AMT NOV 2014 by AMTIL

nov14 Australian Manufacturing Technology

Your Industry. Your Magazine.

3d Precision

Construction: Building a bright future PAGE 34

WysiWyg 3d What you see is What you get in 3d!

.Construction & Infrastructure .Additive Manufacturing .Material Removal .Management

WYG AMT Nov14 Cover Flap Front Ad.indd 1

21/10/14 2:11 PM

) 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 10 NOVEMber 2014 ISSN 1832-6080

contents

CONSTRUCTION & INFRASTRUCTURE Archer brings ingenuity to electricity High-tech potential in road measurement equipment Bowhill Engineering – success against the odds

38 40 42

ADDITIVE MANUFACTURING 3D printing – Revolutionary or evolutionary? Precision prototyping – 3D printing in injection moulding Facing the realities of additive manufacturing Enabling innovation with design & additive manufacture Bringing 3D printing to Australian manufacturing

49 50 52 54 55

MATERIAL REMOVAL LASERTEC 65 3D: Additive + subtractive Tailored solutions for turbocharger production

56 58

BUSINESS MANAGEMENT The century of ideas The value of utilising local suppliers Changing of the Guard SMEs and the export challenge Addressing the barriers to growth

64 65 66 67 68

MOTORS & DRIVES Rylock doubles output by automating plant

From the Editor From the CEO From the Industry From the AMWU

8 10 12 14

INDUSTRY NEWS Current news from the industry

PRODUCT NEWS Our selection of new and interesting products

ONE ON ONE Harry Moser - founder of the US Reshoring Initiative

AMTIL FORUM Import/Export 72 Quality 74 Law 75 Manufacturing History – A look back in time

AMTIL INSIDE The latest news from AMTIL

nov14 AustrAliAn MAnufActuring technology

your industry. your Magazine.

Construction: Building a bright future PAGE 34

.Material Removal ture .Additive Manufacturing

Building for manufacturing’s future While growth in construction in mining and heavy industry engineering is falling as global demand for Australia’s resources wanes, innovative Australian manufacturers are building a successful future by teaming up on a wide range of projects with major players in the construction and infrastructure sector.

48 3D Central – open for business A special event was held on 10 October to mark the opening of 3D Central, Objective 3D’s new additive manufacturing facility at Carrum Downs in south-east Melbourne. The new, state-of-the-art plant is Australia’s largest additive manufacturing hub and will manufacture parts for the mining, defence, bio-medical, construction, aerospace and automotive industries.

Cover Innovative Australian manufacturers are working with Construction & Infrastructure giants on a wide range of projects. The prefabricated housing sector market is projected to rise over the next few years, representing a big opportunity for manufacturers. Page 34

.Management

.ConstruCtion & infrastruC

6 |

AMT November 2014

Pipe Lining & Coating – R&D paves road to success Pipe Lining & Coating has developed the only Australianowned supply source of cement lining and pipeline coating products and has been involved in some of the biggest infrastructure projects in the country including the first mobile cement-lining plant operating in Australia. This delivers centrifugally applied cement mortar linings to steel pipes on-site.

izes er S Oth ilable a Av

ETT-1D Steel Engine Tear Down Table

IWB-40 Ultimate Industrial Work Bench Package

WBS-3D Steel Work Bench

(A385)

(A380)

SR-DSL Mobile Storage Shelving System with Accessories

(K035)

(K032)

izes er S Oth ilable Ava

Industrial Series Tool Chest & Roller Cabinet (K005B)

izes er S Oth ilable Ava

Trade Series Tool Chest & Roller Cabinet

WTC-1450 Industrial Tooling Cabinet Workstation

(K006A)

(T773)

TCW-900N Industrial Tooling Cabinet on Wheels

TCW-1200 Industrial Tooling Cabinet

(T765)

(T772)

izes er S Oth ilable a Av

PTB-32 Parts Bin (T7952)

PTB-30CHD Parts Bin (T7964)

PTB-48CD Parts Bin

STC-COMBI Industrial Storage & Tooling Cabinet

SC-1800 Industrial Storage Cabinet

(T7958)

(K033)

(T762)

izes er S Oth ilable Ava

See

(S020)

SR-36 Mobile Storage Bin Rack (S021)

RST-4T Flexi-Rack Wood Shelving (S013)

NSW

Website

RSS-4WS Industrial Racking Steel Shelving

for more information

(S014)

QLD

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

9_AMTIL_011114

SR-22 Mobile Storage Bin Rack

FROM THE

Editor

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

William Poole

Sales Manager Anne Samuelsson asamuelsson@amtil.com.au

Get ready for 2015

Publications Co-ordinator Gabriele Richter grichter@amtil.com.au

Okay, so the rest of the world still has December to get through, but for AMT, November marks the end of 2014, with our final edition of the year. Either way you look at it, 2015 is coming up fast. And inevitably at this time of year, there is a tendency to look ahead and contemplate what the future holds, what challenges await us, and how we can equip ourselves for them. Such questions have certainly been playing on the minds at CSIRO, who have addressed them in a new discussion paper ‘Equipping Australian Manufacturing for the Information Age: iManufacturing – Is Australia Ready?’ According to the paper, Australian industry needs to play to its strengths and make the transition from traditional manufacturing into new areas of competitive advantage. The CSIRO argues that significant opportunities exist – both domestically and internationally – in the market for high-value-add, niche-manufactured goods and associated services produced here. However, to capitalise on those opportunities, Australian manufacturers need to embrace modern information technology and develop the associated skills to best exploit it. The paper highlights various trends in global manufacturing towards smaller batches, customised products, rapid prototyping, agile processes and increased ‘servitisation’ – creating value by complementing or even replacing products with services. To deal with this shift, the report’s authors urge Australian manufacturers to develop appropriate business models and prepare for increasingly innovative, competitive offerings in terms of price and flexibility. Companies need to obtain the necessary skills and tools to do business, compete globally, and adapt to the future. Such long-range, forward thinking is always welcome, and the CSIRO’s observations and recommendations are sound. But for manufacturers today, there are more immediate challenges. Barely a month into 2014, Toyota signalled the end of Australian car-making when it announced plans to cease production here. And with the latest Australian PMI showing another contraction in the manufacturing sector, we reach the end of the year with our industry continuing to struggle against a tide of bad news. For many manufacturers, it’s been a year to forget. Nonetheless, the Government’s Industry Innovation & Competitiveness Agenda contains a promising set of policy proposals. And from my perspective editing this magazine, I see more than enough creativity, ingenuity and energy among Australian manufacturers not only to overcome the obstacles we’re currently facing, but to thrive. Here’s to better news in 2015. *** Meanwhile, as we say goodbye to 2014, we must also bid a fond farewell to one of AMT’s longest-serving and most treasured contributors. I’m referring of course to the late, great Fred Colvin, whose memoir “60 Years with Men and Machines” has been serialised in these pages for the last five years. The search is now on for the next book to run on our History page (feel free to send us your suggestions), and we hope to have Fred’s successor in place in time for our next issue in February. *** Finally, I’d like to take this opportunity thank all our readers, contributors and advertisers for their support throughout 2014. On behalf of myself, Anne and Gabriele, and all of the AMTIL team, I’d also like to wish AMT readers and all involved in our industry a Merry Christmas and a Happy, Prosperous New Year.

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.

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 November 2014

SHORT-RUN PRODUCTION

PRODUCTION & TOOLING

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

FROM THE

CEO Shane Infanti – Chief Executive Officer AMTIL

Agenda pushes for reform in collaborative research On 14 October, the Prime Minister and Minister for Industry released the Industry Innovation and Competitiveness Agenda. Although overdue, it was pleasing to see a number of initiatives that will reduce red tape, build skills and provide a good environment by which businesses can be more competitive. There is little question that fostering innovation and entrepreneurship are vital in re-generating our industry, along with a stronger commitment to commercialisation of research. To that extent, the establishment of five Industry Growth Centres will be a very interesting process. This, combined with a review of the existing Cooperative Research Centre (CRC) Program, will dictate how industry-led collaborative research is carried out in the future. The announcement of the Industry Growth Centres has been met with some conjecture. It appears they may be a rehash of the previous government’s ill-fated Innovation Precincts, which have been largely unsuccessful in outcome delivery. In responding to a question requesting clarification of the difference between Industry Growth Centres and CRCs, the Minister stated: “We want to bring industry research development and the whole policy area into focus and having CRCs as an adjunct to this simply won’t work. We’ll be looking at how we bring Industry Growth Centres into this process.” This is a key statement. Industry Growth Centres must be able to work effectively with existing CRCs and the Entrepreneurs Infrastructure Program to maximise outcomes. The requirement for Industry Growth Centres to be self-funding within four years is also an interesting stipulation. This will drive the Centres to be more business-focused which may influence their activity away from where it should – innovative and collaborative research conducted by SMEs. We will have to wait and see how this plays out. Another key part of the Agenda is the establishment of a $63m Growth Centre Project fund. This is another good initiative and a key component of this fund is to

10 |

AMT November 2014

All in all, the Industry Innovation and Competitiveness Agenda gives enough positive signs to show this Government is committed to helping transform our manufacturing sector so that it can compete globally and competitively.

Local content to be enforced I noted with interest the recent promise from the Victorian Coalition Government in the lead up to the state election later this month, of $4m to fund Local Content Facilitators. This is another excellent initiative. I have heard the state Minister for Manufacturing, Hon. David Hodgett, on a number of occasions talk passionately about local content on Government-procured major projects and delivering on this promise is admirable. Engaging Local Content

Improving the capacity and capability of major established companies, through enhancing their supply chain, has the potential to deliver immediate results. Facilitators to ensure the delivery on the promised percentage of local content on a specific project is overdue. For too long, this has been given lip service and I commend the Minister and the Government on taking this stance. This is an ongoing issue though with our Federal politicians. We are still awaiting the Government’s decision on the Future Submarine Project, even though it was an election promise to have them built at ASC in South Australia. The Future Submarine Project would be an enormous boost to Australian manufacturing. A strong statement of support for this project to be built in Australia, with ASC held to account on a set percentage of local content, would greatly enhance the recent Agenda announcement.

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

improve the supply chain integration of major companies. AMTIL has been pushing for assistance in this area for a number of years. Improving the capacity and capability of major established companies, through enhancing their supply chain, has the potential to deliver immediate results. There are many companies that are currently at maximum capacity that can generate increased business in the short term by developing supply chain infrastructure around them.

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

Tackling the need for economic rebalancing The recent release of the Federal Government’s Industry Innovation and Competitiveness Agenda brings the focus back to the policies we need to embrace to help rebalance our economy. The Government has adopted many of Ai Group’s suggestions, including measures around: linking businesses and research organisations; easing taxation burdens; reducing red tape and maintaining strong business capability programs, along with a number of initiatives to bring industry closer to the centre of a range of training and education programs. The downside of course is that funding to these types of programs overall has been greatly reduced, and it will be harder for businesses to access such support. Broadly speaking, the Agenda addresses the need for rebalancing in our economy across industries to build an industrial base to ensure strength and resilience for the future. This is particularly important today with the mining-investment boom winding down and commodity prices in retreat. New sources of growth from other sectors, including manufacturing and services, need to resume their contributions to economic development, and the Competitiveness Agenda will help in that regard. The Agenda has a welcome range of measures aimed at stimulating the investment in new ideas and processes that are so fundamental to innovation-led improvements in productivity and competitiveness. Proposals to build greater collaboration between Australia’s research organisations and the business community are particularly important, as are plans to lift the commercialisation of Australian research. The commitment to five Industry Growth Centres contained in the Agenda has been controversial. The Government is looking to deliver a practical focus on commercialisation of research, as well as the need for Industry Growth Centres to build on the success of the initiatives of the Entrepreneurs’ Infrastructure Programme. For this to be successful, it is vital that these centres are industry-driven, rather than research-driven, and have a clear rationale and purpose. There should be a focus on the outcomes of the network, rather than creation of a network per se. This could be made even more effective with a program designed to encourage the participation of small businesses and start-ups, and the creation of ‘linking organisations’ to facilitate the creation of partnerships between research organisations and industry. Another initiative in the Agenda that has received broad support is the changes to the Employee Share Scheme for start-up companies. This has the potential to improve the landscape for start-ups to attract talented employees and finance. However, we do have some concerns that the eligibility criteria may be too tight and we will need to consult with member businesses on the design of the program. The decision to allow Austrade to redefine the scope of eligible investments in the Government’s Significant Investor Visa program will also help attract much needed investors from overseas. In our submission to the Financial System Inquiry, Ai Group asked that financing venture capital be included as an eligible investment, and we are strongly urging Austrade to consider this. The Government’s proposal on international product standards is to adopt the principle that if a system, service or product has been approved under a trusted international standard or risk assessment, then Commonwealth regulators should not impose additional requirements. We are talking to the Government and urging them to build on the undoubted effectiveness of this proposal by encouraging the States and Territories to adopt the same principle and by ensuring greater support for Australian participation in international standardssetting forums.

12 |

AMT November 2014

The Government has adopted many of Ai Group’s suggestions… The downside is that funding to these types of programs overall has been greatly reduced, and it will be harder for businesses to access such support. On the important subject of labour migration, the Government’s streamlining of 457 visas will help remove compliance burdens from businesses with a positive track record in using the program and put the focus rightly on the very few who misuse the scheme. A more reasonable approach to language testing will also open the program up to more applicants with skills that are in short supply in our economy. Unfortunately, the removal of the unnecessary Labour Market Testing regime for 457 visas was not included in the Agenda. In regard to training, there are important reforms to the VET system that would enable training to be industry-led, and ensure that businesses can find or train employees in skills that will be relevant. However, it is a concern that the Government has targeted only a narrow range of industries for growth in training. A sound addition to the established apprenticeship path has come in the form of a pilot program to provide 7500 scholarships to small businesses in regional areas who employ and train 18-24-year-olds – an approach that will re-engage workers in areas of high unemployment and boost labour participation. The latest Ai Group and World Economic Forum’s survey of Global Competitiveness Report shows that Australia’s relative Global Competitiveness Index has deteriorated since 2009-10, dropping continuously from a peak ranking of 15th place in 2009-10 to 22nd place in 2014-15. The need for reform, therefore, is urgent. Australia must find multiple sources of growth, rather than relying so heavily on resource and energy commodities as we have over the past decade. A broader range of businesses need to be encouraged to step up investment, employment and productivity if we are to lift the quantity and quality of jobs and to improve incomes and living standards across the community. This rebalancing is important not only for the strength of the economy but also to improve its resilience. Ai Group members consistently tell us that Australian industry and governments need a concerted focus on reducing labour costs, regulatory costs and energy costs, which all erode our international competitiveness. We also need to reduce Australia’s high corporate tax burden. We look forward to working on behalf of our members with the Government on the upcoming reviews covering these areas.

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

FROM THE

AMWU Paul Bastian – National Secretary Australian Manufacturing Workers Union

Digging us deeper into a resources hole We had to wait through many delays before seeing the Abbott Government’s new Industry Innovation and Competitiveness Agenda last month. It was billed as a bold response to both the impact of the closure of Australia’s automotive manufacturing industry on the economy, persistently low multifactor-productivity growth and a post-mining boom economic reality. Now we’re wondering why we waited so long for an agenda that is piecemeal, unambitious and woefully inadequate. The centrepiece is a $188m commitment to five Industry Growth Centres to support research and industry collaboration and provide services aimed at growing the nation’s strength. If assessed in a vacuum, this would seem like a decent policy initiative, if not quite a bold one. But policy and economics do not live in a vacuum. In the Federal Budget, as part of $970m of cuts to industry programs (not including automotive or training support) the government announced the scrapping of the former government’s Industry Innovation Precincts policy. That had 12 Precincts in various sectors of the economy, with an open tender process for industry and research consortia to bid on what sectors would be included. A $500m fund would support joint projects to improve industry competitiveness, create new products and deploy new technologies. The Abbott Government’s equivalent is a $63m Growth Centre Project Fund, split between five Growth Centres. No sooner than the ink was dry on the statement, the flaws were apparent. The choice of sectors has been criticised, not surprising considering the secretive process that saw unions, many manufacturing experts and peak industry bodies shut out. The advanced manufacturing and food centres were a no-brainer, having already been established under the previous government’s policy. The inclusion of both an Oil and Gas centre and a Mining Engineering, Technology and Services centre means two of the five centres concentrate on the resources sector. Is this wise, given that the point is to diversify the economy away from an increasing reliance on mineral and energy exports? These two centres represent 40% of the total and by implication, 40% of the government support provided. Yet mining represents 10% of the economy and just over 2% of employment. So, this government is actually putting more of our eggs into the mining basket – not preparing for a scenario where much of that basket is lost. This is especially foolish when you consider some of the sectors excluded, such as education, tourism, renewable and low-carbon energy, and information technology. Like manufacturing, these are crucial to our long-term growth and prosperity, with greater employment prospects than resource extraction. But they have been utterly ignored. That leaves the Pharmaceutical and Medical Devices centre. This is an important industry, but why should it get special support in front of others that are larger, growing as strongly, and employ more people? About 15,000 people actually work producing pharmaceuticals in Australia. Compare that to the 90,000 jobs we expect to see lost as a result of a withdrawal of government support from automotive manufacturing. Yes, pharmaceuticals is an extremely advanced industry technically, but then so is automotive manufacturing. Automotive skills and its production and management processes are transferable to other manufacturing industries such as aerospace, shipbuilding or capital equipment manufacturing. That’s a far greater spill-over than pharmaceuticals, and we certainly will need that knowhow.

14 |

AMT November 2014

Yes, pharmaceuticals is an extremely advanced industry technically, but then so is automotive manufacturing. The case for a Pharmaceuticals and Medical Devices centre would be stronger if it was one of 12 industry precincts rather than one of five. And remember, it is supposed to be a prime beneficiary of the Abbott Government’s Budget policy of a $20bn medical research fund from the Budget. Beyond the issue of which sectors have or haven’t been chosen, the fundamental point is one of scope and ambition. To do the Australian economy and our future justice, we can’t be restricted to five sectors and a paltry $63m fund. The government’s Growth Centres are not substantial enough to have a lasting, essential impact on our economy. So what is presented by Prime Minister Abbott as a bold new direction in industry policy is revealed as both insufficient and a rehash of Labor initiatives. In trying to replicate the previous government’s policy, but on the cheap, the government has neutered it of scale. It has left vital industries outside the scope of this government’s industry policy, diluting its substance and providing relatively paltry resources to perform the same tasks. The Government has given the Growth Centres just four years to become financially self-sufficient. They are also to replace Cooperative Research Centres. Such conditions were never placed on the previous government’s Precincts and betray a fundamental misunderstanding of the whole problem. Whether you call them Growth Centres or Industry Precincts, their goal is to foster the type of collaboration that researchers and industry do not engage in on their own; these centres are designed to solve a co-ordination or collective action problem. To do so they need to entice participants to engage, not with empty words and promises, but with real outcomes that will be valued. This can only be achieved by a real commitment of resources over a significant amount of time. A four-year deadline with limited funds? I sympathise with the sceptics. Added to Growth Centres are a tax break for employee share ownership schemes, especially for start-ups, further loosening of an already-rorted 457 visa scheme, and a half-baked idea to have corporations train employees by taking over high school curricula. None of these initiatives address the real challenges facing industry. To do this, the Government should try to answer some basic questions. What can it do to ensure our trade playing field is fair? What can it do about an impending gas supply and price crisis? What actions should it take to turn around sluggish demand and moderate big players in the market throwing their market power around? What can the Government do about a finance sector that is increasingly geared toward mining and housing but wary of anything else? And workers, organised or not, want to know where the jobs for their kids will come from. They are questions the Government answers by digging us deeper into a hole – “off to the mine with you!”

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

industry news

Competitiveness Agenda – Industry responds Manufacturing leaders have responded after the Federal Government unveiled its National Industry Investment and Competitiveness Agenda. Released on 14 October, the Competitiveness Agenda is a central part of the Government’s Economic Action Strategy. In the foreword to the report, Prime Minster Tony Abbott stated that strengthening Australia’s competitiveness is the key to the nation’s future prosperity. “Australia has experienced 23 years of economic growth,” wrote Abbott. “Over the last three decades the value of our exports has risen four-fold. Exports now represent one dollar in every five of national income. “However, our success should not be an excuse for complacency. Commodity prices have fallen from their peak in 2011; the deterioration of Government finances since 2008 has made Australia a borrower rather than a lender; our population is ageing; and multifactor productivity has been flat for a decade.” The Competitiveness Agenda sets out four ambitions for Australia to pursue to ensure job creation and higher living standards: • A lower-cost, business-friendly environment with less regulation, lower taxes and more competitive markets. • A more skilled labour force. • Better economic infrastructure. • Industry policy that fosters innovation and entrepreneurship. To achieve these goals, six initiatives will be implemented over the next 18 months. They are:

prosperity and that the role for government is to remove barriers to innovation and competitiveness.”

• Establishing Industry Growth Centres (for more on this see page 24).

Osborn added: “Business welcomes the agenda’s focus on innovation and fostering excellence not only within the five priority sectors but across the entire economy. It’s important to remember that innovation is predominantly a dynamic firm-level process that can come from anywhere at any time, so we cannot afford to be too prescriptive.”

• Encouraging employee share ownership. • Reforming the vocational education and training sector. • Enhancing the 457 and investor visa programmes. • Promoting science, technology, engineering and mathematics skills in schools. • Accepting international standards and risk assessments for certain product approvals. The Government will host a series of roundtables around the country over coming months to consult the business community, industry associations and peak bodies, as well as academia, on the policy directions outlined in the Competitiveness Agenda. These sessions will be chaired by ministers and co‑chaired by business leaders, including the heads of the Business Council of Australia, the Australian Chamber of Commerce and Industry (ACCI) and Infrastructure Partnerships Australia. Responding to the release of the Competitiveness Agenda, Australian Industry Group Chief Executive Innes Willox described it as “a sensible set of measures designed to lift productivity, encourage innovation and reduce red tape”. Willox gave specific praise to policies aimed at stimulating investment in new ideas and innovation, in particular the proposals to build greater collaboration between research organisations and the business community. “The Agenda addresses the need for rebalancing in our economy across industries to build an industrial base to ensure strength and resilience for the future,” said Willox. “This is particularly important today with the mining-investment boom winding down. New sources of growth from other sectors, including manufacturing and services, need to resume their contributions to economic development and the Competitiveness Agenda will help in that regard.” The ACCI applauded the Competitiveness Agenda for a focus on “four overarching ambitions aimed at fostering entrepreneurship and making it easier to do business in Australia”. ACCI Director of Economics & Industry Policy, John Osborn, said: “The agenda recognises that entrepreneurs and business are the real drivers of

16 |

AMT November 2014

Business Council of Australia President Catherine Livingstone called for bipartisan support for the Agenda, saying that it “sets out a compelling economic vision” by drawing together new and existing policies into a “cohesive strategy for restoring Australia’s competitiveness, diversifying our economy and delivering the jobs of the future”. “We welcome the Competitiveness Agenda as a vital complement to the government’s other major economic reform processes on tax, the federation, and energy and competition policy,” said Ms Livingstone. “With Australia’s international competitiveness declining across almost all indicators, the government’s agenda recognises that reform is an increasingly urgent task.” However, Senator Kim Carr, the Shadow Minister for Higher Education, Research, Innovation and Industry, was dismissive of the Agenda, dismissing it as “a package of reheated Labor reforms and reannouncements”. “With no funding and little by way of new policy, it is clear that the Government’s real agenda is scrounging savings – not investing for growth,” said Carr. “The Government’s approach to building competitiveness is fundamentally dishonest: it has no credibility, coming on the back of $9bn in cuts to higher education, science, research, innovation and industry programs.” AMTIL CEO Shane Infanti welcomed initiatives that will reduce red tape, build skills and provide a good environment by which businesses can be more competitive. “There is little question that fostering innovation and entrepreneurship are vital in regenerating our industry, along with a stronger commitment to commercialisation of research,” said Infanti. “All in all, the Industry Innovation and Competitiveness Agenda gives enough positive signs to show this Government is committed to helping transform our manufacturing sector so that it can compete globally and competitively.”

1 SETUP 4 SIDES 1/2 THE COST WITH MORE STANDARD FEATURES . . .

The Haas EC-400 Horizontal Machining Center Standard Features Include:

The choice is simple.

• Side-mount tool changer • 1-degree pallet indexing • 400 mm twin-pallet system • 40 taper inline direct-drive spindle

Haas Factory Outlet Australia:

1300

201

www.HaasCNC.com

230

New

Haas. The Lowest Cost of Ownership.

Zealand:

525

6907

industry news

Larry Marshall appointed to lead CSIRO Dr Larry Marshall has been named as the new Chief Executive of the Commonwealth Scientific and Industrial Research Organisation (CSIRO). Dr Marshall will join CSIRO in January 2015. He is currently Managing Director of Southern Cross Venture Partners, an early stage venture capital firm specialising in creating Australian technology companies and growing them globally in Asia and the US. His appointment was announced by the Chairman of the CSIRO Board, Simon McKeon. “Dr Marshall has an impeccable record as a scientist, a technology innovator and business leader,” McKeon said. “His wealth of experience in developing and applying science and technology makes him an excellent fit. The Chief Executive of CSIRO is probably the most important position in national science administration, so we conducted an extensive global search for an innovative scientist with strong business leadership qualities, and more than 70 candidates were considered. “Dr Marshall combines scientific credentials with experience, making him leader we were seeking

commercial and extensive global the world class for CSIRO. The

McKeon also thanked outgoing Chief Executive Dr Megan Clark for her leadership of CSIRO for the past six years. Dr Clark will leave CSIRO at the end of December this year. “Dr Clark leaves CSIRO with a legacy to be proud of, most notably for her long term commitment to the global competitiveness of Australian science through the establishment of research precincts; and to major knowledge infrastructure projects such as the new research vessel,” McKeon said.

Board is confident that Dr Marshall will lead CSIRO in a manner which ensures that it continues to provide advice of the highest quality to Government as well as provide best practice collaboration with the private sector.”

Dr Marshall was educated at Macquarie University (Sydney) where he took a doctorate in physics. He began his career in the Defence Science and Technology Organisation and has 25 years of experience as an international technology entrepreneur, holding 20 patents protecting commercial products. He has founded six successful US companies in biotechnology, photonics, telecommunications and semiconductors.

Quickstep to create automotive division in Geelong Quickstep Holdings has been awarded a grant of $1.76m from the Geelong Region Innovation and Investment Fund (GRIIF) to establish a dedicated automotive division, co-located with Deakin University at its Waurn Ponds campus in Geelong. helped to develop new carbon-fibres, reduce production costs and speed up manufacturing processes, and we will benefit from their expertise as we improve our volume production capacity. The project complements the creation of a carbon-fibre composite cluster with Carbon Nexus and Deakin University, which has a significant involvement in composite research. The cluster will be one of only two independent carbon-fibre research centres in the world.

Quickstep will establish the new facility to design and develop automotive manufacturing cells that will incorporate the innovative Quickstep Process, which uses liquids to cure components, and the Quickstep resin spray transfer (RST) system. The company will benefit from access to composite research and automotive specialists from Deakin and the wider Geelong community. The facility will also enable the production of customer prototypes and initial production quantities. Total project expenditure is anticipated to be $5.6m from now to June 2017, and the new facility is expected to create 30 new jobs. “Having collaborated with Deakin University for over a decade this activity is a key step in our growing relationship,” said Quickstep Executive Chairman Tony Quick. “We are capitalising on Deakin’s knowledge of Quickstep and the area’s wealth of automotive skills to create a new automotive division associated with the Carbon Nexus facility. This grant will make an important contribution to enable us to build a strong

18 |

AMT November 2014

Deakin University’s Carbon Nexus facility.

automotive culture and propel Quickstep further into the global automotive market.” Carbon Nexus provides access to industry and a team of researchers who have

“We welcome this strong support for Quickstep, a company we are proud to have a long-term partnership with,” added Professor Lee Astheimer, Deakin University Deputy Vice-Chancellor (Research). “Deakin has established Carbon Nexus, our open access pilot carbon-fibre manufacturing line and research facility, with the aim of developing exactly this kind of working relationship with companies like Quickstep to help create the jobs of the future, for Geelong and Australia. Today’s announcement clearly demonstrates the power that such a world class carbonfibre manufacturing research facility has on driving new industry development.”

industry news

Australian PMI: Manufacturing slows further in September The Australian Performance of Manufacturing Index (Australian PMI) remained in negative territory in September. The PMI, compiled by the Australian Industry Group, slipped by 0.8 points to 46.5 in September, indicating a mild contraction in activity across the sector (readings below 50 indicate a contraction in activity). Among the eight manufacturing sub-sectors, only the large food, beverages & tobacco (54.9 points) and the smaller wood & paper products (63.2 points) sub-sectors expanded in September. All of the activity sub-indexes contracted during the month except supplier deliveries (up 4.1 points to 51.8). Manufacturing exports experienced the most significant deterioration, dropping 11.0 points to 42.2 – its lowest level in 18 months – with weakness most pronounced in the petroleum, coal, chemicals & rubber products; metal products; and machinery & equipment sub-sectors. “Falls in production, sales and new orders underpinned the further slowing of manufacturing in September and have left the sector struggling short of the recovery that was tentatively suggested in July,” said Ai Group Chief Executive, Innes Willox. “While businesses welcomed the significant correction in the value of the Australian dollar in September, it will take some time before competitiveness in domestic and export markets improves.”

The very large metal products (up 0.6 point to 48.0); machinery and equipment (down 0.3 points to 45.1); and petroleum, coal, chemicals and rubber products (down 3.2 points to 40.9) subsectors all continued to contract during September. The nonmetallic mineral sub-sector, which mainly produces building materials, slipped a further 2.4 points to 44.7 despite a pick-up in local building activity – a reflection of the dollar’s continued drag on import-competing local products. New orders declined for a second month (down 3.0 points to 45.8), while manufacturing employment moved up 1.2 points to 49.0. Production dropped 3.8 points to 42.5, and sales dipped for a fourth consecutive month (down 3.2 points to 46.0). “Respondents to the Australian PMI suggested that the winding down of Australian automotive assembly and the ongoing downturn in mining construction activity are dampening demand for locallymade products and components,” added Willox.

Confidence rising among SMEs Confidence among small and medium businesses (SMEs) has bounced back strongly, according to the latest Sensis Business Index (SBI). The report found confidence levels among SMEs rose 16 percentage points following a steep decline recorded in the May survey. The SBI, based on research of 1000 small and medium enterprises (SMEs), revealed 53% of small businesses are confident about the year ahead, up from 47% in June. Only a quarter of businesses are worried about their prospects. Encouragingly, the SBI shows that businesses are feeling more positive about the economy overall. “Confidence levels have almost returned to the February 2014 level though they remain below the post-election peak recorded last year,” said Sensis Chief Executive Officer John Allan. “Businesses that were confident reported that they had a solid customer base, good profitability and a steady pipeline of new business. The report found that a lack of work or sales is the most pressing problem faced by small business.“There’s a real sense people aren’t spending and there’s increasing concern about competition. We’re seeing more and more businesses looking for help in finding new customers using a range of marketing tools.” The economic climate, competition, bureaucracy and cash flow were among other challenges that businesses reported. The finance and insurance sector recorded the highest confidence level. Confidence was also above average in the wholesale trade and health and community services sectors. The lowest confidence level was again recorded in the manufacturing sector. Transport and storage sector confidence is also well below average. There was a sharp rise in the proportion of SMEs reporting increased wages over the last quarter, with this indicator now at its highest level since July 2012. However, SMEs recorded only marginally stronger performance results last quarter for key indicators such as profitability and sales. Employment declined with more SMEs reporting decreased than increased employment levels.

20 |

AMT November 2014

With economic expectations for the year ahead improving, the next 12 months look positive on key indicators. SMEs are more likely to be expecting increases in sales, employment, wages, prices, profitability and capital expenditure than in the previous quarter. The report also found support for the Federal Government among SMEs remains soft, despite a five percentage point increase over the last quarter. SMEs in the manufacturing sector and businesses in the ACT were the most critical of Federal Government support. “Business owners are supportive of the Government’s aims to reduce debt, red tape and boost the economy,” said Allan. “However, there are perceptions that the Government is more focused on big business, that there is too much bureaucracy, and that their policies are affecting consumer spending.” Similar results were echoed across the country for State and Territory Governments, with 22% of SMEs believing their State or Territory Government was working against small business. SMEs’ perceptions of the current state of the Australian economy were neutral or negative in every state and territory with the exception of Tasmania. Those in South Australia were most pessimistic about the current economy, with over one third of SMEs believing the economy is slowing.

Industry news

BAE Systems lands F-35 components contract BAE Systems Australia has signed an agreement to provide advanced manufactured components for the F-35 program as part of a long-term arrangement with Northrop Grumman Corporation. Under an agreement valued at approximately US$15m that commences in 2015, BAE Systems will manufacture around 1000 Audio Control Electronic (ACE) modules, a component for the F-35 aircraft’s Communication, Navigation and Identification (CNI) avionics suite, developed by Northrop Grumman. The agreement initially augments Northrop Grumman’s in-house manufacturing of the ACE module but provides potential to become the single-source supplier with increased delivery quantities until the year 2036. “BAE Systems will use the latest technology to support one of the world’s most advanced integrated avionics systems,” said David Allott, BAE Systems Australia Chief Executive. “Our company will establish the only defence-accredited parylene-coating capability in Australia and apply advanced manufacturing techniques to produce high-end components for the digital battlespace.” The 120-strong team at Edinburgh Parks, Adelaide, will build and assemble parts, as well as integrate and test the electro-mechanical assemblies. The new parylene technology will use gas to uniformly apply a coating on the parts, which is done in a vacuum chamber, at room temperature. It is hoped that this capability will generate opportunities with other defence, medical and telecommunications companies.

Northrop Grumman’s integrated CNI system provides F-35 pilots with the capability of more than 27 avionics functions including voice and data communication. By using its industry-leading software-defined radio technology, the design allows the simultaneous operation of multiple critical functions while greatly reducing size, weight and power demands on the advanced fighter aircraft.

expert a Thales to produce Robotics winner in NSW awards innovative A University of Sydney robotics and information systems expert has received the prestigious F90 assault rifle ‘Excellence in Engineering and Information and Thales has secured a Department of Defence contract to enter Low Rate Initial Production for the company’s innovative F90 assault rifle. “This is a major milestone in the F90 story,” said Kevin Wall, Vice President Armaments at Thales Australia. The engineering and development of Australia’s F90 has created a light, versatile weapon that has met the highest standards of performance and reliability. “Backed by over a century of military weapons experience, Thales’s Lithgow facility will now begin manufacturing F90 rifles as part of a de-risking exercise designed to smooth the transition in production from the existing in-service weapon to the F90.” The F90 recently achieved Provisional Design Acceptance following an extensive testing period that saw over one million rounds fired. It includes an integrated side loading 40mm grenade launcher that can be attached in just a few seconds by the soldier – a potentially decisive capability advantage facilitating speed and flexibility on operations.

22 |

AMT November 2014

Communications Technologies’ prize at the 2014 New South Wales (NSW) Science & Engineering Awards.

Salah Sukkarieh, Professor of Robotics and Intelligent Systems in the Faculty of Engineering and Information Technologies, is the Director of Research and Innovation at the Australian Centre for Field Robotics. He received the award for his cutting-edge robotic and information systems research and for his engagement in a wide range of automation applications for multibillion-dollar industries including agriculture, environment monitoring, shipping, education, mining and aerospace. The NSW Science and Engineering Awards are awarded annually and acknowledge the state’s leading researchers in science and engineering for their leading-edge work that generates economic, health, environmental or technological benefits for the state.

Government news

Industry Growth Centres to boost competitiveness The Federal Government has announced that it will invest $188.5m in Industry Growth Centres designed to “pursue global excellence in areas of competitive strength”. Government will look to establish further centres based on the success of the programme.

The new Centres will provide the infrastructure needed to drive growth and jobs creation in five key sectors of the Australian economy. These are: food and agribusiness; mining equipment, technology and services; oil, gas and energy resources; medical technologies and pharmaceuticals; and advanced manufacturing sectors.

Funding of $60m will be available to convert ideas with great potential into profitable commercial realities. This element, comprising grants of up to $1m, which must be matched by the company, will be delivered through the new Entrepreneurs’ Infrastructure Programme. In addition $63m will be available to the Centres to develop and deliver largescale collaborative projects to build the capability and competitiveness of their sectors. There will be a staged roll out of the Centres from early 2015.

A key part of the Government’s Industry Innovation and Competitiveness Agenda, the Industry Growth Centres will help industry exploit new global markets and supply chains, invent and commercialise new products and services and generate new jobs. These industry-led Centres will bring together expertise from business and industry, the scientific and research communities and the university sector. Currently fewer than 5% of Australian businesses turn to the higher education sector – including scientists and researchers – directly for expertise and ideas. According to the Government, collaboration between business and research has proven to be the basis for enhanced international competitiveness in other countries. Industry Growth Centres will foster these links and relationships which are critical to future economic success.

Ian MacFarlane, the Minister for Industry will seek expressions of interest from businessled consortia to establish five non-profit Industry Growth Centres. Project funding will focus on market, value chain or technology issues to deliver commercial outcomes with sector-wide impact. Each of the five Centres will receive funding of up to $3.5m per year. The Centres will be required to establish a plan to become self-sustaining after four years and the

The Industry Growth Centres Initiative complements the Government’s $155m Growth Fund and $50m national Manufacturing Transition Programme. It also builds on the $484.2m Entrepreneurs’ Infrastructure Programme. A series of Competitiveness Agenda stakeholder roundtables are currently being held across the nation. This will be the first step in consulting with industry and research on the implementation of the Industry Growth Centres initiative. More information on the Industry Growth Centres Initiative can be found at www.industry.gov.au/growthcentres.

Treasure trove of IP data made available Finding collaboration partners to develop innovative new products will soon be easier as the Australian Government makes 100 years of Intellectual Property (IP) rights data available online. Bob Baldwin, Parliamentary Secretary to the Minister for Industry, said this world-first move would help companies find each other more quickly to collaborate, build their product and get it to market. “Placing IP rights data on the web in a way that is easily searchable will make it easier for business to come together to innovate, create jobs and boost our economy,” said Baldwin. “The data includes information about IP rights applications that can be matched to individual firms along with information about their size, their technology and their geographic location. This data allows Australia to continue to encourage the collaboration and innovation to help our nation be globally competitive into the future.”

24 |

AMT November 2014

The information being made available comprises more than 350m data points, including rights to patents, trademarks, designs and plant breeders’ rights, and will be updated annually. This information also allows the Government to map innovation and pinpoint exactly where new ideas have been developed in Australia, and by which companies. This means that IP rights can be linked with geospatial data and business information. This information can be used to identify where Australia’s growth sectors are. The Intellectual Property Government Open Data is available from www.data.gov.au

Government news

Efic – Increased focus on SMEs The government has announced an expansion of Efic’s loan powers to enable the organisation to support more small and medium-sized Australian exporters.

NEW Introducing the HDV300

Video-based Measurement System

Efic is a specialist financier that delivers solutions for Australian companies to enable them to win business, grow internationally and achieve export success. As Australia’s export credit agency, Efic operates on a commercial basis and partners with banks to provide financial solutions for:

The power of an optical comparator, meets the precision of digital video.

• Small and medium-sized enterprises (SMEs) that are exporters.

• Electronic overlays – no more Mylars!

• Australian companies in an export supply chain. • Australian companies looking to expand their business operations overseas to better service their clients. • Australian companies operating in emerging and frontier markets. Through loans, guarantees, bonds and insurance products, Efic helps Australian exporters and subcontractors take advantage of new contract opportunities that may otherwise be out of reach. The latest changes are consistent with the government’s focus on deregulation and reducing red tape, and will allow Efic to support SME exporters more efficiently and cost-effectively. The decision complements ongoing work that Efic has been doing throughout to make it easier for SMEs to conduct business through standard form documentation, reduced turnaround times via a new accelerated execution process, and lower minimum support thresholds.

• 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.

Efic will gain new powers to lend directly to SMEs, which will help to reduce the substantial administrative burden and financial costs they face when accessing finance. The current process of having two parties - Efic and the bank of the client - involved in financing these transactions, means Efic’s support is less efficient and more costly to SME exporters due to the additional processing time and duplication of fees and charges. These new powers will also allow Efic to lend for the export of all goods, not just capital goods, through a proposed amendment to the Export Finance and Insurance Corporate Act. This will allow Efic to service more SMEs efficiently and expand the pool of smaller exporters that will be eligible for financial support. In line with recent recommendations from the Productivity Commission, Efic will no longer support resource projects located in Australia (and related infrastructure). This decision will only have a small impact on Efic’s future operations, as the strong liquidity in global capital markets has meant that such projects continue to be difficult for Efic to support on market gap grounds. Efic’s Structured Trade and Project Finance division will continue to support resource projects overseas, as long as the project has significant Australian content, including through SME participation. “These new powers are a strong endorsement by government of our mandate to provide financial solutions to exporting SMEs and those SMEs in an export supply chain,” said Andrew Hunter, Efic’s Managing Director. “These changes are a positive outcome for our clients and will allow us to help even more SME exporters.”

What company has such vision?

Innovation Rules www.starrett.com.au

| 25

Tech news

UK: Eradicating harmful impacts of manufacturing

Germany: Analysing steel – rapidly and precisely

The human and environmental dangers posed by a widely used manufacturing technique could be almost eradicated. Fibre-reinforced polymer matrix composites are employed in a vast array of industries. But that finishing process causes the vapours of a volatile organic compound – styrene to be emitted, posing health risks. Now a team has identified that in-mould gel-coating could reduce average styrene levels by more than 98%. The occupational exposure limits for styrene currently vary across the European Union, but a recent directive (REACH) is likely to result in the harmonisation of permitted styrene levels

Optical emission spectrometers to analyse the composition of steel are widely used in the steel industry but the instruments currently employed are relatively large and bulky. A novel sensor that shrinks the size of the spectrometer optics, has significantly reduced their size. Additionally it enables a more precise analysis in half the time previously required. It is capable of measuring signals in the microvolt range at the same time as signals measuring some 100 millivolts. Until now, this required several measurement cycles

Plymouth University

Slovakia: The latest flying car A prototype of the Aeromobil “flying car” has been unveiled. Aeromobil’s version 3.0 is the latest model in the company’s 24-year flying car project. The vehicle fits a standard parking space, its can be fueled at any gas station and as a plane it could both take off and land at any airport in the world. The Aeromobil transforms itself from plane to car by folding its wings behind the cockpit, while the propeller is fitted in the rear. The company’s co-founder Juraj Vaculik said that the prototyping process had been sped up after having seen “enthusiastic reactions of the global engineering and design community”. Weighing 450 kg, with folding carbon-fibre wings, it has a top flight speed of 200kph and driving speed is 160kph. Mixed

Germany: Inspection system for high-strength steels Researchers have developed a new inspection system that allows the examination of high-strength steels contact-free. Named the MAGNUS hybrid inspection system, it combines micromagnetic and ultrasound techniques to characterise materials. “We placed particular emphasis on coming up with a cost-effective tool and sensor concept” says the research scientist leading the project. Fraunhofer

Russia: Industrial synthesis of a material harder than diamond Researchers have developed a new method for the synthesis of an ultrahard material that exceeds diamond in hardness. An article published in the journal Carbon describes in detail a method that allows for the synthesis of ultrahard fullerite. Fullerite, which was first synthesised more than 20 years ago, has surpassed diamond to become first on the list of hardest materials, with values that range from 150 to 300 GPa. The carbon spheres within fullerite can be arranged in different ways, and the material’s hardness largely depends on just how interconnected they are. The superhard carbon form is of primary interest for specialists in the field of metals processing: the harder a tool is, the longer it works, and the more qualitatively the details can be processed. Scientists have shown that adding carbon disulfide to the initial mixture of reagents can accelerate fullerite synthesis. Moscow Institute of Physics and Technology.

26 |

AMT November 2014

Fraunhofer

US: US-made wind turbine blades more cost-competitive Sandia National Laboratories – as part of the Advanced Manufacturing Innovation Initiative, is helping makers of wind turbine blades improve the labor productivity associated with blade fabrication and finishing. This improved productivity makes domestic blades more cost competitive versus countries with lower wages. The projects included automated laying and finishing, using simulation to develop more efficient manufacturing process flows, and improved NDI capabilities. Wind turbine blades are large and heavy, and tolerances must be within millimeters of perfection. They must withstand decades of harsh conditions and handle punishing speeds at the blade’s tip, and much of the work must be done by hand. The combined AMII improvements and innovations reduced the cycle time to manufacture a blade by nearly 50%. Sandia National Laboratories

Singapore: Nanocomposites toughen up An alternative fabrication route to improve the properties of aluminiumbased nanocomposites has great potential for the car, space and defence industries. One challenge in producing strong, elastic and hard-wearing nanocomposites is obtaining an even distribution of the nanoparticles in the metal matrix. Now, researchers – via “stir processing” (friction) have produced an evenly distributed mix of nanosized aluminium oxide particles in aluminium. The team drilled hundreds of holes into a thin sheet of an aluminum alloy, injected a slurry of aluminum oxide nanoparticles into the holes and heated the sheet, cooled it and plunged a rotating tool into it. The friction generated caused the material to plasticise. The nanoparticles were uniformly dispersed (ie the material has no weak points). Composites made in this way had significantly improved hardness and tensile strength compared to untreated aluminum alloy sheets. A*STAR

US: Researchers print their own syringe pumps Furnishing a research lab can be expensive. Now a team has published an open-source library of designs that will let scientists slash the cost of one commonly used piece of equipment: the syringe pump. These pumps are used to dispatch precise amounts of liquid and they can cost hundreds or even thousands of dollars. The library of free syringe-pump designs mean anyone can make them on a RepRap 3D printer just for the cost of the plastic filament and the designs are customisable. The team also incorporated a low-cost Raspberry Pi computer as a wireless controller. The work is described in the paper “Open-source Syringe Pump Library,” published in PLoS One. Michigan Technological University

Product news

Seco brings versatility and value to holemaking Seco has expanded its selection of holemaking products by adding the new Threadmaster Tap and Seco Feedmax Universal drills to its comprehensive cutting tool portfolio, designed with performance, versatility and value in mind. With the introduction of the high-speed steel Threadmaster Tap, which is the company’s first tap product offering, manufacturers can thread holes in a wide range of workpiece types and materials. Because of its universal design, the tap also accommodates the most common thread sizes as well as reduces tooling inventory and lowers costs. The Threadmaster Tap features a modern coating technology that enables it to achieve higher cutting data and output in steel up to 350 HB, stainless steels and cast irons when compared to the uncoated solutions typically found in this product area. The incorporation of special geometries and edge treatments optimise chip formation to provide efficient evacuation. The tool also comes in four different types of taps – spiral helix, spiral point, straight flute and form taps – so that it can produce blind and through holes, as well as accommodate the most common thread sizes and tolerances found in job shop and contract manufacturing environments. Threadmaster Tap products are compatible with Seco’s EPB tapping chucks, such as the new EPB 5867 tapping chuck with microcompensation for synchronised tapping, EPB 5865 ER collet tapping chucks, EPB 5260 quick change tapping chucks and EPB 5283 quick change tapping chuck with axial compensation. Seco Feedmax Universal drills are well suited for holemaking applications across all industry segments, especially those requiring reduced stockholding costs for low and medium batch production. The line features a multi-purpose, four-facet point geometry that provides excellent centring capability, maintains an IT8/9 hole tolerance and is easy to regrind. The drills also feature a polished AlCrN coating that offers high-abrasion resistance, toughness and good chip evacuation. The drills are available in diameters ranging from 3mm to 20mm (in increments of 0.1mm) and cylindrical shanks with 3xD and 5xD depths of cut. The 3xD shanks are available in coolant-through and non-coolant options. Seco Feedmax Universal products are compatible with Seco’s EPB shrinkfit holders, hydraulic chucks and high-precision collet chucks. When used together, the Threadmaster Tap and Seco Feedmax Universal drills establish a highly productive and versatile combination of tapping and drilling operations. www.secotools.com/au

AMT November 2014

| 27

product news

DELTA Element: precious metal and alloy XRF analyser Non-destructive testing (NDT) of manufactured materials by X-ray fluorescence (XRF) is a crucial tool in many industries. The latest handheld XRF analyser from Olympus, the Delta Element, is ideal for scrap metal sorting, positive material identification (PMI), alloy QA/QC, and precious metals analysis. Moreover, the Delta Element is the most affordable hand-held XRF analyser produced by Olympus to date. “The model was developed for those customers who require the speed, reliability and ease of operation expected from the DELTA Premium, yet do not require the extended element range necessary only for some specialty applications,” says Andrew Taylor, Regional Sales Manager with Olympus. With a powerful X-ray tube and Si-PIN detector, the Delta Element provides quick identification, screening and sorting of alloy and precious metals. The analyser also still incorporates the latest handheld XRF technologies, at an affordable price for small-to-mediumsized businesses. The Delta Element’s unique combination of features is ideal for most alloy identification and sorting applications. “The analyser is a powerful tool, yet simple to operate,” Taylor added. “Operators can switch between precious metals and alloy mode at the touch of an onscreen icon.” The Delta Element displays measured results and grade identification in seconds. With Olympus’ unique Grade Match Messaging (GMM)

Eximo – tough, flexible ducting for CNC machining Eximo’s CNCFlex ducting has been specifically designed for CNC processing centres and has a medium weight and a very flexible polyetherpolyurethane construction. CNCFlex comes with wall thicknesses ranging from 80mm to 500mm, a clear colour, and temperature resistances ranging from -40 degrees Celsius up to +100 degrees. It is available in ten metre rolls or it can be cut to any length to order. Applications of Eximo’s CNCFlex include suction and removal of dust and particles in woodworking and metalworking industries, especially those using CNC processing centres or for use in any CNC machining applications where fumes and/or dust particles need to be effectively and quickly removed from the machining process. The main physical properties and benefits of Eximo’s CNCFlex include: • Flame retardant according to DIN 4102. • Resistant to hydrolysis and microbes. • Good abrasion resistance. • Excellent flexibility. • Resistant to oil and patrols. • Free of halogen and softeners. • Electrically conductive according to BGI 739-2 by grounding the wire. www.eximo.com.au

28 |

AMT November 2014

feature, you can assign customised messages to any grade and use real-time or pop-up messages for immediate sorting instructions and improved user efficiency. The Delta Report software then allows for fast and professional reporting and certificate generation of any analysis. With its lightweight, handheld design and durable construction, the Delta Element features rubber overmoulding to protect the analyser and an ergonomic grip for comfortable operation. www.olympus-ims.com

SEW-Eurodrive expands safety options SEW-Eurodrive has extended its range of safety technology to include the integrated S12 safety option for Movifit FC/MC drive units. Safety technology from SEW can be implemented in most applications – from control cabinet technology with integrated or independent axis monitors to decentralised technology alike. SEW- Eurodrive now offers the integrated S12 safety option for its decentralised Movifit FC/ MC drive units, used for constructing modular and flexible conveyor systems. The two option card versions S12A and S12B support different numbers of safety-related inputs and outputs. The new S12 option offers the additional safety functions STO (safe torque off), SS1a/c (safe stop 1), SLS (safely limited speed) and SDI (safe direction) on top of the standard Movifit functions. The SLS function can be easily applied using the EI7C/(FS) simple motor integrated encoder. The safety functions are an integral element of the Movifit modular system. SEW-Eurodrive’s Movitools MotionStudio engineering software is used to program the S12. SEW-Eurodrive’s S12 safety option is a cost-effective, integrated safety solution. It can be used either independently or as a fieldbus slave with PROFIsafe via Profibus or Profinet. The inputs can also be set as one- or two-channel, and they can read OSSD (Output Signal Switching Device)-capable sensors such as light grids and scanners. The safety option is useful wherever materials need moving, e.g. on roller conveyors, rotary tables, electrified monorail systems for light loads. This is particularly relevant for the intralogistics sector. www.sew-eurodrive.com.au

Product news

Laserline enhances diode laser range Laserline has completed a number of enhancements to its portfolio of diode lasers, distributed in Australia by Raymax Applications. With up to 4000W of laser power, the newly developed LDF diode laser (8mm-mrad) with integrated beam quality converter sets a new benchmark. Based on the long-established and proven technology of actively cooled laser diodes, the beam parameter product has been optimised using an active fibre – the ‘converter’. For the first time this opens up applications that were previously unfeasible for diode lasers, such as remote welding and laser cutting. The LDF is available in a mobile unit, where the principle of modularity is applied throughout. This makes it easy to adapt the beam source for specific applications. Applications with small focuses and corresponding power densities up to focal lengths of well over 500 mm can be implemented. Flexibility is assured by variable laser power and an optional two fibre outlet configuration (robot compatible). Optionally equipped with an enhanced dust and humidity protection unit, the diode laser can be operated in multi-shift mode without failure, and is virtually maintenance free, even under hostile ambient conditions such as high humidity or excessive metal dust content. This robust LDF system carries a fiveyear warranty on diode laser elements and two years on the laser system and converter fibre, all contributing to its cost effectiveness. Laserline diode lasers have a successful track record in Australia working in a range of environments from cladding and restoring heavy industry parts, welding sheet metal and aluminium, hardening and heat-treating. www.raymax.com.au

FLIR releases Muon thermal imaging core FLIR Systems has announced Muon, its latest thermal imaging core, designed specifically for manufacturers capable of integrating uncooled FPAs into their own camera solutions. FLIR has simplified processes by offering a thermal subassembly that generates calibrated CMOS video out, using industry-standard interfaces. Because Muon is calibrated for TEC-less operation, manufacturers no longer have to develop their own elaborate factory calibration equipment or processes. Muon is a thermal “engine” developed to operate on standard imaging device power and communication protocols. Muon is based on FLIR’s 17µ pitch Vandium Oxide (VOx) 640x512 or 336x256 FPAs and offers frame rates of 9Hz up to 60Hz. Optimised for size, weight and power (SWaP), Muon has a form factor of 22mm by 22mm by 6mm, a mass of less than five grams, and depending on the configuration, uses less than 300mW of power. “Muon is an innovative solution for OEM manufacturers intent on using their own image processing, packaging and optical technologies,” said Bill Terre, FLIR GM of OEM and Emerging Markets. “It represents FLIR’s ongoing leadership in developing OEM technologies that give our customers greater flexibility, while reducing up front manufacturing costs.” www.flir.com/muon

Complete Machine Tools Pty Ltd

AMT November 2014 CMT Advertisement 13.06.14.indd 1

| 29

13/06/2014 1:08:31 PM

product news

Kaeser – ultra-efficient oil-free compressed air Kaeser is tackling the need for the production of cost-effective, high-quality and clean ‘oil-free’ compressed air with its extensive range of dry-running rotary screw compressors. This includes the proven CSG-2 models. Producing clean compressed air is vital for many processes where the risk of oil contamination within the compressed air system is unthinkable. For such demanding applications, Kaeser offers a powerful range of dry-running two-stage rotary screw compressors. This range includes the proven CSG-2 models, which ensure highquality, oil-free and ultra-efficient compressed air is produced at all times. At the heart of these versatile units lies a quality, tried and tested dry-running, two-stage rotary screw airend, which provides optimum performance and maximum efficiency - even under the toughest of conditions. The rotors are equipped with “Ultra Coat”, which is resistant to temperatures up to 300 degrees Celsius. Because this cost reducing coating is also highly abrasion-proof, the sealing and protection performance of this coating remains virtually unchanged, even after years of operation. As a result, compressed air delivery also remains consistent, which in turn means that dryrunning rotary screw compressors from Kaeser consume no more energy after years of use than when first commissioned in order to deliver their rated free air delivery. In addition, utilising “Ultra Coat” assists in keeping total system costs to a minimum. Air-cooled systems designed for use in ambient temperatures up to 45 degrees Celsius also provide further significant potential for additional long-term savings. Dependability and efficiency in the CSG-2 systems is further enhanced by the PC-based Sigma Control 2 internal controller. A powerful combination of multiple control modes, a timer and base load sequencing provide additional energy savings. Moreover, a precision electronic pressure sensor keeps switching differential to a minimum thereby saving even more energy. All CSG-2 compressors are powered by IE3 premium efficiency motors. Standard equipment also includes PT 100 sensors for measurement and monitoring of the motor winding temperature. This enables full use of the maximum motor switching frequency and minimises costly idling periods. These advantages, coupled with

numerous other technical refinements, ensure that every unit lives up to the Kaeser quality promise. Like the other models in the Kaeser range of dry-running rotary screw compressors, the CSG-2 series offer super-quiet performance. Using the very latest in computer-aided measurement technology, Kaeser’s development engineers have been able to precisely analyse all sound sources and ensure that these versatile systems operate with minimal sound levels. Kaeser has evaluated the total life-cycle costs of these machines to ensure that maintenance and consumables for these compressors are extremely cost effective, backed up by a nationwide network of experienced service technicians. The two-stage CSG-2 series dryrunning rotary screw compressors from Kaeser are available air- or water- cooled, with drive powers ranging from 37kW to 90kW, and provide free air deliveries from 5.4 to 13.0 cubic metres per minute for pressures between 4 and 10 bar (g). www.kaeser.com.au

New search tool for machine tools MachineTools.com has launched New Machinery Finder, a new specialised search tool designed to help you whether you are buying or selling equipment. If you are a buyer, New Machinery Finder is designed to be simple and quick to use. You put in the specs you need and the tool searches through a database of 250,000 machines, before returning a manageable list of brands to consider. You can compare machine models and choose which ones interest you. Then, with a single click you can request a quote from each brand you are considering. For sellers, the New Machinery Finder takes a lot of the hard work out of the sales process. Buyers come to you, and you are already armed with the knowledge about which machines are of interest this potential customer. While there are inevitably more questions that will need to be answered, this advance knowledge is a great introduction to your next customer. According to MachineTools.com, buyers and sellers have already voiced their enthusiasm about the new tool. One seller was surprised

30 |

AMT November 2014

when he received a sales lead from abroad. After contacting the buyer, he was able to sell the customer two machines in a country where he had never done business before. He remarked: “Suddenly, I’m a global company.” One buyer reported: “I had hoped my dealer was giving me good advice, but I wasn’t sure. After using the New Machinery Finder, I determined that the machine I have been advised to buy is, in fact, the best machine for my needs. It solidified my confidence in my local dealer.” MachineTools.com has been effectively connecting buyers and sellers for 16 years, with over 10,000 daily visitors generating 1000 sales leads. Buyers and sellers deal direct with each other, with the website receiving no commission. Searching is simple, quick, and free. www.machinetools.com

Product news

TransSteel 2500 Compact – powerpacked welding The latest variant of Fronius’s tried and tested TransSteel series – the TransSteel 2500 Compact is compact on the outside but packed with power on the inside, making the gas-cooled system perfect for steel welding The new Fronius TransSteel 2500 Compact MIG power source boasts a compact and robust construction, 250 amps, wire diameter of up to 1.2mm, proven Steel Transfer Technology inside, and an optional voltage reducing device (VRD) for stick welding if required. To complete the package it is supplied with a specially developed welding torch. The TransSteel 2500c features a compact housing on the outside, and expert know-how on the inside. Modular in design, it can be networked and controlled, offering smaller enterprises a space-saving yet high-performance tool. The compact, robust, portable TransSteel design is complemented by a plastic wirespool viewing window on the side. This not only provides insulation for the side panel, but also enables the welder to see how much wire is still on the spool at a glance. A further highlight is the compact control panel – which includes gas test and wire threading functions – and its self-explanatory layout. For guaranteed stable welding results, even at the power limit, the integrated power limitation has the answer (displayed on the power source when activated). This prevents extinguishing of the arc by reducing the wire feed speed to automatically restrict the output. Another benefit for steel welding that is also integrated in the TransSteel 2500c is the Steel Transfer Technology with its Steel, Root and Dynamic characteristics. The former provides quick and easy welding settings, while Root is characterised by a soft, stable dip transfer arc, simple root pass welding with no pool support and a high gap-bridging ability. Dynamic is the characteristic of choice for a concentrated and flexible arc, a deep and narrow fusion zone and high welding speed. As the first Compact power source that is also available as a multivoltage variant offering the convenience of 240V when required (output reduced to 180amps with 15amp supply), the TransSteel 2500c offers an extensive range of applications. A welding torch developed specifically for this power category (3.5 m and 4.5 m) provides the finishing touches. As a further benefit, a second positive socket integrated as standard means that the TransSteel 2500c also ensures that those who want to use their MIG power source for electrode welding are well-served. www.smenco.com.au

AMT November 2014 AMT_MTI_QuantuMike_06_14.indd 1

| 31 13/05/14 10:10 AM

product news

Exair spray nozzles positively stop liquid flow Exair has released a new range of spray nozzles that mix liquid and air inside the nozzle and produce the finest atomisation of liquids up to 300 centipoise. Distributed by Compressed Air Australia, Exair’s No Drip Atomising Nozzles are available in five patterns: narrow-angle round pattern, wide-angle round pattern, flatfan pattern, deflected flat-fan pattern and 360-degree hollow circular pattern. They are for pressure-fed applications that don’t require independent air and liquid control.

The new No Drip Internal Mix Atomising Spray Nozzles work in the same way Exair’s standard atomising nozzles do, but have the added benefit of positively stopping liquid flow when compressed air is shut off. When spraying any type of liquid, post-spray liquid flow can cause big problems. Unwanted drips can ruin product function on sealing or mating surfaces. Drips can also ruin the appearance of painted or coated finishes. In addition, excess liquid flow wastes precious resources such as expensive coatings, chemicals or water.

Applications include painting, coating, rinsing, cooling, quenching, wetting (moistening), humidification and dust control. The compact atomising nozzles are fully adjustable to minimise air and liquid consumption and have interchangeable liquid and air caps. They are CE compliant and conflict mineral free.

Exair’s No Drip Atomising Nozzles are ideal where no post-spray drip is permissible. When the compressed air supply is shut off, the no-drip nozzle positively seals off the flow of liquid, eliminating the possibility of drips.

www.caasafety.com.au

ChaseFeed SBMT 13 – enhanced endurance TaeguTec is expanding its ChaseFeed line with the launch of the SBMT 13, a high positive helix cutting edge insert designed for smooth machining during high-feed machining applications. The single-sided positive four cutting edge SBMT 13 inserts achieve better cutting force over other double-sided inserts and its increased insert thickness gives the line better endurance under high feed conditions. The SBMT 13 ChaseFeed easily handles feed rates of up to 2mm per tooth at maximum depths of cut of 2mm. The strong and positive single-sided SBMT 1306 insert with its 6.35mm thickness provides the necessary durability for smooth low power machining in high feed milling of various kinds of workpiece materials. Moreover, the inserts are available in two kinds of geometries, “M” for optimum machining in stable setups as well as “ML” which is suited for low power machining in unstable setups and long overhangs. The new ChaseFeed includes cylindrical shank end mills in 32, 33, 35, 40 and 42mm diameters; modular end mill type in 32, 33, 40 and 42mm diameters; and also in face mill types from 50mm to 125mm diameters. During extensive product testing, TaeguTec reports that its new SBMT 13 inserts outperformed the competition in various tests on many different materials.

32 |

AMT November 2014

Soaring forces on a tiny scale Advancements in brushless DC motor technology are transforming linear actuation useful for engineers designing manufacturing equipment. Shown below is an example of an 8mm diameter brushless DC motor fitted with an 8mm diameter planetary gearhead. The gearhead output flange contains not only the standard set of preloaded radial ball bearings, but also an additional set of bearings mounted between the radial bearings configured as an axial thrust block.

When tested on a material made from KP4 tool steel, the SBMT 13 outlasted the competitor’s similar tool by almost 70% and increased productivity by just under 200%. Tool life was also increased while testing the SBMT 13 on SKD 61 steel. In this test, the tool life for ChaseFeed’s new addition outlasted the competition by 211%. Productivity increase and tool life were also greatly improved during tests on a FCD500 work piece. For this test, with all cutting conditions the same on both ChaseFeed’s SBMT 13 and the competitor’s tool, the new TaeguTec line increased productivity by 62.5% and tool life by 25%. www.taegutec.com

By mounting the gearbox thrust bearings between the radial set, it provides additional separation and increased radial capability. The importance of this bearing system is intrinsically related to the shaft. Close scrutiny of the shaft on this tiny gearmotor reveals its true function – linear movement. The ceramic thread is manufactured with tight tolerances on runout and pitch and with extremely smooth surfaces. On this example a thread of only 3mm diameter provides up to 27N. This, combined with the precise position control capabilities of DC servo motors, is what enables this device in a world of miniaturisation and automation. All combinations of motor gearhead and actuator are meticulously customised to suit the application and avoid any unnecessary size or weight compromises. www.maxonmotor.com.au

Construction & Infrastructure

Australian manufacturers are building a successful future by teaming up on projects with major players in the construction and infrastructure (C&I) sector. By Carole Goldsmith.

34 |

AMT November 2014

Construction & Infrastructure

Nepean Building and Infrastructure helped in the completion of a $30m refurbishment of the Scenic Railway at Katoomba Scenic World.

The Australian Construction Industry Forum (ACIF) supports and facilitates communication between the key players in residential and non-residential building and engineering construction, as well as other industry groups and government agencies. Its ACIF Forecast reports, published twice-yearly, are prepared by economic modellers ACIL Allen Consulting, using data from the Australian Bureau of Statistics and Cordell Information. In ACIF’s latest forecast, Executive Director Peter Barda says: “Total construction activity is projected to amount to around $228bn in 2014-15, slightly down on the 2013-14 estimate of $237bn.” The report reveals that construction growth is increasing in New South Wales (NSW), while Western Australia (WA) and Victoria are slowing down. Growth in construction in mining and heavy industry engineering is falling as global demand for Australia’s resources wanes. However, innovative Australian manufacturers are working with C&I giants on a wide range of projects, ranging from health facilities and water and drainage structures, to residential complexes and even scenic railways, to mention a few.

Nepean B&I – Railway refurbishment Nepean Building and Infrastructure (Nepean B&I) was recently involved in the $30m refurbishment project of the Scenic Railway at Katoomba Scenic World, in the Blue Mountains west of Sydney. The refurbishment project was completed in late 2013 and utilised 164 tons of galvanised metal. Nepean B&I’s subsidiary Galserv® provided hot-dip galvanising services on the project, galvanising heavy structural material including support structures for the new upper and lower platforms and all stairways and maintenance access walkways. Some of these were installed at a 52-degree incline. Galserv worked closely with long-standing partner client Combell Steelfab to ensure quick turnarounds for full semi loads of material, which were fabricated, galvanised and delivered to site within strict lead times. With Galserv’s assistance, Combell delivered the completed project in just seven months working alongside Grindley Construction and architects PMLD.

The Scenic Railway, which now delivers the world’s steepest ride, travels 310m through a cliff side tunnel and spectacular rainforest, carrying 84 passengers and operating every ten minutes. It attracts around one million visitors annually and is one of NSW’s top tourist attractions. “Nepean is very proud of the Katoomba project,” says Grant Tenni, General Manager – East Coast Weldlok®/Mastermesh® at Nepean B&I. “The galvanising was done at our Galserv Yagoona plant in Sydney and the material was airlifted to the refurbishment site.” In his current role Tenni is responsible for the manufacture and sales in NSW, Queensland, Victoria and Tasmania of two of the company’s brands: Weldlok grating, handrail and drainage; and Mastermesh perforated and expanded metal. A further brand - Galintel®- produces galvanised steel lintels. Nepean B&I is one of four divisions under the Nepean brand, one of Australia’s largest, integrated manufacturers of fabricated metal products for a wide range of industries, including construction, infrastructure, civil, industrial, agricultural, architectural, civil and mining sectors. The company employs 270 people at manufacturing facilities and branches located across Australia, including in Sydney, Perth, Melbourne, Brisbane and Coffs Harbour. Its main manufacturing site at Yagoona, in Sydney’s west, is accredited by the National Association of Testing Authorities (NATA) for the testing of storm-water drainage grates. “We needed the NATA approval for our Weldlok drainage grate production,” says Tenni. “To meet Australian Standard AS3996:2006, every storm-water drainage grate must be batch tested and we test from 200 to 300 batches per annum. Other drainage grates may not have the same high performance and compliance to Australian standards that we maintain. ” The company’s production employees are being trained to work across the four different product lines. Tenni says that while some of the equipment is automated, it is often the knowledge and skill of the operators that leads to improvements of the manufacturing or welding processes and of the final product. “Some robotic welding is done in our factories for standard products, but a lot of our products are custom made for customers,” Tenni adds. “An example of this is the Weldlok Balltube® handrail, used in many industrial and commercial facilities. Continued next page

AMT November 2014

| 35

Construction & Infrastructure

A key project for Wilmat has been the rebuilding and replacing of jetties and pontoons at Patterson Lakes.

Continued from previous page

The very large number of possible configurations for Balltube components means it is often a lot faster for a well-trained and skilled operator to fabricate a component manually, especially where only small quantities are required.” The majority of Nepean B&I’s steel and other supplies is locally sourced and the company has a strong relationship with major Australian steel manufacturers BlueScope Steel and OneSteel. Another recent project that Tenni and his team are particularly proud of is the Weldlok® drainage grates for Santos GLNG in Gladstone, Queensland. “We manufactured a large quantity of heavy-duty Class D Weldlok drainage grates for GLNG through the building contractor Walz Construction and overseen by Bechtel as Project Manager,” says Tenni. “Nepean is the only Australian manufacturer of 100mm Forgebar® grating, following modifications to our machines to make the heavier gauge required to meet the project specification.” In another of Nepean B&I’s projects, Mastermesh® supplied 72 perforated aluminium sheets that were used as window sunshades and building sides to the $33.59m Hornsby Mental Health Unit. This four-year project was funded by the NSW Department of Health and completed late last year. Looking towards the future, Tenni says: “We will focus on customer service, product innovation and further enhancing the value we offer our customers to grow our business through 2015 and beyond.”

Wilmat – A buoyant venture Manufacturing jetties and floating pontoons for Patterson Lakes in south-east Melbourne has kept manufacturer Wilmat very busy over the past two years. Based in Dromana, on Victoria’s Mornington Peninsula, Wilmat is a family business that trades as two separate companies: Aluminium Applications Victoria and Victorian Marine Constructions and Maintenance. “Around 85% of our current work has been involved in the rebuilding and replacing the jetties and pontoons at Patterson Lakes,” says Scott Edwards, Wilmat’s owner and Managing Director. “We are contracted to Queensland’s Superior Jetties company, which is managing the replacement of these jetties and pontoons, owned by Melbourne Water. Civil construction and infrastructure firm Fulton Hogan is the overall project manager.” Edwards explains that fixed jetties last for around 20 years before they need to be replaced. The jetties and floating pontoons are built at Wilmat’s factory and transported by truck or floated to Patterson Lakes. Each month the company builds around six of these structures, and has built 200 to date. Melbourne Water requires around 270 new jetties and pontoons to enable all existing structures to be replaced.

36 |

AMT November 2014

Wilmat’s aluminium fabrication business has also been engaged in a variety of construction projects.

The jetties are made of high-grade aluminium and treated pine, while the pontoons have a high-density polyethylene (HDPE) shell, with a concrete top surface and foam base. Wilmat employs eight permanent workers and engages several contractors, depending on manufacturing workloads. Wilmat’s contract for the Patterson Lakes project will expire in May next year. Edwards says: “We are trying to grow the other side of the business, the aluminium fabrication. Currently we are concentrating on doing jobs for smaller construction companies, like aluminium panels, screens and furniture for houses, buildings, shopping centres and wineries. A lot of our products are custom made for individual clients. “Our customers are mainly in Victoria as the cost of transporting our products inter-state is very high. An aluminium-with-timber insert table can measure 2m x 1m, and 760mm high. We are now doing R&D on flat-packed products, which will be easier and more economical to transport.” Wilmat also provides CNC router milling and cutting services to local businesses. Edwards explains: “We bought the Multicam CNC routing machine last January at a cost of $106,000. It’s a fantastic Australian-made machine supported by excellent customer service. Local businesses heard that we had the machine in the first week, and they have been using it ever since for their metal routing, milling and cutting. “One of the jobs our company does on the Multicam is to cut a 22mm hole in 80mm by 10mm plate washers, used to hold pile rings (metal bands). Previously using the mill drill, we produced 20 washer holes in an hour. With the Multicam, we can make 140 in 22 minutes. This is providing huge savings in time and we expect the cost return on the machine will be within three years.” Edwards speaks excitedly about the future: “Having the Patterson Lakes project behind us will allow us to grow the other side of the business. The CNC machine will enable the business to do a lot more customised work moving forward.”

Tektum – Sustainable building While more conventional building projects continue to provide a steady flow of work for Australian manufacturing companies, the prefabricated construction sector is currently undergoing a surge in growth and innovation, producing a wealth of supply chain opportunities for manufacturers. One company leading the prefab field is Tektum, headquartered at Rushcutters Bay near Sydney Tektum’s SPACE 2.0 modular pre-assembled buildings are manufactured from renewable, recycled and recyclable materials and built to achieve high levels of sustainability. Produced to Australian Building Standards, the buildings all include high-performance

Construction & Infrastructure

Construction of Tektum buildings, including wiring and plumbing, is undertaken at its Campbelltown assembly plant.

insulation with double-glazed and remote-controlled windows, slipresistant tiles, solar hot water systems, LED lighting and rainwater storage tanks. The architectural design and engineering work is done at the company’s head office. Its suppliers, mainly from around Australia with some from Asia and Europe, provide Tektum with a range of high-quality manufactured components. Construction of the complete building, including electrical wiring and plumbing, takes around 12 weeks, is undertaken at the company’s assembly plant in Campbelltown, south of Sydney. The fully assembled property is then transported in a shipping container, by truck, ship or rail, to the client’s location, where these innovative buildings take just three to five days to erect on-site. The price of the pre-built buildings is about the same as a standard build cost, but in more remote areas the cost of labour outweighs transport, making modular, pre-assembled house a much more appealing solution. Tektum’s joint Managing Director and co-founder Nicolas Perren explains: “We have a team of labourers who work with us to assemble the buildings in our factory, as they understand our business. They also sometimes travel with us to assist with construction. However we are trying to use local labour as much as possible, especially in remote areas.” An innovator in the readymade housing market, Tektum builds efficient, sustainable, safe and transportable modular buildings, including mining accommodation, resorts, schools, houses, offices and residential centres across Australia. The company employs seven people who are all designers, architects or engineers. Perren is particularly proud of the Wodonga Assisted Living Cluster housing project, built for a community of people with special living requirements. The Cluster was delivered and installed on site in late 2013.

The Wodonga Assisted Living Cluster housing project.

“When we see a component in the factory, that may need improving, we can take a picture and send it to the supplier via UniPhi for suggested modifications required. Each of our buildings’ parts have a Quick Response (QR) code, which can be read with a smartphone. This QR code leads to a page on UniPhi and it tells our labourers the changes required. “Technology is used in our design and we have introduced manufacturing processes into the construction of buildings. All windows, for example, are built exactly the same, so they are replaceable around the building. In traditional construction, there is a big problem with different-sized windows and building parts. For us, having conformity in our buildings allows us to reduce the entire building costs.” Innovations in Tektum’s Bucasia Beach House in Mackay, northern Queensland, won the company the Products, Manufacturing Facilities and Processes award, in the Engineers Australia’s Engineering Excellence Awards Sydney 2013. Commenting on the award, Perren says: “This award shows the foresight of Australia’s engineering industry and their support for how our buildings are made.” Perren is very positive about Australia’s future demand for prefabricated buildings. “Currently only around 4.5% of Australia’s housing market is pre-built, and I predict this will rise to around 20% over the next five to ten years. In Sweden around 70% of the houses are pre-built.” Australia has some catching up to do, and that represents a big opportunity for manufacturers. www.acif.com.au www.nepean.com/building www.wilmat.com.au www.tektum.com.au

“We were contracted by the National Disability Living Solutions to build this project, which was funded by the Victorian Government,” says Perren. “The entire building is assessable and colour has been used to make it a safe and pleasant environment for residents”. Known globally for his environmentally advanced, healthy building designs, Perren is a registered architect in NSW and Queensland, and is also trained in property finance, development and sustainable design. He is also a Visiting Fellow at the University of Technology Sydney; prior to moving to Australia in 2005, the Swiss-born architect ran the Berlin office of a major German architectural firm. Perren explains the technology used in the company’s design work: “We use the portfolio and project software management tool UniPhi, which helps us to manage all of our designs, contracts, documents, risks, cash flow, labour and time. It enables us to control our company’s operations from our laptops.

Tektum’s award-winning Bucasia Beach House

AMT November 2014

| 37

Construction & Infrastructure

Archer brings ingenuity to electricity What do you do when a piece of invaluable equipment has to be replaced but the original equipment manufacturer (OEM) no longer makes them, doesn’t provide maintenance or overhaul services, and there are no spare parts available? By Craig Hingston. This was the dilemma faced this year by the Stanwell Power Station which provides electricity to millions of people and industry across Queensland. The 1460MW facility located near Rockhampton had reached a point where it was necessary to replace specialist control valves within its special hazard water deluge fire suppression system. The multi-jet control (MJC) valves had been in service for 20 years, and Stanwell was faced with the decision as to how best to service and maintain the valves to ensure another two decades of performancecritical protection for the site’s four coal-fired generating units. One alternative was to approach other OEMs and change over to their type of valve, but there were several negatives connected with this option. Firstly, introducing different valves would require modifications to the interfaces and fire suppression pipework. Moreover, modifying the system would require it to be shut down for a prolonged length of time. In addition the existing valves had a metal-to-metal seal design that was prone to leaking, and the other OEMs had the same design. Finally, it would take months for the new valves to be delivered. Stanwell preferred the more efficient option of commissioning specialist engineering and manufacturing company Archer, based in Somersby, New South Wales (NSW). A third-generation family business that remains Australian-owned and -operated, Archer has a long-standing reputation of innovation and problem-solving for complex projects and performance-critical systems. The Archer solution ticked all of the boxes for Stanwell. The team would design and manufacture new-generation components that were compatible with the existing system while also improving on the old design to prevent further water leaks. Moreover, there would be no need for a lengthy shutdown and the project would be completed ahead of the deadline set by the Stanwell Corporation. “This project was typical of the type of work that we specialise in,” said Archer’s Managing Director Bradley Byrne who, along with his brother and Operations Director Russell Byrne, operates the company that was originally founded by their grandfather. “It involved many of

the capabilities that we have in our world-class Manufacturing Centre of Excellence: CAD design, CAM technology, precision machining, precision fabrication, disassembly and assembly, and hydrostatic pressure testing. Everything we needed was here under the one roof at Archer.” Archer had previously worked with power stations and large performance-critical sites such as Bluescope Steel and NZ Steel in the past so it was well prepared for the project. After developing a full understanding of the unique nature of Stanwell’s requirement, Archer proposed a ‘swap out-swap in’ approach to the electricity provider. “We decided to design and manufacture an exchange set of 60 valves for the first unit, which could be installed in just four days during a scheduled shutdown of the fire suppression unit,” explains Russell. “Then, we would receive the older valves back at our facility, where they would be stripped and upgraded. These would then be installed in another unit and the ‘swap out-swap in’ process would be repeated until all four units were completed.” Aware of the failings of the original valves, Archer came up with new internal and actuation mechanism designs for the new MJC valve. This included a new sealing seat and piston, a new actuation linkage mechanism, and the Archer FL505 Glass Bulb Fusible Link – the specialised heat-sensitive actuation mechanism that actuates/ opens the valve in the event of it being activated by heat from a fire. These were incorporated in a valve body designed with the same connection-to-connection dimensions and pattern as the existing OEM MJC valves to allow connection straight into the existing system without modification of existing pipework. The improved design offered an additional benefit beyond improved performance. MJC valves require off-site performance testing of a representative percentage after 20 years of service and then every 12 years thereafter. The performance test is a destructive test, destroying the heat-sensitive actuation mechanism. Currently all other available OEM valves on the market, once put through this Stanwell Power Station

38 |

AMT November 2014

Construction & Infrastructure

Archer’s manufacturing facility in Somersby, NSW.

Stanwell Power Station holds the Guinness World Record for the longest continuous operation of a power plant turbine: 1073 days and 1 hour. The team at Archer are proud to be a contributor to the ongoing reliability and success of the Stanwell facility. “We enjoy the projects that others regard as being too hard,” says Bradley. “This is why companies and organisations from around the world come to us for advice and solutions. The conventional course of action in any industry would be to find a new OEM supplier, but Stanwell Corporation showed that Aussie initiative and know-how was the smarter option.”

The MJC valve designed and manufactured by Archer.

“sensitivity” performance test, are not able to be rebuilt and reused as the other OEMs don’t offer the spare parts required and don’t offer such a service back at their factories. Essentially the MJC valves are scrapped and complete new valves have to be procured – a costly exercise.

“Stanwell Power Station is very pleased with the outcome of working with Archer,” says Stan Beattie, the Stanwell Corporation’s Project Manager, SPS Asset Services. “We were impressed that they were quick to understand our situation. They came up with an innovative and cost-effective solution, which enabled us to keep providing uninterrupted power supply to our customers throughout Queensland, and they were able to deliver it to us on time. “Their ability to think outside the square, their workmanship and constant communication throughout the project was outstanding.” www.archerenterprises.com.au

Archer purposely invented the new generation valves so that the actuation mechanism was modular in design. This means the MJC valves can be rebuilt and reused after performance testing by simply replacing the Archer FL505 Glass Bulb Fusible Link on the valve.

State of the art technology Archer designed and created the new MJC valve design using latest-generation 3D CAD/CAM software, which was integral to programming the tool paths required for the precision machining on its nine-axis Okuma Multus B300-W machine centre. The components were manufactured from stainless steel 316 and brass 385. The valves were hydro-statically pressure tested in Archer’s on-site laboratory and then road-freighted to the power station in a purposebuilt crate for safe and secure transit. The robust crate, specially designed by Archer, also allowed for the multiple return journeys to and from Archer and Stanwell Power Station of the other OEM MJC valves for overhaul. “When the first batch of 60 OEM MJC valves for overhaul arrived here we pulled them down and discarded the 20-year-old and compromised OEM internal components,” says Russell. “The only parts we kept were the gunmetal valve body casting pieces. The castings were cleaned up and precision machined to allow for reassembly and installation of Archer’s proven new-generation design and components.” The existing OEM MJC valves, having been overhauled to include Archer’s design, now included the same benefits of the new Archer MJC valves initially manufactured and supplied for the first ‘swap out-swap-in’. Once the MJC valves had been overhauled and fully reassembled they were hydrostatically pressure-tested and then sent to Stanwell for the next unit’s ‘swap out-swap in’ and the process was repeated again. Each batch was required according to a strict timetable set by Stanwell.

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 November 2014

| 39

Construction & Infrastructure

High-tech potential in road measurement equipment Based in Vermont, eastern Melbourne, ARRB is a market-leading supplier of road equipment and services worldwide, with revenue growth for its manufacturing arm projected to exceed 20% per annum. Garry Warren, General Manager of ARRB’s Systems Division, explains the secrets of its success. The manufacturing industry across the country is going through an interesting period. At the same time major plant manufacturing is declining, high-tech manufacturing for smaller employers is going through a phase of significant growth. ARRB is a perfect example of this trend. Not only are we the country’s leading roads researchers and advisers, but also a manufacturer of the world’s most advanced road measurement equipment with substantial growth in new product development and international sales.

Pavement cracking and road quality deterioration is difficult to effectively monitor and record.

The question is: why do high-tech manufacturers like ARRB continue to buck the trend and succeed, when bigger more traditional players are struggling? Let’s explore this through a case study.

Niche manufacturing Pavement cracking and road quality deterioration is a dangerous and ongoing problem that is difficult to effectively monitor and record. Previously, it was done by painstakingly taking pictures of the road and picking out cracks – a tedious process that isn’t truly reflective of the road’s condition. Then came ARRB’s landmark offering, and the combination of two key technologies. The Traffic Speed Deflectometer (TSD), which uses Doppler lasers to measure the strength of road structures, was combined with ARRB’s Hawkeye Automatic Crack Detection (ACD) system to provide, for the first time, a cost-effective, efficient way to monitor road quality. Engineers are able to analyse road pavements while actually driving at the same speed as other traffic. Moreover, by combining data sets, they can accurately predict which parts of the road are likely to fail, greatly assisting road agencies in directing maintenance efforts.

Another key aspect to ARRB’s international growth is the decision to customise and translate software into different languages, to better overcome barriers between Australia and other countries. This has won us buyers from Saudi Arabia, Mexico, Indonesia and Japan in the past year alone. Currently, ARRB is doing trials in Russia, beginning the process of establishing an office in the US, and developing a joint venture in India. Yet for us to continue putting the right energy into these emerging markets, finding the right skills in Australia is absolutely essential.

The search for skills

Having already captured the Australian market, the two technologies together have also increased our share of the international infrastructure market; a market that the B20 group has recently stated has a $57 trillion shortfall in funds. This will be a significant growth driver in the near future. While road measurement equipment might be a niche area, it is solving important problems for economies globally.

For a manufacturer in a growth phase like ARRB, hiring the right staff is critical to keeping up with demand. To do this ARRB has been actively hiring from the car manufacturers and the airline industry, which have unfortunately been shedding staff. For example, a recent hire and a great transfer of skills was actually from Qantas at Avalon. More recently we hired a Senior Development Engineer from GM Holden.

International markets and customisation

ARRB has also recently employed new staff in its production area that were retrenched from large electronics manufacturers, as well as truck drivers for the TSD and new operators for general computing tasks. In 2015, with further growth both here and abroad, we are expecting to see our staff numbers increase by a further 20%.

International growth has been a key focus area for ARRB, with 85% of our equipment is sold internationally, equating to 30% of overall business in total. This is expected to continue growing into the next year.Part of this growth has to do with ARRB’s decision to focus more on concentrated and incremental product development, as opposed to radical development for the sake of it. A good example of this is our relationship with the Saudi Arabian road agencies, who have been buying new crack detection systems from ARRB. To cater to them, we’ve been actively making technological improvements so when existing customers come looking for upgraded, more advanced technology, we are already prepared to service them. ARRB’s advanced road measurement equipment.

Additionally, ARRB is sponsoring five people studying for Masters degrees, which is a key part of ARRB’s emphasis on further education. We are very much about investing in up-and-coming engineers and encouraging an innovative research & development (R&D) culture. In fact, nearly half of the 25 people working in the equipment department are involved in R&D. There are a number of factors underpinning ARRB’s manufacturing division’s continuing growth. These include a focus on delivering high-quality, market-focused products, regular exposure to different environments through active travel, and a diverse workforce that helps generate innovative ideas. With a constantly evolving market and an increasingly global customer base, ARRB places great importance on understanding the market, creating the right products for it, and finding the necessary staff to make it a reality. While there is often pressure to build new equipment for the sake of having something different to sell, we don’t believe that is the path to success. Clever, quality innovation that benefits customers, solves genuine problems and makes people’s lives easier, is our focus and priority. www.arrb.com.au

40 |

AMT November 2014

Construction & Infrastructure

Lysaght – LOX, stocks and barrel vault When the Royal Australian Air Force (RAAF) set about building a distinctive new liquid oxygen facility at Richmond, west of Sydney, it sought out steel roofing products from rollforming specialist Lysaght. The new facility at Richmond is not your everyday building. Not simply because it is located at the end of a military runway. Or because its form is unconventional, especially compared with other buildings scattered around this sprawling military base. This building’s near uniqueness rests with the fact there are only a handful of such facilities in Australia, which, in turn, largely influenced its ultimate corrugated steel shape. For those in the business, liquid oxygen is simply referred to as LOX. The Liquid Dry Breathing Oxygen Maintenance and Storage Facility, to give it its full name, performs a specific task for the RAAF, it tests, maintains and services the oxygen (and nitrogen) used for breathing air on military planes. “The new facility had to accommodate LOX liquid,” said architect Guy Luscombe of Campbell Luscombe Folk Lichtmam Architects. “It has two main functions, storage and maintenance. “For safety reasons each function is housed in a separate building. “The storage building, essentially a rain and sun protection shelter, services the planes directly and abuts the main runway. Its roof

is made from Colorbond steel in Lysaght Custom Orb profile. The maintenance building, the ‘command module’, is the more sophisticated structure and sits about 100m away. It has three main testing laboratories/ workshops with smaller rooms for specific testing functions.” Construction of this command module borrows heavily from military ‘shed’ tradition. On the one hand it is somewhat reminiscent of the archetypal Nissen hut, used extensively by Allied forces during World War II. On the other, it borrows heavily from the basic design and shape of a plane’s wing. The building’s single, streamlined form was primarily influenced by its location at the end of the main runway and designed to resist noise and wind pressure. The single, curved shell, clad in Colorbond steel in

Lysaght Custom Orb profile, and highlighted in panels of Colorbond steel in Lysaght Mini Orb profile, protects the sensitive procedures undertaken inside, and also guards the web of pipes, ducts and extraction fans that allow these procedures to be carried out. www.lysaght.com

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 November 2014

| 41

Construction & Infrastructure

Bowhill Engineering – success against the odds Bowhill Engineering specialises in fabricating large steel components for small projects, with a knack for developing methodologies for things that have never been done before. By Jack Baldwin. The company has worked on parts for some of South Australia’s most recognisable infrastructure projects, from fabricating the complex, rotated frame of the Wayville Pedestrian Overpass, to transporting major sign gantries and bridge beams for the Southern Expressway. Bowhill has also had a hand in national projects such as the Square Kilometre Array in Western Australia, and upgrading just about every loch and weir of the lower River Murray. Their client list includes McConnell Dowell, Lend Lease and Raytheon. The business is a long way from where it started and, quite literally, a fair way from most things. Brendon and Averil Hawkes moved from the beachside Adelaide suburb of Glenelg, to Bowhill on the banks of the Murray River in the early 1970s. It lies around 150kms out of Adelaide. Brendon and Averil’s son Jeremy Hawkes, now Bowhill’s Managing Director, explains that the family plan of becoming broad acre farmers took something of a turn. “My grandfather had a mechanical repair workshop in Glenelg,” says Jeremy. “When my father moved up to the country to be a farmer he still had that in his blood and developed a facility to repair his own equipment.” That marked the beginnings of Bowhill Motors, as it was known then. Other locals and farmers in the area saw Brendon’s capabilities and came knocking on the door to have him work on their equipment too. “My father prided himself on being able to fix almost anything inhouse,” adds Jeremy. “That was his goal, his ambition. He was able to be very resourceful with what he had.” It’s an attitude and ability that has been carried right through to Bowhill Engineering today. Jeremy took up his apprenticeship as a heavy vehicle mechanic. Eventually his older brother Simon returned to join the family business, which marked a restructuring towards steel fabrication. The Wayville Pedestrian Overpass.

42 |

AMT November 2014

“It came to a point when we were half doing farming and half doing engineering, and we didn’t feel like we were doing either really well,” says Jeremy. “We had an ambition to do whatever we were doing as well as we possibly could.” They leased the farm and built a new facility in Bowhill, starting the hunt for structural steel fabrication work. Tragically, in October 2002, the family received a call that Simon had been killed in a car accident. Accepting a business award last year, Jeremy gave a powerful speech to a rapt audience explaining the role his brother played. “My brother Simon had a very strong entrepreneurial spirit,” he said. “He was technically brilliant as well. It’s accurate to say that Bowhill wouldn’t exist, certainly not in its current form, without Simon’s vision and unwavering courage. “Back then we were employing about 13 people, and rocking up and facing those guys was one of life’s most difficult moments. At that point the Hawkes family was galvanised forever. Myself, a 28-yearold, relatively uneducated larrikin, spoke on the family’s behalf. I stood in front of everybody and delivered a message to everybody that I had no right to. I said to our staff ‘We can do this. If you guys stick with us, step up and have a crack, I guarantee you the Hawkes family will not let you down.’” That was 12 years ago. There have been many ups and downs since then too – but according to Jeremy, that’s part of the tapestry of life. Meanwhile, the Hawkes family has come good on its promise. The company has expanded and the scope of its work includes projects that the family would have never dreamed about a decade ago.

Construction with a twist One of the company’s most striking projects has been the twisting pedestrian overpass that was recently installed at Adelaide’s new Wayville train station. The overpass is a complex, 50m-long structure

Construction & Infrastructure

Bowhill Managing Director Jeremy Hawkes.

with a frame that twists 90 degrees over its length, built in collaboration with major engineering and construction firm McConnell Dowell.

Bowhill’s fabrication workshop.

“The way to succeed in those jobs is to approach it collaboratively with the client. If we can all work together we can all make each other’s lives so much easier,” says Jeremy.

“We tap in to all the technology we possibly can, and there’s plenty of it in South Australia,” says Jeremy. “We don’t own it ourselves though, and that’s a deliberate strategy because it gets out of date so quickly.

Each section of the frame rotates by nine degrees. The process was, by necessity, low tolerance and high precision. Bowhill had to be very, very involved right at the start of that job in methodology development.

“We want to be like a chameleon. We want to be so flexible, so attuned to the next job that we don’t want to be locked into owning equipment that won’t suit that next job.”

“Everybody sat across the table and looked at me, asking ‘how are going to build this thing and get it to the site?’” recalls Jeremy. “I really relish that opportunity to be involved in design, and for engineers and architects and builders to look across the table at me, I felt quite special about that.”

Bowhill’s relationships with suppliers depend on paying on time, on being reasonable and being loyal. Jeremy’s attitude to staff runs on the same lines. Overtime is reserved for emergencies rather than having it as a given. If a staff member’s relationships with their family or partner are being stretched, it’s not healthy for them or their performance.

Bowhill had to figure out a way to build the structure and error-proof it along the way. The solution was a massive, 60m-long jig to trial the components before they went to site.

“We’re really focused on having a sustainable workforce,” he says. “We don’t work 70 hours a week. We make sure we can do what we do with a sustainable work-life balance, and I think that’s a unique thing.

“The jig didn’t just stop there,” adds Jeremy. “We took it to the site and used it for sub-assembly, for each half of the bridge on each side of the track. So that jig went from being an error-proof tool at our facility to being an erection tool on the site.” As further proof of Bowhill’s outside-of-the-square methodologies, the beam they used for the jig was a second-hand component from their client’s previous job, making the whole process more affordable. “We try and come up with a win-win situation. You’re not just trying to build a jig for one thing, you’re building a jig that’s suitable for multiple purposes.” Because of the larger components that Bowhill typically deals with, clients will often task it with transport to the site to minimise their own risk. It’s a responsibility Hawkes cherishes –it means they have total control over the process, reducing the risk of damage to the components or their coatings. Transporting massive beams for a bridge development on the Southern Expressway development on a tight budget offered a showcase of Bowhill’s expertise. Traditionally, the job would take four trucks with cranes waiting for them to arrive on time – an expensive undertaking. Bowhill designed and fabricated a cradle with all eight beams loaded on it. The truck would raise its hydraulics, lifting the cradle and load with it, drive the load to the site and lower their hydraulics. “We had to take a calculated risk, and we transported all eight beams of that bridge down on one truck. No one had seen that done before,” says Jeremy. “The client could pick any beam they wanted from the cradle at any time they wanted. No pressures to have the cranes meet the trucks and unload quickly, no double handling. It was a pretty cool load too – 33m long and it weighed about 80 tons.”

Flexibility and leadership The secret to the company’s flexibility in being able to complete such diverse projects is not to overcommit to any specific technology. Its fabrication workshop has focused strongly on surface treatment, but Bowhill relies on suppliers for other equipment.

“It’s about caring for people, listening to people and being genuine. They’re not just a number, they’re not just a tool. They’re a person and they matter a lot. They’re valuable to the company and what they do makes a difference.” In recognition of his leadership, Jeremy has been awarded as a recipient of the Industry Leaders Fund for the last two years running, the only person to have done so. The grant sent him on Shinka Management’s Lean Japan Tour, visiting companies like Toyota, Rinnai and Panasonic and learning about their processes – both on the factory floor and in management. “The take-away for me was getting employees engaged,” he notes. “You have to look at it from the employee’s perspective – you have to build the story and build the incentives around focusing on and looking after their company.” Bowhill’s location on the banks of the Murray provides a good lifestyle for the company, but it brings along challenges as well. The beauty for Hawkes and his team is that collaboration comes easily over the internet. Clients can see what Bowhill is designing and proposing, and likewise Bowhill can send queries when a technical issue arises – with both parties looking at exactly the same model. “Electronic tools are making our location a lot more competitive. You don’t need expensive software. It’s great to involve your client with a model while you’re developing it.” It’s that dedication to delivering service and quality, despite the remote location, that saw Telstra name Bowhill as its SA Regional Business of the Year 2014. “We very much take is as win for our region, as a beacon of light that you can do amazing things,” says Jeremy. “If you put the expectations there that you want to be world-class and you want to be something special, it doesn’t matter where you are. If you’re genuine and you firmly believe that you can achieve it, amazing things can happen. That’s our attitude.” www.boweng.com.au AMT November 2014

| 43

Construction & Infrastructure

FreeForm hits a six at SCG Fielders Australia has completed the supply of FreeForm, a brand new standing seam roofing solution, in the $197.5m redevelopment of the Sydney Cricket Ground (SCG). Fielders’ Australia-wide operations employ more than 700 people across 15 manufacturing sites in four states. Its main business is in the manufacture and distribution of a range of roll-form metal building products – including roof and gutter material, downpipes, steel flooring systems, carports, sheds and purlins – for the commercial and residential building markets. Fielders has a long tradition of supplying materials to iconic sporting arenas, including the MCG, WIN Stadium, Perth Arena and Adelaide Oval. The SCG is the first in the company’s stadium portfolio to use the new FreeForm profile and the largest project since its release in 2013. Fielders worked with Australian construction business AW Edwards, which is the head design and construct contractor responsible for initially selecting the FreeForm profile. On-site rolling and installation of the roof was completed in March, involving more than 5000sqm of tapered material. Matt Lloyde, General Manager of Sales, Marketing and Engineering at Fielders, explained how FreeForm was one of the only products to suit the design capabilities of the project. “The unique design of the new Pavilion meant the roof shape was sprung-curved in a helmet like profile that required a roofing solution that could offer extreme flexibility in curved application to match the exacting requirements,” Lloyde explained. “The ability

of FreeForm to create the curves required made it one of the only profiles on the market capable of delivering on the design brief and we were eager to work closely with AW Edwards and the design team during the planning phase to ensure all-encompassing FreeForm system ticked all the boxes.” The sheets, rolled onsite using a mobile roll-former, extend to a maximum length of 45m and tapered from 400mm right down to 250mm to meet the design requirements, with Fielders also supplying the soffit lining in S-Rib to complete the project. “The ability of FreeForm to create the curves required made it one of the only profiles on the market capable of delivering on the

design brief,” added Lloyde. The new $197.5m Pavilion, which will replace the existing Noble, Bradman and Messenger grandstands, is a modern threetiered structure with a capacity of 13,000 seats. The stand provides general admission areas with corporate facilities and food and beverage throughout. “As a local supplier, we were proud to be given the opportunity to not only demonstrate the design features of the new FreeForm system at such an iconic and exciting development, but also offer the suitable warranty that comes with Australian steel,” concluded Lloyde. www.fielders.com.au

ICN: Supporting industry in construction and infrastructure projects For the past 30 years, Industry Capability Network (ICN) has been providing supply opportunities to local businesses across a number of construction and infrastructure projects. With a proven reputation for matching buyers to suppliers, ICN’s national network provides access to projects throughout Australia and internationally. At the heart of its service is ICN Gateway, a comprehensive online system that allows suppliers to browse and register interest in specific project opportunities. ICN Gateway enables project owners to manage their supplier registration and pre-selection process. ICN Gateway currently features approximately $330bn worth of projects and more than 75,000 suppliers. Major projects listed on ICN Gateway include Christchurch Earthquake Recovery, Geelong’s newest private hospital Epworth Geelong, and the Victorian Government’s highest-priority rail project, the Regional Rail Link. In addition to linking buyers and suppliers online, ICN also facilitates meetings and

44 |

AMT November 2014

direct introductions between to major projects. In August, ICN led a trade mission of 22 companies to Christchurch to gain better understanding about construction timing and work opportunities, and to attend several Christchurch rebuild information sessions. ICN continues to work with New Zealand government agencies to offer assistance by matching suppliers to the shortfalls and challenges some construction teams face. Back in Australia, construction has commenced on the $470m, not-for-profit Epworth Geelong private development, which will become the largest hospital to be built in regional Victoria. ICN, in collaboration with Epworth Healthcare, builder Brookfield Multiplex, the City of Greater Geelong and Engineering Network Geelong hosted a series of information sessions detailing the work packages available for the project.

Work packages are listed on ICN Gateway and the team has been assisting Brookfield Multiplex to assess the capability of suppliers that have registered interest. For Regional Rail Link, ICN has again partnered with the Alliance project team to assist with supplier identification, local industry development and supplier engagement, including industry information sessions. Steve Pittonet, Alliance General Manager, stated: “Through ICN’s commitment, we have successfully delivered on our local industry participation plans and local economic development activities.” ICN’s involvement in public and private infrastructure projects continues to grow. By registering on ICN Gateway, your company too can access these opportunities. www.icngateway.com.au

FACTORY TRAINED SALES & SERVICE STAFF FOR MITSUBISHI LASER.

Applied Machinery, one of Australia’s largest and most respected Dealers of new and used machinery is proud to be the authorised sales and service representative of Mitsubishi Laser in Australia. Proof of Applied’s commitment to the brand is evidenced by a sales and service delegation that has just returned from Japan after intensive training at the Mitsubishi plant in Nagoya. Applied’s team of laser sales and service experts are now fully factory trained by Mitsubishi, so you can rest assured that when investing in Mitsubishi you have the local knowledge and support required to ensure that your transition to Mitsubishi is seamless. Following on from this factory visit, one of Applied’s key customers who also made the trip to Japan placed an order for a Mitsubishi ML-3015 45CFR. If you’re considering upgrading your current laser, or adding laser processing to your production capabilities, Mitsubishi Laser will be an exceptional choice for your organisation. Featuring laser power up to 6kW and sheet capacities up to 6000 x 3000mm, there’s a Mitsubishi laser for practically all applications.

NOW THAT’S APPLIED THINKING.

To find out more: Call: 03 9706 8066 YOUTUBE LOGO SPECS Email: sales@appliedmachinery.com.au PRINT on light backgrounds Visit: www.appliedmachinery.com.au 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

Connect with us socially

on da

standard

sta

no gradients

watermark

stacked logo (for sharing only)

sta

PMS 1815C

BLACK

One on one

Harry Moser is the founder of the Reshoring Initiative, a US not-for-profit organisation campaigning to attract offshored manufacturing back into the country. He spoke to William Poole. AMT: Tell us about the Reshoring Initiative and its aims. Harry Moser: The Initiative’s objective is to bring manufacturing jobs back to the US. Our method of doing that is to educate companies to re-evaluate their offshoring decisions by providing the data: on what companies and industries are coming back; from what countries; to what states; for what reasons; how many jobs and so on. We make that data available and promote it. I give a hundred presentations a year round the country, plus TV, radio, all kinds of media, to get companies’ interest. Then they come to our website, where we have a free piece of software called the Total Cost of Ownership (TCO) Estimator that companies use to understand all the costs associated with offshoring. Instead of just looking at price or ex-works manufacturing cost, which most companies tend to do, it also includes duty, freight, packaging, carrying cost of inventory, travel costs, intellectual property risk, impact on innovation when you separate engineering from manufacturing… altogether 29 different costs, such that if they stop at price, as most do, they miss 20%-25% of the total cost.

40,000, and reshoring maybe 40,000, so we’ve taken the net annual loss from about 150,000 jobs a year – maybe 1.2% of total manufacturing employment – to zero. Now the challenge is to turn it net-positive, because we still have 3m-4m manufacturing jobs offshore, about 25% of the current total US manufacturing workforce, and there’s the potential to bring that back. And that would balance the trade benefit. Our objective is to have a neutral trade deficit where we import as much as we export, like every country should do. AMT: What should government be doing to aid the process? HM: The single most important thing, for manufacturing in general and reshoring in particular, is skilled workforce. I think the US is the worst of the developed countries in terms of training a skilled workforce: tool-and-die makers, precision machinists, welders, chemical technicians, all those things.

By getting them to consider all those costs, to do the math properly, to use TCO, then they find that of the work that makes sense today to be offshore based on price, it makes sense to bring back perhaps 25% based on TCO. And in the future, if Chinese wages continue to rise at 15%-18% a year, increasing percentages will make sense. About 25% today, maybe 35% in three years, or something like that.

Everyone here is told: “Go to university, doesn’t matter what you study. English, history, philosophy…” But they’re not encouraged to go into manufacturing, because they see offshoring taking all the jobs, and it’s no fun and it’s “dirty and dangerous” and all that historical stuff. They’re told to go to university rather than picking up a trade. Manufacturing is now about the least attractive career for intelligent, competent, responsible people. The challenge is to convince the youth that it’s a lot of fun, high-tech, very well paid, secure, provides entrepreneurial opportunities, and so on. I and others are working on that.

We also track work coming back. We have a 1600-article Reshoring Library that you could go into and see what’s coming back from that country, in this industry, for these reasons, to this state. About 60% of what has been reshored has been reshored from China. The rest is largely Asia.

Two years ago, the Labor Department called me down to tell them how to get the workforce ready for reshoring. I was in the Secretary of Labor’s conference room, and I said: “First we have to understand that the Labor Department is part of the problem and has to become part of the solution.”

AMT: It sounds very mathematically rigorous.

And they didn’t throw me out. They said “Tell me what you mean.”

HM: Yeah, we pride ourselves on doing what the US Commerce Department or Labor Department haven’t done. We’re the go-to source for actual data on what’s actually happening. Other groups have done surveys asking what companies plan to do, but we track what they have done, which we think is at least equally important. It puts us in demand.

So I pulled up a graph on their Bureau of Labor Statistics website, which showed income going up with number of degrees, headlined ‘Education Pays’, and I said: “This is what causes all of the economists, superintendents and guidance counsellors to send all of the smart kids to university and close the tool-and-die schools. This should say ‘Education and Training Pay’, and it should have the average income of someone who’s passed an apprenticeship or has five or more certificates. And the guidance counsellors would see they make more money than Bachelors degrees and advise kids to become apprentices.”

Our job is to convince companies to take a look. We have the free calculator on the website to help them do the analysis. All the material on our website is available free, and everybody in the world is encouraged to use it, including in Australia. The logic that we provide, for calculating the true economics of local production as opposed to importing, applies equally well to Australia as it does to the US. We encourage people to take our methodology and use it. AMT: What’s been the outcome in terms of shifting jobs back to the US? HM: To put it in perspective, back in 2003 we were offshoring incrementally about 150,000 manufacturing jobs a year, and reshoring maybe 2000. By 2013 we were offshoring maybe

46 |

AMT November 2014

Instantly they said “You’re right”, and they changed the website and are doing a survey to get the data on apprentice incomes. So we actually got Washington to act. We have $1.3 trillion worth of outstanding student loans, 20% or 30% of which will be defaulted upon. Loans for philosophy and anthropology and things where we have vast excesses of supply already. Yet we don’t do much of anything to subsidise apprentices getting the training they need. We’re subsidising what we don’t need, and not doing anything to help what we do need. So skilled workforce is the biggest issue.

Other than that, the government puts almost all its emphasis on exports. It’s very sexy to talk about exports, so the government spends 60 times as much promoting and enabling exports as it does on reducing imports. But the two have equal impact on the economy, and it’s a lot easier reducing imports than increasing exports. We have a program for governments to use to identify imports and substitute them with local production. It’s very simple for the government to do, and they’re inching in that direction, but they’re still working vastly disproportionately on the wrong thing. I’m not saying they shouldn’t work on exports, but they’ll get a much higher return on investment working on reducing imports. We calculate that, at the least, a company can sell something here for about 15% less than it would sell for in China because of costs like duty, freight, packaging, languages, legal systems. Take a product made in the US and sold in the US for $100, competing with a product made in China and sold in the US for $100, so there’s no price difference. That same US product has to be sold in China for $115 to make the same margin, and the Chinese product can be sold in China for $85 and make the same margin. Therefore when the US company exports to China, it will be 30% too high relative to the Chinese product. It’s easier to supply US demand via US production than trying to export more to China or India or elsewhere. And this fits with sustainability and localisation. There’s a lot of pollution from the ships going across the Pacific using bunker fuel. So for the environment it’s good, for the economy it’s good. It’s simple economics that the government rarely talks or thinks about.

AMT: Finally, tell us about your background and how you came to found the Initiative. HM: I think I’ve got the right background for it. I’ve got a BS and MS in engineering from MIT and an MBA from the University of Chicago. I’ve run manufacturing companies for around 28 years, been involved in international trade, and I know everybody in the industry. So I was well positioned to do it. I was retiring from being the North American President for AgieCharmilles, the Swiss EDM and milling machine company that’s now Georg Fischer Machining Solutions, and I’d been speaking and working on the skilled workforce issue and promising students that if they became toolmakers and precision machinists they’d have great jobs. But all the jobs were sliding away, so I had to redeem my promise to them by bringing the jobs back. AMT: And what’s an ordinary day like? HM: I work about 80 hours a week, every week, maybe 60 Christmas week. Either I’m home, or away. I give 100 speeches a year around the country, so I’m away a lot of the time, and it’s allday-long travelling and presenting and networking. If I’m home I’m up and working at 7.30. I eat breakfast and I eat lunch. I exercise from five to seven. I eat dinner, and work till 11pm. Then I go to bed, and I get up and do it again, seven days a week. And I’m 70. I’m supposed to be retiring, but the need and opportunity are too great! www.reshorenow.org

Then there’s the standard list: corporate income tax rates are too high; there’s too much regulation. The US dollar for decades has been too high. And the government is often not very supportive of business. Obama’s actually been very supportive of reshoring, but he’s perceived in the industry as not overly supportive of industry as a whole. Where does industry go? Where it’s loved. AMT: Nonetheless, US manufacturing has enjoyed something of a revival. What can Australia learn from the US experience? HM: I’m convinced manufacturing will go to the country that has the largest quantity and quality of skilled workforce. Even if manufacturing in Australia isn’t really busy, I suspect you still have shortages of the kind of people I’m talking about. Training a bunch more of them gives jobs to people who wouldn’t otherwise have them, companies are happy, and it makes it a lot easier to attract more companies into the country. I worked on a project in South Africa, to have the best supply of tool-and-die makers in the world. They’re convinced you need not only machinists but tool-and-die makers, because you need the moulds, dies and fixtures to go into the factories. You can buy the machines, you can buy the factory, but you need the tooling to put into it. So they’re convinced that if they can make the tools quickly and well, that the factories will come to the tools. That’s a good solution. I don’t know anything about the tax rates and regulations in Australia, but countries that have really low tax rates get a lot of industry because the after-tax return is better. I would even evaluate taking corporate tax rates to zero, because with the number of additional workers you’d have making high incomes, the taxes they would pay could be more than the loss from corporate tax. Finally, Australia can use our TCO tool to bring more work back to Australia. I would be delighted to hear from individuals or organisations that would like to do so.

AMT November 2014

| 47

Additive Manufacturing

3D Central – open for business A special event was held on 10 October to mark the opening of 3D Central, Objective 3D’s new additive manufacturing facility at Carrum Downs in south-east Melbourne. The new, state-of-the-art plant is Australia’s largest additive manufacturing hub. Objective 3D will use the facility to manufacture parts and devices for the mining, defence, biomedical, construction, aerospace and automotive industries, in a more costeffective way than traditional methods. Matt Minio, Managing Director of Objective 3D, said the plant would initially employ 15 people, and estimated that these numbers would double over the next three years as the business grew. Blessed with fine, sunny weather, the opening ceremony was attended by a large and diverse group of guests, encompassing industry, academic and research bodies, government and media, all sharing an interest in the continued evolution of additive manufacturing and the growing array of applications it is driving . Representatives from the mining, health and automotive industries were on hand to discuss how they are using this manufacturing process to reduce costs and improve quality.

Bob Baldwin, Parliamentary Secretary to the Minister for Industry, (centre right) performed the ribbon-cutting to open 3D Central.

As the Friday afternoon sunshine streamed through the open doors of the impressively large facility, those in attendance enjoyed speeches by Minio; Bob Baldwin, Parliamentary Secretary to the Minister for Industry; Jeff Hanson, Director – Global Partner Network of RedEye by Stratasys; and Michael de Souza, CEO of the Australian 3D Manufacturing Association (A3DMA). In addition, there were opportunities to take a tour of 3D Central and hear about Objective 3D’s plans for the new venture. The plant boasts an impressive array of equipment, comprising both Polyjet and fused deposition modelling (FDM) machines, and Objective 3D staff on hand to answer questions about the technology. As striking as the hardware on display was, the sheer size of the facility, with the abundance of space available for more machinery, was indicative of Objective 3D’s ambitious plans for expansion. “Industry demand for this type of manufacturing process is growing at a rapid rate,” explained Minio “We estimate on average we’re reducing expenses to manufacturers by between 30 and 80%, depending on application.”

A boost for Australian manufacturing Baldwin performed the duty of cutting the ribbon to declare 3D Central open for business. In his speech, he hailed the facility as a boost for Australia’s manufacturing sector, commenting that advanced manufacturing was critical to the country’s future economic success.

48 |

AMT November 2014

“Australia is on the brink of a new era for Australian industry where advanced manufacturing will be critical to the nation’s future economic success,” said Baldwin. “We are transitioning into higher, value-added, industries that are based on innovation, research and the sophisticated skills base of our workforce.”

closer to the point of sale. The reduction of developmental costs will shorten product lifecycles, allowing access to better products more often. As the barriers between getting an idea from the drawing board to production are removed, I would expect to see an explosion of both innovation and invention from Australians.”

In De Souza’s speech, the A3DMA CEO noted that 3D printing had the potential to revive manufacturing sectors like tool-making that were currently unable to compete globally from Australia. He emphasised the considerable savings in time and money that Australian business will be able to realise by utilising this type of facility, and saw it heralding a new wave of innovation in Australian industry.

Baldwin added: “Cutting edge manufacturing hubs like the one created by Objective 3D here today are giving the manufacturing sector the edge to allow it to compete with the rest of the world on quality and not simply on cost. This can only be good for manufacturing in Australia. 3D printing is proving to be part of the new industrial revolution taking place in Australia.”

“3D Central is a cleaner, safer and greener manufacturing facility,” De Souza explained. “We are seeing manufacturing happening

“Manufacturing in Australia is not dead,” Minio concluded. “It’s in a transition period and ready to grow again.” www.objective3d.com.au

Additive Manufacturing

3D printing – Revolutionary or evolutionary? Despite all the hype, 3D printing is far from a new innovation. However, a convergence of key technologies is currently driving a rapid acceleration in its development, writes Professor Ian Gibson. I recently had the pleasure of attending the launch of the new 3D Central facility hosted by Objective3D in Carrum Downs. During the presentations and discussions, I was a little surprised to hear 3D printing referred to on a number of occasions as the ‘next industrial revolution’. It’s not that I am sceptical as to the potential of 3D printing – far from it. It is more that I am amazed that so many people believe this to be a technology that has somehow appeared out of nowhere to change the world of manufacturing as we know it. A little more than 20 years ago I was a fledgling lecturer at Nottingham University in the UK, trying to understand what advanced manufacturing technology was, so that I could teach it to undergraduate and Masters students. A colleague named Phill Dickens had recently returned from a trip to the US where he had found out about this amazing new technology called ‘rapid prototyping’. Following a conference on the subject, he went on to visit a number of early-adopter universities and companies and was blown away by the capabilities of these machines. With two other colleagues, we went on to form what was arguably the first rapid prototyping research facility, running some of the first machines in the UK. For those who don’t know, rapid prototyping is what 3D printing used to be called before it became clear that additive manufacturing technology was good for making other things as well as just prototypes. A period of more than two decades is not “revolutionary” in my book – in fact many of the applications that are currently being hailed were being researched even then. Some 22 years ago, I was using one of the first machines in the UK to develop manufacturing solutions for local aerospace and automotive companies. And 15 years ago I was in Hong Kong developing customised solutions based on medical and anatomical scans of individuals. Nearly 10 years ago I was in Singapore working on 3D-printed human tissues. Now I’m in Australia and I am watching people here, like many in the rest of the world, marvelling at this ‘new’ technology. So what has changed? Why is 3D printing all of a sudden the centre of attention? In my view, rapid prototyping is fulfilling its potential in the form of 3D printing due to the convergence of a variety of key technologies. The printed models are driven by 3D virtual solid model data that is becoming easier

One CADET student used 3D printing to optimise a surfboard fin set-up quickly and efficiently, yielding a tangible product now on sale in shops.

and easier to manipulate. Previously, what required at least a higher diploma and months of experience, running software that cost thousands of dollars on workstation computers, can now be achieved on a laptop at home. Nowadays, some of the software used is free of charge and can even be run inside a browser without even having to download it.

in turn has exposed the technology to a huge number of bright, innovative minds, fuelling vast media interest that we are seeing today. One may see some interesting developments in the future as other patents expire, but for the time-being there are still some expensive 3D printers around that are needed to create some of the more advanced parts. Which is partly why I have moved to Deakin University.

The internet permits transfer of large amounts of data around the world, making it possible to set up 3D printing services like 3D Central, backed up by data security and financial systems. Even our worldwide distribution networks are vastly superior to what we had in the last decade, with advanced logistics thanks to companies the likes of eBay and Amazon.

The Centre for Advanced Design and Engineering Training (CADET) at Deakin University School of Engineering recognises that 3D printing is a vital technology that assists our students to realise their engineering design projects. Students will be able to start using the low-end machines in their first year, allowing them to turn their CAD models into physical parts. As they learn, they will gain access to higher-end machines like our Stratasys Connex3 machine, which will allow them to create accurate, functioning products with interesting multiple-material properties, perhaps driven by advanced sensory devices and sophisticated microcontroller systems.

So in my view we are experiencing evolutionary change rather than a revolution. Small increments in the various technologies over many years have seen the machines becoming faster, offering greater precision and better material properties in the resulting parts. Above all, these improvements have driven the costs down. However, it should be noted that, in my opinion, many people have made too big an issue about 3D printers costing only a few hundred dollars compared to the tens or hundreds of thousands that they were only a few years ago. Expiry of key patents for extrusion-based technologies has opened up a hugely competitive market for these ‘low-end’ printers. Such cost reductions have certainly moved the products from a significant capital investment to almost a consumer item. This

The students in CADET are starting to consider 3D printing technology as an everyday part of their lives as engineers. They realise that 3D printing is a tool that combines well with many other new and existing tools to create rapid and innovative solutions. Just like those involved in the original Industrial Revolution, they probably wonder what all the fuss is about. Ian Gibson is Professor of Industrial Design at Deakin University’s School of Engineering. www.deakin.edu.au/engineering/cadet

AMT November 2014

| 49

Additive Manufacturing

Precision prototyping – 3D printing in injection moulding The development of moulds for injection moulding processes is often painstaking, highly expensive and time-intensive. However, 3D printing is helping manufacturers make significant savings, both in costs and time. Injection moulding (IM) — injecting plastic material into a mould cavity where it cools and hardens to the configuration of the cavity — is best used to mass-produce highly accurate, often complex, threedimensional (3D) end-use parts and products. Hard-tooling moulds are usually made from tool steel with a CNC milling machine or via electrical discharge machining (EDM). When used in mass production, they can last for millions of cycles, but they cost hundreds of thousands of dollars. What’s more, lead times to produce these moulds are often measured in months rather than weeks or days. When tens of thousands of injection moulded parts are needed, soft-tooling is an option. Made in aluminium, these moulds are less expensive (typically $2500-$25,000) and faster to produce (two to six weeks). Unfortunately, the cost and time of tooling moulds is often compounded by factors like design mistakes that require the mould be remade correctly or the need to create multiple iterations before the final part design and quality are achieved. It is with these issues in mind that manufacturers have begun to embrace the use of 3D printed moulds to create functional IM prototypes.

Polyjet: The modern alternative PolyJet technology is an exclusive method of 3D printing offered by Objet 3D printers from Stratasys that gives companies the ability to build injection moulds in-house, quickly and easily. PolyJet printing creates 3D objects by positioning successive layers of liquid photopolymer into desired configurations. The plastic is then cured (solidified) with UV light. Once fully cured, moulds can immediately be placed into IM equipment and used to create prototypes from the same material that is specified for use in the final product. These precision prototypes give manufacturers the ability to create realistic, finished-product examples that can then be used to gather true-to-life, performance data. PolyJet injection moulds are not intended to be replacements for soft or hard tools used in mid- and high-volume production. Rather, they are intended to fill the gap between soft tool moulds and 3D printed prototypes. Key points related to PolyJet moulds: • The initial cost of creating a PolyJet mould is relatively low. However, PolyJet moulds are best suited for runs ranging up to 100 parts depending on the type of thermoplastic used and mould complexity. As a result, the cost per part is medium. • Building a PolyJet mould is relatively quick; a mould can be built within a few hours as compared to days or weeks to create traditional moulds. • In cases where design changes are required, a new iteration of the mould can be created in-house at minimal cost. This, combined with the speed of PolyJet 3D printing, allows designers and engineers greater design freedom. • Moulds created in Digital ABS material can be precisely built in 30 micron layers, with accuracy as high as 0.1mm. These production features create a smooth surface finish so postprocessing is not needed in most cases. • Complex geometries, thin walls, and fine details can easily be programmed into the mould design. What’s more, these moulds cost no more to make than simpler moulds. • No pre-programming is needed to create PolyJet moulds. Also, once the CAD design files are loaded, the 3D printing process can run without manual intervention.

50 |

AMT November 2014

• The manufacturing time to injection mould a part using a PolyJet mould is relatively low, though not as low as conventional moulding.

Material selection Proper material selection is important for success when injection moulding using PolyJet moulds. Digital ABS is the best choice for printing IM moulds; it combines strength and toughness together with high temperature resistance. Other PolyJet materials like rigid FullCure 720 and Vero also perform well as IM moulds. However, when used to create parts with complex geometries, moulds made from these materials will have shorter lives than those made with Digital ABS. The best materials for creating injection moulded parts are those that have reasonable moulding temperatures (< 300 degrees Celsius) and good flow behaviour. Ideal candidates are polyethylene (PE), polypropylene (PP), polystyrene (PS), acrylonitrile butadiene styrene (ABS), thermoplastic elastomer (TPE), polyamide (PA), polyoxymethylene or acetal (POM), polycarbonate-ABS blend (PCABS), or glass-filled polypropylene or glass-filled resin (G) Plastics requiring processing temperatures of 250 degrees Celsius and higher, or those that have high viscosity at their processing temperature, will shorten the life of the mould, and in some cases, the quality of the finished part. It is also useful to take a look at how the use of injection moulding with a PolyJet mould compares with injection moulding with an aluminium mould. The time savings can be highly significant, ranging between a few days and several weeks. Additionally, the cost to produce the moulds is generally 40% -70% cheaper.

Additive Manufacturing Field testing

3. Finishing the mould

Along with Nypro Healthcare, a global manufacturer of precision plastic products for the healthcare and packaging industries based in Bray, Ireland, Stratasys conducted a series of tests to assess the performance of rapid prototyped cores and cavities with critical features that included gears, interlocking legs, ratchets and catch features. During one of the many tests conducted, sample ABS parts were injection moulded into a single PolyJet mould made from Digital ABS. Parameters such as maximum pressure, cushion, and core and cavity temperatures were tracked.

A key benefit of PolyJet moulds is that they can be designed, built and used within hours. Most will require little or no post-processing work, however further finishing may be needed if:

Upon completion of the tests, the mould was deemed to be stable as indicated by a constant injection pressure and cushion, and that by using the recommended procedure for mould cooling, the temperature in the core and cavity did not exceed 58 degrees Celsius. What’s more, the quality of the injection-moulded prototypes was deemed by Nypro to be “good.”

• The mould will be fitted to an ejection system. To ensure a tight fit between the ejector pins and the ejector pin holes, program the holes into the STL file but reduce their diameter by 0.2mm0.3mm. Then, when the mould is cured, ream the holes to the exact final size. • Inserts are being fitted onto a base. • Extra smoothing of surfaces is needed. Occasionally, light sanding of surfaces transverse to the mould opening is recommended. For example, prior to using a mould with a tall core, some light smoothing can facilitate part removal.

4. Mounting

Nypro offered the following analysis of the tests: “It can be concluded that the injection moulding trials were very successful. The process of printing cores and cavities can be considered an advantage in terms of time, initial functionality evaluations and reduced tooling cost.”

Stand-alone moulds – those that are not constrained to a base frame – can be mounted directly onto standard or steel machine back-plates using screws or double-sided tape. Figure 8 mould inserts are fitted onto a base mould using bolts.

Best practice guidelines

With any chosen mounting option, it is critical to avoid direct contact between the nozzle and the printed mould by using standard sprue bushing. An alternative option would be to centre the mould’s runner with the sprue located on a regular steel plate.

Injection mould design, an art in itself, requires years of experience and a profound understanding of the injection moulding process. Although the design considerations for creating and using a PolyJet mould are fundamentally the same as traditionally crafted moulds, there are some variations. Tool designers should consider the following changes when creating a PolyJet mould as opposed to a conventional steel mould design.

1. Designing the mould • Increase draft angles as much as the part design allows. This will facilitate ejection and reduce stress on the tool as the part is ejected. • Increase gate size to reduce shear stress. • The gate should be located so that the melt entering the cavity will not impinge on small/thin features in the mould. • Avoid using tunnel gates and point gates. Instead, use gates that reduce shear such as a sprue gate or edge gate.

2. Printing the mould To maximise the opportunities created by PolyJet 3D printing, the following guidelines are recommended: • Print in glossy mode to ensure smoothness. • Orient the part in Objet Studio software so that the glossy surfaces are maximised. • Orient the mould so that the flow of polymer is in the same direction as the print lines.

5. Injection moulding process When using the PolyJet mould for the first time, the best practice procedure is: • Start with a short shot and a slow injection speed. The fill time can be high as the melt does not freeze off as it enters the mould. Increase shot size until the cavity is 90%-95% full. • In the holding process, use 50%-80% of actual injection pressure and adjust the holding time as needed to avoid sink marks. • Apply normal calculated clamping force value (injection pressure x projected part area) as initial value. • PolyJet moulds have low thermal conductivity so they will require extended cooling times. For small or thin parts (wall thickness of 1mm or less), start with a 30-second cooling time and adjust as needed. For larger parts (wall thickness of 2mm or more), start with 90 seconds and adjust accordingly. The cooling time will vary depending on the type of plastic resin used. • Minimum cooling is recommended to avoid too much shrinkage of the part on the printed cores. Extensive cooling may stress the mould when the part is being ejected and cause it to fail. • After each moulding cycle, it is critical to allow the mould’s surface to cool by applying pressurised air. This will preserve part quality and mould life. Alternatively, automated mould cooling fixtures may be used. The use of PolyJet 3D printed moulds allows manufacturers the ability to take functional testing to a new level, by creating product prototypes from the same IM process and materials that will be used to create the final product. With this technology, companies can generate superior performance data and validate certification confidence. PolyJet moulds are unique in that they perform in the same way as metal moulds but are much cheaper, easier and faster to make. With PolyJet technology, manufacturers can produce prototypes at speeds and costs far below traditional methods. As a result, 3D printing allows manufacturers to easily evaluate the performance, fit and quality of potential products before mass production starts. www.tasman3d.com.au

Mould inserts are assembled on a standard steel base and held in place with machine screws.

AMT November 2014

| 51

Additive Manufacturing

Facing the realities of additive manufacturing The Vernier Society held a special event last month entitled ‘The Truth about Additive Manufacturing’. Executive member Jack Parr reflects on the outcomes to be learned from the event. What is the truth about additive manufacturing (AM)? Is it all hype, or is it the future of manufacturing? How is Australia embracing this new technology? These are the questions the Vernier Society attempted to discover at their special October event, held at the spacious Kooyong Tennis club in Melbourne. As a further demonstration of the Vernier Society’s passion for supporting Australian manufacturing, members and guests heard from two of the leading academics in Melbourne, if not in Australia, explaining where they saw the future of AM and their efforts to increase awareness and capability in this still-developing technology. The event commenced with the Society’s amateur view of AM, but the professionalism was provided by Professor Milan Brandt, the Technical Director of RMIT’s Advanced Manufacturing Facility, and John Barnes, the Director in charge of the CSIRO’s High Performance Metal Industries program. Both gave excellent but quite differently themed presentations on what their respective organisations are doing in this innovative field. The two speakers were then joined in a panel Q&A session by Mike Brown, Managing Director of Renishaw Oceania, whose UK parent is one of the top six manufacturers of metal additive machines in the world. According to Brandt, AM is growing significantly globally and will be playing a key role in many industries in the future due to its versatility and its process advantages. The technology can and will contribute to the future growth of manufacturing in Victoria and Australia through creating new opportunities, in particular in areas such as medical device manufacturing, and creating low-cost lightweight structures for automotive, aerospace and defence applications. The growth facts about AM clearly underpin this emerging technology. The total market for the products across both plastic and metal additive is $3.07bn, a compound growth rate of nearly 35% since the first sales in 1989 and the market is forecast to be over $10bn by 2021, according to the Wohler Report. In 2012, 70,000 low-cost (around $1500) plastic desktop machines were sold worldwide, and by last year nearly 350 metal additive machines had been sold.

According to Barnes, while Australia is well represented in this field with over eight academic organisations doing research and more than 11 commercial organisations offering service solutions, it is New Zealand that is leading the Australasian initiative through their ‘Titanium Investment & Development Association’ (TIDA), a combination of government, education commissions and private companies supporting ongoing research and parts provision to their industry. Australia is aiming to catch up in this field. Invented in the early 1980s, the plastic, polymer and ceramic side of AM is now well developed, and led predominantly by two US companies, 3D Systems and Stratasys, who are now exploiting the innovative product opportunities in the fields of medical, industrial, automotive and even fashion. Metals AM was only developed in the late 1990s, but offers great potential as a challenge to conventional machining in terms of strength-to-weight ratios, complex geometries, smaller batch sizes and new alloy structures. However, with it come new issues on process conformity and metallurgical composition. Barnes explained that there are a total of seven different processes using combinations of melting source with either wire or powder as the material, with each of the processes offering differing application opportunities, but each with conditional restraints. According to Brandt, there are seven major players in the metals sector, all European, though the recent purchase of one by 3D Systems creates the first manufacturer to offer capability in both materials. Both RMIT and CSIRO seem to be concentrating on different but complementary development areas of AM. CSIRO is focused on improving the consistency of its titanium powder through their “Ore to More” program, as well as offering a third-party service house to a range of companies. As Barnes says, while 80% of his commercial work comes from overseas co-operations, it is hoped that CSIRO’s new venture “Lab 22”, which will be officially opened in early 2015 will see this 80/20 rule reversed in terms of an Australian majority. RMIT, which offers AM as an intrinsic part of its engineering courses, concentrates on laser cladding with 3D as a repair and refurbishment

Professor Milan Brandt, Jack Parr, Mike Brown and John Barnes during the panel discussion.

52 |

AMT November 2014

Additive Manufacturing

An additivemanufactured part from Renishaw.

The Vernier Society was held at Kooyong Tennis club in Melbourne.

tool to extend the life of high-cost industrial products like power station turbine blades and through selective laser melting. It also boasts an impressive array of desktop plastic machines. Both these institutions welcome visitors to their facilities as the first step in focusing on collaboration with commercial projects creating mutual benefit for both parties. Following the excellent presentations, Mike Brown joined the panel discussion and the first question gave him an opportunity to explain how Renishaw’s first experience of additive processes was through work performed by a subcontractor, in a variety of applications across the company’s other product divisions, notably its dental arm, for making crowns individual to the client’s mouth; and its medical division in neurosurgery robots and also in encoder products. Renishaw was so impressed with the potential of the technology, it went out and bought the company! It was a fast and furious technical Q&A session from an audience of engineers with questions on the application of new alloys and diversification into new areas. New conceptual thinking about additive design was identified as a major learning point; traditional machining designers think in terms of “metal off”, taking a cubic or cylindrical stock of metal and then removing material to attain the final shape but in additive, the designer starts with a blank screen and literally builds the component. While this may sound an easy adaption, the presenters stressed that it takes time, and this is really the area that is underexploited in AM. It opens up new conceptions of design creativity from a blank canvas that may well be limited currently by imagination.

Questions over metals Judging from the comments in the networking session that followed the event, the audience left knowing much more about both the potential and the complexities of additive manufacturing. However, what perhaps, and not unexpectedly, was not developed enough in the presentations are the challenges of metals-based AM. Machines and materials used can be expensive and the processes require high expertise and long processing times, and do not really offer agility of manufacture. Therefore the current machines cannot be regarded as production machines unless there is a high volume requirement for certain parts that can either only be made or additive

methods or offer a great cost benefit in application that outweighs the increase in manufacturing cost. As with conventional machine processes where metal removal rates are vital, metal laying and fusion rates are crucial to productivity in AM. Therefore, the development task for the machine manufacturers has to be speed of operation. Whether this is achieved by multiple energy sources, increased deposition rates or other technologies, the development race still has a long way to go. Both speakers stressed that metals in micro form do not operate in any controlled way that a block or material needed for conventional machining does. Therefore, reproducibility, reliability and overall process control are further areas for controlled development and from the presentations, are areas that both organisations are working on. Large US aerospace and automotive manufacturers are investing heavily in this technology, but Australia does not have such global players to pull the rest along. It seems therefore that the most promising commercial way forward in this country is via Service Provider channels – as both CSIRO and RMIT are offering. The question is how well these academic organisations can promote the technology’s potential given that industrial partnerships are still not yet a core skill of academic organisations. It is a twin problem because Vernier’s 2013 audit of companies, in conjunction with the Victorian Government, showed that the companies are poor at collaboration, whether with other companies or institutions. The other challenge for companies is to ‘think outside the square’; in other words to identify current parts that can be improved by this process, or even more importantly, features and benefits that cannot be even produced by current production methods. This ‘open field’ commercial perspective, is the equivalency of ‘blank screen’ design thinking. The challenge will be how to reach manufacturers and provide the impetus for new ways of thinking and collaboration AM is going to become increasingly integral to metal manufacturing, but it will be complementary to, not a replacement for, traditional machining techniques. It is now up to Vernier members and friends to utilise the knowledge gained from an excellent event to keep supporting AM; both as ‘Additive Manufacturing’ but also as ‘Australian Manufacturing’. www.vernier.org.au

AMT November 2014

| 53

Additive Manufacturing

Enabling innovation with design and additive manufacture As with all disruptive technologies, additive manufacturing provides opportunity for innovation and commercialisation. However, an informed approach is required to ensure that pitfalls are avoided. Writes Dr Martin Leary and Professor Milan Brandt of the Centre for Additive Manufacturing at RMIT University. The disruptive nature of additive manufacturing (known in non-commercial applications as 3D printing) exists due to fundamental differences in traditional and additive methods. Traditional manufacturing can be considered to be an ‘outsidein’ process, whereby production begins with a feedstock material, such as a billet, and material is removed as required to fabricate the final product. A common feature of additive is that manufacturing begins with a common feedstock, such as a polymer filament or a metal powder, and manufacturing occurs ‘inside-out’ in a layerby-layer fashion to fabricate the component. Production economics is well established for traditional manufacturing methods. It is understood that either increasing batch size or reducing complexity results in lowered unit cost. The economics of additive manufacturing is entirely different, and must be understood to avoid flawed commercial decisions. In particular, the unit-cost for additive is largely independent of batch size; consequently additive will be challenged by traditional manufacturing for high-volume production. However, for low-volume manufacture, additive has a significant competitive advantage. Another competitive opportunity for additive manufacturing is associated with high-complexity geometries that are not economically manufacturable with traditional methods.

Low volume Low-volume manufacturing provides a commercial opportunity for additive manufacturing within the fields of rapid prototyping and mass customisation. Rapid prototyping enables commercial pre-prototyping and concept validation to increase confidence prior to investment in hard tooling. Rapid prototyping is not only restricted to polymers, it is increasingly applied in metal. For example, it is quite feasible to prototype cast or forged components with metal additive manufacturing at a fraction of the traditional lead time and cost. Mass customisation refers to the ability of additive manufacturing to fabricate components with unique variation without incurring a bespoke manufacturing price-tag. Mass customisation has enabled significant commercial opportunities in innovative medical device design, including customised teeth alignment fixtures, hearing aid housings and structural implants. An example of mass-customised production

54 |

AMT November 2014

Figure 1: Mass-customised water intake insert developed by RMIT and DSTO. Left: Custom simulation to ensure manufacturability. Right: Manufactured insert.

currently under development between RMIT University and the Defence Science and Technology Organisation (DSTO) is the manufacture of customised water intake inserts for maritime vessels. Vessel fouling is a significant cost and environmental threat, as toxic species readily live in turbulent water intakes. Additive manufacture enables the mass customisation of inserts that are tailored to the various unique dimensions of water intake cavities that exist in a modern sea vessel, and have automatically generated shape to correct turbulent flow to reduce intakes fouling (Figure 1 above).

Vincent’s Hospital is the manufacture of custom structural implants with enhanced performance. Medical implants are used to replace cancerous bone that is removed during surgery. Traditional implants have significant deficiencies, including a stiffness that is incompatible with the replaced bone, which can lead to stress shielding and failure of the implant. The RMIT-St Vincent’s approach utilises the high complexity enabled by additive manufacturing to fabricate custom titanium geometries with a stiffness that matches the bone being replaced (Figure 2 below).

High complexity

Additive manufacturing is a disruptive technology that will enable opportunities for commercial innovation. An awareness of the production economics of traditional and additive techniques will ensure that commercial decisions are well founded, maximising opportunities for commercial innovation with additive manufacturing. Design optimisation coupled with materials and process optimisation is part of the RMIT Centre for Additive Manufacturing research strategy in assisting local companies improve their local and global competitiveness.

As additive manufacturing generates part geometry from the ‘inside out’, cost is largely independent of part complexity. Additive manufacturing allows the fabrication of highcomplexity components, including internal cavities and non-line-of-sight features that would be extremely challenging traditionally. This attribute of additive manufacturing is highly compatible with the commercialisation of high-value, high complexity products that would otherwise be cost-prohibitive. An example of high-complexity manufacturing under development by RMIT and St

www.rmit.edu.au

Figure 2. High-complexity implant developed by RMIT and St Vincents Hospital. Left: Custom simulation. Right: Manufactured inserts.

Additive Manufacturing

Bringing 3D printing to Australian manufacturing The use of 3D printers is creating an opportunity for Australian manufacturers to bounce back in a market that is predicted to be worth over $5.2bn by 2020, writes Paul Goepfert, Marketing Manager, Pronto Software. An innovative new environment has emerged for manufacturers due to the transition of 3D printing into mainstream technology. With the cost of 3D printers continuing to decrease and the technology becoming more widespread, it’s drawing escalating attention from the industry. According to Deloitte, additive manufacturing, a process that’s been steadily developed since 1984, allows businesses to innovate products from the inside out, a process that can’t be obtained through traditional manufacturing techniques. A common perception is that 3D printing is optimum for the creation of small, compound and unique objects. While this was certainly the case historically, it’s not the case today. The capabilities of 3D printing move far beyond the creation of simple objects, allowing manufacturers to design and create objects that are complex and challenging in nature – all in a cost-effective way that’s providing immense opportunities for the manufacturing sector. Now, we are even seeing projects to build standalone houses using 3D technology. From manufacturing concrete wall structures to doorframes, 3D printing is overwriting traditional construction methods, and providing real cost- and time-saving benefits. Additive manufacturing can be used to print a wide range of materials – including titanium, clay, food, ceramics, composites and even solar panels and organic cells – making the possibilities endless. With the emergence of 3D printing, businesses can save costs by implementing a Lean manufacturing environment. Previously, I worked as a Manufacturing Manager in the automotive industry. Presses and machines were running the same batch for hours, and over time we introduced Lean manufacturing processes to reduce the work in progress (WIP) stock wherever we could by developing manufacturing cells, reducing setup time and batch sizes. All manufacturers know that a Lean approach is less productive when you look at the work order level. However, at a company level, the reduction of capital immobilised in WIP stock, the significant reduction of manufacturing cycle times, as well as the improved product quality and enhanced employee satisfaction, far outweighed the lower cost of producing thousands of items in a single batch and then storing them long-term, waiting for final assembly.

Designing products in new, innovative ways Additive manufacturing is revolutionising the way businesses design products. With 3D printing, the product design process can be accelerated and developers can create objects that can’t be made by traditional manufacturing methods. Traditionally, an engineer would often be constricted and limited in product design as he or she would be forced to take into account manufacturing process limitations. This is no longer the case, as design engineers can now print parts with less manufacturing and design constraints. 3D printing has allowed almost any idea or design to become a possibility, and because of the capability of seeing a product outcome before it is physically created – without having to build a prototype – concepts and designs can be pushed beyond previously accepted boundaries. From my perspective, the greatest challenge around the growth of 3D printing is educating design engineers around this new technology, prodding them to apply it where makes sense. 3D printing is an exciting technology, and it is critical for businesses today to assess where additive manufacturing is going to create opportunity and growth, or negatively impact activities. Change can be difficult, and it is important that businesses educate engineers on the new possibilities and flexibility brought by 3D printing, fostering creativity and innovation. The companies that will look at 3D printing as an opportunity will create better, more ground-breaking products. They’ll innovate in ways that we can’t even imagine. There are undeniable benefits associated with 3D printing, and as the technology continues to grow and improve, so do the prospects for the Australian manufacturing industry. www.pronto.com.au AMT November 2014

| 55

Material Removal

LASERTEC 65 3D: Additive + subtractive DMG MORI has unveiled its LASERTEC 65 3D, a hybrid machine that is currently unique on the market, and which incorporates additive laser deposition welding into a fully-fledged five-axis milling machine. In times of ever-shorter product lifecycles and increasingly complex, more individualised components, additive manufacturing processes can help companies to produce new and innovative products more quickly. Additive manufacturing enables the production of complex geometries and workpieces. The unique technology combination of laser deposition welding by means of a powder nozzle and milling gives the user completely new application and geometry options. With the LASERTEC 65 3D, DMG MORI now offers a hybrid solution for combined laser deposition welding and five-axis milling. This process uses a deposition process by means of a powder nozzle, which is up to ten times faster than generation in a powder bed. The market for additive processes has grown rapidly in the past. However, up until now, these processes have been restricted to the production of prototypes and small parts, which otherwise could not have been manufactured using conventional methods. With the combination of the two processes – metal deposition and metal removal – on one machine, additive technology complements and enhances traditional ‘subtractive’ machining methods. To enable additive manufacturing, the LASERTEC 65 3D is equipped with a 2kW diode laser for laser deposition welding, while the fully fledged five-axis milling machine in robust monoBLOCK design also makes it possible to carry out highly accurate milling operations. “Thanks to the fully automatic changeover between milling and laser operation,” explains Friedemann Lell, Sales Director at Sauer Lasertec. “The LASERTEC 65 3D is suitable for the complete machining of complex components with undercuts, as well as for repair work and the application of partial or complete coatings for mould making, and mechanical engineering or even medical engineering.” In contrast to laser melting in a powder bed, laser deposition welding enables large parts to be manufactured using a metal powder nozzle. With a deposition rate of up to 1 kg/hour, this process is up to ten times faster than the laser generation of parts in a powder bed. The combination with milling opens up completely new applications. The component can be built up in several steps, whereby milling can be interspersed with deposition welding in order to allow areas that the cutter would no longer be able to reach when the component was finished due to the component geometry to be machined to final accuracy. The hybrid machine combines the advantages of milling, such as

56 |

AMT November 2014

high precision and surface quality, with the flexibility and high deposition rate of powder deposition welding. “In the case of integral components, where today 95% of the material is removed by milling, with additive processes material is only built up where it is needed,” explains Lell. “This leads to significant savings in raw materials and costs.” The laser, combined with the powder deposition head, is fitted into the HSK toolholder of the milling spindle. It can be automatically parked in a secure docking station while milling operations are being carried out on the machine. The machine and process are operated and controlled by means of the new 21.5-inch ERGOline control, with CELOS and Operate 4.5 on SIEMENS 840D solutionline.

Production of 3D contours Using a laser diode, the metal powder is deposited in layers onto a base material and fuses with this without pores or cracks. The metal powder forms a high-strength welded bond with the surface. A coaxial inert gas prevents oxidation during the build-up process. After cooling, a layer of metal forms that can be machined mechanically. As laser deposition welding has long been established as a stand-alone technology, it is ideal for incorporation into DMG MORI’s highquality CNC machines. Lell explains: “The combination of chip-removal and additive processes will become more important in future, as it opens up so many new options and advantages for the user.” One strength of this process is the option of successively building up layers of different materials. Wall thicknesses of 0.1mm to 5mm are possible depending on the laser and the nozzle geometry. Even complex 3D contours can be generated with any supporting geometry.

The individual layers can then be accurately machined before the areas become inaccessible to a cutter or other tools due to the component geometry. The combination of the two processes is a sensible choice for repair work and the production of tools and moulds. However, it also offers many interesting options for lightweight components, prototypes or small series production – particularly in the largepart manufacturing sector where other additive manufacturing processes cannot be used due to limited space. Large machines, such as those used for machining bulky components in the energy or aerospace industries, tend to be expensive. The possibility of carrying out roughing, deposition and finishing on a single machine therefore represents a financially advantageous solution for the customer. Another example here is the energy and oil industry where components often have to be coated with corrosion-resistant alloys to protect them against wear. Deposition welding provides protection for products such as pipes, fittings, flanges and special constructions, which are used in aggressive environments. With a hybrid solution, machining of the base material, coating and finishing can be carried out on one machine. This results in cost savings and a reduction in throughput times. www.dmgmori.com

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

Material Removal

Tailored solutions for turbocharger production The worldwide demand for turbochargers in automotive construction has been increasing for many years and this trend is set to continue. However, turbocharger production is one of the more technically complex challenges of mechanical engineering. Geometrical and physical conditions call for an extremely high level of theoretical and practical knowledge. Walter has mastered the technology and offers a number of cutting materials and tools for the professional manufacturing of turbochargers. “The requirements for the energy efficiency and performance of engines are becoming ever more challenging in times of diminishing resources,” explains Friedrich Auinger, Product Manager, Engines, of the Automotives and Engines department at Walter. “The extreme complexity of turbocharger production requires manufacturers to deliver an exceptional degree of precision and absolute process reliability.” Turbochargers have the job of boosting the performance of traditional piston engines. The necessary increase in fuel/air mixture throughput of each induction stroke is realised by a compressor in the intake manifold, which is driven by an exhaust gas turbine. Turbochargers can use either pressure (constant-pressure turbocharging) or the kinetic energy of exhaust gases (pulse turbocharging) as their energy source. With constant-pressure turbocharging, the exhaust gases are converged and collected before being directed to the exhaust gas turbine. The flow towards the turbine is usually induced by a build-up of pressure in the manifold section upstream of the turbine. A turbocharger essentially comprises a turbine and a compressor mounted on the same shaft. Turbine and compressor both work with vane or blade wheels to convert flow energy into rotational motion and vice versa. The exhaust stream forces the turbine wheel on the exhaust side to rotate. The torque is transmitted by a shaft to the compressor wheel in the intake manifold. The shaft bearings of the turbocharger have to withstand 260,000rpm, which is why they are of the hydrodynamic sliding type. The high temperatures produced during compression are reduced by an airair heat exchanger known as the intercooler. In addition to oil supply ports, some turbochargers also have ports that interface with the coolant circuit. VTG turbochargers feature adjustable guide vanes arranged on a vane ring encircling the turbine wheel. With variable turbine geometry (VTG), the inclinations of all guide vanes surrounding the turbine wheel can be adjusted simultaneously and almost steplessly during engine operation. Today, turbochargers are a common component of diesel engines and many spark-ignition engines developed in the automotive industry. They are fitted to motorbikes, cars, trucks, ships, light aircraft and locomotives. In addition, turbines in the energy industry also account for a high percentage of turbochargers in use today. “To keep up with changing requirements whatever the build of turbocharger, Walter develops tailored solutions for its customers and then presents them as an implementable and practical proposal as a costs per part breakdown,” says Auinger. To achieve this, the product manager’s team collates the necessary information and formulates a concrete solution following an accurate analysis of all parameters.

58 |

AMT November 2014

Different components demand different tools A turbocharger consists of a turbine with housing and vane wheel (material 1.4848), the bearing housing, the compressor and its housing (aluminium) and vane wheel and the vane ring. Today, particular importance is placed on the ‘blisks’ (blade-integrated disks) located on both the hot (turbine) and cold (compressor) side of the turbocharger. This term is derived from the two components it replaces in turbine construction, with up to 120 individual blades per disk being replaced by a single blisk. This principle reduces weight and saves on the assembly costs associated with the vane wheel. Blisks are generally produced on computerised cutting machines. A forged disk, the outer contour of which is worked in a metal cutting process to create the blade profiles, forms the basis of a blisk. The joint between the shaft and blisk is achieved by friction welding, which imposes demanding requirements on the subsequent machining process. The blisks on the compressor side are usually made of aluminium, while the powering blisks on the turbine side are made predominantly of a surface-hardened steel/nickel alloy (Inconel). Increasingly, composite materials also tend to be used. Other components with a diverse range of geometries include the exhaust charger, exhaust manifold, charger housing and vane ring in cast steel 1.4845/1.4848/1.4837 and the valve insert in GX40Cr17. Manufacturing generally sees the use of super-heat-resistant cast steels with a high content of chromium and nickel for turbines and exhaust manifolds for operating temperatures of up to 850 degrees Celsius in the case of diesel engines and 1200 degrees Celsius with petrol engines. wFor the production of most turbine housings, Walter offers special solutions. At the interfaces to the vane wheel, the component is worked internally with the turning method for roughing and finishing. This involves the use of combination tools with Tigertec PVD-Al2O3 indexable inserts, which ensure rapid completion in one pass and help to deliver maximum productivity and a high degree of process reliability. The cutting materials used are WSM 10, WSM 20 or WSM 30, depending on the requirement.

Material Removal

Walter developed these two milling tools specifically for processing turbine housing interfaces.

In the actual machining of the housing, different methods are similarly employed: surfacemilling, inside special turning roughing, inside special turning finishing, drilling, tapping, countersinking, v-band specials and reaming. This is where the Walter Xtratec F4045 heptagon cutter sets standards. Equipped with the 14-edge Tigertec Silver indexable inserts and the WSM 35 cutting tool material, it is perfectly suited to roughing operations. The B2084 combination tool is also used here, as are the Walter Titex Xtreme CI drill, the Walter Prototyp Prototex ECO-HT tap and the ConeFit solid carbide milling programme – Walter Prototyp Protomax and Walter Prototyp Protostar ‘Tough Guys’. An important role in the machining of turbine housings is played by the specially developed Walter milling cutters F2001-5859071 with a diameter of Ø = 61 mm and F2001-5961878 with a diameter of Ø = 100 mm. These are equipped with propeller-like indexable inserts and square indexable inserts each having eight cutting edges for milling contours, radii and for machining edges. The manufacturing of the exhaust manifolds imposes very similar requirements on the tools. In this case, however, a distinction is made between low, medium and high power that characterise CNC-controlled machines. As a rule, Walter facemills F4080 ODMT050408-D57 WSP45 are used for low performances, the F4045 XNHF0705ANN-D57 WKP35 for medium power, and the F4033 SNGX120512-F57 WSM35 for high-power machines. It is essential that the tools selected meet the challenging demands associated with the use of super-heat-resistant steels. For other machining processes, as with the turbine housing, the Walter Titex Xtreme CI drill, the Walter Prototyp Prototex ECO-HT tap and Walter F2001 special tools are again put to use. The bearing housings also need exact machining, which is something that Walter tools are able to accomplish quickly and precisely. To produce the intricate surface structures, selected facemills of the

Xtratec series are combined with the latest Tigertec and Tigertec Silver coated indexable inserts. For the various holes needed here, the Walter Titex XD deep-hole drill, the Walter Titex Xtreme Pilot 180 C drill and the Walter Titex Xtreme DH20/DH30 are on hand. Tapped holes are produced by the Walter Prototyp Paradur ECO-HT. Special attention has to be given to the complicated manufacturing of the blisks described above. These single-component blade integrated disks are milled along with their axle linkage on CNC lathes. The workpieces comprise two materials: Inconel 713 C for the disk, 42CrMo V4 for the axle. Tigertec Silver coated indexable inserts of the ISO P generation are again the tool of choice for this purpose. WSM30S, with a tool life of 150 workpieces, is used for the disk while WPP20S, which lasts 500 cycles, takes care of the axle shaft. Producing the aluminium compressor housing presents an entirely different set of requirements because, for the most part, different tools and inserts are needed for the workpiece machining process. Machinists opt for specially designed turning tools D1110-6153465, D21PS-60212116 and D54PK-6021218 equipped with a PDC P5800-6153439 special insert or a PM 2 WXN10 standard insert. Walter F4050 PCD mills are used to machine the regions that interface with the vane wheels in AlSi8Cu3. In the next few years, developers in the automotive industry are going to unveil further significant innovations associated above all with the economy and efficiency of engines. With marine diesel engines, too, and even in aviation, we are likely to see developments in which the technology of turbochargers spurs further advancements. In all fields, complex components are needed that can be manufactured costeffectively, quickly and reliably. The introduction of new, even more temperature-resistant materials will require further developments to cutting tool materials and coating technologies. www.walter-tools.com

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 November 2014

| 59

Material Removal

QuickFlex cuts tool change time. WTO has recently launched QuickFlex, a new and innovative quick change system in one toolholder. Providing an ER collet chuck and quick change system in one toolholder, QuickFlex offers a number of benefits including reduced tool change time and higher flexibility. The comprehensive QuickFlex system covers a full range of different tool clamping adapter types and sizes and the tool change is designed to be quick, easy and safe with a new one-hand wrench. The basic elements of the system are the two independent taper connections. The short taper, located close behind the thread of the collet chuck, is for radial centring and axial support of the QuickFlex adapter. This taper guarantees the high precision of the system independent of possible abrasion at the cone of the ER collet chuck. The location of the taper behind the thread keeps it protected against chips and dirt which guarantees permanently the high precision of the system. Dimac Tooling is the agent for WTO’s range of high-precision static and driven toolholders for turning centres. For many years WTO has continued to set the benchmark for driven tool technology with its innovative products known for achieving higher productivity and long tool life. “WTO’s goal was to develop a compact, simple and safe quick change system for driven toolholders with high cutting performance and long life time key objectives,” said Dimac’s Managing Director Paul Fowler. “One of the other benefits is that the cutting tools can be pre-set while the machine is operating. That means the set-up time for tool change at the machine can be significantly reduced.” WTO has been conscious of the need to offer a product that allows customers to add QuickFlex when budget allows. Starting with a minimal investment, the customer can clamp the cutting tools directly in the toolholder using a standard ER collet. While the toolholder can be used without a quick change system initially, quick change adapters

can be purchased later. “WTO offers a quick change starter kit that allows customers to update to the quick change function easily and cost effectively. Step by step, the quick change function can be added for reducing tool change time,” Fowler adds. “Like all the products we sell, QuickFlex is supported by the full back-up and support of Dimac technical personnel to ensure the right product is specified for the job and the product operates at optimum performance.” www.dimac.com.au

Heule upgrades Cofa deburring tool Heule Precision Tools has released a new generation of its highly successful Cofa deburring tool, distributed in Australia by MD ProductionTechnology. Building upon the existing Cofa tool concept, the new Cofa C provides an increase in the size of the deburring profile, handling and system flexibility for front-and-back deburring. By edge rounding in a unique way, the new tool delivers enhanced levels of accessibility, precision and process reliability. Cofa’s ability to deburr both even and uneven bore edges in one single pass is enhanced with a range of additional features such as larger deburring capacity or the ability to deburr threaded bores. Based in Balgach, Switzerland, Heule is a longstanding pioneer of back deburring. After expanding its range downward to Ø 2mm, Heule has now revised the blade concept of the larger tools (bore Ø ≥ 6mm). The new design allows larger deburring capacities up to R1.5. The easily exchangeable blades enable different deburring capacities without changing the tool. Another new feature created by the Heule R&D team is the deburring of threaded bores. The new tool range covers the ISO dimensions M8 up to M30 (bore Ø 6.7 mm to 26.3 mm). The new design concept with blade support and blade also increases profitability. The modular set-up as well as the extended tool life contribute to improve production efficiency. Meanwhile, the optimised standard range with its reduced tool length creates the potential for a further step towards best achievable deburring quality at best possible cutting data. www.mdprotec.com

60 |

AMT November 2014

Exchangeable blades allow different deburring capacities without changing the tool.

company focus

Pipe Lining & Coating – R&D paves road to success Based in Rutherford, New South Wales, Pipe Lining & Coating has successfully established itself as a key supplier in the infrastructure sector by focusing on continuous research and development. Pipe Lining & Coating (PLC) was established in January 1992, when it acquired a local business dealing in services including abrasive blasting and painting, general steel fabrication and cement mortar lining – the latter of which became its core business focus. At the time, the needs of the water industry for pipe, fittings, fabricated manifolds and specials were serviced by one supplier. Moreover, the strict standards for the selection of material specifications were uncommon to any other industry. These standards, having been developed in Australia specifically for local water industry needs, insulated supply against competition, especially from overseas manufacturers. This was the catalyst for the decision to acquire the Rutherford-based business. PLC’s Managing Director - Charles Russell - describes the acquisition as having been a challenge, but also a rich opportunity to establish a competitive alternative supply source with an emphasis on quality, service and price. Russell and his team’s commitment to meeting the challenge, paired with a successful history in supplying piping materials to the oil and gas industry, formed the solid foundation for PLC’s success today. Built with the ambition to keep profits on local soil, PLC has thrived in its 22 years as a result of strategically investing in research and development (R&D). Its continued success serves as testament to the opportunities available to Australian manufacturing companies in the construction and infrastructure field. Troy Flower, General Manager of PLC, has worked tirelessly in the field of R&D to develop the only Australian-owned supply source of cement lining and pipeline coating products. Since the company’s inception in 1992, Russell and Flower have been involved in some of the biggest infrastructure projects in the country, including the Sydney Desalination Plant, the ACTEW Enlarged Cotter Dam, various projects under Sydney Water’s Network Facilities Renewal Program (NFRP), and Melbourne Water’s Eastern Treatment Plant. Currently engaged in two projects with the help of the Federal Government’s R&D Tax Incentive, PLC is working to develop an Australian-based fusion coating product, as well as focusing on breaking into a new market with the building of a semi-automated pipe mill to manufacture steel pipe.

62 |

AMT November 2014

“Our emphasis on research and development has been instrumental in driving innovation within the industry and has played a large part in allowing us to work on some of Australia’s major water infrastructure projects in recent years,” says Flower. “There is strong demand for innovation and the opportunities are there to be developed.”

Channelling innovation The R&D Tax Incentive has enabled PLC to invest heavily in R&D to build and commission the first mobile cement-lining plant operating in Australia. This mobile plant delivers centrifugally applied cement mortar linings to steel pipes on-site, significantly eliminating the risks of damage associated with long-haul transport, storage and handling. This is particularly beneficial when servicing remote regions. The development of FusionKote, PLC’s fusion-bonded medium-density polyethylene (FBMDPE) coating, as well as the commissioning of its rolled and welded steel pipe mill, have extended its capacity to service customers not only in the water industry but also in the mining, construction and building industries. Over a four-year period, PLC conducted in-house research into the development of Fusionkote, during which time the business faced a range of challenges both big and small. The largest involved the sourcing of a supplier of base materials that would be interested in assisting with the development of the product from the ground up. “We had both the understanding and ability to design and construct the basic application principles and equipment required to process pipe,” says Flower. “But without any readily available technical information for polyethylene powders in the marketplace, we had to commence R&D using a scientific approach.” The business also faced difficulties with the design and construction of prototype equipment in order to conduct product testing. “When it came to determining the optimum application parameters for the product, we had to undergo a series of trials to test a range of variables and then compile a comprehensive database of technical information,” adds Flower. “This was a very time-consuming and detailed process. We also ran into challenges when it came to designing and constructing a production model of the required equipment using our findings from the trial results and the functionality of the prototypes.”

company focus

Despite these setbacks, PLC was able to overcome its challenges by tapping into the R&D Tax Incentive, which served as an incredibly helpful pool of resources. It led Flower and his team to investigate alternative avenues of research and approaches to design and production. PLC also utilised the trial and error period to iron out technical requirements of the product and analyse technical test data. Flower believes the involvement from suppliers was a significant aid throughout the process, enabling the business to have a full suite of tests conducted through third-party laboratories and ultimately see PLC satisfy the performance criteria of AS4321. “Even with challenges along the way, this project allowed us to open up market share previously unobtainable to PLC, all by increasing our product range,” says Flower. “Through these efforts, PLC has successfully developed an Australian-made product that complies with the AS4321 code as required by the water industry.” This achievement would not have been possible without extensive, world-leading research and development, which was made possible through the help of the R&D Tax Incentive. The team at PLC attests that this was crucial in expediting the timeframes of projects like Fusionkote, which is now market-ready. “Thanks to our involvement in research and development, PLC has been able to leverage our involvement in projects earlier and subsequently reap the benefits sooner,” says Flower.

Plans in the pipeline While the primary focus for PLC today is addressing the needs of the water industry, the organisation also supplies the oil-and-gas and building/construction industries, while maintaining a significant stockholding of water industry standard pipe and flanges to service everyday requirements. With the underlying mission of maintaining an Australian manufacturing base and continuing to produce and deliver a competitive, quality product, the immediate aim is to further develop manufacturing capacity. This will enable the business to supply the full profile of piping materials (pipe, fittings and custom fabrications) used within the water supply and delivery industry. Supporting its rolled and welded pipe mill through the supply of steel pipe, casing and piling to the building and construction industries is also an ongoing priority. Looking further into the future, PLC has plans to build a hydrostatic testing facility to certify its rolled and welded steel pipe production and will also investigate various new coating systems including fusionbonded epoxy (FBE) and tri-laminate (3LPE) systems for the oil and

gas industry. If that wasn’t already enough, PLC is also planning to develop ‘slip in type’ pipe joint systems – a common jointing system for water pipelines and fittings. With plans to continue its major role in Australia’s water infrastructure industry, Flower believes that continuing to develop valuable relationships with various stakeholders, including both old and new faces at the water authorities, design firms and independent contractors, will be critical to the future success of PLC. “While one of our greatest achievements to date has been gaining the recognition and acceptance as a supplier to the majority of water industry authorities across Australia, there are market regions where our products are not readily accepted,” Flower explains. “We need to improve marketing and further develop the product range to achieve complete success.” Of course the company’s recent news that its FusionKote product is market-ready, will help to fill this void. Nonetheless, Flower insists the company’s investment in R&D will be the difference when it comes to breaking into the new market of manufacturing steel pipe. “The decision to invest in the pipe mill was made easier and involved less risk as a result of receiving the R&D Tax Incentive,” he says. “While we could outsource supply, we identified the numerous benefits we would achieve by developing and building our own pipe mill. With our only supplier attempting to attack our traditional markets and customers and the high quality and tolerance requirements in force, both competition and security of supply became a concern for us. Within a short period, that supplier was placed into receivership so the added security of the Tax Incentive made a significant difference to our circumstances during this time. “It’s difficult to quantify the exact value of research and development in our industry but it’s a competitive market, and innovation is everything. The most valuable piece of advice I have to offer those in the manufacturing industry is: do your homework, understand the resources you may have available to you, and leverage them where possible, because if you don’t, there is a good chance your competitors will.” As competition on both a local and global scale accelerates, opportunities for local businesses to assert their position and keep business within Australia will become difficult. As such, service, innovation, R&D, and a solid business core, are proving the keys to success, in building a name for Australian manufacturing. www.pipelining.com.au

AMT November 2014

| 63

Business Management

The century of ideas In times past, we considered that Australia rode on the sheep’s back. Times have changed. Now is the time for Australia to surf the innovation wave for our future. By Bob Baldwin, Parliamentary Secretary to the Minister for Industry. Now, we are opening this innovation to the world by placing 100 years of intellectual property (IP) rights data online (see page 24). We are showing the world our inventions and ideas and showcasing our brilliance to the world. This will put companies, scientists and researchers expertise on the map and will also create much-needed jobs. Supporting and enabling innovation and new ideas is important to Australia’s social and economic growth now and into the future. Australia’s intellectual property (IP) system continues to be important to business in Australia and internationally. A well-functioning IP system that strikes the right balance between incentivising innovation and fostering the public dissemination of new ideas is critical. Australia’s growth of new ideas and innovation is evident with the increasing demand for IP rights. In 2013, 29,717 patent applications were received by IP Australia: a 13% increase from 2012. This mirrors global trends, with the World Intellectual Property Organization (WIPO) noting that global demand for IP rights have increased across all types of IP and that patent applications had reached “unprecedented levels”. The last ten years have seen innovation-leading countries fundamentally changing their investment pattern. Private firms operating in the USA and UK now invest more in research and development (R&D), branding, design and ideas than they do in traditional capital, and countries like Sweden and Finland are close to bridging that gap. This has important consequences for how Australia competes in a global market that is driven not by ownership of capital, but by the ownership of ideas. The economic importance of ideas is seen in the increased interest and reliance on IP. Patents, trademarks and design rights are all means by which entrepreneurs can stake a claim on their invention, and decide which markets they wish to have those claims in. It is telling that Australian inventors filed 35% more patents in the US than they did in Australia, and this shows how our ideas are being used in the world’s biggest market.

Encouraging collaboration and innovation In a world where profits flow to the owners of ideas, it is important to have a world-class IP system (which by all rankings we do here in Australia), and also to understand who is innovating and where. In a world-first, the Australian Government has publicly released over 100 years of intellectual property rights data. The ability to search information about IP rights applications around patents, trademarks, designs and plant breeder’s rights means that businesses, researchers and individuals can examine data about IP rights applications. They can now also match IP rights data to individual firms and the firm’s size, technology and geographic location. Moving our IP registries into open data form should help foster collaboration, and also help us understand where our competitive advantage lies. This data helps to enable and encourage collaboration and innovation to help ensure Australia can be globally competitive into the future. The value of innovation in Australia is evidenced by the invention of WLAN, or WiFi as it is commonly known. WiFi was invented through the work of CSIRO radio astronomers and patented in 1996. This technology has been commercialised internationally and saw CSIRO have licence agreements with over 20 companies internationally. These licence agreements represented around 90% of the industry, with total revenue from the technology valued at over $430m.

64 |

AMT November 2014

Australia is also renowned for the development of the Cochlear implant – now used by over 10,000 people across the world. In the 1980s, Dr Graeme Clarke and a team from the University of Melbourne developed an ear implant to assist the hearing impaired, which has since earned the University and the Commonwealth over $8m in royalties from the IP from this invention. The Cochlear implant is manufactured entirely in Australia and exports make up 95% of its sales.

IP data and the global value chain From the IP data now publicly available, we know that Australian firms are already participating in global value chains, and they do so as innovators at the top of the value chain. This is important in the world of global supply chains where the high-value-add often lies with the innovator. A good example of this value is Apple’s iPhone, which is designed in California and made in China. More than 13,000 people work to manufacture the phone in China, but only receive 2% of the value of the phone. The owners of the technology and brand command more than 70% of the value, and this is split between Apple and other technology suppliers in Korea, Japan and Europe. The way into these value chains is through ownership of ideas in patents and designs. Not surprisingly, manufacturing and scientific services are the main patent applicants in Australia, but the thirdlargest are wholesale traders. These traders prefer to develop new products (protected by patents and designs), outsource or license the production to a third party, and then sell the product to consumers. The new data shows that these firms are innovating in everything from containers and fixed construction to kitchen equipment and even pharmaceuticals, and their role in the century of ideas is one which is becoming more important. Understanding these links, creating value and ensuring that there is a strong link from investment in R&D and other intangibles to translate into real economic outcomes is a key priority of this government. The Intellectual Property Government Open Data is available from www.data.gov.au. Find out more about intellectual property rights at www.ipaustralia.gov.au

Business Management

Manufacturing technology – The value of utilising local suppliers Recently there has been an increasing trend for Australasian manufacturing technology users to source their machines directly from manufacturers in Asia, Europe and the USA. Paul Philips makes the case for buying local. As an Australian-based manufacturing technology supplier, I write this in order to stimulate debate, enhance productivity and hence improve living standards for us all. Let’s start by looking at the functions of an effective Australasian-based manufacturing technology supplier and how they add value. An effective supplier may perform some or all of the following:

• Perform safety risk assessments to Australian standards, significantly reducing the user’s risk exposure. Many overseas manufacturers are unfamiliar with our legislation.

• Thoroughly investigate the needs of the user by collecting all information about the present or planned process, including any apparent problems.

• Be available to provide service during the warranty period and beyond. Provide telephone support for quick solutions to minor problems that would otherwise lead to lengthy downtime.

• Draw on their experience to suggest all available solutions and assist the user in making an informed selection of the most appropriate equipment for the required process. Without breaching strict confidentiality, solutions learned from one project or process can be applied to other different processes at other (non-competing) users. • Correspond clearly with overseas manufacturers of manufacturing technology to ensure that the technology and equipment is appropriate for the intended application (fitness for purpose). • Assist the user with financial justification for the acquisition, and connect the user with sources for finance. Even though the initial outlay may not be the lowest, the ROI over time will reflect that “best value” has been achieved. • Correspond with the manufacturing technology manufacturer to ensure that the ordered equipment and all optional specifications exactly match the user’s needs and subsequent purchase order. • Be the Australasia-based legal entity and single point of contact for all compliance and legal matters related to a project and to potentially multiple manufacturers of manufacturing technology – serving effectively as a project co-ordinator. • Agree equipment acceptance parameters and arrange tests to demonstrate those parameters. • Arrange logistics to deliver the equipment to the user’s site by the most cost-effective and expeditious method. • Install and commission the equipment in the user’s facility in the shortest possible time.

• Provides operator and maintenance training to the user’s personnel. Achieving proficiency quickly boosts safety, productivity and ROI.

• Provide preventative maintenance on a regular basis to extend equipment life and reliability. This reduces unexpected breakdowns and makes productivity predictable. • Hold stocks of consumable and repair parts, which are used in common by multiple users. • Arrange for retrofitting or reconditioning when equipment no longer meets a user’s needs, so it becomes useful again. Alternatively arrange redeployment with another user or environmentally compliant disposal. • Provide valuations for various purposes to assist the user meet its business objectives. If all of the above are done well, the supplier will add tremendous value to the user’s business. If they are done badly, they may cause great harm. For this reason, all prospective suppliers should be carefully vetted to ascertain and confirm their capabilities. A good supplier becomes a long-term partner. Often overlooked in addition is the vital role that suppliers play in the transferal of technology.

The hidden costs Let’s talk about saving money, which is the stated reason that most users want to deal directly with manufacturers. Most users who deal directly expect to save around 10% of the value of the equipment. As a headline, this may be correct – but that assumes that everything on the above list goes to plan. How much does the user lose when something goes wrong? When you add in how much time the user spends administering the project (tasks with which

they have no experience, with many pitfalls), the financial gap closes rapidly. Is it worth the risk? An experienced supplier can perform the functions far more efficiently than a user who is involved in acquisitions sporadically, at best. If a supplier was to bill hourly in the same way that a lawyer or other professional does, it is likely the hours charged (and costs) for the above services would be much higher. How much does a user spend on business analysts, consultants and mentoring? Bundling these services into the price of the equipment, whilst not transparent, likely works out cheaper for the buyer. In the past, we have surveyed users, with a view to reducing equipment prices in exchange for charging separately for support services. Our existing customers always firmly stated that they would like to stay with the existing arrangements. Finally, consider this: each piece of equipment purchased directly from a manufacturer sends some work offshore. Each piece not sourced through an Australasian supplier weakens our entire industry and drives up operating costs for every user. Each supplier (and all suppliers collectively) needs critical mass to sustain our manufacturing ecosystem. If the fixed operating overhead of each supplier is spread over fewer and fewer machines, the prices of the individual machines will need to increase. If not, the supplier will cease operations. When the supplier no longer exists, the user will be forced to deal directly with manufacturers. Then the users will come to appreciate just how much value a good supplier adds. Quoting Joni Mitchell’s Sixties song, Big Yellow Taxi; “Don’t it always seem to go, that you don’t know what you’ve got till it’s gone.” I look forward to your feedback, to add to the debate as to how the Australasian precision manufacturing industry will advance, especially in living with the closure of our automotive sector. Paul Philips is Managing Director at Sydney-based Benson Machines, which has been transferring technology since 1908. Paul has requested that this article be available for all to reproduce freely, without attribution, for the greater good. www.bensonmachines.com

AMT November 2014

| 65

Business Management

Changing of the Guard Changes to the industry mean manufacturers face an array of pressures not experienced in previous years. What can companies do to thrive in this new, altered landscape? By Bruno Bello. Wow, how dramatically manufacturing and some business have changed in such a short period of time, let’s say over the past 15 or so years. When your income, personal wealth and that of your employees is at stake, this rapidly becomes a very serious topic. My observations and opinions as follows are purely based on the high level of detailed interaction that I have with many businesses. The good news is that I see some businesses in some sectors doing really well, in part because of the sector they are in and the nature of their products/services. While this is the case, it does not apply to many businesses that only a few years ago were rewarded for their hard work and investment, and supported many employees/families. Today some of these businesses are struggling to achieve acceptable levels of profitability – in some cases, their viability and wealth are at risk. This begs the question: what can these businesses do? Do they simply try and survive in the hope that things will improve? Do they diversify, improve efficiency in order to compete, import low-cost products, set up in a lowcost country, sell their business, buy another, and so on? Each of the options typically requires a very different skill-set, significant effort and investment, while at the same time representing risk and uncertainty. For me the rapid change that we will continue to experience requires a very different approach to that used by many businesses that were successful in previous years. Let’s face it: from about the 1950s until about the 1990s there were major opportunities in so many sectors that employed so many people. During this time, hard work and investment was typically rewarded to the extent that many owners built up significant businesses from a zero base that enabled some to invest in a range of areas, such as other businesses and real-estate. What I have seen in the past 15 years is that hard work and investment is not rewarded to the extent that it was for so many businesses in so many sectors. I suspect that the good news for some owners of businesses that accumulated much wealth during prosperous times is that they will be able to generate a good income from their investments – in effect rewarding them for their hard work and investment. Unfortunately this does not apply to their employees, who rely on the business to receive an income. Nor does this apply to business owners who were unable to build up this wealth, or businesses that have not been established for a significant period. In summary many businesses that were established some years ago generated wealth and opportunities for their shareholders and employees over an extended period when the cost of living – and in particular housing – was much more affordable compared with today when

66 |

AMT November 2014

our housing is some of the most expensive in the world. I guess this paints a good picture for both businesses and employees that had a business or career cycle that enjoyed the benefits from this period. These folk are probably wondering what all the fuss is about, but what happens now that the local and global climate has changed so dramatically that traditional ways of doing and running business may not be rewarded as they once were. In recent years we have been smothered by catchcries of ‘Work Smarter’, ‘Automate’, ‘Introduce Lean’ like Toyota and other automotive businesses. And if you do so you will prosper. There is no doubt that these approaches help; after all if you improve your efficiencies and are smarter in how you manage your business then this will surely help. Unfortunately, as the automotive companies have also proven, putting price pressure on suppliers and improving internal processes may have helped prolong their presence, but they like so many other local sectors are in distress. Fortunately for them, as global businesses they will survive well beyond the demise of the local automotive manufacturing industry. What then is the answer to the complex situation that I have tried to describe in a few words? I am not a fan of the word ‘strategy’ – for some it tends to suggest a huge, high-cost, semiirrelevant document that is often not very good and poorly implemented. Therefore let me use the word ‘reality’. While vested interests, emotions and a range of factors can shape what we each perceive to be reality, if you start with and stick to facts and data, then at least you will be informed and aware of your current position and factors that influence this. Based on this, you will be better able to develop plans to improve your position. Hard work, investment and a gut feel for the local and global market and drivers that impact on your business are so complex and dynamic that a traditional approach to running a business may simply not work or be rewarded, regardless of business capability, hard work and investment. The climate has changed during the past 15 years, so the approach/ management needs to change to survive or prosper. Try and think about what the local or global market will allow you to do and reward you for, using facts to conduct a current position and reality check. This will better enable you to make the decisions that will protect or improve your wealth. Bruno Bello is a Business Adviser with the Commonwealth Government’s Enterprise Infrastructure Programme (EIP). AMTIL is a partner organisation working with the Department of Industry in the delivery of the EIP. www.business.gov.au/advice-andsupport/EIP

Business Management

A question of finance: SMEs and the export challenge Small to medium-sized enterprises (SMEs) are one of the biggest employers in the country, a valuable source of innovation and a key driver of increasing productivity, yet they often find it tough to access the finance they need to succeed. By Andrew Watson. Difficulties in obtaining finance can hold these SMEs back from winning new business, growing internationally and commencing export operations. The good news, however, is that there are a number of options available to ensure that SMEs don’t miss out on the finance they need to expand overseas.

The financial challenges facing SME exporters Australia’s 2014 International Business Survey found that 62% of SMEs found it difficult to source additional debt financing. There are a number of reasons why this is the case. A key one is that the funding requirements of many SMEs are quite specialised — particularly those that are innovative or growing rapidly — and so don’t often fit into the standard lending approach adopted by banks. This is often due to the small amounts involved, the lack of security or not being able to provide information on their ability to service the loan. It is particularly an issue for SMEs operating in emerging and frontier markets, which tend to be seen as ‘higher risk’ by commercial lenders. Recent regulatory changes across the wider Australian financial services industry have also had a significant impact on SMEs seeking finance. Lenders are now required to hold significantly more capital against SME loans, given their higher risk profile, than more ‘capitallight products’ such as residential mortgages. This means that, while Australian banks may often be supportive of the overseas expansion plans of their SME clients, they may be unable to approve the additional funding required.

How Efic can help As Australia’s export credit agency, Efic is a specialist financier that delivers simple and creative solutions for Australian companies designed to enable them to win business, grow internationally and achieve export success. The main reason it is able to support SME exporters is that it has the specialist knowledge and expertise to understand their needs. Efic operates on a commercial basis and partner with banks to provide financial solutions for: • SMEs which are exporters. • Australian companies in an export supply chain. • Australian companies operating in emerging and frontier markets. Efic has a long history of successfully operating in overseas markets, reflecting its specialist knowledge in country risk assessment, its strong relations with other export credit and government agencies, and its willingness to take and manage risk. It uses a range of products to deliver financial solutions for exporting SMEs, including: • Working capital guarantees, where Efic provides a guarantee to the exporter’s bank as security, allowing it to approve the additional working capital needed to fulfil an export contract. • Bonding facilities, including bonding lines and contract-specific bonds, which are used when an exporter’s bank cannot meet the total bonding requirements for a specific project. • Buyer finance through loans provided directly to overseas buyers of Australian exports, when a lack of local presence, weak governance environments and poor quality information can often deter Australian-based banks supporting exporters in this way.

• Project finance, where Efic supports specific opportunities for subcontractors and suppliers that are involved in global supply chains or projects in emerging and frontier markets. • Pre-export finance, where the export order for a valuable contract is abnormally large or the exporter has limited financial flexibility. • Documentary credit guarantees when exporters need their buyer to provide a Letter of Credit issued by the buyer’s bank to guarantee payment under a contract. Australian banks may be unable to provide this letter due to the perceived risk, a lack of information about the foreign bank or its internal country/ counterparty exposure limits. Efic is committed to unlocking finance for export success. Through its range of loans, guarantees, bonds and insurance products, it helps Australian exporters and subcontractors take advantage of new contract opportunities that may otherwise have been out of reach. Andrew Watson is the Executive Director of the SME division at the Export Finance and Insurance Corporation (Efic). www.efic.gov.au

Case study: Camatic Camatic is a Victorian-based company that manufactures seating for stadiums, theatres and cinemas. The company has had success, both domestically and internationally, having completed projects for the Sydney Opera House, Melbourne Cricket Ground and the stadium for the Atlanta Olympics. Camatic needed working capital for a seating contract for the new San Francisco 49ers football stadium in Santa Clara, California. Efic provided Camatic’s bank, NAB, with an export working capital guarantee (EWCG) to support the contract. It was used to support the manufacture, delivery and installation of 68,500 seats for the Santa Clara Stadium. An EWCG supports the provision of working capital for export or export-related contracts and can help a company’s future export growth plans. “The EWCG enabled Camatic to take on this major contract and freed up its working capital, which is important given its strong order book,” said Efic’s Andrew Watson.

AMT November 2014

| 67

Business Management

Addressing the barriers to growth for manufacturing SMEs With the demise of much of Australia’s large-scale manufacturing, the hopes of our sector lie with the more than 45,000 innovative small and medium-sized manufacturing enterprises (SMEs) across Australia. By Tim Mclean. The challenge for most of these businesses is how to grow revenue and profits and carve out a sustainable niche in the competitive globalised marketplace. I have spent my 26-year career wrestling with these challenges. As Managing Director of leading Lean consultants TXM Lean Solutions, my team and I have helped well over 100 SMEs to overcome these challenges and grow their businesses. I have now distilled these experiences into a new book ‘Grow Your Factory – Grow Your Profits: Lean for Small and Medium-Sized Manufacturing Enterprises’, which will be released next month.

The diseconomies of scale In my years working with manufacturing SMEs, I have observed a common pattern. Economic theory dictates that as a business grows, fixed costs stay fixed, variable costs grow in line with sales, and therefore profit margins increase. This is called the economies of scale and most of us will have learned about it in high school economics. In my experience, most SMEs face the opposite. As sales grow, overheads also grow, and variable costs grow faster than sales as productivity falls. As a result, profit margins fall and even disappear. Working capital in the form of debtors and inventory also increases and the business often struggles with finding enough cash to fund its operation. Lead times, customer service and quality are often then compromised as the financial resources and management capacity of the business become overstretched. Eventually the business will need to stop growing or it will fail when it runs completely out of cash. We call this process the “diseconomies of scale”, and most SMEs we meet experience something like it. The root cause of diseconomies of scale is poor internal management processes. A lack of effective management systems means that more managers, supervisors and expeditors are added in a vain attempt to maintain control of the growing business. This increases overheads. A loss of management control, poor communication and reduction in employee engagement as management layers are added lead to reduced productivity and more mistakes and waste, increasing variable costs. Finally poor processes for day-to-day execution of orders and management of backlogs and materials means that lead times often increase, leading

68 |

AMT November 2014

to increased inventory, costly expediting and expanding factory buildings filled with inventory and work in process (WIP). The combination of all these problems means that the leaders of the business spend their days fighting day-to-day fires rather than directing the future growth of the business.

How Lean helps Many managers in SMEs view Lean as a big company, Japanese, automotive industry approach that is not relevant to them. Unfortunately this view is often reinforced by many of my colleagues in the consulting and training industry who take a very rigid theoretical approach. In fact at its core, Lean is a simple, practical and highly adaptable management system. It is ready-made and proven for use by all types of manufacturing SMEs. At TXM we have developed Lean production systems in business ranging from egg farms to electronics manufacturers and everything in between. The key is to adapt the Lean approach to develop a management system suited to the particular business, rather than trying to turn the business into a ‘little Toyota’ – though it is worth remembering that Toyota was small once, and that Lean was the key to its global growth. In our experience, a well-implemented Lean production system reverses the diseconomies of scale. Simplified and

streamlined processes for order fulfilment dramatically reduce lead times, inventory and factory footprint, reducing working capital. Robust systems for planning, ordering and responding to customer needs reduce or eliminate expediting and material shortages. Improved factory organisation and communication and improved problemsolving skills drive decision-making closer to the front line. This increases worker engagement and ensures that problems that lead to waste and defects don’t go unsolved. As a result productivity increases. Middle management and supervisors have increased capacity to lead their teams and improve performance, stemming the growth in overheads. Senior management is freed up from day-to-day firefighting and gets time to focus on strategy and growth. The combined effect of all these improvements is that variable costs, overheads and working capital are all reduced, meaning that profits increase faster than the rate of sales growth. This then enables the business to generate additional sales growth and creates a virtuous cycle of improvement. I’ve read dozens of Lean books over the years and noticed that almost all of them were aimed at big companies. The case studies talked about Toyota, Boeing or GE, and simply were not relevant to the challenges facing SMEs. The books assume that companies have resources such as

Victorian ladder manufacturer Branach Manufacturing demonstrates the benefits of Lean, with sales having more than doubled since the company introduced the Lean Production System.

Business Management

production engineers, human resources (HR) specialists and training departments to drive their improvement. In my experience, at many SMEs the Production Manager is the Production Engineer, HR Manager, Training Manager and Planning Manager as well. The few books written for SMEs tend to be about Lean and Lean techniques. In ‘Grow Your Factory – Grow Your Profits’, my start point was “What are the problems faced by growing manufacturers and how can Lean overcome these problems?” The book therefore goes through the typical steps that an SME needs to follow in order to develop a Lean production system and overcome the barriers to growth that is faces. The book includes many practical case study examples, all from Australian SMEs that the TXM team have worked with. Because Lean is a big subject beyond the scope of a single book, I have included a wide range of references where readers can get more detail on specific topics, particularly on Lean tools and techniques. Businesses are also encouraged to get hands on help from Lean specialists such as TXM, and the final chapter of the book contains advice on how to get started, including how to select the right Lean consultant for your business.

It is not easy Making change in your business is never easy. It is just simpler to go on managing day-to-day, fighting the fires as they come along, and hoping things will get better. When you start to make change, the dayto-day problems do not just go away. Initially the time you will spend on planning

and implementing improvements will be on top of your normal daily workload. This means things might get harder before they get easier. However, at some point (in our experience usually around 3-6 months after the project starts) the improvement efforts start to reduce the day-to-day problems you are facing. Your workload levels off, and as more problems are eliminated, your workload starts to fall. Eventually life gets back to the level of work you had before you started the improvement process. At this point you could opt for an easier life. However if you then use your free time to redouble your effort in improvement, you will enter a ‘virtuous cycle’ as further improvements further reduce problems, freeing up time for even more improvement. In our experience every customer that has been through this process would agree that it is worth it. The benefits will outweigh the costs many times over. Our customers have typically achieved productivity improvements of 20%-50%, reduced inventory by 30%70%, and reduced lead time by up to 90% (!). This has led to increased profits, increased capacity and increased sales. As more than 100 TXM customers can attest, Lean is not a complex theoretical system only suited to Japanese auto manufacturers; it is simply the best and most practical management system available for any manufacturing business, and is ideal when adapted to address the growing pains of manufacturing SMEs. In my book, I sought to capture this thinking in a way that will make sense for leaders in small and medium-sized manufacturers, providing a

Six things manufacturing SMES can learn from big companies • Standardise practices and work methods. • Understand what makes your business great or unique. • Get your structure right and clearly assign responsibility. • Develop your people and provide them with a career. • Focus on the balance sheet as well as the profit and loss. • Planning is essential. practical, step-by-step road map to help you address the problems holding your business back. Tim Mclean is the Managing Director of TXM Lean Solutions. His new book ‘Grow Your Factory – Grow Your Profits: Lean for Small and Medium-Sized Manufacturing Enterprises’ will be released on 18 December by Productivity Press. It is available for pre-order now from the TXM website, Amazon.com and the Productivity Press website. www.txm.com.au

AMT November 2014

| 69

Motors & Drives

Rylock doubles output by automating plant Based in Dingley Village, in Melbourne’s south-east suburbs, Rylock manufactures high-quality aluminium windows for residential homes, expressly for the high end of the market. Rylock concentrates on premium-quality aluminium windows, all with a large colour choice and an enormous range made to exact customer specifications and order. Rylock’s fast turnaround delivery requires a large and regular volume of aluminium extrusions, with emphasis on the highest quality of aluminium and the powder-coated surface. For their new factory located at Cheltenham, Victoria, Rylock’s own engineers designed a new aluminium extrusion pre-treatment plant to suit their proposed increased production output. With the additional extra space offered in the new factory, the engineers created their new pre-treatment plant from a clean sheet design. Significant emphasis was placed on making the structure substantial and long-lasting, with a view to ensure it would remain compatible with Rylock’s longterm production goals. The new pre-treatment plant consists of four large vertical steel towers positioned in a large square pattern, all connected with an overhead structure. Suspended from the overhead structure are two large lifting baskets, which contain the aluminium extrusions. The two lifting baskets are fabricated from stainless steel, and are utilised to dip the aluminium extrusions into cleaning, rinsing and etching tanks, as directed by the process programme. The lifting baskets and their load can weigh as much as 750kg so counterweights are utilised to offset the heavy weight. During the removal from the tanks, the lifting baskets are tilted at eight to ten degrees to facilitate draining of all fluids. There are a total of seven tanks, each measuring 7.2m long by 1m wide and 1.2m high, with each tank containing approximately 4700 litres of liquid. The tanks are made of 316 stainless steel (for the hydrofluoric acid ) and 304 stainless steel (for the water rinse ). The control programme commands four separate 0.75kW frequency inverters, which in turn control four Nord motors positioned at the top of each vertical tower. The electrical cabinet door has an external keypad control for simple operation. For this project, Nord Drivesystems AU supplied the four Nord Helical bevel geared brake motors, unit designation SK9043.1AXZ-80S/4 BRE10 TF IG11, with a 279.60:1 ratio. These Nord geared motors were supplied complete with an electromagnetic brake, and an incremental

70 |

AMT November 2014

The new pre-treatment process plant at Rylock’s new Cheltenham factory.

encoder for individual positioning feedback to the frequency inverters. The hollow shaft design and external foot mount gear case provided simplicity to the installation, especially with the height required. These motors were selected to complete a high duty cycle and for long life expectancy, to help future-proof the pre-treatment plant. In order to produce aluminium extrusions coated with the highest quality of powder coating for the most discerning of customers, extensive cleaning and preparation of the aluminium surface is required. The seven process tanks are arranged in order of the preparation process: Tank 1 has a mix of hydrofluoric acid and sulphuric acid for removal of any oxide layer on the aluminium extrusions. Tanks 2 and 3 are for water rinsing. Tank 4 has chromic acid, which etches the aluminium and provides the lattice work on the metal’s surface for good powder adhesion. Tanks 5 (dirty rinse ), 6 (intermediate rinse ), and 7 (clean rinse ) are for water rinsing to remove all chemicals before the aluminium extrusions are moved to the powder-coating line. Rylocks’ Design Engineer Peter Kennedy advises that the older manual pre-treatment plant required the attention of one operator for a half day, to both load and manually move the lifting baskets in and out of the tanks. This older system processed a total of only seven or eight baskets per day. With the new automated pre-treatment plant, the process system loads and processes one full basket every 25 minutes, which

The NORD motors were located at the top of each tower. The hollow shaft and foot mounted gear-case enhanced the simple installation required.

effectively doubles Rylock’s production output. The new automated system now frees up the operator to allow him to perform production duties elsewhere in the factory. www.rylock.com www.nord.com

WWW.SECOTOOLS.COM/SQUARET4

We’re excited about our new square shoulder mill. Providing a true 90 degree wall, Square T4-08 has the ideal balance of high performance and cost effectiveness. You’ll discover that the new cutter design gets rid of more metal, faster, for most cast iron and steel applications.

YOUR NEWEST SQUARE SHOULDER MILLING SOLUTION

forum – import/export

Take a step back going forward with exports Export controls on defence and dual-use good. If you are in the “High Tech” industry sector and exporting, there are permit regulations you need to be aware of, as explained by Doug Tozer. If you do not classify your product to the Australian Bureau of Statistics’ AHECC (“Australian Export Tariff”), you cannot export it. So the message is: do not leave this to the last moment and write it into your export policy document to start proceedings after production of shelf items or at the purchase inquiry stage from a buyer. Additionally, you will need to ascertain the final destination of the product. One major aspect of classification is to ensure you have the right permits in place prior to your consignment. Current news has seen two exporters heavily penalised, with additional court action on the person. “The company was ordered to forfeit their goods, worth $80,000, and also received a 12 month good behaviour bond with $5000 surety.” If we reduce the number of permit agencies down to the few listed below, there are numerous tariff codes that may require one or more permits in place prior to exporting your products and there could be other agencies not listed depending on the classification of your product. Australian Customs & Border Protection Service Defence Export Control Office (DECO) Defence Trade Control & Compliance (DTCC) Department of the Environment Department of Foreign Affairs & Trade National Industrial Chemicals Notification & Assessment Scheme All these agencies have websites and legislation you should consult if your products or components, gases or fluids, etc. fit within their role or you are exporting into countries that may have sanctions imposed on them at any time. There are two ways you can find out non-tariff export requirements: 1. Consult a customs broker to classify your goods and check the customs declaration system for permit agencies listed against the tariff item and submit an application. You may have to give the customs broker authority to act on your behalf which can also be used by them to do the export entry and manage the consignment.

Defence Export Control Office (DECO) Export controls on defence and dual-use goods, services and technologies support international efforts to stem the proliferation of conventional, chemical, biological, and nuclear weapons and the systems that deliver them. Through international counter-proliferation and export control regimes, Australia works closely with like-minded countries to identify and regulate the export of sensitive military and strategic technologies. Within Australia’s system of export controls, DECO is responsible to the Minister for Defence for regulating the export of defence and dual-use goods, services and technologies. To support its mission, DECO has developed a stakeholder-centric model of engagement, which places the onus of responsibility on DECO to meet stakeholder needs based on the following principles: • specify the technology that is “peculiarly responsible” for the item being controlled by the Defence and Strategic Goods List; • facilitate open dialogue with the exporter and other government agencies to develop a better understanding of technology, controls and/or constraints and discuss solutions; and • develop conditions that will support the exportability of the controlled goods or development of an exportable variant. DECO is focused on connecting with sectors and individual companies or institutions that are captured by the regulations it administers. At all points of its business processes, DECO works to take a proactive approach to stakeholder engagement through face to face engagement, facilitation between government and non-government entities or virtual meetings with individual companies or institutions. DECO is placing particular emphasis on travelling to meet with companies that are particularly affected by aspects of Australia’s defence export controls in order to work through issues relevant to a company’s specific circumstances, and to see what can be done to address these issues.

2. Lodge a Tariff Advice with Australian Customs & Border protection and request advice on permit agencies and make direct applications detailing your product characteristics.

To this end, DECO works very closely with other government agencies including the Department of Industry, the Department of Foreign Affairs and Trade, Australia’s Customs and Border Protection Service and the Defence Materiel Organisation’s Australian Military Sales Office to ensure that export controls are managed effectively in support of the Government’s efforts to support the Australian defence industry and Australian innovation objectives.

Guess work, mistakes or misleading people are not taken lightly in compliance circles. Even if granted permission to export when the proper documents are in place, a penalty of $80,000 or more would certainly take the shine off profit. While this article is business-related, these same rules apply to individuals.

* It is important to note, that the purpose of Australia’s export control system for defence and dual-use goods is not to impede trade, innovation, research or international collaboration, but rather to ensure these exports accord with Australia’s strategic, security and foreign policy objectives.

If you are in the “High Tech” industry sector and exporting, your technical people need a copy of the Defence and Strategic Goods List that defines and lists a vast range of products that are governed by it, eg. certain machine tools for removing (or cutting) metals, ceramics or composites, chemicals, and special metals, to a range of tools, machinery and other products.

What goods are export controls applicable to?

The above is some general background information on exporting, however the main purpose of this article is centred around defence and dual-use products that certainly has the attention of many governments.

Export controls are applicable to defence and dual-use goods including parts, components and related materials, equipment and technologies transported to an external territory or nation, regardless of the state or working condition of the goods. This includes items that are exported for the purpose of: • selling or supply to an overseas entity; • return to manufacturer or owner (including where the goods are damaged); • repair (and subsequent return to Australia);

72 |

AMT November 2014

forum – import/export

• demonstration or loan on a temporary basis, such as for display in trade shows or to establish overseas markets; and • any items, samples or specimens sent overseas as part of a research exchange. The Defence and Strategic Goods List (DSGL) is the document containing the complete list of items subject to control under the Customs (Prohibited Export) Regulations, Regulation 13E. The DSGL is developed through the various international non-proliferation and export control regimes and arrangements to which Australia belongs, and includes: • defence and related goods and technologies designed or adapted for armed forces or those goods that are inherently lethal, incapacitating or destructive and include military goods and non-military lethal goods (such as non-military firearms, nonmilitary ammunition and commercial explosives); and • commercial items and technologies that may be used or adapted for use in a military program or contribute to the development and production of chemical, biological or nuclear weapons systems. This may include equipment; assemblies and components; test, inspection and production equipment; materials; software; and technologies.

How does DECO assess items for export? Export applications for defence and strategic goods are assessed by taking into account the type of goods that are to be exported, the receiver of the goods, the end-use and anticipated end-user of the goods and technology against five criteria. These are: • Australia’s international obligations. Are the goods, end user or destination subject to sanctions or arms embargoes? • Human Rights. Is there a clearly identifiable risk that the goods would be used to commit or facilitate serious human rights abuses? • Regional security. Is the export a threat to international and regional peace and stability, including the internal situation in the destination country? • National security. Could the export compromise Australia’s security interests, obligations or responsibilities, including issues of foreign capability, and power projection capabilities of potential adversaries? • Foreign policy considerations. Could the export support weapons of mass destruction, ballistic missiles, terrorism, or other criminal or mercenary activities? United Nations Security Council (UNSC) and Australian autonomous sanctions are also taken into account when assessing export applications. The Defence Export Control Office will not approve applications to export controlled goods to countries subject to UNSC or autonomous sanctions without the agreement of the Department of Foreign Affairs and Trade (DFAT). A separate approval will also need to be sought from DFAT for exports to sanctioned destinations for entities. Further details on UNSC and Australian autonomous sanctions can be viewed at www.dfat.gov.au. Sensitive applications may be referred to a Standing InterDepartmental Committee on Defence Exports (SIDCDE) which further assesses the potential for export of the defence and dual-use goods and technology. Other than in exceptional circumstances, the assessment time for routine applications is up to 15 working days. For applications requiring referral to SIDCDE, the assessment time is up to 35 working days. Only the Minister for Defence can deny an export application or revoke an existing permit or licence.

Permission to export Exporters must obtain authorisation from the Defence Export Control Office prior to engaging in the export of controlled goods and technologies. Authorisation takes the form of an export permission granted to cover a range of purposes, such as one-off exports, ongoing transactions, and temporary exports for demonstrations or loans. Authorisation may also be obtained for approval-in-principle where the exporter is seeking to establish overseas markets and are unsure about the likelihood of being granted approval to export. Authorisation to export may be subject to conditions and exporters must ensure that conditions are met for the authorisation to remain valid. All export permissions are issued free-of-charge. What is the legislative basis for Australia’s export controls? The legislative basis for defence export controls is exercised through the Customs (Prohibited Export) Regulation 1958 enabled by the Customs Act 1901. This Act controls the outbound movement of certain exportable items, identified in the legislative instrument, the Defence and Strategic Goods List (DSGL). The legislation also includes enforcement provisions to deter noncompliance. In addition, there is the Weapons of Mass Destruction (Prevention of Proliferation) Act 1995 (WMD Act) which enables Australia to control the export of any goods, services and technologies, both tangible and intangible that can assist a WMD program. Furthermore, the Customs Amendment (Military End-Use) Act 2012 (MEU Act) provides the power to prohibit the export of tangible goods that may have a military end-use that would prejudice the security, defence or international relations of Australia. The Defence Trade Controls Act 2012 (DTC Act) includes provisions to regulate the intangible supply of technology, such as by electronic means, and the brokering of defence and strategic goods. Individuals or organisations are not currently required to seek permission to supply DSGL controlled technology intangibly or to broker its supply during the phased two-year transition of the Act, which commenced on 16 May 2013. At the end of the two-year transition period, individuals or organisations undertaking the intangible supply or brokering of DSGL-listed technology will need to seek permission to supply the controlled technology to an entity outside of Australia. Australian Customs & Border Protection Service - import tariff http://customs.gov.au/tariff/tariff2012.asp Defence Export Control Office (DECO) www.defence.gov.au/deco/DSGL.asp Department of the Environment www.environment.gov.au Department of Foreign Affairs & Trade www.dfat.gov.au/trade National Industrial Chemicals Notification &Assessment Scheme www.nicnas.gov.au Australian Bureau of Statistics - Export Tariff www.abs.gov.au – (search for AHECC) Doug Tozer is President of Tradefox Inc. which develops import export compliance libraries for customs brokers, consultants, importers and exporters. Ph: 0487 670 733 or email douglas@tradefoxinc.com FREE access to TradeFox Express standard version is available until end of March 2015 - www.tradefoxinc.com

AMT November 2014

| 73

forum – quality control

Taking quality outside your four walls: Supplier quality Part 2 of 2 In Part 1(AMT, October 14) we looked at various challenges associated with supplier quality management that inhibit an organisation in building a system to interact with their supply chain. Now, let’s look at some ways technology can help overcome these challenges, as explained by SeerSolutions. Real-time participation in the quality process Ultimately, the key to providing a true supplier quality management system is to include your suppliers in your quality process and system. By providing real-time visibility, suppliers will be able to participate in your processes, completing their responsibilities in the quality process quicker than using “offline” methods. This real-time participation can reduce time to correct quality issues in notifying suppliers via email of assignments.

Integrated receiving and inspection tied to supplier rating In the dynamic and complex environment of supplier management, there are many touch-points in which supplier goods must adhere to your quality standards. From receiving and inspection to nonconformance and deviation, it is important to maintain the highest level of quality from your suppliers. In many companies, these elements are dispersed among several business systems (MRP, ERP, QMS, etc.), with little to no integration resulting in inconsistent data, often relying on manual methods to effectively track supplier performance. A singular, integrated and automated system to track supplier goods from start to finish (receiving and inspection, non-conformance, deviation and corrective action processes) is key to tracking supplier and supplied goods quality and providing an accurate real-time method of building the supplier rating.

Understanding the process: Tracking supplier goods from receiving to production Supplier goods shipped to the warehouse are tracked in a receiving record. The Receiving department will determine the correct quantity and whether an inspection is needed. Inspections often follow a specific protocol unique to suppliers and supplier goods, and have unique sampling plans and specifications associated with them. In an integrated system, this is automatically determined and triggers an inspection record, with all the relevant data regarding that particular inspection - skip lot profiles, supplier profiles, sampling plans based on Acceptable Quality Levels (AQL) and more. The results of the inspection will determine the quality of the incoming goods and affect the overall supplier rating. If an inspection fails, the system should automatically trigger a non-conformance and look for any planned deviation records corresponding to the goods. If there is a relevant planned deviation, the goods are used - if not, a non-conformance disposition type is determined and reviewed resulting in a Supplier Corrective Action Request (SCAR), updates to the supplier rating, or risk-based analysis on the goods. With real-time visibility, suppliers can be directly involved in the corrective action, completing their part of the investigation without communication bottlenecks by logging into your quality system (limited access) and addressing activities assigned to them. A corrective

74 |

AMT November 2014

action can be processed between you and your suppliers on the same day it was issued, eliminating administrative overhead in seeking out the supplier’s processes and communicating “offline” about the issue.

Supplier scorecards & supplier exchange The ultimate goal of supplier management is two-fold - Use the best supplier goods for your product and enable the supplier to improve their operations. Automated and integrated inspection ensures the quality of supplier goods is tracked and evaluated in real-time, reducing defects in finished products related to poor supplier quality. Using this data, the supplier scorecard is automatically generated and sent to the supplier, notifying them of their rating and allowing them to improve their deficiencies and remain competitive for your business.

Adding risk assessment to the supplier rating and supplier scorecard Many best-in-class companies take supplier rating to the next level with risk assessment to understand not only the risk of quality events, but derive supplier risk from their daily quality activities. While supplier ratings are integrated into the receiving and inspection process, quality events that occur after the product is finished and distributed can still arise. Risk assessment can link supplier quality to these events. Risk assessment can be used to categorise quality events and establish severity, frequency, or even detectability to distinguish and prioritise high-risk low-risk in the quality system. Integrating supplier information in risk assessments establishes a history of high-risk events and attributes suppliers to them resulting in a quantitative “risk portfolio” indicating the suppliers associated with the highest risk in quality. The benefit of risk portfolios is that the supplier rating is affected in real-time and potential supplier risks can be identified and mitigated more quickly to lower overall risk down the supply chain.

Maintaining the supplier relationship Like any relationship, ongoing maintenance is required to ensure that your suppliers are following proper procedures, providing you with high-quality goods, and holding themselves to the same quality standards. Supplier management should not only involve the process from a production and postproduction perspective, but should also be preventative using tools to audit your suppliers. A best-in-class quality management system should have the ability to schedule and execute audits of various suppliers in order to ensure they are held to the required standards. By automating the auditing and corrective action process, you can identify and mitigate quality gaps quickly with little time lost due to administrative tasks and communication bottlenecks. SeerSolutions implements flexible business process management software solutions to meet individual client objectives. SeerSolutions thanks its business partner EtQ (original publisher of this article) for permission to publish this article in AMT. www.seer-solutions.com.au

forum – LAW

Additive manufacturing: understanding your infringement risk Whilst additive manufacturing is not new, the technology improvement and availability of 3D printers has brought additive manufacturing to new areas. Just as the internet brought a step change to the music industry, there is some concern that the availability of additive manufacturing may bring step changes in other industries, as explained by Ian Lindsay. As with any step change, there are risks to be considered and rewards to be obtained. If your business is considering any additive manufacturing processes, understanding the potential to infringe others’ intellectual property rights, and where others may infringe your rights, is extremely important.

What intellectual property rights may exist in a 3D object? Copyright is normally the domain of books and paintings but it can exist in 3D objects which are “works of artistic craftsmanship”. Copyright also exists in the instruction files for a 3D printer to create a 3D object and is an attractive right to have because of the length of time it can exist for, which can be as much as 70 years. However, in Australia at least, copyright in 3D objects does not apply when the object has been industrially applied, which usually means that more than 50 objects have been produced. The copyright in the instruction files may last much longer due to the text of the files being considered a “literary” work. Importantly, copyright arises automatically and there is no requirement to formally or informally “register” the copyright work. Because copyright arises automatically, there is no register of copyright in Australia and, therefore, you cannot search to find material protected by copyright. A design, in the world of intellectual property, is the features of shape, configuration, pattern or ornamentation which gives a product a unique appearance. To have any design rights in Australia, a design registration must be applied for and registered at IP Australia (www. ipaustralia.gov.au). That is, a formal registration of the design, by submitting drawings and other details, must be made. Clearly, design registrations have the potential to be extremely relevant to products produced by additive manufacturing, as the shape or configuration of a 3D object can be protected by a design registration. A design protects a 3D object even if it has been industrially applied, but only lasts a maximum of 10 years from initial application. IP Australia administers the design registration process here in Australia and a search of past and current registered designs can be made on the IP Australia register of designs. A patent protects the embodiment of a new and non-obvious idea and must be formally applied for at IP Australia to have any rights in Australia. A patent application is examined prior to becoming a granted patent. The embodiment of an idea is a rather wide definition but, to give a simple example, an improved door wedge, which might be a single block of material created in a particular shape, could be protected by a patent if the “improvement” is new and non-obvious. Therefore, even simple 3D objects can be protected by a patent. A patent in Australia, typically, can last for up to 20 years, although an Australian innovation patent,

which has a more straightforward application process, lasts up to 8 years. It is possible to search for past, pending and granted patent applications on the IP Australia website.

How might infringement occur? Copyright, as the name suggests, protects the rights holder from the copying of that right by an unauthorised party. Independent creation of the same or a similar right does not infringe the copyright of an earlier independent creation; there must be some form of copying. Therefore, any 3D production of an independent creation should not suffer from any issues with infringement. Where a 3D object is clearly being copied, consideration of whether the product could be considered to be an “artistic work” and whether it has been previously “industrially applied” may be necessary, to determine whether any copyright actually exists. Before infringing a design is possible, there must be a design registration. Furthermore, in Australia, even if a design has been registered, it must be “certified” before it can be enforced. Once it has been determined that a design registration exists and it is certified, infringement occurs if the potentially offending product is identical or is “substantially similar in overall [visual] impression” to the design registration. Searching the register of designs to see if a similar product is registered and in force is one way to minimise potential infringing activities. Moreover, protecting your own 3D products with a design registration may become increasingly important with the increasing ease of reproduction. To infringe a patent, a 3D product must have all the features of at least one of the “claims”, which are the legal definition of what the patent covers. Notably, the owner of a patent cannot sue for infringement of their patent until it is granted. But they can, in certain circumstances, request damages from an infringer back to the point the infringement occurred, even if that was before the patent was granted. If a 3D product is to be produced which might be covered by a patent, a search of the “AusPat” database is the first task.

Forewarned is forearmed Understanding how a 3D product might contain intellectual property rights is the first step in avoiding potential issues. Once an issue, or a potential issue, has been identified, professional advice should be sought. If the prevalence of additive manufacturing can be seen as creating opportunities, then understanding the rights that exist in additive manufactured products, and taking advantage of those rights, may well also create opportunities. Ian Lindsay Wadeson Patent & Trade Marks Attorneys Ian.lindsay@wadesonip.com.au www.wadesonip.com.au

AMT November 2014

| 75

manufacturing history

60 YEARS WITH MEN AND MACHINES – PART 49

Goodbye Fred, and thanks for the memories!

This will be our last instalment of Fred Colvin’s book - “60 years with men and machines”. We hope you have enjoyed the journey as much as we have in presenting it to you. You started your working life as a 15-year-old apprentice in 1883 at the Rue Manufacturing Co.in Philadelphia. The shop was run by a 25-horsepower steam-engine using shafts and belt drives. You earned the princely sum of five cents an hour for a 60-hour week. This may seem miserly, but it was revolutionary in 1883, when the normal procedure was for parents to reimburse the business owner to teach their son the secrets of the trade. During the span of your working life from 1883-1965, you grew to occupy a unique position in the machine tool industry during this “golden era”. You enriched our understanding because you were not a detached observer of the industry, but an intimate part of it, faithfully and accurately reporting your first-hand experiences in a sector which grew from an accessory of industrial development to a firm establishment as its foundation. Your passion for the industry, your curiosity, reporting skills, energy, prodigious memory and above all – your long, 98-year life (which was productive till the end) - has resulted in a book like no other.

In 1911 you visited the “impossible” project – the Panama Canal construction - where so many gave their lives. Here you were escorted by the Chief Engineer to witness history in the making, By the time the unprepared US entered World War 1, you witnessed “unacceptable” arms production inefficiencies in US factories which kept you awake at night. You took on the Establishment and faced the consequences with irate Brass. Your crusade included authoring a scorching editorial in the American Machinist magazine in defence of your ideas even if it meant “death at the hands of a firing squad”. You faced similar challenges in World War II when you were called out of retirement at the age of 73. Fortunately for the US (and the world), the various War Committees eventually - for the most part - saw things your way. But not without your name first being black-listed, along with the attempted suppression of the offending edition of the magazine. You sure had some Chutzpah! Additionally, during World War II, the US put your 1929 trip to Japan to good use – using your knowledge of Japanese machine shops’ layout to help destroy the war-making capacity of the Japanese.

It has taken two world wars to educate the population on the fundamental importance of the machine shop in modern life and you were an important part in relaying that transition. Your passion for our In your book you reminded us industry never waned. that textile machinery, cars, This is exemplified by your trains, watches, printing presses, appointment, at the age of 80, electric generators, airplanes, as a consultant at Oak Ridge diesel engines, and other machines working on one of the mechanical exist only by virtue of the lathe, the phases of the atomic power pile planer, the slotter, the boring machine, project. You continued authoring and the other members of the great machine tool reference works. In fact, machine-tool family. History has borne by the time of your death in 1965 at the age Woodcut of Fred H Colvin, out the fact that the lack of machines to turn circa 1892 of 98, you were working on a book: “History of and bore and to produce flat surfaces prevented the American Machine Tool Industry” which was, the dreams of many advanced thinkers from becoming sadly, unfinished at the time of your passing. realities. You gave us the example that a model power-driven As this book comes to a close, we salute you Fred, we thank you airplane was successfully flown as early as 1848, but some 55 for the memories and farewell you with these parting words: years had to elapse before machine tools and metallurgy made “It is hardly possible to overemphasize the fact that the heavier than air aircraft a practical reality. seeming miracles of modern science and industry are made Your ingratiating personality led to close friendships with possible by the work of a comparatively few men in an industry many who were trail-blazers. You rubbed shoulders with the that is almost unknown to the general public. Add to this fact Wright Bros, visiting Wilbur in 1909 and being invited to fly that practically any worthwhile project—from the making of in their latest model plane. You were present at the world’s a cheaper automobile to the peacetime harnessing of atomic first aviation show in New York in 1910 where the French energy—can be worked out by this group, and we can begin planes won the speed contests (not the American planes!). You to understand the urge that keeps these men at their task gave us anecdotes about Kate Gleason (the Madam Curie of even without the promise of any greater reward than the machine tools). You drove at 12mph in horseless carriages in satisfaction of accomplishment. 1900 – and wrote about them when there were only 100 cars in “It is a far cry from the old shop in Race Street Philadelphia to production in the US. You had contact with the Ford Motor Co. the vast atomic energy plant at Oak Ridge, and I have greatly in 1907 – only three years after the company’s incorporation. enjoyed writing down the experiences and the observations of Henry Ford was averse to publicity, yet you were invited to that hectic interval of industrial progress. I hope the reader visit his secretive Plant in Detroit in 1913 and wrote about the has enjoyed it as much as I have.” experience … back in the days when “production line” meant inferior quality. Sixty Years With Men and Machines - The Autobiography of Fred H Colvin, Master Machinist Original © 1947, McGraw-Hill Publishing, reprinted by Lindsay Publications Inc, 1988, Bradley IL 60915, USA.

76 |

AMT November 2014

Manufacturing freedom.

The ultimate Laser... Already operational in 42 Countries. AAA UP TO 5g

< 20kW

100% FIBER ONLY

PATENTED

Your production: a range of different products evolving constantly, featured with the highest productivity and more competitive unit costs. Laser L5: a brand new design, 4kW of power source, the ultimate fiber technology. Feel free to use without limitations. Machinery Forum NSW Pty Ltd

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

Shane Infanti – Chief Executive Officer AMTIL

A year of change I take this opportunity to give our members, and industry in general, an update on what AMTIL has been doing over the past year. 2014 saw some critical changes at AMTIL. We changed the cycle of our flagship event, Austech, to run every two years in Melbourne. So 2014 was the first year without an Austech exhibition since its inception in 2000. This has had a major impact on us but was a necessary step for us to take. We downsized our staffing levels and restructured internally, with a stronger focus on member services. Our role is to represent and promote the interests of manufacturing technology suppliers and their customers (the ecosystem). For our Manufacturing Technology Suppliers, our focus is on encouraging investment in technology. We do this through marketing and promotional opportunities, whether it be Austech, our AMT magazine, online offerings, talking to government about incentive schemes and other services. We want people to buy machine tools, automation, robotics, software, cutting tools and ancillary equipment. We need to focus heavily on this area. For our Manufacturing Technology Users, our focus is on providing business opportunities, networking and capability building. We do this through identifying job opportunities and how to tap into them, looking at local supply chains, promoting our members’ capabilities through ManufactureLink, bringing people together through a number of our events around Australia or helping companies identify where their improvement can come from. We want people getting work, educating themselves and building their businesses. We started our regular Hotspot communication with members. This is our way of passing on anything that comes across our desks that we feel is of interest to members, whether it be opportunities for work, networking functions, information on running a business, funding prospects from Government or specific industry information, the Hotspots have been well received by members. We were reappointed as a Partner Organisation for the Entrepreneurs Infrastructure Program (EIP). There is still detail being thrashed out on this program but our role essentially hasn’t changed from our work under the previous Enterprise Connect program; that is: giving business advice and facilitating connections with research institutes. We established the Additive Manufacturing Network under the auspices of AMTIL. This is a sub-group of AMTIL members who have a specific interest in this enabling technology. Some additional activities in this space will be held over the next 12 months. We reconfirmed our primary activities are Austech, AMT magazine and our involvement as a host organisation for EIP. We will continue to build Austech as a biennial “SuperShow”, with exhibitor and visitor growth, a bigger Manufacturers Pavilion and more new initiatives. We will continue to work at having a monthly readership of AMT, both hard and soft copy, of over 40,000 by the end of next year. Our involvement with EIP is twofold as it provides a good service to members but has also allowed us to build good relationships with a number of government departments. We have determined we need to take a stronger stance on industry issues and provide a voice to Government representing the interests of our members. This leads to many questions. What do we say to these government departments that will bring change and opportunity? What influence can we have? What policy decisions can we influence? What can we tell them that they don’t know? If we were to lobby the government for a stronger commitment to manufacturing, what would that look like? These are the questions we are currently discussing at Board level. We will be asking for input from our members in this regard as well. If we are going to go down a path of lobbying, we need to be clear what the issue is, how it can be addressed and what the Government can do to assist this. I see every day the resentment that companies and individuals have towards our politicians that do not seem to care about our manufacturing industry. Without having a solid plan and realistic goals, any continued effort to change them will result in more anger and frustration. I would like to take the opportunity to thank all our members that have been involved in our activities over the past 12 months. Your input is valued highly and I trust that you have benefited in some way from your involvement with us. I wish you all a safe and merry Christmas period.

AMTILinside

Christmas events – Don’t miss out There’s still time to book your spot at one of AMTIL’s upcoming Christmas events. However, places are filling up fast, so book now to avoid disappointment. AMTIL is marking the festive season this year with three events, including a dinner for members in New South Wales (NSW), and a lunch for members in Queensland. For members in Victoria, our everpopular golf day and lunch has long been a highlight of the calendar for this time of year. The events offer you the chance to kick off the festive season, network with other AMTIL members in a relaxed social environment, and simply unwind and enjoy yourself at the end of another hardworking year. You could even bring along staff or colleagues as an end-of-year reward. Details for the events are as follows:

NSW Members Christmas Dinner Criniti’s Italian Restaurant, Parramatta Tuesday, 25 November Members: $39pp Non-Members: $85pp Includes three course meal and drinks

QLD Members Christmas Lunch Breakfast Creek Hotel – Spanish Garden Steakhouse, Brisbane Friday 28 November Members: $39pp Non-Members: $85pp Includes three course meal and drinks

AMTIL Corporate Golf Day & Christmas Lunch Riversdale Golf Club, Mount Waverley, Victoria Friday 5th December Members: $115pp Non-Members: $145pp Lunch Only: Members $45, Non Members $75 If you would like to attend any these events, please register online at: www.amtil.com.au/events. Looking for exposure for your business? AMTIL events offer unique sponsorship opportunities to suit all budgets. For more information contact AMTIL’s Events Manager Kim Warren at 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 November 2014

| 79

AMTILinside

AMTIL members out for AGM AMTIL held its annual general meeting (AGM) at the Riversdale Golf Club in south-east Melbourne, on 1 October. The event drew a strong turnout, with a good mix of new and long-term members in attendance. As always, there was a packed schedule of association business to get through. High on the agenda was the ballot for next year’s Austech exhibition, to decide the order in which exhibitors get to choose the location of their stands. The ballot went through very smoothly with an impressive amount of space already allocated, laying the ground for what looks set be a fantastic show next year.

Amid the usual items of business, the AGM also featured a line-up of speakers giving presentations on issues of importance to AMTIL members. Frank Schrever gave a talk on recent updates to the AS4024 Machine Safety standard. Safety is an issue many companies leave to chance and don’t fully understand their obligations, so Frank’s insights were well received by the members in attendance.

In addition to the ballot, there were a number of other regular items of business, most notably the re-election of the Board, which will continue unchanged from last year. AMTIL President Paul Fowler was reappointed to remain in the post for a further 12 months.

The second presentation was given by Katusha Roca, Account Director, R&D Government Tax Incentives at Deloitte Australia. The Federal Government’s R&D Tax Incentive is a targeted, easy-to-access scheme designed to help businesses innovate, and again the audience were highly receptive to what Katusha had to tell them.

“The fact Paul and the Board were all reelected is good news for AMTIL, as having that continuity will be of great benefit,” said AMTIL CEO Shane Infanti. “All our Board Members give up their time on a voluntary basis, so on behalf of AMTIL and its membership, I want to take this opportunity to thank them for their contribution.”

Meanwhile, the AGM provided an opportunity for AMTIL members to network with each other, catching up with old friends, and establishing new contacts. It was also a chance to interact with members of the AMTIL team, and there were some productive discussions about the association and its direction.

Paul Fowler was re-elected to serve as AMTIL President for another 12 months.

“All in all, the AGM went very successfully” said Kim Warren, AMTIL Events Manager. “I’m looking forward to seeing some of first-time attendees coming to more of our upcoming events such as the golf day, even if it’s just to have lunch.” If you would like contact either Frank Schrever or Katusha Roca to discuss the content of their presentations, AMTIL would be happy to make the necessary introductions. Please contact Events Manager Kim Warren on kwarren@amtil.com.au

HotSpots – Getting to the facts Upcoming events, the latest market data, government support programs… in these information-rich times it’s hard to work out just what is relevant. That’s where Industry HotSpots can help. Launched earlier this year, HotSpots is a service designed exclusively for AMTIL members, providing information and resources concerning our industry and the workplace, as well as various useful services available to your business. Many of the items featured are available exclusively to our members only. HotSpots are broken down into five categories, loosely defined as: • Industry – These are industry-wide notices which AMTIL feels are of importance to its members. • Service –AMTIL has developed relationships with expert service providers in various disciplines and is able to offer these services exclusively to our membership. • Opportunity – These items offer a chance to quote or connect with a contract, available only through the Members Only area of our website. We wish all our members good luck with their tender. • Networking –Here is where AMTIL provides members with notice of events and activities that offer chances to network with other like-minded business leaders and collaborate on strategic activities.

80 |

AMT November 2014

• Workplace – From time to time, AMTIL is able to provide information to our members with regard to the manufacturing environment we work within. HotSpots is one place where AMTIL will try to make you aware. To access the detail behind the HotSpot, AMTIL’s members simply need to follow the links, and log in using their Username and Password. If there are any questions, please feel free to contact our office and an AMTIL staff member will help you with your membership details. If you are interested in gaining access to these HotSpots or you have something you feel will meet our criteria for listing, please forward them on to AMTIL for assessment by emailing info@ amtil.com.au with the subject line HOTSPOT.

Your Industry. Your Magazine.

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

(Conditions apply)

10 Ads sAVE up to 40% 5 Ads sAVE up to 35% 3 Ads sAVE up to 25%

Take advantage of great savings when you book your AMT advertising now.

1227AMT

AMT proudly owned and published by AMTIL

AMT & AMTIL Digital Media Kit 2015

Visibility. Opportunity. Success.

STOp preSS! OUT NOW!

AMTILinside

Livetools Pty Ltd 115 Young Street CARRINGTON, NSW 2294 Ph: 02 4017 0198 sales@livetools.com.au www.livetools.com.au

New AMTIL Members

MuTech 7/173 Salmon Street PORT MELBOURNE, VIC 3207 Ph: 03 9646 2261 info@mutech.com.au www.mutech.com.au

Buden Industries 7 Mosrael Place Rowville Vic 3178 Ph: 02 9764 1256 sales@budenindustries.com www.budenindustries.com

Austech 2015 – Filling up fast Preparations for Austech 2015 reached a major milestone at AMTIL’s annual general meeting (AGM) last month. One of the highlights of the AGM agenda was the ballot to decide the order in which exhibitors will get to choose the location of their stands at the show. The ballot showed that bookings for Austech 2015 are already very strong more than six months out from the event. A total of 61 companies participated in the ballot, which resulted in over 2700sqm of floor space being allocated. This represents just under 60% of the total available space. Australia’s premier advanced manufacturing and machine tool exhibition, Austech will be held on 26-29 May 2015, at the Melbourne Convention & Exhibition Centre. Next year’s exhibition will be the first edition of Austech to be held since the decision was made, following the 2013 event, to move from an annual show to a two-year cycle. “I’m very pleased by the strong support we’re already seeing for Austech 2015,” says Kim Warren, AMTIL Events Manager. “Moving to a two-year cycle was a big decision, and certainly one that AMTIL didn’t take lightly. It already appears to be paying off, and I am looking forward to a rewarding and robust 2015 event for exhibitors and visitors alike.” Some of the biggest names in Australian manufacturing have already booked space at the show. DMG MORI alone is planning a massive 300sqm stand and is lining up an impressive showcase of machines to fill it. Equally striking exhibits can be expected from other industry heavyweights such as Amada Oceania and Hare & Forbes Machineryhouse, as well as Australian manufacturers including Sutton Tools and Techni Waterjet. Many other companies have indicated that they will also book in over the coming months. As always, Austech will include an exciting range of special features, and strong interest has been shown in the Manufacturers Pavilion and the Digital & Additive Manufacturing Pavilion, with several exhibitors already committed in these areas.

Making its debut at Austech 2013, the Manufacturers Pavilion provided a showcase for some of Australia’s most dynamic, exciting manufacturing businesses. With small-to-medium-sized companies exhibiting alongside major OEMs, the Pavilion also provided the venue for a range of presentations from renowned industry experts, as well as a series of well-attended networking events. Next year the Manufacturers Pavilion will be capitalising on its success at the 2013 show and expanding upon it, with an enhanced Speaker Program and extensive networking opportunities. The Digital & Additive Manufacturing Pavilion lifts the lid on the fast-evolving field of additive manufacturing, featuring many of the key players driving what has been described as “the next Industrial Revolution”. Alongside manufacturers and suppliers of 3D printing equipment, the Digital & Additive Manufacturing Pavilion will also bring together the very latest in associated technologies, from 3D scanners to software. All in all, the stage appears to be set for Austech 2015 to be the biggest and best yet, and the sense of anticipation is building. “We were always confident that moving to a two-year cycle was the right decision, and the level of interest already apparent at the ballot certainly bears that out,” says AMTIL CEO Shane Infanti. “But it’s certainly seemed like a long time coming, and we’re all looking forward to May and the chance to put on a show that really showcases the best of Australian manufacturing.” For more information on Austech 2015 or to enquire about booking exhibition space, please call 03 9800 3666, or email Events Manager Kim Warren on kwarren@amtil.com.au.

82 |

AMT November 2014

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 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 Global Industrial Expo 2014 India, Pune 21-24 November 2014 National Exhibition on Manufacturing and Engineering Industry in India www.globalindustrialexpo.com DMP China 19-22 November 2014 China Dongguan International Mould and Metalworking Exhibition. Concurrent exhibition: Plastics, Packaging & Rubber Exhibition. Special Pavilions: Stamping Machine Zone; Laser Cut Zone; Mould Materials & Parts Zone; Hong Kong Plastic Machinery Asscn. Pavilion; Chemical and Plastics Raw Material Zone; Taiwan Pavilion. www.dmpshow.com 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 Manufacturing Indonesia Indonesia, 3-6 December 2014 Concurrent exhibitions are, Automation & Logistics Indonesia and ‘Tool & Hardware Indonesia. Includes boring/drilling machines & tools, automation; inspection; material handling. www.manufacturingindonesia.com World of Industry India, New Delhi 10- 13 December 2014 Hydraulics, electro-mechanical transmission, automation,, materials handling, logistics, surface technology products, electroplating and surface engineering techniques. www.win-india.com

casting products, metallurgy and thermo process technology. www.indometal.net

& IT solutions, instruments, control systems, robotics, components, accessories. www.chinaciai.com.cn

Kolhapur Industrial Expo India, Kolhapur 14-17 December 2014 Focusses on the machinery, industrial & engineering sectors. Includes machine/cutting and allied tools ; CAD/CAM; special purpose machines; metrology; automation www.visionindustrialexpo.com

Automate USA, Chicago 23-26 March 2015 Demonstrates the full spectrum of automation technologies and solutions for a broad array of industries. www.automateshow.com/index.cfm

2015 Arabian Essen Welding & Cutting Dubai 10-13 January 2015 Includes plants and equipment for joining, surfacing and cutting processes, heat treatment and other production processes, computeraided production, automation and accessories. www.arabia-essen-welding-cutting.com IMTEX India, Bangalore 22-28 January 2015 Metal-cutting machine tool exhibition www.imtex.in Steelfab Untied Arab Emirates 26-29 January 2015 Metal working, metal manufacturing and steel fabrication trade show. www.steelfabme.com Expo Manufatura Mexico 3-5 February 2015 Machine/cutting/forming/micromaching tools; CAD/CAM; automation; metrology. www.expomanufactura.com.mx Automation Technology Expo West USA, California 10-12 February 2015 Automation applications:aerospace, medical, automotive, electronics, food and beverage, and varied industrial products www.canontradeshows.com/expo/atxw14 3D Printing - Next Revolution in MultiMaterial Fabricated Parts USA, Las Vegas 17-19 February 2015 3D Printing has begun reshaping the manufacturing base and promises to be the 21st Century’s industrial revolution. Practically all industries will be impacted. www.dddprintingconference.com

Midest Morocco, Casablanca 10-13 December 2014 Tools for sheet metal manufacture, machine tools, plastics, subcontracting equipment. www.midest-maroc.com

TIMTOS Taiwan, Taipei 3-8 March 2015 Includes metal cutting/forming machine tools, accessories, welding, surface treatment equipment, tube & wire processing, measuring, software, China pavilion. www.timtos.com.tw

Indo Metal Indonesia, Jakarta 11-13 December 2014 Metal and steel trade fair, with a focus on the synergistic capabilities of foundry technology,

China International Industrial Automation & Instruments Exhibition China, Tianjin 12-15 March 2015 Automation exhibition. Includes automation

84 |

AMT November 2014

Blech Russia Russia, St Petersburg 23-26 March 2015 Exhibition for sheet metal working which encompasses all core sectors of the sheet metal working process www.blechrussia.com/english Industrial Automation Malaysia, Kuala Lumpur 25-27 March 2015 Platform for manufacturers and providers of components, production systems and processes. Co-located with Electric, Power and Renewable Energy Malaysia 2015. www.asean-ia.com/home/home.php Hannover Messe Germany, Hannover 13-17 April 2015 Covers all core themes of the industrial value-adding chain at a single location – from individual components to the complete smart factory. Current hot topics such as Industry 4.0, energy efficiency and lightweight construction will be discussed. www.hannovermesse.de/home MTA2015 Singapore 14-17 April 2015 Asia’s leading precision engineering exhibition. Serves high-value sectors such as aerospace, complex equipment, electronics, energy, medical technology and oil & gas, marine & offshore engineering. Meets these industries’ growing demand for fully integrated precision engineering capabilities. www.mta-asia.com Intermold Japan 14-18 April 2015 Includes machine tools; metal forming/grinding/ moulding machines, CAD/CAM and related equipment www.intermold.jp CIMT China, Beijing 20-24 April 2015 14th China international machine tools show. Brings together the most advanced machine tool products in the world. www.cimtshow.com PMTS USA, Ohio 21-23 April 2015 Precision Machining Technology Show. For manufacturers of precision machined parts. Includes cutting tools, automatic screw machines; lathes, CNC turning centres, EDM equipment, accessories. www.pmts.com

industry calendar local Advanced Manufacturing Summit 2014 10 - 11 November Four Seasons Hotel, Sydney Advanced manufacturing can transform the Australian economy as we move away from the focus on the resources sector. Australia needs to be positioned to develop and sustain more knowledge-intensive, high value, globally competitive manufacturing industries and companies. www.advancedmanufacturing summit.com.au 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 The Australasian Oil and Gas Exhibition & Conference Perth Convention & Exhibition Centre 11-13 March 2015 Australia’s largest oil and gas event www.aogexpo.com.au Auspack Melbourne Convention & Exhibition Centre 24-27 March 2015

Specialised trade exhibition for packaging and processing machinery www.auspack.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 Australian Auto Aftermarket Exhibition Melbourne Exhibition Centre 16-18 April 2015 The latest in auto parts, equipment, accessories tools www.aftermarketexpo.com.au Safety in Action Brisbane Exhibition & Convention Centre 22-23 April 2015 Dedicated workplace health & safety event www.safetyinaction.net.au/brisbane DesignBUILD Sydney Showground 28-30 April 2015 Australia’s largest and most comprehensive trade event for the domestic and international design and building industry. www.designbuildexpo.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/ Safety in Action Melbourne Exhibition Centre 15-17 September 2015 www.safetyinaction.net.au/melbourne Austech

CeMAT 5-7 May 2015 Sydney Olympic Park Materials handling and Logistics exhibition, including materials handling, intralogistics and logistics solutions. Features Australia’s key players in the process manufacturing, retail and FMCG www.cemat.com.au

Advertiser Index Hare & Forbes 7 3D Systems Asia Pacific 8 Industrial Laser 15 Acra Machinery 13 Iscar 2-3 AlfexCNC 17 LMC Laser 61 Amada 86-87 LS Starrett 25 AMTIL AMT 10, 81 Machinery Forum 77 AMTIL Impact card 67-68 MAPAL 41 AMTIL Membership 83 MTI Qualos 31, 57 AMTIL ManufactureLink 79 OMAX 33 AMTIL Austech 9 OSG Asia Pty Ltd 4-5 ANCA MOTION 27 Sandvik Impact Card 51-52 Applied Machinery Aust. P/L 45 Seco 71 CeMAT 21 Standaco Machinery Sales 55 Complete Machine Tools 29 TECO Tooling 23 Compressed Air Australia 19 Walter 11 Dimac Tools 39 WYSIWYG cover flap DMG Mori Seiki 88 G-Zero five 59

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

jan15 Australian Manufacturing Technology

Your Industry. Your Magazine.

NEXT ISSUE…

AEROSPACE We get 2015 off to a flying start, with a look at the developments and trends that are creating new opportunities for manufacturers in the field of aerospace. CUTTING TOOLS FORMING & FABRICATION MATERIALS HANDLING QUALITY & INSPECTION

AMT November 2014

| 85

AMADA AE & MPC1 Reduce lead-time and lower cost per part

AMADA offers a range of practical solutions for executing flexible production with a high degree of automation and low labor input. The selection ranges from compact load, unload systems to fully automated production lines connected to automated storage and retrieval systems. The Amada MPC1 is designed to help you improve productivity and increase profits whilst reducing lead-time and cutting costs. It provides the most compact, cost effective automation solution available. The MPC1 is the ideal system to increase your manufacturing capacity. • Automatic loading and unloading of up to 3 ton of material • Reliable lights-out production • Compact solution with minimal footprint • Handling of raw material and processed sheets • Fast cycle time provides continuous operation

Amada Oceania Pty Ltd www.amada.com.au

STAYING AHEAD OF THE GAME

WITH INTELLIGENT AUTOMATION & INNOVATION “Amada has a deserved reputation for reliability” “We are constantly innovating and improving our products and the way we do things. We keep up with technology and modern manufacturing trends and methods to give our customers a better product. “ “Having full control over our sheetmetal fabrication is definitely an advantage when selling switchboards.” Josh Barnes, owner of Aussie Switchboards

With its in-house automated sheetmetal workshop equipped with state-of-the art machinery, QLD-based Aussie Switchboards stays ahead of the game competing with multinational corporations from interstate and abroad. True to the motto “we don’t take orders, we give solutions”, the 50-head strong family-owned business has never been busier, averaging sales over $1m a month and growing, company owner Josh Barnes says. Since 2003 Aussie Switchboards has been manufacturing sheetmetal enclosures for a variety of applications. “The bulk of the product is used for our own in-house products specialising in electrical switchboards,” Josh explains. “We have a very strong presence in Queensland and continue to grow interstate and overseas.” Today, the state-of-the-art factory spreads over 2000 m², hosting a range of quality sheetmetal machinery, including an Amada HDS press brake, a Togu tool grinder and an

AC2510NT turret punch with an MP1225NJ automated sheet and part loader/unloader. “Having full control over our sheetmetal fabrication is definitely an advantage when selling switchboards,” Josh says. “The combination of turret and loader was a huge improvement in speed and reliability

from our old 1985 machine which it replaced around five years ago. The machine doesn’t stop for lunch breaks. It keeps going while unattended.” He adds that staff found loading or unloading sheets and parts boring and mundane. Now that the trained staff are better utilised elsewhere in the factory, the

retention rate has also improved. But not only the operators benefit from Amada technology. Programmers benefit too, Josh says. “The Amada bending software is fully automatic without any need for further programming. Once the part is in SolidWorks, you don’t even have to tell the software there are new parts to process and bend. It does it all for you in the background! This saves programmer time and eliminates any possibility of human error.” Moreover, the company processes a lot of unorthodox materials for sheetmetal shops. “Not only do we fabricate steel, aluminium and stainless, the Amada machinery also processes a variety of plastics, rigid insulative materials, and copper up to 10 mm thick,” Josh explains. “The Amada solution centre in Sydney and Japan have been an enormous help with tooling for the non-standard materials.”

Lights-out: Amada’s MP loading/unloading unit increases productivity and labour cost efficiencies. The combination of turret and loader was a huge improvement in speed and reliability from Aussie Switchboard’s old 1985 machine which it replaced. Software: “The ease and usefulness of the software is well ahead of their competitors,” Josh says. The Amada offline software interaction with SolidWorks made it effortless for programmers to transform a 3D model to a high-precision bent part. CNC punching: The trend setting, servo electric AC series delivers the highest levels of performance, accuracy and flexibility.

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

c o o peratio n sustain s in nov at i on

Additive Manufacturing

LASERTEC 65 3D â&#x20AC;&#x201C; Laser deposition welding and integrated milling

Turbine housing // Aerospace

from DMG MORI

Laser deposition welding

Milling

National Technical Hotline: 1300 457 124

Intelligent combination of laser deposition welding and 5-axis milling for best surfaces and component precision

Laser deposition welding with a powder nozzle: up to 10x faster vs. powder bed method

Complete 3D parts production up to Ă¸ 19.7 in., including overhanging contours without support geometrie

Direct machining of areas that would otherwise not be accessible on a finished part

Technical information and brochures available at: www.dmgmori.com or through your local DMG MORI Australia representative, Tel: +61 3 8545 0900