials like aerospacegrade composites so easy it is like ‘cutting through butter’. It involves a technique called ultrasonically-assisted machining (UAM), which uses a specially designed piezoelectric transducer working in tandem with a traditional turning, drilling or milling machine. The device creates ultrasonic vibrations at 20k-39kHz, which softens the area of the composite material being worked on that much less force is needed from the cutting tool, resulting in less damage, less waste, and a better finish.

machining of brittle composites can damage the composite material. The challenge is to minimise this and, if possible, completely eliminate damage due to drilling. Ultrasonic drilling has shown excellent damage mitigation with remarkable drilling force reductions.”

UAM is the brainchild of Professor Vladimir Babitsky, from the Wolfson School of Mechanical and Manufacturing Engineering, and has been developed extensively in the last few years with the support of Dr Anish Roy and Professor Vadim Silberschmidt..

Recent work by Vaibhav Phadnis and Farrukh Makhdum has also been instrumental in tackling the challenging task of drilling in carbon/epoxy composites. Vaibhav worked on composites and believes that when the device has been perfected for other materials like Ni-alloys, it will be a major boost for manufacturers.

“We ought to be looking for better, economically efficient and sustainable manufacturing methods in the immediate to near future,” Dr Anish Roy says Dr Roy. “UAM could well be the answer to this. The technique has been successful in the laboratory where multi-fold improvements in cutting intractable aerospace alloys have been demonstrated. “Ultrasonically assisted drilling has shown significant improvements in drilling carbon/epoxy composites with significantly reduced damage in the machined composite. This is particularly interesting, as any kind of

The technique is currently being extended into biomedical applications such as drilling holes in bones for orthopaedic surgery. Also, preliminary studies in drilling tiny holes in printed circuit boards show excellent potential for component assembly that require high precision.

Vaibhav, who has been working with Airbus, says the ease of set-up, usage and cost-friendliness of the technology makes it a perfect candidate for future manufacturing processes. The technique is currently being extended into biomedical applications such as drilling holes in bones for orthopaedic surgery. Also, preliminary studies in drilling tiny holes in printed circuit boards show excellent potential for component assembly that require high precision. www.lboro.ac.uk

AMT September 2014

| 51

Material Removal

Masport’s new Okuma “a step up” When a monster truck shares the road with a small passenger car, the car driver usually prefers to be pretty sure the truck’s parts were well built and left the factory functioning perfectly – especially the brake system. Chances are Auckland-based Masport Foundries played a part in ensuring those crucial truck brake systems will do what they must. By Jenny Pretorius. Masport recently boosted its workshop’s capacity by acquiring a state-of-the-art Okuma VTM65 vertical lathe (VTL) machine, having signed contracts with three prominent global truck builders to manufacture brake drum and hub subassembly units. The units will be exported to be used on Kenworth and Paccar’s assembly lines in Bayswater, Melbourne, and Volvo’s truck plant Brisbane. Formed in 1911, Masport is New Zealand’s largest metal casting production plant. Employing around 100 people at its Mount Wellington plant, the foundry manufactures high-integrity iron castings. Each of these castings requires close monitoring to ensure dimensional accuracy and adherence to the metal’s tight metallurgical properties. Masport has Telarc accreditation in ISO 9001 and ISO 14001 management systems. The company supplies a wide range of castings and manufactured products into the agricultural, automotive, structural and mineral processing industries, as well as consumer durables, including for Masport-branded solid fuel heaters. More than 90% of the products manufactured are exported to customers in Australia, India, China, Brazil, South Africa and the US. Masport has extensive and flexible machining capability, with ten CNC machining centres. It specialises in finish-machined automotive cylinder heads, brake drums, hubs and rotors for truck and auto OEMs and aftermarket sectors. Specialist rock crushing machine spares are another niche market, such as tungsten carbide/iron composite wear parts. The foundry uses a high-speed Disa Forma green sand moulding system, high-efficiency electric furnaces, and both shell and coldbox core making. In-house tooling manufacture and heat-treatment furnaces as well as the latest model spectrographic alloy analyser round out the foundry’s equipment. Magmasoft solidification simulation software is available for special projects. Masport’s General Manager Wolf Schmahl says the company’s engineers had worked with an Okuma on loan from a sister company before and knew the efficiencies that the brand offers were an exact match with what the new production model required. “We sat down with Okuma’s Fred de Jong, and he and his team advised us of our options,” says Schmahl. “Okuma is known to be a market leader in all respects, the Rolls Royce of machining centres. We got what we paid for – reliable plant with impeccable workmanship, focused assistance before, throughout and after the sale, a company who kept us appraised and on whose promises we could rely. Even considering Masport is a successful company with an established reputation for excellence, the Okuma is a step up.” Schmahl explains that, when making the variety of hub, brake drum and brake rotor castings for light and heavy trucks and trailer applications Masport supplies to the market, dimensional accuracy and very tight tolerances must be achieved. “Our older CNC lathes did not always deliver these specs reliably,” says Schmahl. “The new Okuma VTM65 VTL significantly improves our ability to deliver these tolerances while being able to machine large and heavy hubs and drums, some of which require interrupted cutting and are balanced following assembly.” According to de Jong, the VTM65 was an obvious superior solution when considering Masport’s particular requirements for machining larger diameter and quite deep truck brake drums. “The VTM-65 has all the features of a vertical lathe but has the distinct advantage of a single tool mount turret with 36- or 60-tool

52 |

AMT September 2014

Masport’s general manager Wolf Schmahl with the new Okuma VTM65 machine.

auto tool changer (ATC), which means the issue of interference from adjacent turret mounted tools is completely eliminated,” says de Jong. “In addition, the VTM65 arrangement has highly rigid milling, drilling and tapping capability using standard BT50 taper rotating tools. Turning tools are also BT50 taper mounted via the ATC and are unique so the machine knows to clamp the spindle rigidly with a curvic coupling arrangement to orient it correctly, which results in high accuracy and repeatable turning performance, even with intermittent cutting.” Reflecting on the Okuma machines that the Tiri group of companies, to which Masport belongs, have purchased in the past, de Jong says that he is pleased to see that the group has once again found good justification to invest in a higher-quality, longer-term Okuma solution for this project. He believes vertical lathes are not considered often enough in the New Zealand market. “VTLs typically have high rigidity and are easier to load work pieces into, with gravity being helpful rather than a problem,” says de Jong. “VTLs also tend to have a smaller foot print than typical horizontal lathes and because of their simplicity of design tend to be slightly lower cost.” Okuma produces the full range of VTLs and vertical multi-tasking machines, as previously built by the Japanese Okuma & Howa. The VTM series offers turning diameters ranging from 650mm to 2000mm, and respective swing diameters of 750mm to 2400mm. “Now that these machines are all in the Okuma stable they can be offered with either Fanuc or Okuma OSP controls, which gives the customer even more choice,” says de Jong. “For additional flexibility of five-axis capability the VTM-YB series offers some really good solutions as well.” www.masportfoundries.co.nz www.okumaaustralia.com.au

AMT proudly owned and published by AMTIL

Visibility. Opportunity. Success. AMT – your No 1 industry-trusted magazine. • • • •

Expose your business to the right market Instill effective brand awareness Target the key decision makers Grow your business

96% of readers surveyed found advertising in AMT extremely useful in sourcing products

For further information and advertising rates call Anne Samuelsson at AMTIL on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

Your Industry. Your Magazine.

1166(B)AMT

Material Removal

Milling down to the micron Splitting the micron remains something that has only ever been achieved by ultra-high precision machines in laboratory conditions. However, Röders is taking giant steps in the right direction. By Harald Klieber. In 1800, tin casting was what counted in Soltau, north-west Germany. Ultra-high precision machining – in steps of one tenth of a micron – was surely something that Jasper Röders never imagined when he founded his company. Today, under current Managing Director Jürgen Röders (Jasper’s great-great-great-grandson), the company is Soltau’s largest industrial employer with 340 employees, 38 trainees and another 450 employees worldwide, and the outlook is good. “We have grown about 30% during the last year,” says Röders, attributing this primarily to the quality of his machine tools. Further expansion is planned, with the company’s state-of-the-art air-conditioned production facilities set to increase its footprint from 5000sqm to 8000sqm. The development department, however, is to remain in the founding premises in the heart of Soltau. Röders only began to build its own highspeed cutting (HSC) machines about 25 years ago. “Even the first machines in 1991 were equipped with our own control units,” says Röders. “For me, that was and still is the key to business success and to even more precise machines that can produce still better surfaces and contours.” Röders has already sold more than 2000 machines, with more than 150 delivered per year. The emphasis is therefore the 85% share of sales for machine tool construction, which puts it well ahead of the company’s second mainstay: mould manufacturing for PET bottles, of which Röders produces around 5000 moulds annually as a service provider “Not too long ago, the ratio was still two to one,” Röders adds. “But since mechanical engineering is developing so well, we naturally need to think bigger: not only in terms of capacity, but also our equipment. Last year we upgraded our measurement technology by purchasing a Zeiss Prismo ultra, with which we are now able to measure with micron accuracy.” Röders explains that the manufacturer currently only guarantees an accuracy of two microns. However, due to the air conditioning of the assembly hall, microns can be definitely and reproducibly documented. “This portal measuring machine already enables very fine measurements,” Röders says. “When needed, we can measure with a 0.5mm probe, with a needle, that is, which we can then probe with a minimum adjustable four grams of pressure.”

54 |

AMT September 2014

The Röders RHP 800 machining centre.

The pivotal point: 32kHz control Length-measuring systems with a fourmicron pitch, instead of the conventional 20 microns, have become standard for Röders HSC machines. The same applies to the patented vacuum counterbalance for the linear, extremely stiffened Z-axis with four guide rails and Y slides bolted to form a triangle. It also is the case for the company’s in-house-developed control and regulation technology. “The trick is to control the slow-moving axes as well as possible,” says Röders. “The focal point in this is our in-house-developed 32kHz servo control.”

“As a machine manufacturer you must master the whole repertoire, be able to handle the frequencies and know filtering options,” says Röders. “Without extensive knowledge, real precision is not feasible. We have been working in this area for 20 years. We now have 20 developers who use their skills to advance the programming and design of the control systems, including cards and software, compensation, axis planning as well as the software for any necessary automation.”

Its clock frequency is crucial. This is vital for minimising the position deviation, thus ultimately achieving increased dynamic path accuracies, as Röders explains. “The other controls available on the market usually provide only 10kHz. Thanks to our significantly higher frequency, the control gets feedback in the worst case on a milling process malfunction much earlier, for example after 0.03ms instead of after 0.10ms.” That, according to Röders, is clearly noticeable already at the surface contours. Ballscrews would, however, dampen all this away. But linear motors do have their weaknesses. Their natural frequencies are not insignificant factors to be reckoned with when it comes to precision and surface quality.

Jürgen Röders.

Material Removal

The hydrostatic machine bed base minimises friction, saving energy.

maximum smoothness, since the axes virtually run by themselves thanks to their oil bearings,” he says. “This minimised friction is of course ideal for jig grinding, since less friction resistance obviously means less energy expenditure, power and heat.”

Röders therefore places a lot of focus on the synchronisation of dynamic axes. “Nowadays you can no longer excel in machine construction by offering a broad range of production,” says Röders. “That is why most of our mechanical parts are designed by us but manufactured externally according to our specifications. In this way, we can pick the best suppliers of mechanical components, spindles, measuring and cooling systems. These days, the decisive factors are the electronics and the adjustment and compensation of the drive components and axes – in an airconditioned assembly process. Only in this way can maximum precision and optimal surfaces be achieved.” Nevertheless, Röders optimides the machine parts, the frame and the individual axes of his machine tools for maximum dynamic performance, precision and rigidity. Two years ago, Röders presented significant improvements with the RXU series and the Quadroguide concept. Here, the Y-slide of the five-axis RXU portal machining centres was connected with the portal on a large surface via eight additional carriages arranged in a rectangular pattern. All axes were equipped with linear or torque drives, high-resolution optical encoders while the Z axes received an even stiffer, square crosssection and four guide rails along the corner edges.

showing that the previous model RXP1200 reacted to a deformation when roughing with a deflection of 0.06mm, while the new Quadroguide concept in the RXU1200 allowed no more than 0.02mm. “This proves that the RXU series offers the ideal basis as a machine for large roughing efficiency in hardened steel or hard to machine materials, but also for jig grinding,” explains Röders. “For this, we integrate either very strong or very fast spindles with up to 67Nm in S1 or 60,000rpm.” The new RXU 1400 also offers 1,400mm travel in X, 1,050 in Y, and 600mm in Z, an A-axis and C-axis, and the ability to machine workpieces weighing three tons. The machines are completed with spindles by Kessler or Fischer, which have multiple cooling circuits. “We offer many of other cooling circuits for our machines as an option,” says Röders, who emphatically recommends cooling the track guides. “Some manufacturers only cool the environment. Our cooling circuit, however, runs directly through the screwedon guide rail. No other manufacturer does this, even though it results in eight microns less deviation.”

Mill first, then grind

“In this way we can significantly improve the power transmission to our 30-ton machine frames. Specifically, the rigidity of the Z axis is tripled.”

For jig grinding, Röders now offers three machine designs: the three- and five-axis RXU and RXP machining centres based on linear direct drives and roller guides. There is also the three-axis RHP machine concept, which Röders expects will offer significant precision benefits.

A finite element method (FEM) analysis provided Röders with proof in numbers by

“In particular, the hydrostatic guides reduce friction to a great degree and result in

Consequently, on Röders’ standard machines, accuracies of less than one micron and surface accuracies of below 0.01 microns can be manufactured without any problems. The great advantage is, as Röders points out, that his very precise standard machines can already feed very accurately. “Milling cutters need chip volume,” Röders adds. “A few hundredths of a millimetre at a minimum. So we start by cutting the contour up to an oversize of about 20 microns. We grind the rest with mounted points in up to 30 cycles, including some final cycles with no feed, which only serve to compensate the elasticity of the grinding tool. “The mounted points oscillate by an upward and downward movement of the Z-axis while rotating at up to 60,000rpm. Depending on the temperature and the equipment, you can feed in one or two microns, thus being able to finish wonderful surfaces and contours in a single clamping on one machine with the highest precision. This is much faster than having to grind allowances of a few hundredths as with other machine concepts.” Röders makes the case for a mill-first-thengrind-and-finish strategy. “Our machines really turn out the parts. Grinding is limited to the absolute minimum.” An additional plus for contour accuracy is provided by dressing and measuring the mounted point on the machine – and again before the final grinding cycles if this is required by the processing. For jig grinding, Röders recommends cooling the guide rails. “With up to 300 strokes per minute, the Z-axis naturally heats up and expands in the X direction by up to eight microns. Due to the temperature control of the Z-guides, we can limit this expansion to less than one micron.” www.roeders.de sales@thornhill.com.au AMT September 2014

| 55

Software

CELOS – From idea to finished product First unveiled last September at the EMO exhibition in Hannover, Germany, the new CELOS controller from DMG MORI improves the profitability of manufacturing operations and the entire corporate process chain. A total of 24 world premieres in 2014 attests to the status of DMG MORI as a global leader in machine tool innovation. In addition to joint product innovations such as the Milltap700, the company’s development work increasingly focuses on the optimisation of customer processes. In this context, its new CELOS controller marks a turning point for many companies. At its launch at EMO last year, CELOS was received with great interest and contributed to a record number of sales for DMG MORI at the event.

apps via the App Menu with colour coding to simplify the classifications. All apps are broken down into five different groups consisting of:

“We are excited to see the global alliance between DMG and MORI generating direct customer benefits, on a product level as well as on a software level,” says Matthias Koch, Managing Director of DMG MORI Australia. “CELOS simplifies and accelerates the process from the idea to the finished product. It improves the profitability of manufacturing as well as the entire corporate process chain.”

Of crucial additional benefit to the customer are the key CELOS apps like Status Monitor, Job Manager or Job Assistant.

CELOS provides the user with integrated and digitised management, documentation and visualisation of order, process and machine data. Moreover, CELOS is compatible with production planning and scheduling (PPS) and enterprise resource planning (ERP) systems, it can be networked with CAD/CAM applications, and is ready for future-oriented CELOS app extensions. CELOS is available for all new DMG MORI high-tech machines, with the clear layout and intuitive operation of Siemens Sinumerik 840D solution-line or Mitsubishi MAPPS V via a multi-touch operating panel for pioneering operating comfort and unique functionality. According to Koch, the first customer deliveries in Australia will be made from beginning of 2015. “Our customers have the flexibility to choose between the classic control and the CELOS version,” adds Koch. “We will present our first ‘CELOS machine’ at our Melbourne Technology Center in January 2015.” At first glance, CELOS provides the user with a standardised user interface with touch functionality. However, CELOS is much more than that, with many more capabilities. It is focused on a more userfriendly design, featuring a 21.5-inch ERGOline Control with multi-touch screen and icon-supported, gesture-driven user interface. Customised user authorisation is provided by the SMARTkey, allowing individually adapted access privileges to the control system and machine. Similar to a smart phone or tablet PC, the user has direct access to all available

56 |

AMT September 2014

• Production: Job Manager, Job Assistant, Control. • Accessories: CAD-CAM View, Tech Calculator, Documents, Organiser. • Support: NetService, Machine Check. • Configuration: Energy Saving, Settings. • Machine Views: Status Monitor.

Status Monitor is the starting point for the interaction between operator and machine. Here, CELOS visualises the current status of the machine with regard to the process, important key performance indicators on the current order and on the order progress, and notifies the operator with special icons as well as text messages about any errors or upcoming maintenance work. Job Manager and Job Assistant support the operator on the machine with regard to network-integrated planning, preparing, optimising and systematic processing of new machining jobs. First of all, all manufacturing-relevant data for the NC program, workpiece, tools, clamping devices and so on can be combined to a machining job and instantly visualised with the Job Manager. The documents, data and information required for an order can also be managed in a structured way. The data are quickly available during later processing or for a recurring order. With Job Assistant, the digitally processed orders can then be systematically filed at a later stage. In this process, first of all the availability of all NC programs and equipment (tools, devices, etc.) required

for machining is checked. The operator is then guided by a dialog through the set-up process and preparation of the machining job. Respective queries and necessary confirmations ensure that the worker makes no mistakes. Only then, machining is approved. This ensures a high degree of machining reliability even for complex orders or complicated components. CELOS combines the production perspective with corporate structures, and thus forms the basis for a paperfree production process. It is targeted to increase the efficiency by 30% from the idea to the finished product by reducing interfaces between workshop and parent company structures and is therefore applicable for various companies from small general engineering job-shops to large corporations. You can experience a live demonstration of CELOS by contacting DMG MORI to register your interest. www.dmgmori.com

Software

Five trends that will shape the future of ERP Businesses today are required to deal with technological advancements occurring at a pace never experienced before. Moreover, trends like the consumerisation of IT have lessened the ability to regulate which technologies are used alongside the corporate network. By Rob Stummer, Managing Director, IFS Australia and New Zealand. As trends like Bring Your Own Device (BYOD) continue to make an impact, it is important that the IT department embraces new technologies for a number of reasons. Aside from missing out on any potential benefits, being too proscriptive regarding the technology employees can use risks the emergence of shadow IT; when IT solutions are built or adopted without explicit organisational approval. Enterprise resource planning (ERP) in particular has a lot to gain from adopting an open approach to new innovations. Here are the five technology trends that have the potential to shape the future of ERP, if implemented correctly:

1. The Internet of Things The Internet of Things (IoT) is a concept that provides objects, such as cars and electrical appliances, with the capacity to transfer data over a network without requiring human interaction. In the case of ERP, devices are available that can be attached to tools and even vehicles, feeding data back to applications hosted in the cloud. Information such as location, usage and performance can then be easily accessed, allowing organisations to identify issues like where unused assets are, or if maintenance is required.

2. Wearable technology Gartner has predicted that the wearable technology market will be worth $10bn by 2016. While much of the attention generated by wearables has focused on consumer propositions like fitness trackers,

4. The age of context

there are also a host of applications in the workplace. Augmented Reality-enabled glasses like Google Glass will enable hands-free operations, which can be of great benefit for many blue collar workers. Even smart watches represent a step forward compared to PDAs and smartphones, since they are more easily accessible and less likely to be misplaced or dropped. Devices designed to monitor external factors like UV exposure or heat can help improve management of employee health. For example, IFS Labs has created a proof-of-concept that shows how users of business applications can benefit from wearable technology.

3. Big data analytics Organisations have become more dependent on IT and, as a result, they have accumulated a wealth of data that has been traditionally underutilised. As the IoT connects tools and employees to the internet, this data generation is set to grow exponentially. By employing analytical tools, organisations can begin to use this data to make accurate predictions that form the basis of a more intelligent approach to business strategy.

With businesses increasingly operating in a multichannel world, using technology that understands the situation you’re in, what information you would like to see, and how you would like to see it, will begin to have a real impact on performance. PCs and mobile apps will increasingly integrate context-aware functionality to anticipate user needs and improve the efficiency of day-to-day tasks. For example, a field service engineer will automatically receive all the asset data, job instructions, customer relationship history as soon as they arrive at the repair site.

5. Opening business to innovation Over the next few years, technology like wearables, the IoT and big data analytics stand to reinvent business processes across many different industry sectors. Organisations need to keep an eye on technological advances, even those that may seem to be irrelevant. Recent developments have shown that solutions that first appeared to be designed for consumers are increasingly finding profitable applications within businesses. By taking an innovative approach to the adoption of technology, businesses stand to save time and increase productivity; results that will be reflected in the bottom line of enterprises that choose to embrace new technologies. Rob Stummer is the Managing Director, Australia and New Zealand, at IFS. www.ifsworld.com/en-au

The Standard in Solids Based Manufacturing

The realistic, high-performance CNC simulation Experience

• • • •

• Eliminate Prove out time and dry run testing at the machine • Verify & Simulate any G-code and Machine builder macros in a virtual environment • What you see is what you cut • Support of unlimited amount of Channels • Composites lay up simulation & collision checking • Mainstream CAM interfaces • Tool length Optimization • Toolpath Optimization (Reduce machining time from CAM output by 30%) • Review and Share 3D Simulation

• • • • • •

Mill-Turn (Multiple Turrets) 4 & 5 axis Simultaneous Machining Production Machining Solution Standalone CAM Solution for all Main stream CAD Systems Automatic Features Machining Mold & Die Cad to Cam Interoperability Waveform Roughing Strategies Reduced Programming Reduced machining time

M A N U FA C T U R I N G S O F T W A R E S O L U T I O N S www.gzerofive.com

AMT September 2014

| 57

Software

FEA: Saving time and costs Finite element analysis (FEA) allows product designers to proof their ideas without the high costs of making multiple physical models for destructive testing. According to Shigeaki ‘Steve’ Kinoshita, FEA Simulation Applications Engineer at CADspace, FEA can dramatically reduce costs because the costs of 3D design and analysis are dramatically less than those incurred once the development reaches the manufacturing stage. If you are not going to rely on FEA to fully test your design, the alternative is to make physical versions of every configuration until you get it right. “FEA enables us to shift the costs in the product cycle,” explains Kinoshita. “The traditional peak at the end is moved to the beginning, when more time is invested into the 3D CAD model and simulated analysis. Once the product has been verified, the appropriate tooling and manufacturing can be set up.” Some companies produce prototypes on their CNC machines and 3D printing has made this process easier. However, the process can still be costly and timeconsuming relative to utilising CAD and FEA software. Furthermore, FEA gives greater insight into the behaviour of the product, such as the various stress components experienced by the product. This insight empowers the product designer and engineer with tools to improve the design in the early stages. Although able to be used for testing, with standalone prototypes you may not be able to assess such parameters as easily. Kinoshita says the tradition of relying on manual calculations and sound engineering is still essential and can never be forgone. However, the market is demanding more innovative products, some of which are complex to solve manually. In such situations, FEA comes in very handy. If multiple test runs are required, analysis using manual calculations can be timeconsuming. Running a parametric study through SolidWorks Simulation would be a more efficient process. Kinoshita, who used FEA to conduct parametric studies for his PhD studies, says another benefit of FEA is that it enables the product designer and engineer to test a product design’s integrity. Using SolidWorks Simulation, the virtual 3D model can be subjected to extreme operating environments until it “breaks”. Fine-tuning of a design can be conducted within Simulation, reducing production and testing of prototypes. Trial and error in physical testing can lead to huge waste, adds Kinoshita. With the traditional design-to-manufacture cycle, costs can ‘blow out’ in the latter stages if flaws in the product design are not identified and resolved in the early stages of the cycle. Tooling and CNC machining are high-cost undertakings. If a conceptual part has to be changed numerous times those costs accumulate. “Outside of the research and development phase, I believe there is another benefit that SolidWorks Simulation offers to engineers,” adds Kinoshita. “That is when they have to present their concepts to non-engineering stakeholders such as corporate executives, investors or marketing and sales personnel. FEA is a highly visual tool and it can be used to prove the design, demonstrate its performance capabilities and verify the integrity of the product design to people who need more evidence than a standalone physical model.” At the end of the day, FEA is only as good as the person using it and Kinoshita says it is imperative to get professional training and acquire experience with the tool. “It’s no different to the first time you used SolidWorks CAD,” he says. “To get the most out of it, you were trained. Practice and usage than adds and hones the skills. SolidWorks Simulation is a highly complex computer simulation. At CADspace, we will train people to analyse a FEA model using Solidworks Simulation.

58 |

AMT September 2014

Conversion of real-life problem to a FEA model requires understanding of the problem, knowledge of FEA, and engineering judgment. The inputs will dictate your outputs. When used properly FEA has incredible benefits.” Kinoshita adds that validation of a FEA model is an important process in conducting simulation analysis that increases your confidence in your outputs. “I tell everyone to validate their FEA model if possible. For example, it might require starting out with an experiment with a parameter at one extreme then another experiment with a parameter at the opposing extreme. You can then conduct FEA within that parametric range and, having determined your boundaries, you can go on to test other configurations of the model in the same range. With experience and knowledge, analysis outside this range can be conducted.” Example of a validation may include comparison of strain results with field results obtained using strain gauges. Alternatively, you might determine a rather standard outcome using both computer and manual calculations and when they match you can then go to the FEA for more complex calculations. “This should give confidence with the workings of the FEA package,” adds. “Once you have determined your process the application becomes a powerful tool.” Combination field/test data with simulation is a very good practice and makes FEA a suitable tool in the design analysis. The model can be validated against strain gauge results and the FEA model used to obtain greater insight into the behaviour of the product. This includes finding regions of high mechanical or thermal stress. The design can then be adjusted accordingly to meet the requirement such as thickening its walls to increase its robustness. www.cadspace.com.au

Software

Managing increasing complexity The ever-increasing complexity of the world in which manufacturers operate means old-fashioned manual processes are no longer adequate. By Rob Barrow. Imagine a manufacturer’s customer service department that is faced with processing 80,000 lines of orders each month. These come through a bank of nine fax machines, which constantly churn out paperwork for the department’s staff to manually process. To comply with financial and customer service regulations, each document is filed after processing, then kept on-site for 18 months before it is sent to an off-site facility for seven years’ retention. This process is not only inefficient, but also adversely affects customer service. Why then, do so many organisations around the world, still rely on these laborious, manual processes for core business tasks?

Explosion of data While technology has made more data available to manufacturers than ever, it has also increased the stress of having to manage that data and turn it into useable information. Workers need to interpret information quickly and sort through large amounts of data to get to the facts required to make critical real-time business decisions. Moreover, with the advent of the Internet of Things and the rise of the connected enterprise, the amount of data that will be generated, processed and analysed will significantly increase, as well as leading to an increased demand for a new level of mobility in order to deliver information to the consumer anywhere, anytime. Consequently it is becoming increasingly difficult to process data into timely business decisions. In a global environment, distributed locations and systems can make it difficult for information to travel from one enterprise location to all other hubs that need it. Further, as the diversification of available data increases, management of this data is difficult as much of it is unstructured – that is, information that either does not have a predefined data model or is not organised in a pre-defined manner. Finally, the sheer volume of data required to run a global business can create problems for those employees within the business to find the information they need in a timely, contextualised manner.

key data cannot be easily accessed and managed. Complex paperwork in various languages, along with ad hoc processes region by region, can stagnate information flow and decision-making, making document retrieval slow and cumbersome. Finally, when information is not communicated clearly or not made available in a timely manner during key audit periods, providing the required documentation can be a daunting, costly task. Inconsistency of systems within a manufacturing organisation created through acquisitions or from autonomous groups not working together also creates a web of disparate systems such as financial, transportation and warehouse management systems that often cannot communicate with one another. Manufacturing, above all, is a process-driven industry that should thrive on the ability to work business operations to its advantage and meet customer needs more effectively. While many of the moving parts in global manufacturing cannot be controlled or managed, it is now the manufacturers’ responsibility to implement process and content management solutions, and potentially business automation, across the enterprise to bridge the information gaps between production and corporate environments, improving overall productivity and efficiency – and ultimately, customer satisfaction. Rob Barrow is the Regional Director for ANZ, Perceptive Software. www.perceptivesoftware.com

Supply chain complexity As businesses continue to expand their reach into new markets around the world, sharing information across multiple systems and vendors can slow processes, decreasing productivity and efficiency. For example, dealing with logistics in the industry can be an arduous process when document-driven processes are not connected, which is the case when workers have to contend with ‘siloed’ information systems that make it difficult to share. In addition, the sheer movement of materials and parts, not to mention the servicing of products in the global arena, add to the complexity. While some manufacturers have a good system for forward logistics – getting the product to market – most do not have a good process in place for reverse logistics, such as taking products back when they have been damaged and returned. Quite simply, gone are the days where the manufacturing plant is next door to headquarters, with shipping happening on the back dock.

Regulatory and compliance concerns Understanding the operational differences country to country is difficult enough for many manufacturers, with the continual challenge of managing government changes and span of control. Ongoing change worldwide creates compliance concerns and a mountain of paperwork, which can make it difficult for manufacturers to stay audit-ready. How are these trends affecting global manufacturers? The sheer amount of data flowing through an enterprise can paralyse an organisation as decisions cannot be made in a timely manner when AMT September 2014

| 59

Software

Met Optix opens for business Met Optix is a new Australian-owned business formed in early 2014 to promote, sell and support a wide range of metrology and testing products to the Australian and New Zealand market. Established as an operating division of DWE Systems, Met Optix aims to provide customers in Australasia with new choices and a wider selection of metrology and testing products than has been available in the past. With more options and an assurance of full back-up and support, Met Optix aims to give its customers the confidence that in dealing with them they are working with passionate people from the industry with the necessary knowledge and experience. “When the opportunity came along to establish Met Optix earlier this year, I felt that the time was right,” says owner David Eldridge. “I felt that I should put my industry knowledge, as well as my network of contacts both locally and overseas, to good use for the benefit of customers in the industrial market within Australia and New Zealand.” Eldridge has almost ten years of experience in the metrology business in Australia. He spent nearly seven years with Hi-Tech Metrology as their inaugural General Manager from 2005 to 2012. That was followed by a two-year spell with the LS Starrett Company, working as the Business Development Manager for its high-end metrology products, such as optical comparators and vision systems, as well as also its new range of force measurement and materials testing system products. The relationship with LS Starrett has been maintained, with Met Optix now its exclusive sales agent in Australia and New Zealand for optical, vision and force/materials testing products. “With support from LS Starrett globally – from its head office in the US, Singapore, the UK, and importantly the Starrett Kinemetric Division in California – we have a very strong and reliable foundation partner for the new Met Optix business,” adds Eldridge. “Other foundation partners have also joined us, such as Verisurf Software from the US, as well as Starrett Bytewise, the Starrett division that supplies innovative laser measurement solutions for continuous processes such as extrusions, moulding and the tyre industry.” In May 2, Eldridge visited the Control Show in Stuttgart, Germany, the world’s largest annual exhibition of metrology and testing products in search of new potential partners. As well as meeting up with a number of new contacts and associates arranged through Met Optix’s foundation partners, he was also able to catch up with a number of old contacts from overseas equipment manufacturers. After a week of meetings, discussions and subsequent negotiations, he was able to establish the distribution rights to a number of key agencies, many of which represent some of the world’s leading brands of metrology and testing products, including several that are new to the ANZ market. The Met Optix portfolio now includes the following brands and agencies: COORD3, TouchDMIS, Fixlogix, PRODIM, Starrett Bytewise, Verisurf Software, Kreon Technologies, API, Brunson Instrument, Steinbichler, Artec, 8-Tree, Alicona, LaserGauge, DataLyzer, LightStar, Nirox. In terms of future trends in the metrology and testing sectors, Eldridge believes – based on what he observed at the Control Show in Germany this year – two developments will be of particular significance: ease-of-use software for metrology and testing products; and field-of-view (FOV) measurement.

Keeping things simple The first of these trends, the need for metrology and testing software that is easy to use has been evidenced in LS Starrett’s latest offerings for its optical comparators, vision systems and force and materials testing systems. The M-Series and the L-Series products have been developed by US software firm Metlogix. According to Metlogix CEO and owner Bob Green, the idea driving these new packages is to make the software as simple and as easy to use as possible. “Most people these days can use a Smartphone,” says Green. “And so we

60 |

AMT September 2014

wanted to develop a software platform that is icon-driven and that runs on a touch screen Tablet or all-in-one PC running Windows 7.” The simplicity of the software and the ease with which simple feature measurements can be accomplished is almost revolutionary in the world of metrology. Gone are the multiple layers of pull-down menus and ‘tree-systems’. In their place the user just needs to tell the system what they want. For example, if they want to measure a circle or a hole, all they need to do is hit the circle icon and touch the edge of the circle to be measured. Automatically a video probe is ‘fired’ and over 200 points of X-Y data are taken instantaneously, and the user knows immediately the diameter of the hole or circle, its position in X-Y space, and the form or shape of the hole. This type of functionality takes the metrology tasks out of the metrology room and away from metrologists, and hands them very firmly back to the production and shop floor personnel, who can measure the parts that they are making, as they make them. “I’ve seen situations,” adds Eldridge. “Where customers are now using products such as Starrett’s vision systems with M3 software positioned back on the shop floor – between the use of hand measuring instruments such as Verniers and micrometers, and the complex, high-end CMM in the inspection lab.” Starrett has also applied its “simple, ease of use” software philosophy across its range, installing the M2 software package in its optical comparators, and most recently introducing a variation of the L2/ L3 software range for products such as force measurement and

Software

materials testing systems. Eldridge believes in the future we will see cut-down versions of the M2 software operating from devices such as mini-tablets and smartphones for use with optical comparators. This emphasis on simplicity of operation and the removal of complexity is also a priority for Keith Mills, a 30-year metrology veteran and now the Managing Director of Next Metrology Software, the developers of TouchDMIS, a brand-new software package for co-ordinate measuring machines (CMMs). CMM software has long been criticised for being too complex, requiring long training periods and extended learning curves. TouchDMIS is a full-feature CMM software package with an intuitive touch interface, offering an unparalleled user experience and benchmark CMM productivity. Developed for both manual and CNC CMMs, including portable devices, TouchDMIS is loaded with innovative time-saving features, with immediate productivity benefits. Traditional CMM software provides access to functionality through complex systems of toolbars, dropdown menus and tedious window selections. TouchDMIS offers a revolutionary user interface using smart technology, whereby suggested next steps are dynamically presented for user confirmation, minimising learning time to just a few hours. TouchDMIS represents a new and innovative presentation of software functionality for industrial metrology applications.

The future is FOV The other leading trend in the metrology products business concerns the increasing use – particularly in Europe and the US – of FOV measurement systems. This technology allows a video camera system, once programmed, to automatically measure all of the defined features on a part that are within its field of view, all at once and almost instantaneously. This saves moving the measuring stage to measure features, dramatically improves measurement times, and enhances productivity. Moreover, with this type of technology, automatic pattern recognition allows users to place the part to be measured anywhere on the measurement stage, with the system ‘recognising’ its orientation and datum positions by virtue of a previously recorded pattern of features on the part. The larger the field of view, the more of the part that can be measured at the one time. However, for larger field of views, accuracy can be affected. FOV systems are now offered as part of LS Starrett’s range of vision systems, using new telecentric-lens technology. Users can still move the stage either manually or via CNC to measure features that are outside of the field of view of the lens. Other manufacturers are also moving in this direction, with some now only having fixed stages on their equipment, and are relying totally on FOV measurement to quickly and accurately measure part features on small and intricate parts. Undoubtedly there will be more developments in FOV measurement technology to come in future. www.metoptix.com.au

AMT September 2014

| 61

Quality & Inspection

Aerospace manufacturer gains edge with AIFM When measuring hundreds of points a day becomes a regular exercise, you need a system that assists you with fast measurement time, ease of use and high measurement accuracy. Quickstep Technology is an Australian-listed company that manufactures advanced composites for the aerospace and automotive industries. One of its most significant contracts is supplying composite parts for the new F-35 fighter jet, part of the Joint Strike Fighter (JSF) project. To produce precise measurements, Quickstep relies on laser tracker technology developed by Leica Geosystems of Switzerland and supplied here in Australia by Industrial Measurement Solutions. “The Leica laser tracker is an essential piece of machinery for the Quality team here at Quickstep,” says Santhan Naidoo, a project officer at Quickstep. “We utilise the tracker to measure the lay-up tools for the JSF. The Leica tracker was the only suitable solution which provides us with the portability, aerospace accuracy and generous measurement volume required for our specific task.” Interferometers (IFMs) are used to determine relative distances accurate to the nanometre level. As a laser beam is reflected back from a moving reflective target, the return beam moves and the wave peaks cross each other, creating a superposition wave. This is known as “IFM counting”. With it the exact change in distance can be calculated. Not only is this incredibly accurate, but it is almost instantaneous. The issue that confronts manufacturers with standard IFMs is that despite their ability to produce highly accurate relative measurements, they are unable to locate an absolute position in 3D space. Absolute distance meters (ADMs) measure absolute distances and are also extremely accurate, but it takes time to conduct the processes that determines a target’s location in 3D space. This integration time is bad for dynamic measurement. Long integration times mean fast-moving targets cannot be measured accurately. ADMs can never achieve the dynamic measurement ability of IFMs. Developed exclusively by Leica, absolute interferometry (AIFM) technology combines both IFM and ADM to produce a laser tracker that can generate precise dynamic 3D co-ordinate positions. Roughly explained, this technology compares the ADM’s co-ordinates and constantly references them to the IFM’s relative movement. AIFM technology is unique to the Leica AT901 laser tracker, making it the most accurate and stable dynamic distancing unit that Leica has created. When the laser tracker is combined with the T-Cam camera and T-Probe hand-held probe, Quickstep is able to easily measure hidden points in situations where there is no clear line of sight to the reflector.

“The complex surfaces of our lay-up tools have extremely tight tolerances, which conventional laser scanning is not able to achieve,” adds Naidoo. With the Leica AT901, AIFM has been utilised world-wide for prototyping, tooling inspection and part-mating by the aerospace, automotive and large scale manufacturing sectors. This, as Quickstep has realised, gives manufacturers a significant commercial advantage by early detection of potential problems resulting from poor dimensional control, which in turn helps to ensure that parts are produced to specification first time, every time. www.measure.com.au

PMX – streamlining production and testing Test and measurement group HBM has released PMX, a new industrial measuring amplifier designed to optimise production and testing processes. “PMX enables rapid integration in complete system and machine concepts and delivers numerous web-supported operating options,” says Tinh Ngo, Sales and Application Engineer, HBM Australia. “Quality assurance and system integration of measurement technology are important cornerstones in industrial production and in end-of-line test benches for the success of a product, and PMX has been developed to provide this.” With HBM’s PMX, production data can be access passwordprotected via a web browser using an Internet-capable end device. This guarantees an overview of the processes and ensures maximum security. In addition, the combination of ethernet technologies and

62 |

AMT september 2014

the internet enables uncomplicated remote maintenance. Moreover it is possible to access a test device online from anywhere in the world at pmxdemo.hbm.com. “Users can parameterise the system within seconds, using an upgradeable sensor database in the data acquisition software,” Tinh explains. “Measurements during start-up and for quality control can be immediately visualised and recorded. In addition, the free driver package enables simple integration within existing software and therefore within the complete system or machine concept.” www.hbm.com

Quality & Inspection

PolyWorks 2014 – NEW Metrology-grade Introducing the HDV300 laser scanning Video-based Measurement System To mark its 20th anniversary as an independent, hardware-neutral, 3D metrology software company, InnovMetric Software has released PolyWorks 2014, a groundbreaking new version of its universal 3D metrology software platform.

PolyWorks 2014 brings to the market an industry-first that InnovMetric believes will transform the field of laser scanning. With its new real-time quality meshing technology, PolyWorks 2014 introduces the first systematic and objective metrological approach to laser scanning. PolyWorks can now create polygonal models of digitised parts in real time, as well as compute quality metrics that reveal ineffective scanning methods. Laser scanning operators are then able to visually review the areas that do not meet predefined quality criteria and scan those areas until quality metrics reach their prescribed values. PolyWorks’ real-time quality meshing technology enhances the quality and precision of all laser scanning measurement sessions, eliminates the variations of point cloud measurement quality and precision that occur from operator to operator, and accelerates learning for a new laser scanner operator. In addition, PolyWorks 2014 offers a variety of new and enhanced functionalities that deliver significant productivity gains and facilitate the deployment of PolyWorks solutions on the shop floor. New functionalities include:

The power of an optical comparator, meets the precision of digital video. • Electronic overlays – no more Mylars! • Easy to use M3 software – for both shop ﬂoor and lab • Fast measurement processing • Interchangeable lenses for large part images • DXF CAD Import • Touch-screen Windows 7/8 technology • A new generation of Optical Comparators for the 21st Century.

• A Geometry Controls interface to add, configure, and review geometry controls for all measurement objects. • New table and annotation editors and an automatic reporting workflow that dramatically accelerate production of part inspection reports • Guiding points for feature probing, to improve measurement repeatability. • Device position uncertainty analysis to control the global accuracy of large-volume measurement projects. • Speech recognition to invoke typical measurement commands and macro scripts by talking to PolyWorks. PolyWorks 2014 also introduces two new major algorithmic capabilities: datum targets to construct geometric dimensioning and tolerancing (GD&T) datum reference frames, and fitted sketch dimensions that capture design intent when reverse-engineering a part. By providing real-time feedback about quality, PolyWorks 2014 is designed to deliver an immediate return on investment for customers operating probing and scanning devices. Hi-Tech Metrology provides ongoing supply and support for PolyWorks into industrial manufacturing organisations within Australia and New Zealand. www.hitechmetrology.com.au

What company has such vision?

Innovation Rules www.starrett.com.au

| 63

Quality & Inspection

3D measurement arm technology for the automotive industry Quality management systems are essential for any manufacturer in any the market, but the need is particularly acute for those operating in the automotive sector. By Gannon O’Reilly. Articulating arms

Typically, a shortfall in quality could negatively impact a brand’s reputation or profit margins. However, for an automotive manufacturer, the damage is far more severe, since human lives are directly implicated by the quality of a vehicle. For this reason, automotive manufacturers require good inspection systems in its manufacturing process to provide confidence in its output. The implementation of suitable test and inspection devices help ensure that quality levels are consistently met every step of the way – right from receiving parts to sub-assembly stations, final assembly of bodies in white, and testing. Today, a majority of automotive assembly plants rely on portable co-ordinate measuring machines (CMMs) to provide accurate 3D measurements efficiently and easily.

Portable CMMs – A brief history For hundreds of years, hand measurement tools such as micrometers and Vernier callipers were utilised to capture dimensions on parts. However, due to their mechanical simplicity, hand tools could only provide basic measurements such as widths, lengths and thicknesses. If complex dimensions such as form (such as flatness or circularity) or hole-to-hole dimensions were desired, manual measurements would be too time-consuming. At the same time, while hand tools provided the best accuracy and precision, it often required skilled operators because manual measurements were always susceptible to human error. CMMs were then introduced in the 1960s for machinists and engineers to capture various geometries and measurements with higher accuracy than hand tools. Fixed CMMs typically consist of a measurement bed, a measurement probe fixed to a bridge, a computer, and measuring software to program the measurement probe. The probe can only move along three planes and only travel within the extent of the CMM’s measurement bed. With the advancement of technology, articulating arm CMMs were invented to provide the same functionality as a fixed CMM, but also provide portability and flexibility as well. Though articulating arms may not have as fine an accuracy as fixed CMMs, they are lightweight (10kg or less), simple to operate, and far less expensive than a fixed CMM, all while providing the necessary accuracy for a wide variety of measurement applications.

64 |

AMT September 2014

3D measurement arms, commonly known as articulating arms, are portable CMMs that determine and record the location of a probe in 3D space and report the results through software. The name derives from the actual look of the hardware, resembling a human arm with a shoulder, elbow, forearm and a wrist. To ascertain the position of a probe, the arms contain proprietary glass discs called encoders in each joint, and these encoders calculate the probe’s position as the arm moves freely throughout its workspace.

The measurement arm resembles a human arm. Each joint has encoders that calculate the probe’s exact position in space.

Articulating arms combine the efficiency, reliability and accuracy of a traditional CMM with the portability and simplicity of hand tools. With the addition of a laser line scanner, parts that were once considered too sophisticated or complex can now be easily inspected with an arm. Reduced scrap, faster inspections, fewer defects, and an improvement in product quality are just some of the many benefits a company will enjoy when they implement an articulating arm for their inspection and manufacturing needs. These benefits ultimately result in a significant return on investment for a company.

When fully extended, the radial reach of an arm typically ranges from 60cm to 1.8m. In the CMM industry, arms are usually classified by the overall working volume, which corresponds to a range of 1.2 to 3.6m. The shorter the arm, the more accurate it will be as there is less mechanical error linked to the length of the sections. At times, arms are also classified by the number of rotation axes it has. Most arms come with six axes of rotation, but there are seven-axis varieties that possess an additional handle at the end of the unit to control a rotating wrist. One of the main benefits of using an arm is its portability. Compared with a traditional fixed CMM, articulated arms are considerably smaller and lighter. This allows users to bring the arm to a part for inspection instead of the part traveling to the fixed CMM, minimising machine downtime and quality control bottlenecks. Furthermore, articulated arms are designed to adapt to most temperature conditions so they can work in a wide range of environments and are not confined to a temperature-controlled inspection room. A seven-axis arm with rotating wrist.

Quality & Inspection Performing dimensional analysis with an articulating arm.

The accuracy provided by an arm CMM far exceeds a majority of the hand tools often used to do an inspector’s job. In addition to being substantially less expensive than fixed CMMs, arm CMMs are also easier to use, with simple buttons on the handle that are used to collect data.

An articulating arm with a laser line scanner attachment.

Typical applications for an articulated arm include: • Dimensional analysis: Collect information on parts to compare data to drawings and blueprints. • CAD-based inspection: Compare your part to a 3D CAD model in real time for instant feedback. • On-machine inspection: Utilise the portability of an arm and inspect a part before, during, and after its production, all while mounted on a machine tool. • First article inspection: Review preproduction samples and compare against nominal data. • Alignment: Align tools and fixtures to the correct orientation. • Reverse engineering: Capture unique details on a part with the arm or laser line scanner to create CAD models for fabrication or digital documentation.

Articulating arms with laser line scanners Articulating arms may also be affixed with a laser line scanner. The laser line scanner allows users to collect data on a part without direct contact, akin to painting a part with a spray gun. A laser line scanner can quickly capture data (known as point clouds) at a high frequency, resulting in millions of points that can later be turned into a CAD model. Benefits of scanning with a laser include speed in collecting the data, ease of use, and less risk of impacting a part during a measurement. Laser line scanners used with articulating arms typically consist of a camera and a laser. The camera captures information based on the way the laser line (either a

stripe or a moving dot) is projected onto on the part, creating 3D points that are then communicated to a computer. The number of points can be collected anywhere from 10,000 to 500,000 per second. Typical applications for an articulated arm with a laser scanner include: • CAD-based inspection: Compare point cloud data to a CAD model in real time • Reverse engineering: Collect threedimensional information about a part to produce a 3D model. • First article inspections: Capture details on an individual part to compare to a CAD model and archive for company records. • Artefact documentation: Archive digital information for research or historical replication. Gannon O’Reilly is the Product Marketing Manager (Metrology) at FARO Technologies. www.faroasia.com AMT September 2014

| 65

company focus

Multi Slide Industries – Hard-wired for success Based in the Adelaide suburb of Edwardstown, Multi Slide Industries was hit hard by the decline in the local car-making industry, but it shifted strategies and is now getting back into growth. By John Merriman.

Six years ago South Australian manufacturer Multi Slide was at its zenith, employing 165 people working over three shifts and operating 24 hours a day. The multi-million dollar company manufactured car seat frames for Holden, critical parts for Mitsubishi and Toyota, metal bucket handles, wine racks, air-conditioning components, and supporting brackets for a range of items from air conditioners to gutters. In addition it was a major player with white goods supply chains including Electrolux. Today, the privately-owned and operated company continues to operate Australia’s largest range of CNC wire-forming, mechanical wire and strip-forming equipment. It uses bending technology to provide its customers with innovative solutions. Complementing the manufacturing operations are robot welders (mig and spot), wire straighten and cut machines, pedestal welders, 2D and 3D CNC mesh welders, special purpose welding equipment and a nylon coating line. The company began operation in 1986 by owner Rod Rebbeck, who used his back shed in the western suburbs of Adelaide to manufacture parts and delivered them to customers with an ageing, yet serviceable Land Cruiser and a small trailer. Rebbeck borrowed forklifts to unload goods and lived by a philosophy of never letting the customer down. It is a philosophy the company still embraces 26 years later. With the closure in 2008 of the Mitsubishi factory in nearby Tonsley Park and planned shut-down of Holden’s plant in Elizabeth, combined with the loss of some contracts to cheaper, offshore manufacturing over the past few years, Multi Slide Industries needed to reinvent itself – or close its doors. “The decline of the automotive sector had a significant impact on our business and still continues to drive revenues down,” says Multi Slide General Manager Al Kalvaitis. “Our business had contracted to from being one of the largest employers in the western suburbs, to operating a single shift with only 38 employees. But during this downturn we didn’t stand still.

66 |

AMT MAY 2014

“We had to think and act quickly, pursuing new business opportunities to stay relevant and profitable. We remain totally committed to forging a future in manufacturing and growing our staff numbers again.” According to Kalvaitis, the very high skill base that the company possessed, along with a workshop boasting some of the world’s best CNC wire-forming equipment, had provided a foundation for its evolution and adaptation. Such attributes had helped Multi Slide forge a well-earned reputation for excellence and leading-edge technology. “When we found ourselves needing to diversify in to other areas quickly, we drew on those well-earned strengths and abilities,” said Kalvaitis. “The benefits of building strong, working relationships and building components using quality materials for consistent delivery and a customer service driven focus was repaid with client loyalty. This allowed us to continue to provide solutions for our clients over the option of cheap imports.”

company focus

One of Multi Slide’s key expansion areas has been in the agricultural sector, with a focus on products used to train and grow vines for the wine industry as well hot-house infrastructure and irrigation solutions. Among the company’s new products are tree guards, fencing, specialist mesh and orchid clips. It also supplies wire trays and shelving to Heatlie Engeineering, which will be fitted into the new air warfare destroyers that are currently being built in South Australia. The company has also been working collaboratively with other South Australian businesses on a variety of new products that present exciting export potential. “Inevitably automation and clever technology and materials will see less numbers employed in the factory industry,” says Kalvaitis “However, the front end of the business in engineering will grow by designing and developing products for the Australian and international market. “We are exceptional at coming up with ideas to support industry in any sector, and Multi Slide Industries wishes to embrace that going forward. According to Kalvaitis, the Multi Slide mantra is that ‘there is a bit of wire in everything we touch’. The company has highly experienced engineering and tool room capabilities complementing its extensive wire-forming knowledge. Quality-accredited to ISO9001: 2000 and 14001 standard, Multi Slide Industries is committed to continuous improvement and Lean manufacturing techniques. Kalvaitis believes that superior project management, inventory systems and production capabilities leave the company well-positioned to lead the market in delivery, cost and lead-times. Underpinning Kalvaitis’ confidence is a belief that, after several years marked by offshoring, the tide is turning back toward manufacturers who understand the client intimately and deliver services that the customer desires, as opposed to operating with a “sausage factory mentality”. At the moment Multi Slide processes more than 2000 tons of stainless steel, galvanised, spring and hard drawn, low carbon wire each year. “Our business is also well adept in supporting entrepreneurs who regularly present at reception and ask for help and support. They know what they desire in a product but don’t have the capability to realise the potential, that’s where we can step in. Our engineers have been in the business for collectively 20 years and there is no one better versed in how to assist and develop their creation. There are many products that we currently produce that were nothing more than a sketch and after full development, are now used regularly within the agriculture, building and construction or manufacturing industry. From concept to realisation of a commercially viable product, we can support many from our base in South Australia.”

Manufacturing with pride Kalvaitis is adamant in his conviction that it is critical that Australia, and in particular South Australia, maintains a successful and robust manufacturing industry. “We are passionate Australians who believe in supporting the local industry and giving the next generation employment opportunity,” he says. “Manufacturing is another space for Australia to remain at the forefront of innovation, by adding value to our raw items. Not everyone wishes to be in the service, information technology or banking sectors. In fact, without manufacturing these sectors will wane. “A finished manufactured product gives people a sense of pride, a belief that they can achieve and provide something that will be used daily, and the knowledge that the item was built by clever people in Australia, not just overseas. Part of Multi Slide’s company culture is creating opportunities for collegiate interaction among all of its employees, from the shopfloor sweeper to the lead engineer, IT specialist, welder, dispatch clerk, financial controller, toolmaker and forklift driver. “It is an engaging environment and how we wish it to remain,” he explains. “What is continually forgotten by many people in our society is that work is social. At Multi Slide Industries we work at building our company culture because we believe that beyond what we produce, our team also needs to feel invested in. We aim to provide opportunities for all of our team to engage with one another, enjoy social interaction and feel valued.” Multi Slide’s ambitions extend beyond sustaining and growing the business. As Kalvaitis sees it, the company aims to thrive, while playing its part in supporting its local economy. “We hope people think about us the next time they open an Electrolux dishwasher, they should know the baskets inside are manufactured, coated and assembled by Multi Slide Industries. If a person drives a GM Holden product manufactured in Australia, it is likely the rear seat frames come from us. The gutter brackets holding up the gutters on a person’s home are probably made on our multi-slide machines, and if someone drives a Toyota Camry, the boot is held up by two of our torsion bars. “We want Aussies to think local before they make that purchasing decision – not just to positively impact local jobs and the economy, but to also enjoy high-quality products and service, it’s about sustainment and quality of life,” Kalvaitis adds. “If we can get people to understand some basic moral principles about value adding to the community and society, everyone would benefit and the industry would be sustained. If people are satisfied with conditions in the country – and a majority of us are –buy Australian!” www.multislide.com.au AMT MAY 2014

| 67

forum – HR

Changes to superannuation guarantee Can you deduct the super guarantee increase from your employees’ salaries? Charles Power explains this and other aspects of the Fair Work Act provisions. On 1 July this year the superannuation guarantee increased from 9.25% to 9.5% and since then I’ve had many clients ask whether this increase can be absorbed into an employee’s overall package. In other words, can you offset the increase in the superannuation cost against the employee’s salary on the basis that your agreement to the employee is only to pay a certain salary package to the employee (i.e. salary plus super). The answer is ‘yes’ – provided the employee authorises it. Without authority from the employee it would be difficult to reduce their salary to maintain the employee’s total package figure in the face of the superannuation guarantee charge (SGC) increase. This allows me to introduce some Fair Work Act (FW Act) provisions which, in my experience, many employers do not know about.

Fair Work Act provisions: What you can and cannot deduct from your employees’ wages Part 2.9 Division 2 of the FW Act imposes rules about the payment of wages and what you can and cannot deduct from wages as an employer. The rules apply to wages, salaries, commissions, bonuses, loadings, monetary allowances, overtime payments, penalties, and payments for leave – it does not apply to superannuation. These rules only apply to amounts payable to the employee in relation to the performance of work. Therefore if the entitlement to be paid these amounts has not yet accrued or has been lost or forgone, these rules do not apply. The first rule is in section 323 and states an employer must pay the following amounts:

Authorisation from an employee to reduce payment: what’s required? Authorisation from an employee to reduce payment must satisfy the following: • The employee must authorise it in writing. • If the employee is under 18, the employee’s parent or guardian must also agree to the deduction. • The authority must specify the amount of the deduction. • The deduction must be principally for the employee’s benefit – an arrangement under which an employee chooses to forgo wages payable in return for an increase in superannuation will meet this test. I have been asked whether an employment contract signed by employees that provides for an employee to receive a certain salary package amount is sufficient written authorisation to reduce wages or salary commensurate with SGC increases. In my view it isn’t, because the amount by which the employer may reduce salary is not specified. The contract clause needs to explain how the employer is entitled to reduce the salary component of the remuneration package commensurate with any increase in the SGC component.

What if you reduce the employee’s salary without their authorisation? An unlawful deduction contravening section 324 exposes an employer to civil liability, which may lead to: • orders to compensate the employee; and

• in full (subject to lawful deductions);

• penalties.

• in money (as opposed to in-kind);

Of course, if you have already reduced an employee’s salary to absorb some or all of the SGC increase and the employee has not objected and has continued working as normal, the employee has probably accepted the variation to the remuneration terms of their employment contract. In this case, you will not attract any liability.

• by either cash, cheque, EFT or a method authorised by an applicable enterprise agreement or award; and • at least monthly. The second rule is contained in section 324 and entitles you to deduct an amount from an amount payable to the employee if the deduction is authorised. The authority can derive from a legal instrument, ie. legislation, Fair Work Commission (FWC) order, Court order, modern award or enterprise agreement. Alternatively it can derive from the employee. An example of authority deriving from a legal instrument is if an employee resigns but does not give the notice required under the applicable modern award. In this situation the modern award authorises an employer to deduct from any monies due to the employee on termination of employment under the award, or under the National Employment Standards, “an amount not exceeding the amount the employee would have been paid under this award in respect of the period of notice required by this clause less any period of notice actually given by the employee.” No legislation or modern award authorises an employer to reduce wages or salary proportionate to an increase in SGC. In the absence of any enterprise agreement provision for this authority, the reduction can only occur if it is authorised.

68 |

AMT September 2014

Charles Power is Editor-in-Chief of the Employment Law Practical Handbook and Partner in the Workplace Relations department of Holding Redlich. He has practiced in employment and industrial relations since 1992. www.holdingredlich.com

About the publisher The handbook is published by Portner Press - a Melbourne-based business-to-business publisher that specialises in producing handbooks and other helpful resources for Australian businesses. Complex legal, financial and compliance information is conveyed in clear, readable language via publications which provide practical tips, case studies and definitions. These help simplify the workload of thousands of managers, supervisors and business owners across Australia. The Portner Press team of writers and contributors are all experts in their field – whether it be labour law, workplace safety, corporate taxation or social media. Email: cs@portnerpress.com.au Ph: 03 8696 6175 www.portnerpress.com.au

forum – import/export

Australian export challenge Doug Tozer explores the issues dealing with Australia’s inability to manufacture and successfully export The US exported $195.9bn of goods and services in June 2014. Exports of goods and services over the last 12 months totalled $2.3 trillion, which is 46% above the level of exports in 2009, and have been growing at an annualised rate of 8.8% when compared to 2009, according to the Export Import Bank of the United States. This makes one question Australian industry when our annual (not monthly) 2013 exports totalled $252bn and much of that is raw materials.

Australian import and export trade figures $billion Year

Export Import Balance

2009

153 158

2010

206 188 -18

2011

269 234 -35

2012

256 250

2013

252 232 -20

Country

-6

Population (Millions) Exports ($ Billions)

Netherlands 17

571

Belgium 11 511 Singapore

410

Australia 23 252 Source: United Nations Comtrade

The first excuse is: “we don’t have the population to provide the volume of sales”. This excuse is followed by: “We are too far from the markets, but we currently export to many countries and containers into Australia full of products made overseas need backfill products so rates should be competitive.

There may be partnerships you put in place that take advantage of Free Trade Agreements (FTAs) either into Australia or final manufacture may be overseas. My Freight Career is one such company. Customs Brokers are an essential but often overlooked part of planning. They will classify your components and products for essential research on trade statistics for initial planning and to look into export and import permits such as dual use products that have a commercial or military application and other trade rules your products may be subject to as well as advise on approved packing materials and any quarantine requirements for remanufactured machinery, or field-tested in dirt, lubricants or water in machinery or other biosecurity risks. You can engage a local broker with global contacts or a larger firm that has international offices to assist with export from Australia and import rules into markets. The major accounting firms all have global access through their offices as do the larger freight forwarders. It may well be that they are dealing with local companies in the markets you are targeting that they could match up. They can also expedite components and manage door-to-door delivery. They can also advise on the countries like Japan - one of the newer FTAs about to come into force with Australia which has adopted a similar US 24 hour rule for seafreight consignments before leaving Australia. Mapping out your supply chain tier 1 and possibly tier 2 partners all involved in the cross-border process will soon take centre stage in Australia - which is catching up with other countries which have in place an Authorised Economic Operator (AEO) program that is aligned with the World Customs Organisation’s (WCO) Safe Program for secure supply chains. The Australian Defence Department wants to showcase Australian Industry - this could lead to approvals and a listing on the NATO database of approved suppliers.

Another excuse: “We cannot compete with China and other low wage countries”. Before I agree on that, there would need to be analysis of niche markets where for example the EU and US are trading between each other and the opportunity exists to compete on price, quality or product characteristics.

The range of products, equipment and spare parts is very diverse. I cannot stress enough the importance of classifying your products and aligning your company into a global WCO tariff standard used by over 160 countries for trade.

Yet another excuse: “We don’t have the equipment to meet the volumes out there or the working capital to invest in growth” - Hold on a minute! There is potential in Australia to get working capital through EFIC and export insurance is also available to cover loss due to non-payment by the buyer or against other circumstances.

35.7 million Manufacturers or Vendor Reference (Part) Numbers

Is the real reason why we don’t manufacture and successfully export due to the fact that there are wrong people in place to compete in the global arena from within government down to the business owners or managers? Trade Statistics seem to support this.

Things to consider Engage your organisation and set up interest groups to analyse export potential in a friendly and supportive setting and plan steps and coordination through your organisation. Seek a training organisation that can tailor a course to demystify the import and export rules for your industry. I say “import” because you may need overseas materials or components and need to review duty- free imports for goods that will be combined or transformed and exported.

17.8 million NATO Stock Numbers (NSNs) 2.6 million Manufacturers and Vendors (NCAGE codes, names and addresses) 27.6 million User Registrations 11 million NSNs with Technical Characteristics Data display, of which 1.7% have drawings 9.5 million NSNs with TARIFF CODES There are many considerations to a successful export, where planning alternative scenarios and risk management requires engaging the right people who will partner and facilitate your industry to give you a no-surprises success story. Doug Tozer is President of Tradefox Inc. Tradefox develops import export compliance libraries for customs brokers, consultants, importers and exporters. Ph: 0487 670 733 douglas@tradefoxinc.com www.tradefoxinc.com

AMT September 2014

| 69

forum – OHS

Directors now charged for WHS issues Understanding your obligations as an officer is vital, particularly following the prosecution of an ACT business manager, as explained by Brendan Torazzi. For those still trying to wrap their heads around the new Work Health and Safety (WHS) Act, a recent case in the Australian Capital Territory has shed some light on the roles and responsibilities of company directors. In 2012, a 48-year-old ACT truck driver was electrocuted while offloading gravel. At the time of his death, he was working for a contracting company which has since gone into liquidation. In the past, a company being dissolved before the case could reach the court would result in the proceedings being dropped. Under the new WHS Act, however, senior company managers can still be held accountable for incidents no matter what happens to the business. Issues were raised about the positioning of the dump truck, due to low-hanging power lines in the area. When the case reached the ACT Work Safety Commissioner Mark McGabe, he investigated the accidents and identified alternative locations for the truck. “You have to question why the dump was put in such a location. They could have located it across the road, well out of the reach of power lines,” he said. Under the new Act, the circumstances leading to the truck driver’s death are considered a category two offence. This means that the business could be penalised up to $1.5m, while the company officers may be fined up to $300,000. McGabe explained that the WHS Act was designed to “ensure that people at the highest level have personal accountability for what happens with the company”. He revealed that the ACT would be the first jurisdiction in Australia to charge an officer under the new laws, with proceedings scheduled to begin in December.

Understanding the WHS Act The WHS Act replaced the occupational health and safety laws on January 1, 2012. This review of WHS legislation was designed to provide greater clarity and consistency across the board and in all Australian states and territories.

Director and officer obligations In its simplest form, the Act requires officers to exercise due diligence and high standards in regard to OHS standards. This means senior company managers must ensure that their business and undertakings fulfil WHS obligations as outlined under the Act - such as providing employees with a safe environment in which to conduct their work. Meeting the high standard of due diligence required of an officer can be achieved by following a few general steps, including: • Staying up to date with WHS matters • Understand the hazards tied to business-as-normal operations • Access and invest in the appropriate resources and processes to identify and control risks • Record and report any incidents, hazards and near-misses in a timely and responsible manner • Ensure the employer and business owner has undertaken processes to comply with their own legal duties • Engage a qualified person to verify, monitor and review WHS practices and compliance

70 |

AMT September 2014

Senior company managers can still be held accountable for incidents no matter what happens to the business. With the ACT case outlined above, the officer failed to complete a comprehensive risk assessment. With a properly conducted review of the location, the officer and employee would likely have noticed the low-hanging power lines and chosen an alternative location for dumping.

What this means for manufacturing Those working in the manufacturing sector, and any other industry, should take notice of the results of the ACT officer trial. When proceedings get underway in December, the results will likely influence future cases related to WHS. All company officials and business owners need to understand their obligations and responsibilities under the WHS Act. By meeting these standards of due diligence, individuals can effectively mitigate their risk of potentially damaging legal liability. While regular inspections, personal protective equipment (PPE) and thorough reporting are all crucial considerations, training is considered a vital factor in complying with officer obligations under the WHS act. According to WorkCover NSW, one of the major responsibilities of senior business managers and directors is the provision of information, training and instruction to workers.

The training requirements for employees and officers There are three main areas where training is required in a highrisk workplace, such as those found in the manufacturing sector. This includes general WHS programs that help employees identify, mitigate and control common risks to their own health and safety. Additionally, officers are required to provide representatives with training related to their role in the workplace. And finally, each position along the manufacturing supply chain can be faced with a varying range of WHS hazards. It is therefore vital that officers can access specific training to minimise risks relevant to every sector. For example, those working in loading and transport roles will benefit from traffic management training, along with competencies related to safe-lift practices. At the same time, individuals whose main responsibilities are confined to machinery maintenance will require a different set of training, including equipment awareness and the use of PPE. Understanding your rights and responsibilities as a business director or officer can help protect you from serious legal proceedings in the future, while also minimising the risk to your staff. For a basic understanding of these obligations, WHS training could be the key. Brendan Torazzi is CEO of AlertForce - a Registered Training Organisation. AlertForce specialises in compliance training for Workplace Health and Safety by offering quality online, facetoface and/or blended training approaches to create fast, flexible and competitive OHS training & compliance solutions. Ph: 1800 900 222 www.alertforce.com.au

forum – Law

Directors’ duties – are your personal assets at risk? In this article, Laura Young of HWL Ebsworth Lawyers explains the various duties and obligations that can apply to directors, officers and even to managers & senior staff members of companies. Directors of Australian companies are subject to a wide variety of duties and obligations. A failure to comply with those duties and obligations may expose a director to personal (both civil and criminal) liability. Generally speaking, directors’ duties in Australia are designed to promote good governance and ensure that directors act in the best interests of the company. Such laws have been imposed in recognition of the position of power that directors hold and the comparative vulnerability of the company of which they are a director. What are the various directors’ duties and obligations? Directors’ duties are found in the common law, in equity, under the Corporations Act 2001 (Cth) (Act) and other statutes (state, territory and federal) and a company’s constitution. In brief, these duties include: Common law and equitable/fiduciary duties include: • the duty to act bona fide (good faith) in the interests of the company as a whole; • the duty not to act for an improper purpose; • the duties of care and diligence; • the duty to retain discretion (essentially, a duty owed by directors not to place themselves in a position where they are unable to make decisions in the best interest of the company); • the duty to avoid conflicts of interest; • the duty not to disclose confidential information; and • the duty not to abuse corporate opportunities (essentially, a duty owed by directors not to encourage the company to enter transactions because that director has a personal interest in the transaction).

What penalties apply if a director breaches these duties? A number of differing consequences apply where a director breaches his or her duties. These vary significantly depending on the nature and extent of the breach, ranging from damages, equitable compensation, account for profits, an injunction or rescission of contract in the case of a breach of common law duties, to civil and criminal penalties ($200,000 or imprisonment for up to five years in limited circumstances) for a breach of the duties set out in the Act. A breach can also have a significant (and detrimental) effect on the company itself, both from a financial and a reputational perspective. The company may be subject to various penalties (for example, a breach of OH&S or employment laws is primarily a company breach and a penalty would be imposed on the company itself before any specific directors were prosecuted), and these kinds of cases can tend to attract significant (negative) media attention. It can also have a significant impact on the reputation (and indeed career) of the director. Application of directors’ duties and obligations to non-directors / officers The duties and obligations discussed in this article may extend to other officers or personnel of the company who are involved at a management or decision-making level. (i) Company secretaries The Corporations Act imposes certain obligations directly on the company secretary of the company. For example, the record-keeping requirements of the company (referred to above). The company secretary is also subject to many of the same duties that apply to directors under the Act. (ii) Alternate directors

In addition to common law directors’ duties, the Act imposes the following statutory duties on directors:

The company constitution or shareholders’ deed of the company may permit the appointment of alternate directors.

• the duty of care and diligence (s 180);

• the duty of good faith (s 181); • the duty not to make improper use of position or information (ss 182-183); • disclosure of material personal interests (ss 191-195); • the requirement to obtain shareholder approval for financial benefits to related parties (ss 208 - 210), and

Alternate directors are legally responsible during the term of their appointment as an alternate director as if they were a permanent director of the company (ie. they will be subject to all of the duties and obligations imposed on a director in respect of the powers delegated to them by the appointing director).

(iii) De facto and shadow directors

Other obligations:

Executives, managers and other staff members in a position of influence or control may be deemed to be directors even where they are not technically appointed to the company as directors. This is because the Act provides a broad definition of ‘director’ which includes any person in accordance with whose instructions or wishes the directors are accustomed to act.

• Record keeping requirements of the company

Key take-aways

• Compliance with:

Directors, officers and other personnel in a position of influence or control should ensure they are aware of the duties and obligations that may apply to them, and discharge their role in accordance with such duties and obligations.

• duties of care and diligence specifically in relation to financial reporting obligations (ss 285 - 318). It is also possible that the constitution of a company may impose further duties and obligations on its directors.

- OH&S and environmental laws - employment laws - competition and consumer laws - tax and superannuation requirements • Obligations owed under any personal guarantees • Duty to prevent insolvent trading

It can be very difficult to navigate the numerous directors’ duties and obligations that may apply and to determine which ones have greater significance to you in your particular industry or company. Please contact Laura Young on lyoung@hwle.com.au or (03) 8644 3625 if you wish to discuss. www.hwle.com.au AMT September 2014

| 71

manufacturing history

60 YEARS WITH MEN AND MACHINES – PART 47

Machine tools and global warfare Part 6 Disney at war – Plane crazy

We continue our instalments from the book “60 years with men and machines” - the autobiography of US machinist and author Fred Herbert Colvin (1867-1965). It is approaching the end of WW2, but Fred’s work in the Aeronautics division in the US Navy continues – complete with a stint in Hollywood at the Walt Disney studio. By Fred Colvin Although I was passing seventy-five, I really enjoyed the considerable amount of travel which my war work involved. I had to make four trips to California to visit airplane and other types of plants in that vicinity, and on the way I stopped off in Dallas, taking side trips also to Houston and Oklahoma City. Two developments found at the Alameda (California) Air Base are deserving of mention. Both have to do with Plexiglas, the plastic material developed for airplane windshields and navigator’s domes in the Second World War. One of the workmen at the Alameda Base discovered that by inserting a very fine nichrome or other high-resistance wire in a crack that required mending and then applying a weak current, the Plexiglas would weld itself behind the heated wire as it followed the crack. The method was discovered in an almost unbelievably simple manner. The workman’s first idea was to cement the cracks, but he found that he must widen them enough to admit the cement. So he sandblasted a fine wire to roughen it and thus act as a file, and then started to file the crack with this wire. To his surprise, he found the crack closing behind the wire, and thus realized that the low heat of filing was all he needed—that all he had to do was to substitute the weak electric current to provide the necessary heat instead of the friction heat of the filing action. The other development was in the making of the navigator’s dome, or cover, which is, for all practical mathematical purposes, a hemispherical surface. After trying various methods of forming with dies and by forcing the sheet into a hemispherical form by air pressure, a much simpler method was found. A sheet of Plexiglas was clamped to a steel plate by a steel ring that determined the outside diameter of the dome. The plate had a connection for an air hose to the lower plate. The air pressure then forced the Plexiglas into a perfect hemisphere, its height being determined by means of a preset gauge. Before continuing, I must recount a brief anecdote involving John Cautley, the manager of the Bendix Corporation’s landinggear department at South Bend, Indiana. While I was engaged on the oleo problem (see AMT July’s reference to the “oleo” or hydraulic shock absorber section of airplanes’ landing-gear), I had to call on the Bendix Plant, and was looking forward to seeing John again after a lapse of several years. When I arrived early one morning while the plant was already humming with activity, I stuck my head in the doorway of John’s office and said, “Hello, John—how are the landing gears coming?” John looked up from his desk, saw me, and turned a ghastly white. He stared wide-eyed at me for several seconds. “My God—my God!” he finally gasped. “Ain’t you dead yet, Fred Colvin?” Along about the time the Allies entered Rome and the famed Gothic Line* was being pounded by the Eighth Army, while the Navy was destroying 700 Japanese planes and 30 ships in the first battle of the Philippines, my employer - the U.S. Navy Department - had got wind of my long editorial experience, and I was assigned (temporarily, they said) to the Production Aids Division.

The purpose of the assignment was to assist members of the International Correspondence School (I.C.S) editorial staff to prepare a series of instruction books designed to aid workers in plane factories to increase production. Paralleling these books was a series of animated cartoons made by the Walt Disney Studios, which showed how the various operations were to be performed. It so happened that the I.C.S. group had their offices in the Disney Studios, and I accordingly had the rather unique experience of working in Hollywood for nearly a month. Not that I was screen-tested or asked to act as stand-in for Lionel Barrymore; but I did get to stand on the corner of Hollywood and Vine and watch some of the hectic life that the press agents in this glamorous movie colony never tire of telling us about. Over one million copies of these instruction books were distributed among the workers in plane plants and the plants of subcontractors, and there is no question that they played a vital part in increasing production during the war. To be continued…

*Germany’s last major line of defence in Italy during the final stages of World War II

72 |

AMT September 2014

Rethinking factory logistics, product design, & profitability.

ZERO SET UP

PRODUCTION ON DEMAND

ZERO SCRAP

The Salvagnini S4+P4 automatic panel production line is the worldâ&#x20AC;&#x2122;s most efficient, flexible way to punch, shear and form fabricated steel parts. Products can usually be designed to require fewer operations. Manual handling is completely eliminated. Work-in-process time is slashed. Factory logistics and profitability improve. Salvagnini S4+P4 lines. Lights out and hands free since 1979. Machinery Forum NSW Pty Ltd

salvagninigroup.com

43 Brodie Street, Rydalmere NSW 2116 Phone: +61 2 9638 9600 - Email: machinery@mafosyd.com.au

Shane Infanti – Chief Executive Officer AMTIL

Government announcements expected over the next month We are looking forward to some announcements over the coming month or two which will highlight the Government’s position and support for our manufacturing sector for the future. The Entrepreneur’s Infrastructure Program (EIP), announced in the May budget, is a $484.2m program which will replace a number of existing programs and bring them all together under a new Single Business Service initiative. AMTIL supports the concept of having a single point of contact at AusIndustry with which industry can engage. Whilst some details of the EIP are still being finalised, one of the benefits under the Business Management stream currently in operation is the provision of Business Evaluations. These evaluations are conducted by advisors with significant privatesector experience, and they are a free service. The evaluation includes targeted and tailored advice, and connections and recommendations for productivity and business improvement. For those people familiar with the old Enterprise Connect program, this service is not dissimilar to the Business Review component of that program. As a long-term partner organisation for Enterprise Connect, we are looking forward to continuing that support under the EIP. The EIP will also focus much attention on Research Connections and Commercialising Ideas. The Entrepreneur’s Infrastructure Program will also support the Government’s National Industry Investment and Competitiveness Agenda, which is also expected to be finalised and announced in the coming month. We have been waiting for this announcement for some time as it will further clarify the commitment this Government has to the future of our manufacturing industry. The Agenda will focus on initiatives that boost competitiveness, lower the cost of doing business in Australia, encourage innovation, research and development, accelerate the growth of infrastructure, provide support services to our small-to-medium-sized organisations, and develop mechanisms to promote investment. These are all issues that AMTIL has been pushing to have addressed so it is with a great deal of anticipation that we wait for the detail of the Agenda. Another pending announcement is the approval for funding of the Innovative Manufacturing Cooperative Research Centre (IMCRC). The IMCRC will be critical in helping us transition into knowledge-intensive, market-aware, globally integrated, specialist and niche producers of high-value-added products and services. With programs around Additive Manufacturing Processes, Automated and Assistive Technologies, High-Value Product Development and Industry Transformation, this CRC has over $250m of investment from industry, the research community and government over the next seven years. As a core participant, AMTIL is hoping to see a positive announcement in the next few weeks on the $40m funding from the Commonwealth. Our manufacturing industry is halfway through a decade of transformation. We need to develop, adapt and utilise enabling technology platforms to accelerate Australia’s transition into high-value, high-knowledge-based industries. AMTIL is as committed as ever to this cause.

AMTILinside

Book now for the AGM AMTIL is holding its annual general meeting (AGM) at Riversdale Golf Club in south-east Melbourne, from 5.00pm to 7.00pm on 1 October. As usual, the AGM boasts an interesting and varied line-up of speakers. Frank Schrever will be giving a presentation on the recent updates to the AS4024 Machine Safety standard, subtitled “What you always wanted to know about machine safety but were afraid to ask”. With over 36 years of experience in the instrumentation and automation markets, Frank has managed a number of subsidiaries of multinational companies before setting up his own training and consulting business - MSBD. He is also the chairman of the Australian standards committee for Safety of Machinery SF 041. The second presentation will be given by Jason Crawford, who will be talking about the R&D Tax Concession and what it could mean for your business. Jason is the Victorian Lead Partner of the Deloitte R&D and Government Incentives practice. He is a qualified solicitor with over 18 years of experience delivering R&D consulting and compliance services to a range of clients. Jason is a member of the Deloitte Global Leadership Team and is the global liaison Partner for the Asia Pacific R&D Tax and Government Incentives service line. Also on the agenda will be the Austech ballot and various other regular items of business. Most importantly, the AGM gives you the chance to interact directly with AMTIL staff, and have your say about how the organisation is run.

Meanwhile, the AGM provides an outstanding opportunity for you to spend time with other AMTIL members, catching up with old friends, and networking with new contacts. Attendance is free to AMTIL members, with finger food and drinks available. If you would like to attend the AGM, please register at www.amtil. com.au/events. For more information, please call 03 9800 3666, or email Events Manager Kim Warren on kwarren@amtil.com.au.

ManufactureLink proudly owned and operated by AMTIL

Follow our members on

Go Get linked! Manufacturelink is your directory for all things Manufacturing. processes. services. technology.

1186AMT

We’ve got the link to make it happen. Visit www.manufacturelink.com.au to learn more.

AMT September 2014

| 75

AMTILinside

The Austech floor space allocation ballot – Don’t miss out Austech 2015 is getting closer and closer, and at the AMTIL AGM on 1 October we’ll be holding the Ballot to decide the order in which exhibitors will get to choose the location of their stands. Australia’s premier advanced manufacturing and machine tool exhibition, Austech will be held on 26-29 May, 2015 at the Melbourne Convention & Exhibition Centre, and a number of companies have already signed up as exhibitors. To ensure that the floor space is allocated fairly, AMTIL has always held a ballot among the companies who register early. There is still time to register as an Austech exhibitor and be included the in the ballot. It pays to book early and maximise your pre-show exposure. The Austech ballot is divided into groups: the first ballot includes exhibitors applying for 144sqm or more; the second is for exhibitors applying for 54-143sqm; and the third is for exhibitors applying for less than 54sqm. Exhibitors are encouraged to book stands of an appropriate size for their entire display. The names of all ballot participants will be placed into groups depending on the stand size required. Exhibitors from the 2013 exhibition who fell into the bottom 25% of each ballot, will be elevated into a priority draw for the 2015 event. Six draws will then take place including the priority draws. The ballot will be conducted via a supervised draw at the AGM. The company names will be recorded in the order that they are drawn out and the companies will be contacted in that order. They will select the stand they require and the master floor plan will then be sent to the next company on the list. Once all companies participating in the ballot have chosen their space, the floor plan will be issued to the remainder of the membership and other prospective exhibitors. Bookings will then be taken on a first come, first served basis if there is any remaining space available.

The Austech Ballot is only available to AMTIL members. Nonmembers may either join AMTIL to qualify for participation, or apply for stands once the ballot applicants’ stands have been allocated. To take part in the ballot process, a signed contract and booking form together with a 10% deposit must be received at AMTIL by Friday 26 September 2014. Please be sure to complete the preferences section of the booking form to help speed up the process. Please note that AMTIL accepts all major credit cards. For more information on Austech, please call 03 9800 3666, or email Events Manager Kim Warren on kwarren@amtil.com.au.

Get your costs under control Available completely free of charge to AMTIL members, Expense Check is an exclusive service designed to help you reduce your operating costs. Expense Check is a service to reduce non-core business expenses. It achieves reductions in non-core costs by negotiating with suppliers on your behalf to ensure they are on the most competitive market rates for your needs. Expense Check is able to ensure they continually deliver better-than-market offers, through established relationships with a broad range of suppliers across all non-core cost categories.

Expense Check can also help you remain on the best rates permanently and not be exposed to expensive roll-over contracts or price increases. Expense Check achieves this by building a long-term relationship with you and reviewing your expenses on an annual basis, giving you the knowledge that you will continue to remain on the most competitive market rates, even if you are currently locked into contracts.

The process is simple. Expense Check collects the required data (invoices) in a brief 15-minute meeting or phone call. After seven days, they will present you with a report that details their analysis of the most suitable suppliers for delivering cost savings for your business. The report includes comprehensive detail on all of Expense Check’s suppliers, within the agreed scope of work, and their competitive rates. The report enables you to benchmark against current suppliers, identify cost savings and improve business efficiencies. The service is at no cost to you – it’s simply a ‘no-cost health check’ for your business.

You also have the option of choosing whether to change one or more suppliers based on Expense Check’s recommendations, so you are not locked into accepting their recommendations. Expense Check even does all the work in transferring you over to new suppliers.

76 |

AMT September 2014

For further information please visit www.amtil.com.au or contact Greg Chalker, Corporate Services Manager on 03 9800 3666 or email gchalker@amtil.com.au

great ideas and more opportunity. Australiaâ&#x20AC;&#x2122;s Premier Advanced Manufacturing & Machine Tool Exhibition 26th â&#x20AC;&#x201C; 29th May, 2015 Melbourne Convention & Exhibition Centre Melbourne, Australia www.amtil.com.au/austech

1215AUSTECH

AMTILinside

New AMTIL Members

First events for Additive Manufacturing Network AMTIL’s new Additive Manufacturing Network got up and running in the last month, with a series of events held across the country.

The events were designed to help those attending to learn about the mechanisms and resources currently available in the fast-growing field of additive manufacturing (AM), and grow their business through opportunities for learning and collaboration. All of the events featured presentations from AMTIL CEO Shane Infanti, and Chad Henry, the Additive Manufacturing Operations Manager at the CSIRO. Each event also included a talk by a representative of a prominent local business, who discussed their stories, the benefits of AM, and how you can transform your business with this technology. CSIRO’s SME Engagement Centre was also on hand to offer assistance to companies seeking to connect to technical expertise and develop research projects for industry, and guidance around access to funding for research. “The AM Network has been set up to help take a lot of the mystery out of additive manufacturing, and events are crucial to that,” said Infanti. “We want the Network to provide a more formal mechanism for providing connections and delivering opportunities, and so far we’ve received a lot of interest from our members. We’re delighted with the response.” The first event – held on 13 August, hosted by the CSIRO at the Riverside Life Sciences Centre in North Ryde, NSW – was fully booked with around 100 people in attendance. They enjoyed a presentation from Peter Freedman, Managing Director of RØDE Microphones, about how his company has gone from humble beginnings in the 1990s to globally renowned industry leader.

78 |

AMT September 2014

Round 21 Finish line in sight

Chad Henry

Further events were held in South Australia – where the local speaker was Jack Hoogland, from Measurement Engineering Australia (MEA) – Western Australia and Queensland, each of them again drawing strong turn-out. A final event (for now) to be held in Victoria on 9 September was sold out as AMT went to print. “These events are just the beginning,” added Infanti. “We’ll be running more events and activities as the AM Network continues to grow. Watch this space.” The AM Network is an industry-driven collaborative network of organisations that will foster and grow the AM sector. Membership of the Network is free to AMTIL members. For more information or to become a member of AMTIL and the AM Network, you can email Shane Infanti at AMTIL: sinfanti@amtil.com.au.

Leading up to round 21, there’s been more shifting of positions on the ladder than deck chairs on the Titanic. Sydney seems to have locked away top spot with Hawks and the Cats to fight out the coveted second spot - a tasty feast of good football from the best Victorian teams. Richmond are coming with a burst but it will end up in tears as they’ll probably stitch ninth place and miss out on the finals once again. The biggest tumble comes from the anything but ‘Mighty’ Magpies, their second half of the season has been mighty average. Daniel Fisher and Brendan Smith have made the right moves at the right time of the season with Fethers dropping to third and SKN going for broke plummeting to fourth - a connection to the Magpies? Me thinks so – happy tipping. Laurie Sanchez 1 Daniel Fisher

130 (471)

2 Brendan Smith

129 (478)

3 Fethers

129 (478)

4 SKN

126 (553)

5 WSG

125 (511)

6 Jeff Hedger

125 (567)

7 EluMan

124 (491)

8 Shane Infanti

123 (527)

9 Seco

123 (541)

10 Craig Linssen

123 (669)

Australian Manufacturing Technology Institute Limited

Keeping it Simple. One Membership, Many Benefits.

connect.inform.grow. MeMbershIp pAckAges AvAILAbLe AMTIL membership for companies, individuals and supporters within the precision engineering and advanced manufacturing sector. For more information visit www.amtil.com.au or contact corporate services Manager greg chalker on 03 9800 3666 or gchalker@amtil.com.au

1220AMTIL

www.amtil.com.au

industry calendar

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event

INTERNATIONAL AmCon New York: 10-11 September Texas: 7-8 October Utah: 22-23 October Michigan: 11-12 November A one-stop-shop design & contract manufacturing expo which includes forming/ fabricating; machining; engineering; prototyping; finishing; assembly. www.amconshows.com Jordan International Industries & Machinery Exhibition Jordan 15-18 September 2014 A leading Sourcing Exhibition in the Levant region. Includes metal working machinery, machine tools, plastic processing, food processing, welding equipment. www.jordanmachineryshow.com METAL Poland, Targi Kielce 16-18 September 2014 International Fair of Technologies for Foundry. Includes: melting of casting alloys, Design and production of foundry equipment, moulding and core-making machines, moulding materials, sand, bentonite, binders etc. www.targikielce.pl Korea Metal Week South Korea, 16-19 September 2014 Includes Fastener & Wire Korea, Die Casting & Foundry Korea, Automobile & Machine Parts Korea, Press & Forging Korea, Tube & Pipe Korea, Metal Surface Treatment & Painting Korea, 3D printing Technology Show. www.korea-metal.com Metalurgia Brazil, Joinville 16-19 September 2014 International Fair and Congress of Technology for Casting, Forging, Aluminum and Services. Includes metallography, testing and metrology, equipment for welding, forgings, castings, furnaces. www.metalurgia.com.br/ en/?page=informacoes AMB Germany, Stuttgart 16-20 September 2014 Leading international metal working exhibition www.messe-stuttgart.de/en/amb Inside 3D Printing Conference and Expo Tokyo: 18-19 Sep 2014 California, Santa Clara: 21-23 Oct 2014 A B2B tradeshow for the 3D printing industry. Explores the business applications of 3D printing. Includes keynote presentations, the latest 3D printers and services in action. www.mediabistro.com/inside3dprinting BIET Bangladesh 18-20 September 2014 Bangladesh Industrial Engineering & Manufacturing Technology Trade Show. Includes CAD/CAM, casting/forging; dies & moulds; automation. http://bietexpo.asktradex.com

80 |

AMT September 2014

Toolex Poland 20 September – 2 October 2014 International machine tools, tools and processing technology fair. Includes machine and measurement tools; CAD/CAM. www.exposilesia.pl/toolex/uk

IGEM2014 Malaysia 16-19 October 2014 “Creating Green Wealth”, 5th International Greentech & Eco Products Exhibition & Conference. Adoption of green technology. www.igem.com.my/2014

Foodtech Packtech New Zealand, Auckland 23-25 September 2014 For the Food Technology and Packaging Technology market – delivers NZ’s largest gathering of suppliers and manufacturers. www.foodtechpacktech.co.nz

Euroblech Germany, Hannover 21-25 October 2014 Exhibition profile covers the entire sheet metal working technology chain. Includes Sheet metal working, forming; processing of sheet metal/plastic hybrid structures; joining, welding, fastening; tools, dies, CAD/CAM etc. www.euro-blech.de/english

M-Tech Japan, Osaka 24-26 September 2014 Mechanical Components & Materials Technology Expo. including: Difficult-to-Cut Materials Fabrication; Motion Technology; Motor; Fluid Power Transmission; Mechanical Parts & Related Products; Fasteners & Fastening Technology; Mechanical Spring; Testing/Measuring; Tools. www.mtech-kansai.jp/en Interplas UK, Birmingham 30 September – 2 October 2014 British plastics event, covering manufacturing processes, technologies and services. www.interplasuk.com MSE2014 Manufacturing Solutions Expo Singapore, Suntec City Convention Centre 8-10 October 2014 www.smfederation.org.sg (click on Calendar/Trade Fairs) Metalex Vietnam Vietnam, Ho Chi Minh City 9-11 October 2014 Includes Machine tools and machining centres; EDM machines; sheet metalworking, welding technology; automation; material handling; mould/dies; metrology etc www.metalexvietnam.com Afrimold South Africa, Midrand 14-16 October 2014 Exhibition for precision machining, tooling, mouldmaking, design and application. www.afrimold.co.za Maktec Eurasia Turkey 14-19 October 2014 MT, metal processing machines, welding, cutting, drilling, quality control etc. www.maktekeurasia.com Design & Manufacturing USA, Illinois 15-16 October 2014 Innovative advances in design and manufacturing including 3D printing, Industrial M2M, and designing next gen medical devices. Includes 3D Printing Conference covering new materials, innovative uses in manufacturing, and a case study of 3D printing used in medical prostheses.” http://dmmidwest.designnews.com

Mining and Engineering (M&E) Indonesia Indonesia, Jakarta 29-31 October 2014 Opportunities for Australian and international suppliers to enhance their business profile, launch latest technologies and services and network with mining professionals from Indonesia and the surrounding region. www.miningandengineeringindo.com JIMTOF Japan, Tokyo 30 October – 4 November 2014 Leading international machine tool exhibition www.jimtof.org/eng Metalworking and CNC Machine Tool Show China, Shanghai 4-8 November 2014 Includes metal forming/cutting machine tools and special purpose machines. MWCS will, for the first time, launch an individual “True Meaning of Sheet Metal” for professional buyers and visitors. www.metalworkingchina.com/EN Myanmar Intl. Machine Tool & Automation Myanmar 13-16 November 2014 Includes Power & Electronics Fair http://mt.emmafair.com/en_US/index.html Metalex Thailand, Bangkok 19-22 November 2014 Includes: machine/metalworking tools; metrology; welding technology; mould & die; sheet metal working; automation; material handling; accessories. www.metalex.co.th Euromold Germany, Frankfurt 25-28 November 2014 World fair for moldmaking and tooling, design and application development. www.euromold.com MACTECH 2014 Egypt, Cairo International Convention Center 27-30 November 2014 Regional manufacturing, trading and networking forum serving the markets of the Middle East and North Africa. Specialising in machine tools, industrial tools, welding and cutting equipment www.mactech.com.eg

industry calendar local Queensland Gas Conference & Exhibition Brisbane Convention & Exhibition Centre 10-11 September 2014 Brings together international opinion leaders from the global energy market and senior decision-makers from the Australian LNG industry and supporting infrastructure www.queenslandgasconference.com.au Bulkex Qld, Rockhampton 17-18 September 2014 Latest in bulk handling products, methods and solutions. Includes latest in conveyor systems, thermal imagers, loader innovation, dust collection, stainless steel feeders. www.bulkex.com.au LandForces Asia Pacific 2014 Brisbane 22-25 September 2014 A comprehensive international industry exhibition to showcase land-defence equipment, technology and services for the armies of Australia, Asia and the Pacific region. www.landforces.com.au Mining & Engineering NSW Newcastle Entertainment Centre 8-10 October 2014 The latest products and technologies for the rapidly growing coal mining sector of the Upper Hunter Valley. www.miningandengineeringnsw.com.au Australasian Waste & Recycling Expo Sydney 9-10 October 2014 Innovations in the collection, sorting and processing of waste from the municipal, commercial and construction sectors. www.awre.com.au

All Energy Australia 2014 Melbourne Convention Centre 15-16 October 2014 an annual, free-to-delegate, business-tobusiness conference and networking forum hosted alongside an exhibition showcasing renewable energy, clean energy, sustainable transport and energy efficiency. www.all-energy.com.au

Australian Motoring Festival Melbourne Showground 26-29 March, 2015 Showcasing the largest cross-section of vehicles ever assembled in this country, including new and historic cars and motorcycles, SUVs, and special interest vehicles. www.australianmotoringfestival.com.au

Sustainability in Business Melbourne Convention Centre 15-16 October 2014 Looks at the core fundamentals needed for a company’s sustainable future and how sustainable innovation can help drive them forward to improve their profitability and social responsibility while reducing their impact on the environment. www.australiansustainability.com.au

Safety in Action Brisbane Exhibition & Convention Centre 22-23 April 2015 Dedicated workplace health & safety event www.safetyinaction.net.au/brisbane

Queensland Gas Conference Brisbane Convention & Exhibition Centre 25-26 November 2014 Dedicated to the latest developments surrounding Coal Seam Gas and Liquefied Natural Gas in Queensland www.queenslandgasconference.com.au

2015 Avalon 2015 Victoria, Geelong 24 February-1 March 2015 Australian International airshow and aerospace & defence exposition www.airshow.com.au/airshow2015

Hare & Forbes 84 Advertiser Index Hi Tech Metrology 61 Industrial Laser 9 3D Systems Asia Pacific 8 Iscar 2-3 Acra Machinery 23 LS Starrett 63 AMTIL AMT 53 Machinery Forum 73 AMTIL Membership 79 MAPAL 21 AMTIL ManufactureLink 75 MetOptix 65 AMTIL Austech 77 MTI Qualos 19, 31 AMTIL Digital Ad 10 OMAX 15 AlfexCNC 17 OSG Asia Pty Ltd 4&5 Amada 82-83 Sandvik 7 Applied Machinery Aust. P/L 29 Siemens Industry Software 13 CeMAT Ad 41 Standaco Machinery Sales 33 Complete Machine Tools 27 Sutton Tools 25 Delcam 59 Taiwan Takisawa 51 Dimac Tools 39 Thyssenkrupp 49 DMG Mori Seiki OFC Walter 11 G-Zero five 57

Would you like to advertise in Australia’s No. 1 precision and manufacturing magazine? Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asameulsson@amtil.com.au

Austech Melbourne Convention & Exhibition Centre 26-29 May 2015 Australia’s premier advanced precision manufacturing and machine tool exhibition. The only show specifically targeted at the metalworking, machine tool and ancillary market held in Australia. www.amtil.com.au/Austech-Exhibition National Manufacturing Week Melbourne Convention & Exhibition Centre 26-29 May 2015 Fully integrated annual manufacturing exhibition showcasing the latest products and constantly evolving technologies in the expanding manufacturing market www.nationalmanufacturingweek.com.au/

oct14 Australian Manufacturing Technology

Your Industry. Your Magazine.

NEXT MONTH…

DEFENCE Our main feature checks out how manufacturers are driving some of the latest innovations in defence applications. CUTTING TOOLS FORMING & FABRICATION ROBOTICS & AUTOMATION COMPRESSORS & AIR TECHNOLOGY

AMT September 2014

| 81

THE ULTIMATE SOLUTION for tube and sheet metal processing. 60 second change time between cutting flat sheet and pipe or tube.

MULTIPLE USE LASER CUTTING MACHINE

The Amada FOM2RI3015NT multiple use laser cutting machine is the ultimate quick switch solution. Effortlessly change from sheet to tube processing in just 60 seconds. • Quick switch from sheet to tube processing • High productivity • High quality cutting • Continual production • Stable cutting • Drastic reduction of setup time

Amada Oceania Pty Ltd www.amada.com.au

SIMPLIFYING SHEET AND TUBE CUTTING

“The FOM2 with Rotary Axis has enhanced our fabrication facility and eliminated hours of manual work.” “I’m a fan of Amada machinery and our companies make a perfect fit.” Mike Bonomelli, Managing Director of Melbon Sheetmetal Pty Ltd

Embracing technology and engaging its employees has led Melbon Sheetmetal Pty Ltd through good and bad times to remarkable success in recent years. What started with second-hand machines and three employees in 1986 in Welshpool, Perth, has grown into an innovative fabrication shop with 40 employees and quality plant and equipment. “I have travelled the world looking for the right technology in machinery that would send the company into the 21st century,” says Managing Director Mike Bonomelli. “I had the opportunity to travel to Amada Japan and see first-hand the latest technology that was available.” As a result, the company has installed seven Amada machines since 2004, including a 4-kW FO Laser and three HDS press brakes, a 6kW Laser (4000 mm x 2000 mm table) and a servo-electric turret punch press EMZ with an ASR automated material

load & unload system. When business slowed down a bit in 2013, it was time for Mr Bonomelli to change direction to stay ahead of the game. Once again he turned to Amada and invested in a Rotary Index laser cutting system, focussing on simplifying the switch from flat sheet cutting to tube or pipe cutting. The system, an FOM2 3015 NT RI Laser, includes an innovative Rotary Index with the power and speed to efficiently cut mid to thick materials. The Rotary Index is located on one of three shuttle pallets – making it extremely easy to switch from flat sheet cutting to tube or pipe cutting. “The FOM2 is able to cut pipe, RHS and channel and then quickly converts back to a flat bed laser which has enhanced our fabrication facility and eliminated hours of manual work,” Mike explains. “This machine

has taken the place of our band saw and tape measure and gives us a much more accurately finished product.” This accuracy is achieved through the machine’s clever design. The Rotary Index is an integrated unit, allowing the cutting head to be positioned near the chuck – minimising the dead zone. Bowed pipe or tubing can be cut without vibration while maintaining accuracy from end to end.

The machine’s strength lies in its versatility Productive: The FOM2 3015 NT RI Laser allows Melbon Sheetmetal to get through large volumes of work, while maintaining the highest standards of production. It also makes a difference to the client, as it means that both the cost and time of production is minimised, allowing for even quicker service delivery. Versatile: The Rotary Index represents a seamless fusion of innovative technology and robust functionality. The innovative design expands process range capabilities to cut a significantly wider variety of tubing and pipe. Machines using 3- or 4-jaw rotary chucks cannot process a similar range of materials without the use of fixtures or collets. Amada’s FOM2 RI can process round, square, rectangle, C-channel, and angle iron, making it the most versatile Rotary Index laser cutting system available. High speed: The features of the high-speed cutting head include increased sensing speed for faster cutting and plasma resistance in thin material, lens burn detection to stop the machine and alert the operator to possible burn damage to the cutting lens, cut process monitoring for automatic pierce detection as well as plasma detection for thick stainless steel and aluminium and auto-focus control.

Sydney 02 8887 1100 Unit 7, 16 Lexington Dr., Bella Vista NSW 2153 Melbourne 03 9020 1400 Unit 1, 3-4 Anzed Court Mulgrave VIC 3170 | Perth | Brisbane

POWER THAT PACKS A

P UNCH

HYDRAULIC PUNCH & SHEARS

SINGLE OPERATION - COMPACT AND VERSATILE 45 - 60 Tonne All work stations guarded Mitre cutting of angle iron

PRICED FROM $ 6,290

Magnetic base work lamp Adjustable stroke for faster punching Curved shear blade for minimal job distortion Punching capacity up to 40mm standard Large punch table with adjustable stops Adjustable cut length stop with graduated scale Single operation process for all stations Hydraulic system is protected with replaceable filter cartridge Includes: 10 sets of round punch & dies (6-26mm) - 45 & 60 Tonne

L FOR L A C E S A E PL ON HOT DEALSCHINES A SUNRISE M DUAL OPERATION - TWICE THE PRODUCTION 60 - 165 Tonne

PRICED FROM $ 12,290

Includes

Five guarded work stations

Single-Vee Pressbrake Attachment

Mitre cutting of angle iron Magnetic base work lamp Adjustable stroke for faster punching Curved shear blade for minimal job distortion Punching capacity up to 50mm standard Large punch table with multi-purpose bolster Adjustable one-touch electronic length stop

Dual operation allows two people to work simultaneously Hydraulic system is protected with replaceable filter cartridge Includes: Single-Vee pressbrake attachment 10 sets of round punch & dies (6-26mm) - 60 & 80 Tonne 20 sets of round punch & dies (6-40mm) - 100, 125 & 165 Tonne

OPTIONAL ACCESSORIES:

ANGLE BENDING

VEE NOTCHER

CHANNEL PUNCHING DIE HOLDER

NSW

CHANNEL SHEAR

QLD

MULTI-VEE PRESS BRAKE

PIPE NOTCHER

VIC

(02) 9890 9111

(07) 3274 4222

(03) 9212 4422

(08) 9373 9999

1/2 Windsor Rd, Northmead

625 Boundary Rd, Coopers Plains

1 Fowler Rd, Dandenong

41-43 Abernethy Rd, Belmont

www.machineryhouse.com.au

8_AMTIL_010914

LARGE HOLE PUNCHING