Australian Manufacturing Technology Your Industry. Your MagazinE
FebIMAR18
Defence & Aerospace Business Management State Spotlight: Tasmania
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Contents
Volume 18 Number 01 Feb/MAR 2018 ISSN 1832-6080
FEATURES DEFENCE & AEROSPACE Naval Shipbuilding –Bringing manufacturers Into digital era FIrst CRC for Defence announced Cutting aircraft maintenance costs Teaming up for electric future NSW teens control NASA robots on ISS
42 46 48 50 52
ADDITIVE MANUFACTURING Renishaw AM tech helps Swinburne electric car RMIT Centre for AM – Printing biomedical implants iOrthotics dips a toe in 3D printing with HP UNSW selected for world-leaing 3D printing tech DMP at the tipping point?
54 56 58 60 62
CUTTING TOOLS Sutton Tools: Aiming for global markets New strategies – Orthopedic component machining The LogIQ of machining intelligently in Industry 4.0 Success in the tap market is all about attitude
63 64 66 69
STATE SPOTLIGHT: TASMANIA Partnerships makes unique learning available Tasmanian advanced manufacturing rides a wave
72 74
FORMING & FABRICATION Yawei HLE fibre laser benefits to Wildcat Industries Technology helps TW Woods set new benchmarks Joining dissimilar materials
78 80 82
BUSINESS MANAGEMENT Mass customisation: A pathway to SME success Inventory – Understand it before you slash it! R&D without AI is not R&D Asset finance – More money in your pocket Varley embraces digital transformation
84 86 87 88 89
MATERIAL REMOVAL NUM Flexium helps maximise productivity Lubricating, cooling and cleaning simultaneously Best tools for stainless steel
90 91 92
QUALITY & INSPECTION Hizeaero – Laser scanner tech for aircraft technology Manufacturing needs quality managers Scanning tech helps solve Dutch shipwreck mysteries
94 96 97
COMPRESSORS & AIR TECHNOLOGY Compressed air: Just buy the air you need!
42 Naval Shipbuilding – Bringing manufacturers into the digital era The Federal Govt. hopes its $90bn Naval Shipbuilding Plan will provide much-needed stability and certainty to the Australian shipbuilding industry and potentially propel Australian manufacturers into the Fourth Industrial Revolution.
56 RMIT Centre for Additive Manufacturing – Printing biomedical implants AM offers opportunities for the manufacture of a range of new products. Discussed here are concepts behind metallic lattice manufacturing using SLM technology and its application to biomedical implants.
70
100
REGULARS From the Editor From the CEO From the Ministry From the Industry From the Union
10 12 14 16 18
INDUSTRY NEWS Current news from the industry
20
VOICEBOX Opinions from across the manufacturing industry
30
PRODUCT NEWS Our selection of new and interesting products
34
ONE ON ONE Michael Grainger
70
COMPANY FOCUS Penguin Composites – Perseverance is key to success
76
AMTIL FORUMS 102 AMTIL INSIDE The latest news from AMTIL
106
MANUFACTURING HISTORY – A LOOK BACK IN TIME 114
AMT Feb/Mar 2018
Michael Grainger Michael Grainger is the Chair of the Brand Tasmania Council. He is also the Managing Director of Hobartbased Liferaft Systems Australia (LSA).
76 Penguin Composites – Perseverance the key to success Diversification, innovation, reinvestment and skilled recruitment has enabled Tasmanian manufacturer Penguin Composites to grow in local and global markets. It recently won a major defence contract.
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From the Editor William Poole
Falling behind in a two-speed world There’s a hole that’s opened up recently in the street near AMTIL’s offices in Wantirna. But before anyone jumps in with the old joke that “police are looking into it”, the hole is actually being watched over by an employee of the NBN Co. He’s been out there most days for the last couple of weeks. That image of a man guarding a hole in the ground for days on end somehow seemed to sum up the National Broadband Network. Whichever way you look at it, the rollout hasn’t gone as smoothly as it might. And if Australia is struggling with something as fundamental as high-speed internet, how is our manufacturing industry likely to fare in capitalising on the Fourth Industrial Revolution? That question is addressed in a new report from the World Economic Forum, which suggests Australia is doing okay, but could do better. The Readiness for the Future of Production Report 2018 which assesses a number of countries worldwide and assigns them to one of four archetypes: Leading (countries with a strong current production base, and high levels of readiness for the future); High Potential (a limited base, with high readiness for the future); Legacy (a strong current base, at risk for the future); or Nascent (limited current base, at risk for the future). That Leading group comprised 25 countries. Australia was in the High Potential category. The WEF’s initial assessment reveals eight main findings: 1. Global transformation of production systems will be a challenge, and the future of production could become increasingly polarised in a two-speed world. The 25 countries in the Leading archetype account for more than 75% of global manufacturing value added, while 90% of the countries assessed from Latin America, Middle East, Africa and Eurasia have a low level of readiness. 2. As countries navigate the transformation of production systems, different pathways will emerge. Advanced manufacturing will not be the chosen path for all: some may seek to capture traditional manufacturing opportunities in the near term, or pursue a mixed approach, or prioritise other sectors altogether. 3. All countries have room for improvement. No country has reached the frontier of readiness, let alone harnessed the full potential of the Fourth Industrial Revolution in production. There are early leaders that we can learn from, but these countries are also still in the early stages of transformation. 4. Common challenges within each of the four archetypes point to potential future pathways. Countries can learn from each other, while pursuing their own unique strategies. 5. Technological advancement brings the potential for leapfrogging, but only a few countries are positioned to capitalise. Lagging countries may be able to enter emerging industries at a later stage without the legacy costs of earlier investment, but only if they have the right capabilities and develop effective strategies for capturing relevant opportunities. 6. The Fourth Industrial Revolution will trigger selective reshoring, nearshoring and other structural changes to global value chains. Emerging technologies will alter the cost-benefit equation for shifting production activities, ultimately impacting location attractiveness. Every country must develop unique capabilities to make it an attractive production destination and capitalise on these shifts. 7. Readiness for the future of production requires global, not just national, solutions. Globally connected production systems need not only sophisticated technology but also standards, norms and regulations that cross technical, geographical and political boundaries. 8. New and innovative approaches to public-private collaboration are needed to accelerate transformation, amid challenges that cannot be solved by the private sector or public sector alone.
Your Industry. Your Magazine.
Australian Manufacturing Technology
Editor William Poole wpoole@amtil.com.au Contributors Brent Balinski Carole Goldsmith Sales Manager Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia 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.
You can read the full report online at the WEF website: www.weforum.org/reports. Meanwhile, the hole in the street remains under observation. Let’s hope it’s worth guarding. 1375AMTFebruary2018
AMT Feb/Mar 2018
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From the CEO Shane Infanti – Chief Executive Officer AMTIL
Boost your business with the Entrepreneurs’ Programme I am very pleased to report that AMTIL recently had its contract extended with AusIndustry to remain an Industry Partner for the Entrepreneurs’ Programme. The Entrepreneurs’ Programme is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. The Programme forms a part of the Australian Government’s Economic Action Strategy and deploys more than 100 experienced Advisers and Facilitators, offering support to businesses through three key elements: 1. a. b. 2. 3.
Innovation Connections offers: • Support from experienced Innovation Facilitators to help you assess your technical, research or knowledge requirements. These Innovation Facilitators will provide you with unbiased recommendations to help you develop new ideas with commercial potential. • Introductions to researchers, technology or knowledge providers to work with you on collaborative projects.
Business Management Business Growth Services Supply Chain Facilitation Innovation Connections Accelerating Commercialisation
• Matched grants of up to $50,000 to engage a research organisation to undertake research projects in collaboration with your business.
To run a successful business, it’s not enough to have a great product or service. You also need to understand your challenges and continually identify and leverage growth opportunities to improve your business performance. This is where the Entrepreneurs’ Programme can help. The Business Management element of the programme provides practical support to help businesses improve and grow through strong, sustainable strategic business management and business capability. The Business Management element offers: • On-site support from an industry specialist Business Adviser or Business Facilitator who will give you objective insights and recommendations aimed at helping you improve and grow your business. • Funding through matched grants of up to $20,000 to implement practical activities focused on supporting your business growth. • Introductions to business networks, access to government services, and specialist assistance for business growth and supply chain projects. In addition, depending on the results of the Business Evaluation, your company may be: • Given recommendations and be eligible for funding to improve your business and maximise opportunities. • Introduced to relevant scientific researchers through Research Connections. • Given advice and/or financial assistance to rapidly commercialise a new product under Accelerating Commercialisation.
AMT Feb/Mar 2018
• Introductions to researchers, technology or knowledge providers to work with you on collaborative projects. Accelerating Commercialisation offers: A Growth Services engagement will enable your business to identify and capitalise on growth opportunities more rapidly, easily, and capably, with less risk. The engagement will help your business build the capacity to accelerate growth. At no charge to you, a Business Adviser will: • Develop a Growth Plan to help you reach your growth opportunity. • Provide support, advice and mentoring to build the necessary capabilities, culture, strategies and connections for growth. • Facilitate access to relevant advice, networks and knowledge. • Help maintain your growth momentum through regular meetings and followup. Supply Chain Facilitation business practical ways to:
offers
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• Connect with, and supply existing and new markets. • Provide you with project opportunities. At no cost to your business, a skilled Business Adviser or Business Facilitator will work closely with your suppliers and customers to: • Strengthen your supply chain. • Improve your ability to access new markets.
• Matched grants of up to $1m to support entrepreneurs on their commercialisation journey. • Support and guidance from independent Commercialisation Advisers who will help you become investor and market-ready. • Introductions to influential business contacts and networks including investors, domain experts, entrepreneurs and strategic corporations through the Expert Network. These connections are crucial to help you develop your business, raise smart capital and get into new markets. • Opportunities to join an exclusive portfolio of high-potential Australian businesses that are marketed to investors and multinational corporations online, through media exposure and invitations to domestic and international networking events. • Opportunities for potential investors, domain experts and strategic corporations to make connections with innovative, young tech companies. Every business has different needs. To find out what the Entrepreneurs’ Programme can do for you, phone 13 28 46 or visit www.business.gov.au or contact Greg Chalker 03 9800 3666 gchalker@amtil.com.au
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014
From the ministry Senator The Hon Michaelia Cash – Minister for Jobs and Innovation
Transforming manufacturing to compete in global markets I am pleased to provide this article for AMT Magazine in my role as the Minister for Jobs and Innovation in the Turnbull Government. The Jobs and Innovation portfolio is about ensuring that Australia has the globally competitive industries necessary to provide wellpaying jobs today, tomorrow and into the future. The Government is focused on ensuring that the best connections are made between science, industry and innovation to drive transformation. Our manufacturing sector is transforming as we gear up to compete in global markets. Its future lies in embracing new technologies and developing high-value-added products and pre/post-production services, including research & development, design, engineering, marketing, sales and after-sales. Manufacturing in Australia currently produces $100bn in value add and employs more than 876,000 Australians. It also has the highest research & development spend of any industry sector at nearly $4bn. The sector is also expanding. Employment increased in five of the 16 sub-sectors over the year to November 2017. In addition, according to the AiGroup’s Australian Performance of Manufacturing Index (PMI), the sector is showing strong growth with an index of 56.2 in December 2017. Results above 50 points indicate expansion. This is the 15th month in a row of expansion and the longest consecutive run of expansion since 2005. The PMI also reported that new orders and exports remained strong, which serves as a positive indicator for growth in 2018. The sector, according to these statistics, looks well-placed to remain a pivotal cog in the nation’s economy. The Government, however, is certainly not going to rest on its laurels and we are working hard to ensure that momentum in the sector continues. The $100m Advanced Manufacturing Fund that we announced in 2017 will help the sector create jobs, grow their businesses, improve productivity and perform on the global stage. The centrepiece of the package is the new Advanced Manufacturing Growth Fund, which is worth nearly $47.5m over two years and will help industry adjust to the changing landscape of manufacturing in Victoria and South Australia. Under the first AMGF grant round, awarded last October, companies shared almost $30m in financial assistance, resulting in $119m of investment. Successful grants recipients include ATi Implants, based in South Australia, which will receive $1.5m for a National Dental Implant and Prosthetics Manufacturing Hub of Excellence; and MiniFAB, based in Victoria, which will receive almost $1.3m to expand its manufacturing capability and range of fabrication materials for the manufacture of polymer microfluidic devices. Late last year we opened the second round of funding to eligible manufacturing firms in Victoria and South Australia, with $16.4m available for small and medium-sized businesses to co-invest in capital projects to enhance their advanced manufacturing capabilities. The Australian Government will offer grants between $500,000 and $2.5m to cover up to a third of eligible project costs. This provides a real incentive for businesses to invest in a step change to advanced manufacturing, improving their productivity and competitiveness here and overseas. The second round of the Advanced Manufacturing Growth Fund is open for applications up until 28 February.
AMT Feb/Mar 2018
Advanced Manufacturing Growth Fund recipient MiniFAB’s high-volume advanced manufacturing facility for medical products.
Manufacturing in this country is in good shape, but to stay ahead of the pack, we must be responsive and forward-looking – and the Government is committed to this. Another key element of the $100m Advanced Manufacturing Fund is the Advanced Manufacturing Early Stage Research Fund (AMESRF), being launched in the coming months. This is a $4m funding initiative under the Advanced Manufacturing Growth Centre to support small-scale and pilot research projects in advanced manufacturing to benefit smaller firms and early-stage research projects. The grants aims to benefit smaller firms and early-stage research, allowing them to rapidly move towards commercialisation.The AMESRF will enable greater access to smaller project proponents and serve as rapid initial feasibility tests potentially as precursors to larger projects. AMESRF projects will complement those under the AMGC’s Project Fund, which is intended to support largerscale projects. Grants towards projects will be for a minimum of $100,000 and a maximum of $400,000, supporting at least 10 research projects. It’s just another way the Government is helping to stimulate the nation’s manufacturing sector, ensuring it remains competitive and creates jobs and opportunities for all Australians. After all, our economic growth and future prosperity rests on the competitiveness of our businesses and industries. Manufacturing in this country is in good shape, but to stay ahead of the pack, we must be responsive and forward-looking – and the Government is committed to this. I am honoured to lead this portfolio and I am looking forward to working closely with the manufacturing sector and peak bodies like AMTIL as we create a bright and prosperous future for everyone who works in manufacturing and for Australian industry as a whole.
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From the industry Innes Willox – Chief Executive Australian Industry Group
Australian CEOs optimistic for 2018 At the end of 2017 Ai Group surveyed a range of businesses across Australia and found a renewed optimism despite the significant headwinds industry has seen in recent years. Manufacturers were no exception and shared the relatively positive outlook for 2018. Ai Group’s Business Prospects report found that Australian CEOs are optimistic about the year ahead and keen to build on the stronger conditions experienced in 2017. Investment plans and expectations of employment growth are higher than at any time since 2012 (except for “spending on technology”, which was higher on net in 2016). For Australian CEOs, 2017 turned out to be stronger than anticipated. General business conditions, turnover, gross margins and employment were all higher in 2017 than they were in the previous year and they all turned out to be considerably better than was expected this time last year. CEOs’ renewed optimism has them anticipating a year of further advance on 2017. Expectations of general business conditions, turnover, employment growth and gross margins are all higher than at any time in the preceding five years. If these positive expectations can be turned into real outcomes, 2018 could be a defining year for the Australian economy. We would see strong non-mining business investment and spending on training, R&D and technologies reach post-GFC highs. And most importantly, we would see a year in which employment growth equalled or even exceeded the record jobs growth experienced in 2017. Given the strength of CEO expectations on employment, Australia could add more than 400,000 new jobs in 2018. An achievement of this magnitude would make critical inroads into both the rate of unemployment and the naggingly high rate of underemployment. Manufacturing sector CEOs expect a continuation of the favourable business conditions experienced in 2017. This is despite major headwinds such as high energy prices and growing skills shortages, as well as Australia bidding farewell to its passenger car assembly sector, which contributed so prominently to Australia’s advanced manufacturing activities for at least 70 years. Intense pressure from global competition, a high Australian dollar during the mining investment boom, high labour costs and disruptive technological change have meant manufacturing firms have had to innovate and invest, with many looking to sell on the global stage. For this year, 48% expect business conditions to improve, while 20% expect a deterioration. Regarding their own specific conditions, manufacturing CEOs expect broad-based improvement in 2018. In particular, 67% of CEOs expect an increase in their own sales turnover and 51% expect an improvement in their gross profit margins in 2018, while 13% expect a decline in sales and 22% expect a decline in profitability. Manufacturing CEOs’ expectations for turnover are significantly higher than they were for 2017 but profitability expectations are similar. Manufacturers expect input price pressures to continue in 2018, with a tellingly high 85% expecting a further increase in energy prices and only 3% expecting a decline. Energy-intensive manufacturers are among the businesses hardest hit by rising energy prices and some are highly trade exposed with little ability to pass through cost increases to customers. Input prices
AMT Feb/Mar 2018
are expected to continue increasing with 73% of CEOs expecting an increase in 2018 compared to 51% expecting an increase in selling prices. When asked about the challenges expected to inhibit business growth in 2018, 31% of manufacturing CEOs identified a lack of customer demand as their most significant impediment. This was down from 41% of CEOs in 2017, and substantially down from 49% of respondents in 2016. The second most concerning constraint for manufacturers in 2018 is competition from overseas and online businesses, with 18% of respondents ranking this as their primary concern. This is comparable to 2017 and higher than 2016 and earlier years. Skills shortages emerged as a considerable concern with 16% of respondents nominating this as their top inhibitor to business growth. Labour force skills and capabilities have increased as a concern for manufacturers since 2013. In 2017 it was the primary impediment to business growth for 10% of respondents – up from 5% in 2016. Wages pressures were a top concern for 8% of respondents, as was a high or variable exchange rate. A high and/or volatile exchange rate is also a concern for businesses importing inputs, exporting or both. A further 7% of CEOs said government regulatory burden is their top concern in 2018, up from 4% in 2017. Manufacturing businesses expect their growth in 2018 to occur primarily from improving sales of current products and services, with 35% of respondents ranking it as their main strategy for growth. This is down from 42% of manufacturers who rated it their principal strategy in 2017, and a similar proportion of respondents (34%) in 2016. While none of these forecasts is guaranteed, key steps can be taken to lift the chances of success: • Policy measures to stem and reverse the rise in energy prices need to be effective. Expectations of high energy price rises are a clear negative for Australian CEOs. • Moderate wages growth will need to continue: the record jobs growth of 2017 and the ability to meet expectations of still higher jobs growth are closely associated with the moderate wages outcomes of recent years and the continuation of this pattern into 2018. • Enacting the proposal to make Australia’s business tax system more competitive by lowering the company tax rate to 25% would significantly strengthen the incentives to invest and reinvest in the domestic economy. We are on the cusp of a year in which businesses are looking to invest heavily in capital equipment, in technology, in R&D, and in staff training. And we are on the cusp of a second consecutive year of record employment growth. If wage outcomes continue to be moderate; if progress can be made on reducing energy costs; and if the proposal to improve the competitiveness of our business tax system are enacted, 2018 could, indeed, be a stellar year.
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From The Union Paul Bastian – National Secretary Australian Manufacturing Workers Union
New Year’s message for corporate Australia Some of the richest and most powerful people in Australia gathered recently on the Victorian coast for the annual KPMG Couta Boat Classic. This quaint yacht race has become an annual litmus test of what the CEOs of the country’s leading corporations are prioritising for the coming year. And more often than not, the things that they want end up as Coalition Government policy. Last year’s Boat Classic was headlined by Richard Murray, CEO of JB Hi-Fi, who stated that the abolition of weekend penalty rates would be a priority for corporate Australia in 2017. Unsurprisingly, 2017 saw 700,000 retail and hospitality workers cop the biggest pay cut since the Great Depression when the Fair Work Commission stripped away weekend rates in that sector. This year the wish list of corporate Australia can be summed up as follows: taxes are too high; energy is too expensive; and we need to cut wage growth for workers. Ironically, if the captains of industry had just taken their yachts a little further offshore, they might have come across the gas fields of one of Australia’s worst corporate citizens, ExxonMobil. ExxonMobil’s behaviour exemplifies many of the problems with the way that corporate Australia is behaving. In 2017, ExxonMobil reported its third consecutive year of paying no corporate income tax. In these three years, ExxonMobil generated $18bn of revenue digging up natural resources from our land. This foregone revenue means there is less money to pay for teachers, nurses, roads and public transport. What’s more, the energy giant has been accused of holding the Australian energy market to ransom. At a time when energy prices dominate the headlines, ExxonMobil sits on 2,000 petajoules of undeveloped gas fields in the Bass Strait. Last year, they bought the Dory gas field but currently have no plans to develop it. According to Fairfax, the Australian Competition and Consumer Commission (ACCC) is investigating whether Exxon and its joint venture partner BHP are delaying development of these fields to artificially inflate energy prices. Inflated gas prices mean higher energy bills for consumers and companies, and put jobs at risk in energy-intensive sectors like manufacturing. Last month, chemical giant Qenos announced it would cut their workforce by 15% because of high energy prices. It’s likely that higher energy prices will disproportionately hurt smaller manufacturing enterprises as they deal with smaller margins and have less capacity to absorb the price increases. If tax avoidance and market manipulation weren’t enough, ExxonMobil has also taken an axe to the wages of their workforce on the Longford onshore and offshore facilities. A group of 200 workers have been campaigning for 200 days since they were told that they would have to take a 30% pay cut after ExxonMobil changed labour firms and re-offered long-term employees their same jobs back at reduced pay. It’s an all too common strategy adopted by bad employers – and yet it’s completely legal under our unfair laws. The ExxonMobil lesson is simple: when corporate power is left unchecked, workers suffer, consumers suffer, small businesses suffer, and our country is left worse off.
Inflated gas prices mean higher energy bills for consumers and companies, and put jobs at risk in energy-intensive sectors like manufacturing. ExxonMobil aren’t alone in the list of companies behaving badly. As we have seen at Griffin Coal, Streets Ice Cream and Murdoch University, we can expect that employers will again be lining up in 2018 to cut wages and conditions by exploiting our broken workplace laws. Moreover, while wage theft continues to be receive the same treatment as a parking fine, you can guarantee that bad employers will get away with not paying their workforce the legal minimum. Wage growth in Australia is at record lows. Workers and their families are doing it tough. We need a Government and a business sector that are ready to confront the challenges of increasing inequality. We certainly don’t need lectures about frugality delivered from the deck of a yacht. The New Year’s message for corporate Australia should be to pay their fair share of taxes and pay their workers a decent wage. And if they won’t do it, then we need a Government in Canberra that will change the rules to force them to do it.
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Real Business Real People Real Members I have been associated with AMITL as a member since its inception and have known most of the AMTIL staff for considerable years therefore I feel that I can say the organisation is of the quality the members should be very proud of. AMTIL conducts its activities with the enthusiasm and direction needed to promote Australia’s manufacturing industry across all appropriate sectors of government and industry alike. Their methods are generally of a consultative nature as they seek out inputs from all concerned and then having done so their feedback is informative. Most certainly confidentiality of matters discussed is paramount for the competitive industry we are in and there is never a concern with regards to such matters where AMTIL is involved. Anyone who has ever attended or participated in a AUSTECH exhibition could only attest to the quality of the exhibition and this is as a direct result of AMTIL’s overall co-ordination of the event and their methods of working closely with all involved. Dean McCarroll, OKUMA Australia Pty Ltd
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industry news
Australian manufacturing faces positive outlook for 2018 Confidence in the manufacturing sector is at its highest level since June 2003, with the sector investing for growth on the back of healthy profits and sales, according to the latest Business Expectations Survey from illion (formerly Dun & Bradstreet Australia and New Zealand). The latest analysis from illion reveals that business confidence across all sectors rose 13.7% compared to the prior corresponding period, primarily driven by expectations for profits, sales and employment. “Manufacturing firms that were able to withstand the global financial crisis and the Australian dollar above parity are now in a healthy financial position, buoyed by a stronger global economy and a lower Australian dollar,” said Stephen Koukoulas, Economic Adviser at illion. Koukoulas added that the broad nature of the result bodes well for the economy in the near term. The Business Expectations index is now at its highest level since late 2015, with companies set to boost employee numbers in the first quarter of 2018 on the back of bumper expectations for profits. The bullish outlook was supported by an 81.9% annual rise in the Business Actuals Index, which hasn’t reached its current level of 16.6 points since June 2004. In line with expectations, the result was driven by strong reported results for actual profits. illion CEO Simon Bligh said capital investment is crucial for sustained economic growth: “Capital investment planning is showing signs of growth, which is crucial for sustained momentum. The manufacturing and construction sectors appear to be in particularly good spirits as we start the year, which is another positive sign of the underlying strength of the economy.” Each month, illion asks a sample of executives if they expect an increase, decrease or no change in their quarterahead sales, profits, employees, capital investment and selling prices compared with the same quarter a year ago. The executives are also asked for actual changes over the twelve months to the latest completed quarter. For the latest survey, the final indexes for the latest quarter are based on approximately 1,200 responses obtained during October, November and December 2017. “It is great see business close out the year on a confident note,” added Bligh. “This bodes well for the beginning of 2018, which judging by the latest Business Expectations results is set to be an active year for business growth. The outlook for
AMT Feb/Mar 2018
profits is the strongest it has been for some time across a diverse range of sectors, suggesting the underlying foundation of Australia’s corporate landscape remains solid.”
ACCI highlights positive outlook The positive outlook for Australian manufacturing was further underscored by the Australian Chamber of Commerce and Industry (ACCI)-Westpac Survey of Industrial Trends. The December Quarter result showed continued solid output, backlog and new orders, while employment and overtime are expanding. “The Westpac-AusChamber Actual Composite Index moderated in December 2017 to 63.4 from an elevated 66.1 in September,” said Westpac Senior Economist Andrew Hanlan. “The robust level of December’s results reflect the boost from increased investment in both state infrastructure projects as well as private non-mining construction. A relatively low Australian dollar and global growth are also supporting exporters. “The uptrend in exports has continued at a moderate pace after stumbling in 2016.
The investment outlook for the sector is positive in response to rising demand and consistent with a reduction in the sector’s spare capacity, as well as improving profitability. A net 15% of firms expect to increase equipment investment in the next year. Hanlan added that the level of home-building activity was still high but slowing, while more pressing negative issues included subdued consumer spending constrained by slow wage growth, and continuing intensity from offshore competitors. The survey’s Labour Market Composite, which broadly tracks economy-wide jobs growth, pointed to continued solid jobs growth in the near term. James Pearson, Chief Executive Officer of the ACCI, said: “The economy appears to be gaining momentum but there is a weak spot - consumer spending - which remains flat. Tax cuts, for individuals and businesses, would stimulate spending, investment and jobs growth, which will lead to higher wages. It will also help ensure Australian businesses remain competitive in the global arena.”
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industry news
Nico Adams takes lead at Swinburne’s Factory of the Future Leading Industry 4.0 expert and former CSIRO scientist, Dr Nico Adams, has been appointed as the new Director of Swinburne’s state-of-the-art advanced manufacturing facility - the Factory of the Future. Adams has a background in materials and manufacturing informatics, and holds degrees from Oxford University and the University of York. Prior to his appointment at Swinburne, Adams was a senior research scientist and Product Manager at Data61, Australia’s leading data innovation group formed by the CSIRO.
explained Adams. “This insight has suggested practical ways of working with companies to formulate and implement new business outcomes enabled by digital technology.”
Adams said he was attracted to the role of Director of the Factory of the Future because of Swinburne’s commitment to research-led innovation. “Swinburne understands that to be successful in the digital economy does not just require technical, design and business model innovation, but also the development of leadership skills,” he said. “Being part of a team working to achieve this is what makes the role of Director so exciting.” During his time at Data61, Adams developed research to assist small-tomedium-sized enterprises (SMEs) in taking advantage of the digital economy and leveraging opportunities afforded by Industry 4.0. Following on from his work with CSIRO and Data61, Adams
assumed the role of Program Lead for Digital Transformation and Industry 4.0 at the Innovative Manufacturing Cooperative Research Centre (IMCRC). At IMCRC, Adams co-developed an innovation diagnostic and an Industry 4.0 business, product and strategy framework tailored for SMEs. This framework is about to be deployed through several organisations in the manufacturing industry, he says. “My previous experience has given me a deep insight into how manufacturing companies in Australia operate today,”
Swinburne Deputy Vice Chancellor, Professor Aleksandar Subic, said Adams’ expertise in digital innovation and Industry 4.0 makes him the perfect fit for the role of Director of Factory of the Future. Subic said he was confident that the industry knowledge and experience that Adams brings with him will strengthen Swinburne’s capability and industry partnerships. “The Swinburne Factory of the Future is the first Industry 4.0 University-based enterprise in Australia, involving a cluster of industries and enterprises to develop new capabilities and workforce for the digital economy,” explained Subic. “In his new role as Director of Swinburne Factory of the Future, Nico is well positioned to help our team further deepen our strategic industry partnerships. Nico will play a key role within our team in developing the Factory of the Future as an innovative Industry 4.0 enterprise.”
Innovation key for high-growth firms There are more than 10,000 high-growth firms in Australia at any given time and these firms make a disproportionate contribution to the country’s jobs and growth, according to the Federal Government’s latest annual Australian Innovation System Report, released in December. The Assistant Minister for Industry, Innovation and Science, Craig Laundy, said the report found that innovation is a key driver of high-growth firms.
and science agenda is so important. Our successful adoption of digital technology is fundamental in boosting productivity growth and maintaining global competitiveness.”
“Since 2010, the Australian Innovation System Report series has been tracking the performance of core components of the innovation system,” Minister Laundy said. “The 2017 report uses newly obtained data from the Business Longitudinal Analysis Data Environment (BLADE) to analyse the phenomenon of high-growth firms in Australia.
Report key findings:
“The report shows that innovation-active firms are more likely to report increases in sales, profitability, productivity, firm, size and other growth-related measures than firms which do not innovate. That is why the government’s innovation
AMT Feb/Mar 2018
• High-growth firms are difficult to predict and rarely sustain high rates of growth for more than four years.
• Innovation has a positive effect on firm growth. Across all firms, product innovation is estimated to lift turnover growth by 3.3 percentage points.
• The proportion of high-growth firms in the economy has been in decline since the global financial crisis. However, the proportion of highgrowth firms in Australia is still above average among OECD countries.
• In 2015-16, an estimated 48.7% of all employing firms were innovationactive. These firms are distributed broadly across all industries, with the highest proportion found in manufacturing.
“The report provides new insights into the importance of business growth and innovation,” Laundy said. “The Australian Government is working to ensure we have the right conditions to ensure highgrowth firms can continue to thrive.”
• High-growth firms make a disproportionate economic contribution to sales and jobs growth, compared to other firms.
The Australian Innovation System Report is available online at: www. industry.gov.au/innovationreport
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industry news
Fishermans Bend to house new UoM engineering campus The University of Melbourne (UoM) will build a new, seven-hectare campus within the old General Motors Holden site at Fishermans Bend. The new campus – just five kilometres from the city – is part of an almost $1bn commitment by UoM to create a world-class engineering school for the 21st century. Set to open in the early 2020s, it will be the centrepiece of Australia’s leading precinct for advanced manufacturing, design, engineering and technology excellence. UoM Vice-Chancellor Professor Glyn Davis said the University bought the site from the Victorian Government to expand the Melbourne School of Engineering. “The University will be a catalyst for new collaborations and investments, connecting industry and research in the precinct,” Davis said. “We have a proud history of innovation in this country. The new campus will give our researchers and students opportunities to work alongside industry, and pursue rich careers right here in Australia. “When surrounded by start-up accelerators, business incubators, cutting-edge research, development and manufacturing facilities, and test sites, our students can immediately put ideas into action.” The new campus will allow the University to build large-scale research platform facilities that the Parkville campus cannot accommodate. This will include wind and water tunnels, smart grid technologies, autonomous vehicle testing and pre-fabricated housing manufacturing.
UoM School of Engineering Dean Professor Iven Mareels said that the new campus will help create the entrepreneurial leaders and transformative technologies of the future. “The Fishermans Bend campus will initially enable 1,000 engineering and IT students and academics to collaborate with world-leading local and international companies across industrial sectors as diverse as transport, energy, food, mining, infrastructure and water,” Mareels said. “The almost $1bn investment includes the purchase, design and construction of this new campus, upgrade to our Parkville campus engineering facilities, our presence at the innovation precinct being built on the former Royal Women’s Hospital site and additional staff to support research, teaching and engagement.” The Victorian Government purchased the site of the former Holden factory in September 2016 to develop it into Australia’s leading precinct for advanced manufacturing, design, engineering and technology excellence. Economic modelling has shown that the University’s 2025 engineering strategy, of which the new campus is an integral part, will provide an $8bn boost to Victoria’s economy and generate over 15,000 new jobs by 2035. Our History page in this issue looks at the construction in 1936 of the plant at Fishermans Bend. Read more on p114.
Ten innovations chosen for CSIRO Accelerator Program A smarter smaller wind turbine, wearable tech to screen for gut disorders, and a solar forecasting system are among the emerging technologies fast-tracked though the national sci-tech accelerator, ‘ON, powered by CSIRO’. Ten teams have been selected for the latest round of ON Accelerate, a structured, full-time accelerator that brings together the experience and expertise of established researchers, entrepreneurs and mentors. CSIRO CEO Dr Larry Marshall said that ON had uncovered science and technology solutions for some of Australia’s biggest challenges in energy, food and agriculture, water quality, wildlife conservation and health. “Establishing ON was about bringing the Australian research sector closer to Australian industry – creating a pathway to help our scientists turn their excellent science into real-world solutions,” Marshall said. “The program is built on the shoulders of scientists who have made the leap into business, and likewise business people who have leapt into the world of science. This collaboration across the innovation system is allowing us to deliver game-changing innovations for Australia and the world.” Since opening the ON accelerator to universities and publicly funded research agencies under the National Innovation and Science Agenda (NISA) in mid-2016, CSIRO has graduated 200 teams of researchers with the business and entrepreneurial skills needed to fast-track great science and technology innovation from the lab to reality. The 10 ideas fast-tracked through this round of ON Accelerate include: • Virtual reality technology that allows carers to learn by doing, safely – University of Newcastle. • A tool for preventing faults in power network assets before energy catastrophes hit – Curtin University.
AMT Feb/Mar 2018
• A solar forecasting system – CSIRO, Energy. • An acoustic belt that uses the natural noises of the gut for health screening – University of Western Australia. • An on-the-go field tool for reliable and transportable water monitoring – James Cook University. • A new pest detection system that cuts costs and delays for Aussie prawn farmers – CSIRO, Agriculture and Food. • An alternative to the expensive and cumbersome ‘leaky gut’ test for suspected sufferers – CSIRO Health and Biosecurity. • A new way to reduce costs and delays in new drug development – Macquarie University. • On the spot testing for elite athletes and their sport scientists – University of Western Australia. • A small wind turbine that can produce nearly twice the power of existing turbines of the same size – University of Newcastle. The 10 successful teams were chosen by ON’s industry mentor network and an expert judging panel. ON Accelerate4 will commence in February and will run for 12 weeks in hubs across the country, where teams will develop business planning, commercialisation and pitching skills. The program culminates in ‘ON Demo Night’ where teams will pitch their innovations to an audience of industry experts, investors and potential partners for further funding and support for commercialisation.
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industry news
Production boost for Boss Engineering Agricultural implement manufacturer Boss Engineering has landed a $750,000 grant from the NSW State Government. The Inverell-based company will use the funds to upgrade its workshop with two new CNC machines from Okuma Australia, a fibre laser cutter and a shed extension. The new investments will help the company increase capacity and create 47 new full-time jobs. Northern Tablelands MP Adam Marshall and Inverell Mayor Paul Harmon visited Boss’ facility to announce the award “Boss Engineering has gone from strength to strength in recent years and this funding will see the business expand by a further 50%, ensuring the future of local industry and jobs for the Inverell district,” said Marshall. “At a time when many claim Australian manufacturing is almost dead, Boss is bucking that trend and not only surviving, but thriving. “This expansion will not only help Inverell’s economic development, but with Boss Engineering’s key role in supplying high-quality machinery to local industry and primary producers, the entire Northern Tablelands will feel the flow-on benefits. Jobs for NSW is helping to drive efforts to significantly grow regional centres like Inverell to become accelerators for jobs growth and investment in the future.” Marshall added that the latest grant comes on the back of 12 new employees recently hired by Boss thanks to a previous grant from
Northern Tablelands MP Adam Marshall (second left) and Inverell Shire Mayor Paul Harmon (far right) with Boss Engineering Directors Andrew English, Dan Ryan and Michael Grills. Photo: Heidi Gibson.
the NSW Government, which also boosted available floor space at the Boss plant by 25,000sqm. “Boss Engineering has a proven track record of using capital investment to grow Inverell’s economy, taking on dozens of qualified tradespeople and younger apprentices,” Marshall said. “Today’s announcement provides a reliable platform for future growth, and ensures that manufacturing will always have a home in our region.”
Innovators announced in Australian Technologies Competition Australian high-tech companies with global potential were celebrated at a gala dinner in Sydney in November to recognise the winners of the 2017 Australian Technologies Competition. The event showcased technology companies delivering solutions across high-growth sectors including energy, resources, mining, agriculture, cities and medtech. The winning companies have solutions for detecting leaks in dams using graphene, surgical devices, safe ore processing, internet voting, precision agriculture, big data and autonomous logistics. The overall title of ‘Australian Technology Company of the Year’ was awarded to Melbourne-based Livac, which also took the Medtech & Pharma category prize. The company has developed the LiVac Retractor System, a device that is used to retract the liver during keyhole surgery of the upper gastrointestinal tract while causing minimal trauma to patients. John O’Brien, organiser of the Australian Technologies Competition, said: “Livac has developed and brought to market a world-leading technology that improves patient and hospital outcomes for upper abdominal minimally invasive surgery. They are set to be a major player globally and become the standard device for liver retraction. They also fit well with all of our Winners since 2011 as they take Australia’s best to make a difference to the world.”
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Sydney-based Premonition took the runners-up spot, as well as winning the Smart Cities category. Premonition optimises fleets in real-time by combining artificial intelligence and machine learning to provide Autonomous Logistics that adapts to traffic congestion, delays and missed deliveries. The Advanced Manufacturing & Energy Resources category was won by Imagine Intelligent Materials from New South Wales. Imagine specialises in graphene materials that are electrically conductive and act as sensors. Its first product is a graphene coating for Geotextiles that is used to locate leaks in dam linings at mines. Winners in the other categories included: • Cyber Security: SecureVote • Food & Agribusiness: FluroSat • Mining Technology: Mining & Process Solutions • New Energy: Future Grid • People’s Choice: BCAL Diagnostics
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Government news
More support for Queensland small businesses Eleven Queensland small businesses will share more than $88,000 in grant funding under the latest round of the Accelerate Small Business Grants Program. Minister for Employment and Small Business, Shannon Fentiman, announced that the 11 small businesses will receive assistance to engage with experts to help their business grow and create jobs. She made the announcement at the Brisbane head office of Sofi Spritz, one of the grant recipients. “Small businesses are the engine room of our Queensland economy and investing in their growth leads to more local jobs,” Fentiman said. “I am pleased to announce these grants will provide targeted assistance to support small businesses looking for advice to help them to grow and expand. Since the Palaszczuk Government came to office we have worked with business and industry to create over 143,000 new jobs in Queensland.” “Sofi Spritz is a Queensland success story and I am pleased the
Palaszczuk Government is able to partner with them with a $10,000 grant that will be used to help take their chic popular drinks to the international market.” Featured on Channel TEN’s Shark Tank, Sofi Spritz is an all-natural Australian wine spritzer, crafted by a fifth-generation winemaker that was a start-up business crowdfunded by fans and is booming in sales across Australia. “It’s inspiring to be able to see firsthand how these grants can assist small businesses like Sofi Spritz and provide them with the help they need to take a home-grown Queensland brand to the world stage,” Fentiman added. Tom Maclean, founder of Sofi Spritz, will be using the grant funds to look into new product development and advice for
sending his wine spritz business into the international market. “I’m employing more staff and more contractors to help manage domestic demand for the existing product range, but we need a solid strategy to make sure the business grows in a sustainable and diversified manner,” he explained. “This grant means I can employ a Brisbanebased consultancy firm to work with me to map out a strategy to realise our vision for the business.” The announcement brings the total number of businesses benefiting from the Accelerate Small Business Grant program to 64, with many businesses using funds to help them manage growth, implement business development plans and look to overseas markets. www.business.qld.gov.au/accelerate
NSW Apprenticeship Act gets 21st century revamp The New South Wales (NSW) Government has announced changes to laws governing the State’s apprenticeship system that will make it more responsive to the demands of the contemporary workplace. Deputy Premier and Skills Minister John Barilaro said the Apprenticeship and Traineeship Amendment Bill 2017 was drafted and passed by parliament in September 2017 after extensive consultations with industry, employers and registered training organisations (RTOs) and came into effect on 1 January. “The amendments to the Act reduce red tape and strengthen the partnership between the training providers and employers in planning and assessing the competencies of apprentices through their agreed Training Plan,” said Barilaro. “It will now be a requirement of the act that employers and RTOs collaborate over development and review of Training Plans and report the on-the-job progress of apprentices at regular intervals.” NSW is also reforming the system of trade recognition, in a move that intended to streamline the process whereby handson experience, skills and knowledge are recognised in a qualification. Under the new system, Training Services NSW (TSNSW) will give applicants advice and direct them to an appropriate Smart and Skilled provider, who will assess the applicant’s practical skills and issue a verification of a trade qualification. The reforms also include the abolition of the Vocational Training Review panel and
AMT Feb/Mar 2018
measures to strengthen the powers of the Commissioner for Vocational Training, who will address complaints without the administrative burden, cost and formality of convening a panel. The Commissioner will also have the power to initiate the cancellation of an apprenticeship or traineeship.” Barilaro said the amendments would support young workers to become better skilled, improve completion rates and
ensure apprentices and trainees receive qualifications that directly meet the needs of their job. “The new Act will help employers meet the growing demand for a skilled workforce and ensure that we are setting up our young workers to fill the jobs of the future that will continue to drive the NSW economy,” Barilaro said. www.training.nsw.gov.au/ apprenticeships_traineeships
Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL
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The Entrepreneurs’ Programme (EP) is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. AMTIL is a partner organisation working with the Department of Industry in the delivery of the EP. The Programme forms a part of the Australian Government’s Economic Action Strategy and will deploy over 100 experienced Advisers and Facilitators, offering support to businesses through three key elements: 1. Business Management a. Business Evaluations – A detailed assessment and action report b. Supply Chain Facilitation – Practical assistance to interact and supply into new markets c. Business Growth Services – Access to specialist advisers and services to accelerate growth d. Business Growth Grants – Co-funded grants to implement actions of the Business Evaluations 2. Innovation Connections a. Identify research needs and opportunities b. Support to connect with sources of expertise, technology and advise c. Make available pathways to collaborative research 3. Accelerating Commercialisation a. Guidance, connection and grants to advance commercialisation
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voice box Opinions from across the manufacturing industry
How do we skill a workforce for Industry 4.0? It’s now well established that industry is in the midst of a new Industrial Revolution otherwise known as ‘Industry 4.0’. What’s less clear is the scale of the changes we can expect, and how manufacturing jobs, work roles and ways of working will be affected. This cornucopia of ‘unknowns’ has generated significant challenges for educators, especially in the vocational education & training (VET) sector, who struggle to make sense of what these new horizons might mean for education and the way students (including apprentices) should be prepared for the workforce. By Dr Karen L O’Reilly-Briggs. At the threshold of Industry 4.0—the technology and innovation Industrial Revolution—we are only beginning to notice a profound shift taking place. The magnitude of this transformation is, according to the founder and executive chairman of the World Economic Forum, Klaus Schwab, unlike anything that humankind has experienced in history, and the industry poised to lead the Australian economy into the 21st century is advanced manufacturing— an industry in the midst of a historic transformation across the entire industrialised world. The Productivity Commission has already confirmed that the labour market will change significantly over coming years, and while the enormity of this change is yet to be fully understood, it has not deterred the Government from promising a ‘pipeline’ of suitably qualified workers with the skills, capabilities and knowhow required to resource the new industrial landscape. So what sort of skills, capabilities and knowhow will the advanced manufacturing industry be needing from its future workforce? Industry groups including Manufacturing Skills Australia (MSA) have asserted the need to begin equipping manufacturing workers with a gamut of abilities and attributes that appear to be, at present, mostly excluded from apprenticeship trade training. Some may even say they are incongruent of the competency-based system in which apprentices are currently trained. Some of the skills and attributes MSA mention include: adaptability; problem solving capabilities; creative thinking; the ability to design and innovate; the ability to use digital platforms; the ability to develop higher-level interpersonal/organisational skills; and ‘broadbased’ capabilities. Many VET educators would agree that these skills and attributes are (or at least are likely to be) essential for their students and apprentices to thrive in the manufacturing industry of the future, but question the VET sector’s ability to accommodate this challenge. Given the highly regulated structure of VET (including training packages, competency-based training & assessment, stringent funding arrangements), and the sector’s inability to keep pace with the rate of change, many involved in VET find it difficult to see how the sector will meet this challenge. What we do know, however, is that should we fail to adequately prepare young people for the future of work, then the nation will be confronted with the very real possibility that the next generation – today’s young people and apprentices – will be ‘left behind’. That is, they will be socially and
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economically disadvantaged, a situation with serious implications for industry and our nation’s economy. As such, it is not an issue to be taken lightly; nor is it one that will resolve itself in the absence of research and education policy resolutions. Of course, where the issues of ‘rapidly changing industry’ and ‘human capital’ intersect, a plethora of questions emerge concerning how we, as a nation, should go about preparing young people with the skills, knowledge and capabilities they will require, not only to resource industry, but to create socially responsible citizens equipped with the knowhow to gain meaningful employment and establish respectable livelihoods for themselves and their families. Questions such as: How do we prepare young people for jobs and industries that are yet to be realised? Is the VET sector able to accommodate the changing needs of industry? How do we skill a workforce for Industry 4.0? And what will happen if the VET sector cannot adapt to meet change? These are all questions of significance, and the impetus behind a new study initiated by vocational and adult education researchers at La Trobe University’s School of Education. Amid so many questions concerning the future, innovation and Industry 4.0, researchers Dr Mike Brown, Professor Terri Seddon and I have embarked on the challenge of gaining a detailed understanding of advanced manufacturing to gain a better sense of what this important industry might mean for the future of manufacturing and engineering trade vocations, and vocational education in Australia. To date, the study has consisted of interviews with individuals identified as ‘key players’ in the advanced manufacturing industry from around Victoria. These individuals include senior managers, experts and other leaders in the field with substantial experience and knowledge of their industry, and of the changes that are currently taking place here and around the world. Although data are yet to be analysed, initial readings highlight multiple areas of significance that will no doubt provide great challenges for our notoriously slowmoving VET sector. A report based on this pilot study will be available from La Trobe University later in 2018, but until then, if you would like to contribute to the industry skills conversation, be updated about the research, or express interest in participating in future skills focused studies, please contact Dr Karen O’Reilly-Briggs at E: k.oreilly-briggs@latrobe.edu.au. www.latrobe.edu.au/education
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voice box Opinions from across the manufacturing industry
No, we aren’t running out of new ideas Theories that productivity growth has slowed over recent decades because we have reached some kind of limit on our capacity to innovate and generate new ideas are flawed, writes Beth Webster. We’ve picked all the low-hanging fruit when it comes to new ideas, and the world is set for more parsimonious times … this is the idea put forward in a recent research paper by Nicholas Bloom, John Van Reenen and their co-authors. The paper argues that productivity growth has been low or declining since the 1940s, despite an increase in the number of people working in research. The idea is that a rising number of researchers should lead to an acceleration of productivity. A proven good idea can potentially be applied to the whole production system and so a rise in researchers should increase this effect. This message should be taken seriously but not simplistically. First, let’s consider the assertion that productivity growth has been declining. In the paper, the data presented is on “total factor productivity” growth. This is a rather convoluted measure of goods and services produced per worker. Economists tend not to use simple measures (such as GDP per worker) to illustrate productivity, as this would also count other inputs into the production process (such as factories). Accordingly, they subtract these assets from output to get a measure of output per worker in a complicated statistical procedure. This measure is called total factor productivity. But really this elaborate measure is making two wrongs equal a right. Measures of assets are based on archaic accounting standards, which are incomplete. It is not surprising therefore to get estimates of total factor productivity that throw up strange results such as unexplained falls in productivity. As a measure of long-run output per worker, this measure is too massaged to be convincing. A clearer measure is the amount of goods and services available to householders per hour worked. Below I have estimated this ratio for the largest 21 OECD countries combined since 1952. It reveals a flat trend rate of growth in productivity of about 2.6% per annum – though this understates true productivity because indexes of price aren’t very good at representing changes in product quality (think of how much better computers have become over time).
Without more consideration, it is a big stretch to go from lowerthan-expected growth in per capita output to “we are running out of ideas”.
There may be other limits on growth What if the bottleneck – if we want to call it that – to faster growth is not the generation of new ideas (only some of which comes from R&D workers in any case), but from the ability to successfully translate those ideas into reality? We know that there tends to be many more ideas than are actually implemented. However, many ideas that are technically feasible are not cost-effective; are out-competed by better ideas; or simply are not invested in. There is a saying that for every $1 spent on research, you need to spend $10 on development and $100 on translation. The issue may not be that spending on R&D is becoming less productive, but that the economy is missing important complementary investments into research translation and change management. Alternatively, it may be lack of risk-loving investors. We know that most productivity gains come from new-to-thefirm innovation – laggard firms catching up to those pushing the envelope. A policy focus at this end is needed. It’s not easy to know what ideas will continue and transform economies and what ones will peter out. Recent examples of scientific progress, including genetic engineering, artificial intelligence, 3D printing, augmented reality and robotics, may have enormous economic impact.
There has been a steady increase in the number of researchers since 1996. But in the past 30-plus years, there has been consistent empirical evidence that higher R&D causes firms, industries and countries to experience faster rates of growth. Governments have responded with incentives to do more R&D, and the number of R&D workers as a percentage of the population has risen. But why hasn’t output per worker accelerated?
They may be the transformations we need to manufacture all our material needs with only 2% of our workforce, to cure or prevent diseases, to provide carbon-free energy, or mitigate political events that destroy lives and livelihoods. It is a bit trite to say our forebears invented electricity, the steam engine and the internet – what did we invent last week? Professor Beth Webster is the Director of the Centre for Transformative Innovation at Swinburne University of Technology. This article was originally published by The Conversation. www.theconversation.com www.swinburne.edu.au
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Tech News
Scotland: New composites manufacturing technology Last December Spirit AeroSystems announced its Advanced Technology Centre in Prestwick, Scotland, has developed an improved method for manufacturing composite parts by developing an intelligent heated tool for curing composite components. The new technology can cure composite parts 40% faster at half the cost and supports a wide range of composite components across industries, from wind turbine blades to the next generation of composite aircraft. Instead of curing components at a standard temperature for hours at a time, the cycle time can now be tailored to match individual part geometries. The autoclave was considered a bottleneck in manufacturing lines, and removing it will reduce cycle times for components, cut production costs and decrease energy consumption. Spirit’s new technology introduces an intelligent, multi-zone heated tool, removing the need for an autoclave. The tool enables complete control of the curing process through realtime monitoring and feedback.
or moulds. The concept involves producing C-frames in a separate process, with frames butted together to create an outer mould line surface, over which the fuselage skin is fibre-placed. The frames are reportedly integrated into the fuselage. Dry carbon fibre tape is used for the skin, which is then infused and oven-cured. The company says that raw material cost could be reduced by up to 50% and by eliminating rivets, fuselage weight can be reduced by 10-30%. 6,000 hours of work were reportedly saved. MTorres is reportedly also adapting the technology to wings. The first demo piece, a large, complexly curved one-piece composite airplane fuselage that contained not a single fastener, was unveiled at the Paris Air Show last June. Composites World and mixed
Spirit AeroSystems
USA: Airless 3D-printed concept tyre
USA: Irradiated plastic strengthens concrete Discarded plastic bottles could one day be used to build stronger, more flexible concrete structures. MIT undergraduate students have found that, by exposing plastic flakes to small, harmless doses of gamma radiation, then pulverizing the flakes into a fine powder, they can mix the irradiated plastic with cement paste and fly ash to produce concrete that is up to 15% stronger than conventional concrete. Others have tried to introduce plastic into cement mixtures, but the plastic weakened the resulting concrete. The team found evidence that exposing plastic to doses of gamma radiation makes the material’s crystalline structure change in a way that the plastic becomes stronger, stiffer, and tougher. Highresolution images revealed that samples containing irradiated plastic, particularly at high doses, exhibited crystalline structures with more cross-linking, or molecular connections. In these samples, the crystalline structure also seemed to block pores within concrete, making the samples more dense and therefore stronger. Massachusetts Institute of Technology
Spain: Revolutionary fuselage concept – no fasteners or moulds Spanish industrial group MTorres, has introduced a new concept for composite fuselage manufacture - a one-piece, monocoque prototype fuselage which reportedly requires no rivets, fasteners
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Michelin has developed a biodegradable concept tyre – named VISION - which is airless, connected, rechargeable, customisable and organic. It is both a wheel and a tire. The materials are both bio-sourced and biodegradable. VISION does away with air, relying instead on an interior architecture capable of supporting the vehicle, ensuring the solidity of the wheel and thus guaranteeing both comfort and safety; it can neither explode nor blowout. Equipped with sensors, VISION provides real time information about its condition. This concept tire can be “recharged” on demand with a 3D-printed tread, designed to be customised with biodegradable materials according to the driver’s mobility needs — using service stations equipped with 3D-printing kiosks. Unlike tires today, the rechargeable tire could conceivably last for the life of the vehicle. The tire structure is embedded with sensors capable of detecting road conditions, maintenance requirements, adherence, and other necessary performances that are communicated to the vehicle, or to infrastructure networks on the smart roadways of the future. Michelin media
Tech Heading News
USA: 3D printing gets a turbo boost from new technology
USA: Next-gen flexible, selfhealing robots
A major drawback to 3D printing – the slow pace of the work – could be alleviated through a recently developed software algorithm. The algorithm allows printers to deliver high-quality results at speeds up to two times faster than those in common use, with no added hardware costs. One of the challenges for 3D printers lies in vibrations as they print – and the faster the machine moves, the more vibrations are created. Armed with knowledge of the printer’s dynamic behaviour, the program anticipates when the printer may vibrate excessively and adjusts its motions accordingly. The software can also be used on a variety of industrial-grade machines which suffer from limitations due to vibrations.
A central challenge in the field known as “soft robotics” is a lack of actuators or “artificial muscles” that can replicate the versatility and performance of the real thing. A research group has developed a new class of soft, electrically activated devices capable of mimicking the expansion and contraction of natural muscles. They can “reproduce the adaptability of an octopus arm, the speed of a hummingbird and the strength of an elephant”. These devices are able to self-sense their movements and self-heal from electrical damage. Called hydraulically amplified self-healing electrostatic (HASEL) actuators, they eschew the bulky, rigid pistons and motors of conventional robots for soft structures that exceed or match the strength, speed and efficiency of biological muscle. “The ability to create electrically powered soft actuators that lift a gallon of water at several times per second is something we haven’t seen before” said doctoral student Eric Acome. The materials are low-cost, scalable and compatible with current industrial manufacturing techniques.
University of Michigan
China: World’s first electric cargo ship The world’s first all-electric cargo ship has been launched in Guangzhou, China. Manufactured by the Guangzhou Shipyard International Co. Ltd, the ship represents a technological breakthrough as it is the first in the world to use lithium batteries in a fully powered cargo vessel. It is 70.5m in length, its highest speed is 12.8 kms per hour, it has a 2,000-metric-ton cargo capacity, has zero emissions and can run for 80kms after a two-hour charge of its 2,400 kWh battery. Designed for short-haul trips (running in the inland section of the Pearl River at the moment), it could in future be used for passenger travel. While loading and unloading at ports, the ship will charge - ready for its next trip. China Daily and mixed
USA: Mini robot - Micrometer precision and high speed Over time, roboticists have designed smaller and smaller Delta robots for tasks in limited workspaces, however shrinking them further to the millimeter scale with conventional manufacturing techniques has proven fruitless. A new design - the milliDelta robot - overcomes this miniaturisation challenge. Pop-up MEMS ( “microelectromechanical systems”) manufacturing has been used for the construction of dynamic centimetre-scale machines and researchers applied this approach to develop the milliDelta robot which measures a mere 15mm x 15mm x 20mm. By integrating microfabrication techniques with high-performance composite materials that can incorporate flexural joints and bending actuators, the milliDelta can operate with high speed, force, and micrometer precision, opening new avenues for microsurgery, microassembly and micromanipulation. Able to operate in a workspace of about seven cubic millimetres, the enhanced speed and control of the milliDelta robot opens entirely new avenues of development for industrial and medical robots, which are currently beyond the reach of existing technologies. Harvard
University of Colorado
Australia: Cleaner, more efficient batteries Under a $3.45m Cooperative Research Centre Project grant, researchers will partner with Australian industry to commercialise the world’s first alternative to lithium-ion battery (LIB) technology by efficiently capturing the energy of graphene oxide (GO).This GO-based supercapacitor is considered to be superior than lithium or even solar: it is long-lasting, safe, has superior energy density, flexibility and environmental sustainability. Graphene is the lightest, strongest, most electrically conductive material available and is believed to be central to the next industrial revolution, industry 4.0, which will see the digital transformation of manufacturing processes. But so far unreliable quality and poor manufacturing processes has prevented an industrial graphene market. The technology behind this invention is based on the Vortex Fluidic Device which was created in 2015 by Flinders University scientists. This machine is capable of “unboiling an egg” by unravelling proteins. The device has been used to process graphene to a high quality for commercial use and has also been used to accurately slice carbon nanotubes to an average length of 170 nanometres using only water, a solvent and a laser. Flinders and Swinburne Universities
“People need fuel to run their vehicles and electricity to run their devices. Now you can make both electricity and fuel with a single device.” Prof. Richard Kaner (University of California, Los Angeles). Researchers have designed a device that can use solar energy to inexpensively and efficiently create and store energy, which could be used to power electronic devices, and to create hydrogen fuel for eco-friendly cars. This could make hydrogen cars affordable because it produces hydrogen using nickel, iron and cobalt — elements that are much more abundant and less expensive than the platinum and other precious metals that are currently used. It could also be part of a solution for large cities that need ways to store surplus electricity from their electrical grids (if electricity could be converted to hydrogen, it could be stored indefinitely). The device has a third electrode that acts as both a supercapacitor, which stores energy, and as a device for splitting water into hydrogen and oxygen. All three electrodes connect to a single solar cell that serves as the device’s power source. Using solar cells and abundantly available elements to split water into hydrogen and oxygen has enormous potential for reducing the cost of hydrogen production.
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product news
High-feed face mill speeds up productivity Cutting tool and tooling system specialist Sandvik Coromant has unveiled a new high-feed version of the CoroMill 745 face milling cutter, featuring a 25-degree entering angle for additional productivity gains when milling steel and cast iron workpieces. The new high-feed version facilitates even higher metal removal rates (MRR) in applications with depths of cut up to 2.8mm. The new cutter is set to benefit sectors such as die & mould, pump & valve, oil & gas, automotive, power generation and general engineering. Despite the elevated MRR and productivity, there is no compromise to surface finish when using the new high-feed CoroMill 745. A light cutting action from the innovative insert positioning provides excellent chip formation, a smooth, soft sound and low power consumption. “An important benefit of the new cutter is low cost per edge from its double-sided 14edge insert design,” says Matts Westin, Product Manager, Sandvik Coromant. “In fact, purchasing departments will be pleased to learn that tool inventory costs are reduced because the CoroMill 745 with 25-degree entering angle uses the same inserts as its counterpart cutter with 42-degree entering angle.” The high-feed CoroMill 745 is aimed at roughing to semi-finishing face milling operations on machining centres and multi-task machines. With its multi-edge concept, the tool is particularly suitable for large-batch production, flexible transfer lines and when
maximum tool utilisation is important. Advantages will be provided when milling components such as valves, engine blocks, hubs, main frames, pump components and moulds, in fact, any type of general engineering component made from ISO P or ISO K materials. The presence of a short, 0.6mm parallel land ensures a good surface finish. The large screw ensures easy handling, while the insert position and the heptagonal insert shape make clamping exceptionally secure for reliable face milling operations. Internal coolant is available on all cutters, which range from 63mm to 160mm. Providing an example of the potential gains on offer, a customer trial application showed impressive benefits when face milling a machine bed component made from cast CMC ST52 (165 HB) on an ISO-50 gantry mill. A 125mm CoroMill 745 with a 25-degree entering angle reduced cycle time per component by 40% in comparison with a competitor tool. The high-feed CoroMill 745 with 25-degree entering angle complements CoroMill 745 with 42-degree entering angle. www.sandvik.coromant.com
New scalable graphic terminals boost productivity in smaller applications Rockwell Automation’s new Allen-Bradley PanelView 5310 family of graphic terminals can help machine builders increase productivity through tighter integration between controller and HMI. The PanelView 5310 graphic terminals are a cost-effective alternative to the PanelView 5500 terminals for smaller applications of up to 50 HMI screens, delivering the same usability benefits and enhanced integration with Logix 5000 controllers. The terminals are available in 7-inch, 9-inch and 12inch display sizes, with a 6-inch display option shortly to become available. “Engineers can use the PanelView 5310 family to scale a tightly integrated automation system down to smaller applications,” said Jonathan Footman, Commercial Specialist – Hardware at Rockwell Automation. “This can help make design, operations and maintenance tasks more efficient. For example, engineers can now reuse controller alarms without creating HMI tags, which can help them reduce configuration time.” Companies can also use the enhanced integration to create highspeed jog buttons in place of cumbersome hardwired buttons. These auto-diagnosing buttons can interact with the controller at I/O speeds to help reduce downtime and improve productivity.
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The intuitive Rockwell Software Studio 5000 design environment allows users to create reusable faceplates, screens and custom graphics to help reduce development time. These objects seamlessly integrate with Logix add-on instructions and different user-defined data types. Emulation capabilities allow engineers to test run projects in the development environment. This can help them make changes without using the PanelView 5000 hardware or disrupting production. VNC connectivity allows operators to remotely monitor operations via a smartphone, tablet or personal computer. Historical-trending and data-logging features also allow operators to easily troubleshoot issues directly on the panel. Engineers can load projects onto the PanelView 5310 graphic terminals directly from removable media to more quickly recover information and make project updates without needing to use the Studio 5000 View Designer application. www.rockwellautomation.com
Product Heading news
BOC revamps its welding line-up BOC has completed a revamp of its welding range with the launch of eight new welding models that offer the latest in welding technology to Australian fabricators and businesses. According to Richard Fowles, Senior Product Manager of Welding Products, the new welding range is affordable and easy to use, with advanced electronics and digital control that focus on delivering improved safety and quality. “Safety is a top priority for BOC and our customers,” said Fowles. “With new legislative changes in electrical safety, our machines now carry the Regulatory Compliance Mark (RCM) required by all welding manufacturers in Australia. Whether it’s small fabrication jobs or automated robotic applications, BOC understands the need to have machines that provide the right power capacity and processes to deliver a quality job. Many of the new models will upgrade or replace products in our current range, designed to deliver the best welding experience.” Four new lightweight and portable models offer excellent reliability and performance. The new BOC Smootharc MMA131vrd and MMA171vrd models are perfect for fabricators on the go, with new TIG capabilities and voltage reduction devices that reduce open circuit voltage to safer levels. While the new BOC Smootharc MultiProcess 180 and BOC Smootharc MIG181 models come with optional spool guns (purchased separately) for added convenience. Two remote power workhorses, Smootharc Advance II MIG250R single-phase and Smootharc Advance II MIG400R three-phase offer MMA capability. Internal toolboxes contain a Binzel MIG torch, regulator, wire feeder, inter-connecting cable, wire feed rollers, gas hose with quick release, electrode holder and work return lead.
As the exclusive distributor of leading German welding brand EWM, BOC now offers two digital, high-end machines: the Tetrix 230 ACDC Comfort 2.0 TIG inverter (with MMA capabilities), and the multi-functional Phoenix 405 Progress Pulse (MIG/MAG with MMA, TIG and arc air gouging functionalities). Peter Kuebler, Technical Manager for Specialised Manufacturing at BOC, said the introduction of EWM patented processes allow users to gain the best possible results when welding: “Our new EWM welding machines offer solutions for the simple task right through to complex automated robotic applications. We offer users gas, equipment and the technical expertise required to get those tricky jobs done.” The new welding models include: • BOC Smootharc MMA 131vrd. • BOC Smootharc MMA 171vrd. • BOC Smootharc Multi-process 180. • BOC Smootharc MIG 181. • Smootharc Advance II MIG250R. • Smootharc Advance II MIG400R. • Tetrix 230 ACDC vrd (EWM). • Phoenix 405 Progress Pulse (EWM). www.boc.com.au
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product news
Salvagnini launches new large-format laser Salvagnini has expanded its product range with the L3 6020, the new laser cutting system for large formats. The L3 6020 is able to process sheet metal with a maximum length of 6,096mm and a maximum width of 2032mm, while retaining the features of the smaller L3 models: high speed and great flexibility over an extremely wide range of materials and thicknesses. Salvagnini’s patented load-bearing beam principle with lightened airplane manipulator has been revised and implemented in this new model too, guaranteeing an extremely rigid structure with even greater stability, without compromising speed or precise and easy positioning. Key factors in the management of such a large machine, such as operator ergonomics and ease of accessibility, are also guaranteed. The six sliding doors on the long side provide easy access to the working area, while the large windows, approved for safe use with solid-state lasers, along with the position of the new control console, offer maximum visibility of the cutting area. Salvagnini has also paid particular attention to the new electrical pallet changeover system: a fast, highperformance system, regardless of the size and weight of the sheet, it has been designed to minimise the risk of issues by transferring the machined material below the raw one.
The result of Salvagnini’s extensive experience in the fibre laser field, the L3 6020 is equipped with a single optics head that provides high-quality cutting across the whole range of workable thicknesses, assuring rapid production changes by eliminating adjustment times. Salvagnini’s patented Dry Cooling technology involves cooling the optics without the use of gas or liquids, and offers real-time control of the lens temperature. The L3 is also equipped with two native cutting functions, Standard and Powercut,
that allow you to choose the operating mode best suited to the different production requirements. Standard mode guarantees greater safety in unmanned manufacturing, while PowerCut offers reactivity and greater operational speed. Both can be easily activated using a toggle switch. The L3 6020 is a productive and versatile solution, with reduced power consumption and competitive operating costs. Its ability to process larger parts offers significant design advantages. www.machineryforum.com.au
Toshiba Machine launches THE400 SCARA robot Toshiba Machine unveiled its new THE400 SCARA robot at the International Robot Exhibition (IREX) 2017, held on 29 November to 2 December at the Tokyo Big Sight in Japan. Alongside the new SCARA model, Toshiba demonstrated its robot programming tool, 3D vision software and models from its six-axis range. Hosting more than 300 exhibitors, IREX is the largest robot trade show in the world. The show provides a platform for robot manufacturers to showcase their latest innovations and demonstrate their technology to the show’s 100,000 visitors.
demonstrating how they could support a 20kg payload and communicate with each other to avoid collisions. The company’s THL500 SCARA model was also on display, which is marketed to price- and energy-conscious users.
Toshiba’s THE400 SCARA model is a highspeed robot designed to help manufacturers meet increasing time-to-market pressures. Toshiba’s demonstration showcased the machine’s fast-cycle automation using a live action display of the robot completing insert movements, as well as circular and linear interpolation movements.
Toshiba’s TVM range, part of its sixaxis offering, was also on display at the show. IREX’s demonstration included the TVM1200, the mid-sized model in the TVM range. The TVM1200 is capable of achieving a maximum reach of 1,418mm, against a 15kg maximum payload. The show also exhibited the unique TVM900, a hybrid in its class with an impressive 20kg payload and a 1100mm reach.
The THE400 is the latest in Toshiba’s extensive range of SCARA robots. The company also exhibited two industrial robots from the powerful TH-A selection, which is specifically marketed for highspeed and heavy-payload applications. The TH1050A and TH1200A, two of the largest in this model type, were on show
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The vertically articulated robot was combined with Toshiba’s latest 3D vision system, TSVision3D. The combination of the passive imaging system with the six-axis robot demonstrates the system’s capabilities as an automated 3D bin-picking
application. “One of the overwhelming things about IREX is the sheer density of visitors,” explained Nigel Smith, Managing Director at industrial robot distributor TM Robotics, which assisted in the Toshiba launch. “The huge number of attendees provides the ideal opportunity for us to showcase our SCARA, Cartesian and sixaxis robot ranges and, importantly, the functionality of the accompanying software. “Our new-generation robot programming tool, TSAssist was demonstrated alongside the machines at this year’s show. The software provides powerful assistance to all types of automation, including planning, installation and enhancement. We’re proud of the easy operation of TSAssist, and IREX provides the perfect opportunity to demonstrate this functionality in action.” www.tmrobotics.com www.toshiba-machine.co.jp
Product news
Cable systems and automation leader Lapp launches in Australia Lapp, one of the world’s leading providers of branded cable and connector systems and integrated electrical and automation engineering solutions, is establishing a fully-fledged subsidiary in Australia. Lapp Australia – headquartered in new 3100sqm premises at Eastern Creek, Sydney – will meet demand nationally for technologies used in future-focussed areas of industry, such as automation, robotics, energy management, data distribution and intelligent manufacturing, buildings, infrastructure and process engineering. Lapp Australia General Manager Simon Pullinger says the new facility – opening in February – will bring new levels of service and choice to the Australian market, offering more than 1,000 product lines onshore as well as direct access to more than 40,000 standard items from Lapp’s global ranges. “We are offering a one-stop shop for highly integrated, efficient and reliable systems which comply with the leading Australian, European and American compliance and quality standards, which are among the most demanding in the world,” says Pullinger. “In addition to major Lapp brands, Lapp Australia will focus strongly on world-class total solutions incorporating highly compatible components from the one source. This integrated approach will save customers time and money when assembling optimum solutions to their particular needs, while ensuring proven reliability in service.” The family-owned Lapp organisation is renowned globally for its levels of quality, innovation and for its commitment to ethical values and service, qualities which it will bring to key Australian markets, including: • Manufacturing and plant engineering, including automation and robotics and process engineering systems. • Electrical engineering systems and energy systems, including wind and solar green energy. • Machine building and machine tools. • Food & beverage. • Automotive, rail and mobility systems. • Intelligent buildings and infrastructure.
• Resources industry, including mining and oil & gas process engineering.
3D Printing High Strength Composite Carbon Fibre
Lapp Australia will work in close cooperation with its established key local distribution partner in Australia, Treotham Automation. Lapp Australia will also extend its strong association with ECS New Zealand, a family-owned business, like Lapp, which has been a Lapp distributor for more than 30 years. Pullinger says Lapp’s investment in a new full subsidiary in Australia is a strong vote of confidence in local industry as it moves into the global industrial automation market, forecast to grow to an annual worth of US$350bn by 2024. “Lapp has delivered its resources, expertise and top-quality German standards to Australia at a time in the country’s industrial development when such support is most needed to prepare diverse industries for a future in which they will use technology to compete cost-efficiently,” he says. “Lapp’s integrated approach to high -technology solutions is also highly appropriate to world-class Australian customers seeking the assurance of top quality products and systems that meet global compliance standards and are fully traceable back to the point of manufacture. “Lapp’s commitments to the markets it enters are always in-depth, long-term and backed by an uncompromising customer focus and dedication to client service.” Pullinger believes the new Eastern Creek facility will provide a strong base for engineering, technical and product support staff, operating in a technology and distribution environment modelled on Lapp’s global facilities supplying more than 100 countries worldwide. These facilities provide fully tailored solutions, service and product backup that are easily accessible to engineers, designers and specifiers.
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1800 632 953 Lapp’s new Australian HQ at Eastern Creek in Sydney. From left to right: Rod Calderon, Marketing & Office Manager; Indy Saggu, Customer Service Executive; Simon Pullinger, General Manager; and Michael De Leon, Warehouse Supervisor.
and discuss how you can print high strength parts instead of milling
EMONA
www.emona.com.au
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ABB unveils new single-arm collaborative robot Building on the success of its YuMi collaborative, dualarm industrial robot, ABB has unveiled its single-arm that combines an impressive array of capabilities with a much smaller footprint ABB previewed its newest collaborative robot, now with a single arm, at the International Robotics Exhibition (iREX) 2017 in Tokyo last November. As their name suggests, collaborative robots are designed to work alongside humans on the factory floor to raise productivity and support the transition to mass customisation. ABB’s new robot will be officially launched in 2018. Like the YuMi small-parts assembly robot, introduced in 2015, the new robot has a payload of 500 grams and, thanks to its compactness, is easily integrated into existing assembly lines, increasing productivity. The new robot also features lead-through programming, eliminating the need for specialized training for operators. “The success of YuMi has exceeded expectations,” said Sami Atiya, President of ABB’s Robotics and Motion division. “It was originally designed for small-parts assembly, but it has turned out to be exceptionally versatile – it can solve a Rubik’s Cube, make sushi, wrap gifts and conduct an orchestra. Based on YuMi’s enormous success, we fully expect our new single-arm robot to be equally well-received, especially since it was developed at the request of customers.” “We continue to build our collaborative robotics portfolio,” said Per Vegard Nerseth, Managing Director, ABB Robotics. “The newest robot is a much anticipated addition to the ‘factory of the future,’ enabling our customers to grow and thrive in the age of mass customisation. Combining this robot with our ABB Ability digital solutions will allow our customers to take efficiency and reliability in their factories to the next level.” www.abb.com
New Freddy Micro Plus – Lighter, more mobile, more cost-effective. The Freddy Micro Plus is the latest member of the Freddy coolant recycling vacuum family. The new Micro Plus is lighter, more mobile, and more cost-effective, offering greater versatility than any other system on the market. The Micro Plus continues on from the very successful Micro which was launched in early 2017. Designed and manufactured in the UK, it is made to the same high standards and specifications that has made the Freddy range a trusted and respected name in coolant recycling. Unlike many alternate systems, the Micro Plus doesn’t use fragile and often unreliable submersible pumps that take up valuable tank capacity and make it incredibly difficult to thoroughly clean. This gives the new machine the ability to take on heavily contaminated liquids without damaging parts or machinery that it comes into contact with. With the ability to pump out rather than have the gravity drain of the Micro, it is now possible to recycle 50 litres of coolant through the machine and back into the sump in just 60 seconds. Available with a 2kW motor, and either a 240v or 110v power source, the motor can generate an airflow rate of 3,000 cubic metres per hour, with a water in-flow rate of 238 litres per minute and an outflow rate of 100 litres per minute. The airflow is switched from vacuum to pressurise in order to force filtered liquids out of the holding tank. It is so powerful the 2kW unit can easily pump out into barrels, intermediate bulk containers (IBCs), or overhead storage tanks. As with the rest of the Freddy range, fluid is filtered through a filter bag, which are available from 1,000um down to 5um to ensure the Freddy Micro Plus captures all contaminants from the machine tool. The new Micro Plus is a cost-effective entry point for coolant recovery and comes complete with a 38mm hose and gulper as standard, with the option to upgrade to a 51mm hose if required, as well as a comprehensive 24-month warranty. “The cost savings of refiltering coolant are enormous,” said Dimac Managing Director, Paul Fowler. “Regular filtering means that the coolant degrades much slower, therefore lasting longer and requiring less to be bought. And because it remains uncontaminated, the associated WHS risks lessen, and your machine tools live longer.
Per Vegard Nerseth and Sami Atiya at the preview of the newest member of the YuMi family at iREX on 29 November 2017.
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“With its remarkably small footprint, 50-litre capacity and weighing less than any previous model, the new Micro Plus is a compact coolant recycling system ideal for smaller businesses. And whichever Freddy you choose, you’re guaranteed outstanding quality, ease of use and most importantly - longevity. We see Freddys that are almost 30 years old come back to our workshop for an overhaul – once completed, we know they will perform for many more years to come.” www.dimac.com.au
An improved design makes the already outstanding Perfomax drill even better. Innovative features – such as a new flute design, wave pattern and laser hardening – add strength, stability and accuracy to ensure consistent performance and dependability for all applications.
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Product News
Hypertherm overhauls its Design2Fab sheet metal layout software Hypertherm has announced the release of Design2Fab 6, a major update of its popular sheet metal layout software for HVAC duct, mechanical, kitchen, industrial roofing, and other specialty fitting layouts. According to Hypertherm, the new version is the most significant Design2Fab update since the software was acquired in 2004. It features an entirely new interface and powerful tools like an advanced modeling engine for its 3D geometric renderings. Better graphics, fluid movement, and real-time updates are further new features that end users will see. Other improvements include easier dimension entry, an unlimited number of zones, easy arrangement of fittings with drag and drop functionality, ProNest nesting software integration, and more.
offers a simple, modern approach that will make it easier to get the job done quickly.”
“We devoted numerous development resources to design and deliver a product unlike any other Design2Fab version in the past. It’s powerful yet simple to use,” explained Product Manager Steve Bertken. “The main screen is clean and elegant, so instead of having multiple screens with a multitude of buttons, the new Design2Fab 6
Engineered to dramatically reduce the time it takes to develop and lay out flat patterns, Design2Fab is known for its superb versatility. It allows users to create both HPGL and DXF output formats. They can use a plotter to print an HPGL layout for manual cutting or use a CNC cutting machine to produce fittings from the DXF files. In addition, prior to CNC cutting, users can export the DXF files to ProNest, ProNest LT or ProNest LTS nesting software for optimal material utilisation. Current Design2Fab users with an active Software Subscription can upgrade to the new version at no additional charge and continue to receive unlimited technical support, and other benefits. www.hyperthermcam.com
SigmaTEK Releases SigmaTUBE X1 SigmaTEK Systems has released the latest version of its automated tube-cutting CAD/CAM software SigmaTUBE X1, with a range of new features and significant improvements. SigmaTUBE helps tube fabricators complete mission-critical work. It is a complete tube cutting solution for four, five and six-axis cutting machines that automatically processes and programs entire assemblies. SigmaTUBE is fully integrated inside SolidWorks and is capable of programming all tube shapes and sizes. The fastest full assembly processing tube software on the market now has even more added features with the release of SigmaTUBE X1. The new Best Stick Nesting feature is a 1D nesting option that gives users the best overall yield possible based on their stock selection. You can either select Best Stick Fixed to use a single length stock or you can choose Best Stick Mixed to allow mixing and matching. SigmaTUBE X1 has also expanded the functionality of the new Best Stick Nesting feature into the Nest Calculator tool. The new SigmaTUBE Nest Calculator is a material optimisation tool that calculates the ideal stock length for a task. Using the minimum and maximum length and allowed increment, the calculator displays a complete stock comparison,
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which shows you the lengths that yield the highest utilisation percentage. This is also a tool that fabricators can use for quoting, to determine how much stock you need to complete a job prior to programming. SigmaTUBE X1 also offers a Single Pierce Open Section Toolpath for channel and angle profiles. This option interpolates cuts on sharp corners, allowing a single toolpath to be used for the end cuts. Basically, this option provides a single cut rather than
multiple passes, decreasing cut times. Dakota Baird, SigmaTUBE Product Manager, is excited about the new features and improvements in SigmaTUBE X1, stating: “Our SigmaTUBE customers drive the direction of our product and we are committed to providing users with the best possible solution for their needs.” www.sigmanest.com
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Naval Shipbuilding Bringing manufacturers into the digital era.
The Federal Government hopes its $90bn Naval Shipbuilding Plan will provide much-needed stability and certainty to the Australian shipbuilding industry. It also offers the potential to drag Australian manufacturers into the Fourth Industrial Revolution. By Brent Balinski. Set to run well past 2040, the three-part, continuous build program will include 12 submarines, nine frigates and 12 offshore patrol vessels (OPVs). Canberra hopes it will do away with the cyclical, feast/famine nature of the sector, allowing it to build up muscle tissue, target export markets, and improve the digital literacy of the small and medium enterprises (SMEs) involved. As Prime Minister Malcolm Turnbull put it, when the winning Future Submarine bid was finally announced in 2016: “The spin-offs to the rest of the economy will be immense.” The nature and magnitude of spinoffs from this “generationslong national endeavour” of naval work will be known later. However, the efforts needed to grow the SMEs (there are an estimated 3,000 SMEs in the sector, according to the Defence Industry Policy Statement) that will support the endeavour are already underway. The Australian Manufacturing Growth Centre has described the submarine project, properly approached, as offering a “moonshot opportunity” for the country’s manufacturers. Get them up to the high standard required as suppliers, and those skills become vastly valuable beyond the confines of the project itself.
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“All of the big shipyards are quite advanced regarding Industry 4.0 approaches to manufacturing, and they have to be, given the complexity of their systems,” says Michael Haddy, Deputy Director – Victoria, South Australia and Tasmania, at the AMGC. “Historically our SMEs are not particularly large, and their traditional markets haven’t been necessarily as sophisticated as some of these international companies.” As with other parts of manufacturing, Australia’s defence SMEs could benefit from being more to the medium-sized rather than small side of the description. Regardless, they are recognised as essential to the ambitious shipbuilding program, with key enablers identified as infrastructure, workforce, industrial ecosystem, and a national approach. Bringing them up to international standard will be a spillover benefit, says the Naval Shipbuilding Plan, and success will include “...an industry that has seized the opportunity to integrate into global supply chains and is able to take advantage of export opportunities in niche export markets”. One effort aimed at assisting this is a Virtual Shipyard project,
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supported by the AMGC, the South Australian Government, industrial software giant Dassault Systemes, and others. A group of 16 SMEs in South Australia will go through a sixmonth curriculum and then six months of mentorship, aimed at bridging digital capability gaps. The goal is to ready these companies – including Redarc, B&R Enclosures, and Mincham Aviation – to serve in the supply chains of naval Primes and other multinationals, in sectors such as defence, energy and health. The first eight began the program in October, with the second cohort scheduled to start in April. “This isn’t just defence,” says Michael Grogan, the AMGC’s Director – Victoria, South Australia and Tasmania. “This can be applied to any of these manufacturing processes; [for example] it’s very similar to some of the disciplines from automotive. This is going to become more and more important in mining, and some of the other major industries.”
value management on Dassault’s product lifecycle management dashboard. According to the AMGC, the program will not lock its participants into this proprietary solution. “It’s about the skills that go around the software, and [these] could be applied to a competitor’s software platform,” adds Haddy. “There’s a lot more to it than just training them for a particular piece of software.” There will be further programs to help digitise the operations of smaller manufacturers. “Industry 4.0 is a non-trivial jump for a lot of SMEs, and really this is one of the first of a number of programs we hope to establish in the coming months and years to assist SMEs nationwide,” says Haddy. Contiuned next page
Each company trains in up to 12 categories, including issues management, production scheduling, quality assurance and
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“What I see on top of this, regarding adopting new technology across Industry 4.0 and all the different buzzwords of technology, is really the digitisation of different systems and processes end to end for many different industries,” he adds. “That starts from shipbuilding and submarines to mining industries, to aerospace and defence, space. Really across all industries is what I see South Australia looking at. So it’s not just shipbuilding, and it’s not just digital submarines.” Masaki “Sox” Konno, Dassault Systemes’s Managing Director for AP South.
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End-to-end digitisation The Virtual Shipyard program is about South Australia reassessing itself and its industry and preparing itself for a digitised future, according to Masaki “Sox” Konno, Dassault’s Managing Director for AP South. The naval focus is just a means to this end. Dassault will establish its Australian headquarters in the state this year, and has offices in Sydney, Melbourne, Perth and Brisbane. Its relationship with Australian shipbuilding goes back over a decade, with ASC (formerly the Australian Submarine Corporation) upgrading its old Enovia software in 2016 for Dassault’s 3D Experience product lifecycle management dashboard. The company’s biggest market in the Australian market is in mining software, says Konno. Future Submarines builder Naval Group (then DCNS) began a partnership with Dassault in February 2016, and has continued to build the naval customer base since for its 3D Experience platform, which includes “3D design, analysis, simulation and intelligence software”. Within Konno’s region, Industry 4.0 capability-building projects have been focussed around the automotive supply chain. Being digitally literate enough to meet the needs of Tier One companies is a highly translatable thing across industries, he says.
Being able to create a virtual, 3D-modelled environment, with a “digital twin” of everything made, was a huge benefit to manufacturers in the supply chain and within companies. Within an organisation, according to Konno, combining ideas and intelligence from different departments, based on 3D data, was “the secret sauce” of innovation. “It’s having a platform able to handle scientific data, engineering data, unstructured data, images, CAD files, simulation data, etcetera,” he explains. “Incredible amounts of data, and being able to really exaggerate that and have it at people’s fingertips and being able to share that with each other.” Konno declines to talk in specifics about the capability levels of participants – who each went through an assessment of requirements – or where the capability gaps are. For those in the program and Australian industry in general, he believes there will be opportunities worth targeting in sectors ranging from the marine and offshore industry, supplying the needs of “smart cities”, and in an increasingly digitally literate architecture, construction & engineering (ACE) market. “Mining for sure is one industry that’s gone through a lot of changes, but in the past year the industry is serious about reinventing themselves and adopting technology,” he notes. “I would say another one is the ACE space: very traditional in the way they’ve done things, but the ability to use digitisation end-to-end, to relook at their processes, see if they can manufacture smarter, better, bringing buildings faster to market with high levels of compliance and quality. I think you’ll see that industry change quite a lot as well.”
B&R Enclosures B&R specialises in manufacturing enclosures, racks and cabinets made from a variety of sheet metal materials, to provide safety to people and protection of equipment. The company, says General Manager Chris Bridges-Taylor, “is seeking to develop their Industry 4.0 methods to achieve an agile, competitive and integrated response to meet customer needs and requirements”.
Being able to create a virtual, 3D-modelled environment, with a “digital twin” of everything made, brings huge benefits for manufacturers. (Images courtesy of CMN)
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The family-owned business, founded in Adelaide in 1955 (it is headquartered in Brisbane nowadays) comprises four separate divisions, each serving a different sector. There is a strong focus on industry-specific knowledge across the business, as well as the ability to deftly respond to a customer’s requirements. Defence work makes a small but meaningful contribution to revenues, and B&R has been a part of projects including the 23rd Squadron RAAF Base Amberley, the Department of Defence Data Centre Migration to Global Switch Data Centre, and the Battlefield Airlifter Phase 2, C and D. Among its accreditations and certifications is the SCEC (Security Construction and Equipment Committee) approval for its range of Class C and Class B security cabinets.
Chris Bridges-Taylor, General Manager at B&R Enclosures.
Defence & Aerospace Headquartered in Brisbane, B&R Enclosures comprises four separate divisions, each serving a different sector.
“We have currently only participated in small work projects, except in the data cabinet area,” Bridges-Taylor explains, adding. “This sector is strategically important to B&R and defence work is something we are hoping to see more of.” According to Bridges-Taylor, the Virtual Shipyard project represents “an important opportunity for us to gain knowledge and experience of the Dassault 3D Experience platform, which is about digital continuity, the reuse of information, and collaboration”. “From the early discussion with a customer there are requirements, both technical, supply chain, and commercial through to the development product lifecycle delivery and after-supply service,” she adds. For B&R, digitalising operations is essential for any Australian manufacturer that wants to be internationally competitive, enabling profitable high-mix, low-volume production. B&R is also currently part of a collaborative project for an agility-boosting Industry 4.0 application at its Brisbane site, enabling transparency throughout production and being able to re-prioritise different work orders on the go. Bridges-Taylor says the Virtual Shipyard program is an excellent educational opportunity and will lead to further trials of digital manufacturing concepts at the company. “It’s a major commitment,” she adds. “And it is worth doing because of the knowledge that we’ll gain and the opportunities presented, is consistent with our Industry 4.0 strategy.”
Redarc Committing as a supplier to defence projects is a long-term project, requiring investment in resources, as well patience to learn a new market and a new language, believes Dr David Murfett, Engineering Manager and Defence Liaison at Redarc Electronics. “It’s something you need to invest in very, very heavily upfront to get any sort of long-term payoff,” he says. “Each tender you receive is packaged in a different way. It’s framed with different expectations. All of these things add to quite a high burden for an SME, upfront, to be able to adequately respond to the Prime and understand what it is that they’re seeking.”. Redarc is a successful, fast-growing electronics manufacturer, best known for its power solutions for vehicles, which have seen it land awards such as Telstra Australian Business of the Year in 2014 and the Endeavour Awards Manufacturer of the Year in 2017. Its 2015 five-year plan involves doubling revenues of $50m by 2020. Plans to continue its growth trajectory include a hefty R&D spend (15% cent of annual revenues), growing exports, acquisitions, and moving into newer areas such as defence and medical. It is currently in the process of adding a 2,000sqm expansion to its Lonsdale factory, expected to be complete in mid-to-late 2018. The company has achieved some early successes in defence by taking existing automotive-grade COTS (commercial off-the-shelf) technology and adapting it into MOTS (military off-the-shelf) gear. Defence vehicle projects include the Land 106 (M113AS4) and Land 121 Phase 4 (Hawkei) programs.
Redarc’s factory in Lonsdale, SA.
More recently Redarc has been targeting maritime work, starting with the Future Frigates program. In November it signed an MoU with naval systems integrator Raytheon Anschutz, initially for Australian projects, which will ideally lead to work within the German company’s supply chain.
Dr David Murfett, Engineering Manager and Defence Liaison at Redarc Electronics.
Digital capability is an important area for Redarc, says Murfett, and the company has invested in strategic advice from organisations such as Germany’s Fraunhofer Institute to this end. He likens it to other methodologies the company invests in to keep the local workforce competitive, such as sending staff to Japan to learn Lean manufacturing ideas from the best. “As we expand the organisation we’re investing in equipment, investing in equipment that is Industry 4.0-ready,” explains Murfett. “And likewise we are investing in the systems for the organisation, be it ERP or PLM or any of these other manufacturing control systems. “We’re certainly making sure that we’re with programs that are available to us to be able to understand the world’s best practice.” According to Murfett, the Virtual Shipyard program “certainly parallels” previous investments in training. “It provides Industry 4.0 capability, PLM capability, it provides a common platform between the different parties who are using that tool,” he says, adding that it will benefit the ambitions of being an international-level company. “And we certainly seek to be a globally recognised organisation, an organisation that can deal and talk with global partners, such as the Primes in defence, or with the global automotive manufacturing we’ve been [involved in] for many years.” The Virtual Shipyard project and other Industry 4.0-related efforts will help Redarc meet a market described elsewhere as “if it’s got a battery and it moves, it’s a customer”. Murfett thinks 2018 will be an exciting year for his company and to be an engineer working in manufacturing in South Australia. Redarc will be eagerly watching the expected Future Frigates and LAND 400 announcements, and is a teaming partner for both projects. “For those and other programs we are very keen to see the work commence, understand better how we can then invest in ourselves and in those programs, and to be able to contribute our part to making those programs the best they can be,” says Murfett. “I think that it is going to be a very exciting next couple of decades to be an engineer in this state.” www.defence.gov.au/navalshipbuildingplan www.amgc.org.au www.3ds.com/anz www.brenclosures.com.au www.redarc.com.au
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FIrst Cooperative Research Centre for Defence announced On 18 December, Christopher Pyne, the Federal Minister for Defence Industry, announced the formation of the first Defence Cooperative Research Centre (CRC) for Trusted Autonomous Systems, with inaugural participating members: BAE Systems Australia, RMIT University, DefendTex and the Department of Defence, represented by Defence Science and Technology Group. Minister Pyne said the Defence CRC is being set up under the Next Generation Technologies Fund, with $50m invested over seven years to deliver trustworthy smart-machine technologies for new defence capabilities based on advanced human-machine teaming concepts. “The Defence CRC establishment is based on a sound formation plan developed by Chair Jim McDowell in collaboration with a panel of independent experienced experts from industry, academia, Defence and the UK Defence Science and Technology Laboratory,” said Minister Pyne. “I thank the panel for their expert advice in shaping the Defence CRC ,which will play a vital role in giving Defence a game-changing capability.” The expert panel included former Australian Chief Scientist Ian Chubb, Professor Hugh Durrant-Whyte, the UK Defence Ministry’s Chief Science Adviser, Air Vice Marshall Neil Hart (Retd), and Paul Merrow, former CEO of GD Defence Australia. “Additional companies and universities will join as participating members and research partners as the Defence CRC grows and takes on more projects,” Minister Pyne added. “Initially, there will be three Defence CRC research projects led by BAE Systems, Thales Australia and Lockheed Martin in the land, maritime and aerospace domains.” “This has been a good start to rapidly form a Defence CRC with a totally novel formation process and to do it on schedule,” added McDowell. “Our focus as we move forward will be industry-led projects with real translation opportunities to move technology rapidly from universities into industry and ultimately into leading edge capability for the Australian Defence Force.”
Multi-million-dollar tech hub for Queensland Minister Pyne also announced that, as the outcome of a competitive process, the headquarters of the Defence CRC for Trusted Autonomous Systems will be located in Queensland. “This announcement is great for the state of Queensland, and clearly proves that our biggest build-up of defence capability in our country’s history is truly a national endeavour,” Minister Pyne said. “Ongoing discussions are also taking place with Boeing Australia and Data61 for their future involvement in the Defence CRC for Trusted Autonomous Systems. I look forward to the first Defence CRC making a significant impact on capability with advances in autonomous systems.” The Queensland State Government welcomed the Federal Government decision to back its bid to host the CRC. Queensland will contribute a Brisbane-based headquarters for the CRC, worldclass testing ranges, support research and technology projects, support industry to develop standards for autonomous systems and the development of platform technologies for unmanned aerial systems. State Innovation Minister Kate Jones said the location of this Centre in Queensland was a vote of confidence in the state’s world leading innovation and technology capability. “This centre will draw together industry, researchers and local businesses to work with Defence to develop new technologies for drones and other unmanned vehicles,” said Minister Jones.
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“This will develop critical mass in key technologies like artificial intelligence, robotics, and autonomous vehicles and will position Queensland as a global leader in these areas.” State Development Minister Cameron Dick said Premier Annastacia Palaszczuk’s Government recognised that defence was a critical industry for the state, employing approximately 6,500 workers. In 2015-16, Queensland companies were awarded more than $4.2bn in Australian defence contract payments. “The Government committed during the election campaign to this bid and to the creation of Defence Jobs Queensland – recognising that the defence industry can generate jobs and business for Queensland,” said Minister Dick, adding that an important feature of the proposal would be to develop sites for testing, trials and evaluation of drones. “We will invest in test facilities, including large drone zones in regional Queensland — both aerial and marine —as part of the CRC.’’ Both Ministers recognised the capability that global companies like Boeing, and small companies like EPE and Nova Systems, contribute to Queensland’s leading technology in this area. “Our supply chains in Queensland are a major asset both for the Defence Force and for Queensland,” said Minister Dick. “The Queensland Government is proud to have the Queensland University of Technology, University of Queensland, and Griffith University as key partners in this bid,” added Minister Jones. “The bid is also supported by capacity across all other universities in Queensland. This technology will have application not only in defence but in using drones in areas like agriculture and environment.” www.defenceindustry.gov.au
Defence & Aerospace
New strategy for South Australia’s defence industry The South Australian Government has announced a new strategy that it believes will usher in a new era of investment, export opportunities and high-tech collaboration for defence industry in the state. The opportunities – outlined in the South Australian Government Defence Strategy: 2030, announced in December – follows three years of advocacy for local industry and workers as partners in major defence infrastructure projects. The strategy outlines measures to accelerate defence investment, create export opportunities and grow its highly-skilled defence workforce. It positions the state as a national leader in innovation as it works to create more high-tech jobs over the next decade and beyond. Defence and Space Industries Minister Martin Hamilton-Smith launched the new 13-year defence plan at the Adelaide office of Boeing Defence Australia, which has grown its workforce at an accelerated rate since signing a partnership agreement with the state government in April. The company is on track to create 250 jobs by the end of 2021, with 60 people currently developing technologically-advanced, innovative and sustainable defence capability for the state. The revised strategy follows a comprehensive review of the state’s defence priorities, prompted by major policy and project announcements in the sector. It reflects changes in the defence landscape, including the release of the 2016 Defence White Paper and the Naval Shipbuilding Plan, the announcement of major projects and a national space agency, and growth in new high-tech areas. Under the strategy, South Australia aims to establish itself as a leader across space, systems and cyber, and defence science and research. Major defence and shipbuilding projects are projected to create an estimated 6,000 direct jobs in the state, plus hundreds
more supply chain opportunities, over the next 10 years. The state’s space industry will also grow significantly, with its current 800-strong workforce expected to double in the next seven years. South Australia released its first ten-year defence strategy in 2003, focusing on four key sectors: maritime, aerospace, land and electronics. It was revised in 2007 when Defence SA was established and most recently in 2015. “South Australia continues to be at the forefront of innovation, cuttingedge technology and defence capabilities,” said Minister HamiltonSmith “And this strategy ensures we maintain our competitive edge in new growth areas while building the state’s highly-skilled defence workforce over the next decade. Boeing is a terrific example of the high-tech companies we want to attract to South Australia to create more highly-skilled jobs in defence and new growth areas – a key priority in our new strategy. “This strategy provides a clear direction to invest in our defence future and build a strong and capable workforce. Our vision to be the nation’s Defence State is now a reality, and it’s important for us to remain competitive through innovation and new technology.” Boeing Defence Australia Managing Director Darren Edwards added: “Boeing Defence Australia is proud to play an active role in expanding the defence industry in South Australia. South Australia’s investment in cutting-edge technology and business aligns with Boeing Defence Australia’s innovation culture. There is a clear focus here to invest in innovation, commercialise research and build global business and export opportunities.” www.defencesa.com
Boeing appoints Mark Donaldson VC as Defence Advisor Australian Army veteran and Victoria Cross recipient Mark Donaldson has joined Boeing Defence Australia as a strategic Defence Advisor. Following a near 15-year military career, Donaldson’s knowledge and experience will support the Australian aerospace company’s continued growth. Darren Edwards, Vice-President and Managing Director at Boeing Defence Australia, said Donaldson was a strong addition to the company’s growing veteran workforce. “Donaldson’s strategic counsel will be invaluable as we continue to find solutions that meet the current and future needs of the Australian Army and its role in an integrated fifth generation defence force,” said Edwards. “The reason we excel is because of our people, and Boeing knows that veterans make us better.” Donaldson was awarded the Victoria Cross when he exposed himself to enemy fire to protect injured troops and rescue an interpreter under heavy enemy fire while serving with the Special Air Service Regiment (SASR) in Afghanistan. Donaldson said he was excited to take on a new
challenge in an industry close to his heart. “Boeing Defence Australia has given me the opportunity to continue to serve my country, ensuring the men and women that defend our nation have the best platforms, tools and services they need to get the job done,” said Donaldson.
Mark Donaldson (left) and Darren Edwards, Vice-President and Managing Director at Boeing Defence Australia.
Boeing Defence Australia is an Australian aerospace enterprise providing leading solutions for the Australian Army including the LAND 2072 Phase 2B Project Currawong, CH-47 Delivery and Operational Maintenance Support, Army Aviation Training and Training Support and the Helicopter Aircrew Training System. With a world-class team of more than 2,000 employees at 14 locations throughout Australia and three international sites, Boeing Defence Australia supports some of the largest and most complex defence projects in Australia. www.boeing.com
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Innovative approaches to cutting aircraft maintenance costs Laser cladding technology is fast becoming a preferred process for the repair and refurbishment of metal aircraft parts damaged due to wear, corrosion, stress, or impact, as it can reduce replacement costs, shorten turnaround times and even improve structural integrity extending part life. As a world leader in laser cladding technology, RUAG Australia was successful in 2016 in winning a highly competitive Capability Technology Demonstrator (CTD) grant from the Commonwealth Government to develop a new laser repair technology using Direct Energy Deposition where powdered metal is applied under controlled conditions. With a track record of research and development in additive repair technologies RUAG’s research and innovation team have already successfully developed an alternative technology for the rapid repair of corroded, worn and damaged components using a cold spray technique, known as Supersonic Particle Deposition. The process is currently being used to restore structural integrity of corroded panels on aircraft. The recent CTD grant focuses on laser deposition of hard steels used in aircraft structures, such as SS4340 and 300M, to develop a rapid repair technology for the recovery of corroded or worn structural parts.
RUAG Austalia has extensive experience in aircraft repair
Corrosion is recognised as a significant contributor to the lifecycle cost of defence aircraft; in March 2017, the Minister for Defence Industry Christopher Pyne estimated that the cost of aircraft corrosion to the Australian Defence Force was around $254m a year. This underlines the importance of research and innovation into techniques that could make significant reductions to repair costs. However, Australia is not alone. In 2008, in response to concerns over the high cost of corrosion, the US Congress enacted legislation to encourage the prevention and mitigation of the effects of corrosion on military equipment and infrastructure. This concern was borne out in a 2013-14 review detailing the continued increase in the costs of corrosion repair and maintenance for US Air Force aircraft and missiles, which placed the total bill at US$6bn. The CTD grant has allowed RUAG to purchase a Laserline LDF 4000-30 from Raymax Applications in Sydney for use in its project. Aside from the system containing the required specifications, and the company’s willingness to meet RUAG’s particular requirements, Laserline has a proven track record in Australia in additive processes, being used for the repair of large components in applications ranging from oil rigs, to turbine shafts and heavy field equipment. Led by research and technology engineer Nicolas Orchowski, the CTD project is being undertaken at the RUAG Australia research and technology department in Bayswater, Victoria, and is highly focused on aircraft parts. All aircraft components are subject to certification conditions that determine their ‘life-limit’ – specified as the operational time or number of operational cycles, or the number of times a part can be serviced before replacement. The project’s focus is on using additive deposition for recovery of worn, damaged or corroded aircraft parts, the aim being to improve part integrity and restore lost material eventually returning the part to its original design specification. The project is currently well under way, with the Laserline system installed and operating effectively. Comprising two fibre laser outputs, a CCD camera and an optical pyrometer for closed loop control and process monitoring, the Laserline system uses a uniquely designed nozzle that simultaneously dispenses metal powder and inert gas along side the laser beam allowing accurate deposition at a very high heat. Metal fusion occurs in a small, localised area, resulting in minimal heat
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The R&D project in operation, showing the Laserline system with the uniquely designed nozzle mounted on a robotic arm.
effects to the original stratum, while the bonding process increases the strength of the fused area. As with all Laserline installations the RUAG process occurs remotely via a robotic arm that guides the nozzle on its prescribed path via a computer program. Sitting alongside the robotic arm, Orchowski says he is happy with the progress of the project and pleased he can call on support at any time from Dr Cédric Chaminade, a laser physicist from Raymax Applications, now that the system is up and running. www.raymax.com.au www.ruag.com.au
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Defence & Aerospace
Airbus, Rolls-Royce, Siemens team up for electric future Airbus, Rolls-Royce, and Siemens have formed a partnership aimed at developing a near-term flight demonstrator that will be a significant step forward in hybrid-electric propulsion for commercial aircraft. The three companies announced the groundbreaking collaboration, bringing together some of the world’s foremost experts in electrical and propulsion technologies, at the Royal Aeronautical Society in London. The E-Fan X hybridelectric technology demonstrator is anticipated to fly in 2020 following a comprehensive ground test campaign, provisionally on a BAe 146 flying testbed, with one of the aircraft’s four gas turbine engines replaced by a two megawatt electric motor. Provisions will be made to replace a second gas turbine with an electric motor once system maturity has been proven. “The E-Fan X is an important next step in our goal of making electric flight a reality in the foreseeable future,” said Paul Eremenko, Chief Technology Officer at Airbus. “The lessons we learned from a long history of electric flight demonstrators, starting with the Cri-Cri, including the e-Genius, E-Star, and culminating most recently with the E-Fan 1.2, as well as the fruits of the E-Aircraft Systems House collaboration with Siemens, will pave the way to a hybrid single-aisle commercial aircraft that is safe, efficient, and cost-effective. We see hybrid-electric propulsion as a compelling technology for the future of aviation.” The E-Fan X demonstrator will explore the challenges of high-power propulsion systems, such as thermal effects, electric thrust management, altitude and dynamic effects on electric systems, and electromagnetic compatibility issues. The objective is to push and mature the technology, performance, safety and reliability, enabling quick progress on the hybrid electric technology. The program also aims at establishing the requirements for future certification of electrically powered aircraft while training a new generation of designers and engineers to bring hybridelectric commercial aircraft one step closer to reality. As part of the E-Fan X programme, the three companies will each contribute experience and know-how in their respective fields of expertise: • Airbus will be responsible for overall integration as well as the control architecture of the hybrid-electric propulsion system and batteries, and its integration with flight controls.
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Dr Frank Anton, Head of Siemens eAircraft; Mark Cousin, Airbus Head of Demonstrators; and Paul Stein, Rolls-Royce CTO.
• Rolls-Royce will be responsible for the turbo-shaft engine, two-megawatt generator, and power electronics. Along with Airbus, Rolls-Royce will also work on the fan adaptation to the existing nacelle and the Siemens electric motor. • Siemens will deliver the two megawatt electric motors and their power electronic control unit, as well as the inverter, DC/DC converter, and power distribution system. This comes on top of the E-Aircraft Systems House collaboration between Airbus and Siemens, launched in 2016, which aims at development and maturation of various electric propulsion system components and their terrestrial demonstraion across various power classes. “The E-Fan X enables us to build on our wealth of electrical expertise to revolutionise flight and welcome in the third generation of aviation,” said Paul Stein, Chief Technology Officer at RollsRoyce. “This is an exciting time for us as this technological advancement will result in Rolls-Royce creating the world’s most powerful flying generator. “Siemens has been driving innovation in core technology fields at full speed,” said
Roland Busch, Chief Technology Officer of Siemens. “In April 2016 we opened a new chapter in electric-mobility with the collaboration with Airbus. Building up electric propulsion for aircraft, we are creating new perspectives for our company and also for our customers and society. With the E-Fan X partnership, we now take the next step to demonstrate the technology in the air.” Among the top challenges for today’s aviation sector is to move towards a means of transport with improved environmental performance that is more efficient and less reliant on fossil fuels. The partners are committed to meeting the EU technical environmental goals of the European Commission’s Flightpath 2050 Vision for Aviation (reduction of CO2 by 75%, reduction of NOx by 90%, and noise reduction by 65%). These cannot be achieved with the technologies existing today. Consequently, Airbus, Rolls-Royce and Siemens are investing in and focusing research work in different technology areas including electrification. Electric and hybrid-electric propulsion are seen today as among the most promising technologies for addressing these challenges. www.airbus.com www.rolls-royce.com www.siemens.com
Defence & Aerospace
Lovitt Technologies – Flying high on global stage Victorian State Parliamentary Secretary for Industry and Employment Vicki Ward visited Lovitt Technologies Australia in December to meet workers and to see the progress in the company’s $1.5m capability expansion project under the Future Industries Manufacturing Program. The Montmorency-based aerospace and defence company has been able to win lucrative global contracts and create new local jobs thanks to support from the State Government. As part of the Future Industries Manufacturing Program, Lovitt Technologies has taken on five new workers and acquired advanced manufacturing technology, including a next-generation computer to create precision aerospace components. The cutting edge technology has allowed the company to extend and secure major new contracts with clients in the aerospace industry such as Boeing and Lockheed Martin. Lovitt Technologies was established in 1954 to manufacture tooling for Australia’s automotive industry. Over the ensuing six decades it has evolved continuously, anticipating the eventual decline of Australian car-making and acting decisively by branching into fields as diverse as communications, defence and food & beverages. Primarily, however, the company has developed a strong niche in the field of aerospace over the last 20 years. Today, aerospace components account for around 95% of the company’s business. In the commercial aviation sector, the company is a key supplier to Boeing, manufacturing parts of the trailing edge for the most technically advanced commercial aircraft in the world – the Boeing 787 ‘Dreamliner’. It also produces components for the 747 and 737 airliners. It also supplies some components for smaller commercial aircraft such as the Gulfstream private jet.
Parliamentary Secretary for Industry and Employment Vicki Ward, and Bruce Ramsay, Manufacturing Director at Lovitt Technologies.
In the defence space, the company supplies the floor structure, bulkheads and the engine mounts for the Lockheed Martin F-35 Lightning II joint strike fighter (JSF), as well as parts for the Boeing F/A18 Hornet and F15 Eagle fighter jets, the V-22 Osprey V/STOL military transport aircraft, P-8 Poseidon and the CH-47 Chinook helicopter. From its manufacturing facility in Montmorency, Lovitt Technologies produces a diverse range of complex structures, working primarily in aluminium and titanium – metals that are vital in aerospace applications owing to their lightweight properties. The company specialises in machining highly intricate components, with an emphasis on diagonal lines and slanted planes – characteristics that instil a greater degree of strength in a component than simple right angles would.
Supporting the Victorian economy Transport, defence and construction technologies are a priority sector under the Future Industries Fund, which supports high-growth industry sectors that are critical to the Victorian economy. The State Government has committed over $100m in manufacturing support, which has created more than 3,000 jobs resulting in $939m in private investment. “Our support for Lovitt Technologies has taken them to the world stage – creating jobs for locals and boosting our credentials as a world-leader in manufacturing,” said Ward. “The company has grown in recent years, creating more jobs for Victorians and boosting our manufacturing sector.” www.business.vic.gov.au/fimp www.lovittech.com.au
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NSW teens control NASA robots on the International Space Station In the early hours of 12 January, teams from five New South Wales high schools watched as computer code they had written was used to control NASA robots inside the International Space Station (ISS). The students gathered with parents, teachers and space enthusiasts to watch the 2017/18 championships of the Zero Robotics international high school programming competition, organised by NASA and Massachusetts Institute of Technology (MIT). The competition was live-streamed across the globe, including at an on-campus University of Sydney event. The Zero Robotics competition challenged students to test their coding skills on basketball-sized NASA robots known as SPHERES (Synchronized, Position Hold, Engage, Reorient Experimental Satellites), which float in zero gravity in the ISS. The competition progressed through multiple rounds of increasing complexity during 2017 before culminating in the final championship event in January, which saw the code that was written by the students being used to move the robots inside the space station, racing against robots controlled by students around the globe, to complete a set of tasks. The NSW schools – Gosford High School, James Ruse Agricultural High School, Mosman High School, Sydney Boys High School and Sydney Technical High School – beat more than 200 schools from around the world to make it to the finals event. Sydney Boys High School and Sydney Technical High School performed particularly well in the competition, making it to the semi-finals but narrowly missing out on progressing to the Championship Match. James Ruse Agricultural High School took out first place in the Zero Robotics Virtual Championship, a separate competition in which teams who hadn’t made it to the Zero Robotics Championship finals got the chance to compete virtually with one another. As one of the top two teams in the virtual competition, the students still got to see their code used to move the SPHERES in the ISS. The students said they were “ecstatic” to have won the virtual title. As part of its STEM outreach activities, the University of Sydney supported more than 300 Year 9-12 students from 56 high schools across NSW in the Zero Robotics competition. This year, the competition was expanded to allow more high school
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The James Ruse Agricultural High School team with former NASA astronaut Greg Chamitoff.
students to participate (up from 20 schools last year), including, for the first time, schools in rural and regional areas such as Orange and Kew. Sixty current University of Sydney Engineering and IT students and recent graduates volunteered to mentor the high school students this year. Over nine months, mentors guided the teams through the process of learning the computer code, maths and physics behind the motion of the robots, while also helping students develop valuable soft skills including teamwork, effective communication and international collaboration. In the finals, teams were made up of international alliances of three schools, who had to work together across cultural, language and time-zone challenges to develop their code for the competition. “Participating in Zero Robotics allows high school students to advance their skills in engineering, science, maths and computing – and in previous years we have seen some of these students be inspired to continue studying these subjects at university,” said University of Sydney Executive Director of Space Engineering Warwick Holmes. “With the Australian government recently announcing plans to establish our nation’s own space agency, these competing high school students could very well be among Australia’s first generation of local space engineers. “Zero Robotics proves that
Three SPHERES robots on the International Space Station.
anyone, of any age, can learn to code if you’ve got the drive to learn,” said Zero Robotics competition coordinator Penny Player, who is studying mechatronics engineering and physics at the University of Sydney. “Zero Robotics offers students that motivation – it’s just like playing a video game, except that it’s actually happening in real life, in space.” This is the third year Australian schools have competed in Zero Robotics. In 2016, one school team (Normanhurst Boys High School) reached the finals. In 2017, teams from North Sydney Boys High School and Gosford High School took out second and third place respectively in the competition. Three other teams – from Barker College, Fort Street High School and James Ruse Agricultural High School – also reached the finals. www.nasa.gov www.sydney.edu.au
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Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result Metal additive manufacturing technology from Renishaw has helped a team of students from Swinburne University of Technology in Melbourne to record the University’s highest overall score in the latest Formula SAE competition. As well as being placed sixth overall, the highest position for a team from Swinburne, the car recorded some of the fastest times in the speed trial part of the competition. Formula SAE is a competition organised by the Australian branch of the Society of Automotive Engineers in which teams of students produce a prototype for a single-seat racing car and present it to a hypothetical firm for manufacture. The cars compete in a series of track tests. In addition, the teams are judged on the design and cost-efficiency of the car, and on a marketing presentation about their project. Along with the practical experience gained, the programme gives students the opportunity to work together in a dedicated, multi-disciplinary team to produce an impressive vehicle for the competition. The skills of the team are pushed to the limit to ensure that the design and the manufacturing methods used are innovative and robust. The team from Swinburne is made up of students in engineering, design and commerce, who work together to design, build, market and race their car. In 2010, the University was one of the first to enter an electric car in the competition. It has continued to race electric cars in subsequent years.
The challenge The fundamental problem in racing an electric car against petrol competition is the
weight of the batteries. This means that the weight of all the other components must be minimised to make the car competitive. Team Swinburne is always looking for ways to reduce weight, including being one of only a few teams to base its car on a carbon-fibre chassis, which is built at the University. Following the 2015 competition, the team undertook a detailed calculation of the energy used by the car in the various trials. One of the findings of this analysis was that the rotational inertia of the wheels during acceleration and braking was using much more energy than expected. Ryan Wise, the Dynamics Section Leader for Team Swinburne, was given the brief to reduce the weight of the wheels and so cut their rotational inertia. Lighter wheels would, in addition, improve the acceleration and braking performance, and enhance the responsiveness of the suspension. Wise had been associated with the Team for the 2014 and 2015 competitions, and had been given responsibility for the suspension, wheels, brakes and steering for the 2016 car.
The solution The use of additive manufacturing was suggested by one of Wise’s colleagues in Team Swinburne following a general search
of new materials and technologies being used by teams in the equivalent European competition, Formula Student. He had found examples of the use of the Renishaw technology by these teams and suggested that Wise should contact the company. Wise approached Renishaw’s office in Australia with a wheel from the 2015 car comprising a centre machined from an aluminium alloy, and a band also made from aluminium. Wise worked through several design iterations, replacing the aluminium wheel centres with smaller ones made from titanium alloy by additive manufacturing. The new design also used a carbonfibre band in place of the aluminium one to give the maximum weight savings. Guidance in design optimisation for additive manufacturing was provided by Renishaw staff to reach an alternative design with which everyone involved was happy. Iterative FEA (finite element analysis) simulations were performed throughout the design process in order to predict the behaviour of the new component and to evaluate the benefits that could be gained. “One of the things that I loved about using the Renishaw additive manufacturing equipment was the ability to increase the complexity of my design,” said Wise.
The Team Swinburne Formula SAE car with its new wheel package.
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Additive Manufacturing Team Swinburne with the 2016 car.
As well as contributing to the team’s success, Wise gained personally from working with Renishaw. “At the start of the year, I knew next to nothing about additive manufacturing of metals,” he admitted. “I soon learnt that, as with any other manufacturing technique, you need to consider the capabilities of the process during the design stage. After a few educational sessions from Renishaw on how the 3D printing system worked and where the issues might arise, I was soon able to adjust the design to be more achievable.
The result The new design, with the titanium parts replacing the machined aluminium centres, and the broader carbon-fibre band, reduced the weight of each wheel by 20%, resulting in a significant 75% reduction in rotational inertia, leading to measurable improvements in acceleration and braking performance. The additively manufactured wheel centres also contributed to an overall weight reduction of one kilogram per wheel, whilst also maintaining safety, leading to an overall improvement in the car’s performance that was evident in the results on the track. A big advantage of using Renishaw’s additive manufacturing technology was the ability to use titanium. “The amount of material for the initial billet, together with the machining time and experience that would be needed, had ruled out using titanium with traditional manufacturing methods,” explained Wise. “Printing the parts required very little effort
on our behalf and they were manufactured much more quickly than the last set of wheel centres that we made. I was surprised at the quality of the surface finish and that we required no finish machining. “I think there were a few people who were quietly sceptical on seeing how thin they were,” Wise added. “I’ll admit that I was feeling nervous after the team next to us broke a wheel centre on the track. However, in the end, we gave them a good testing and they held strong. So it’s a credit to Renishaw to be able to achieve the material properties required.”
“We looked into some unique tricks, such as printing skins around an internal lattice to reduce weight and to keep the thermal stresses down. Once I understood the process, I found it surprisingly easy to come up with a design that was both lightweight and printable.” Wise expects to see more teams using metal additive manufacturing in this year’s competition: “I lost count of the number of people that came into our pits, just to check out the new wheels. They looked incredible and we had no issues with them at all. A lot of people will have gone home impressed.” www.swinburne.edu.au www.renishaw.com
Aurora advances the certification of its 3D-printed parts Aurora Labs has announced the signing of a non-binding term sheet with DNV GL, a leading global quality assurance and risk management company, providing classification, technical assurance, software and independent expert advisory services to the maritime, oil & gas, power and renewables industries. This is an extremely significant step for Aurora as it sets a framework for the company to work with DNV GL having the goal of producing 3D-printed parts created on Aurora machines to be independently certified as fit for their intended purpose and meeting global certification requirements. The non-binding term sheet proposes to: 1. Create a process whereby parts printed by Aurora machines can be independently certified by DNV GL. 2. That the end to end certification process, including the use of Aurora’s management software, allows for parts to be certified whilst being printed and then independently verified by DNV GL.
3. Develop a certification standard for Aurora “This partnership is a substantial achievement for Aurora as it will ultimately allow for certifcation of our 3D-printed parts as fit for their intended purpose,” said David Budge, Managing Director and Interim Chairman of Aurora. “This is particularly important as many industries such as oil & gas and marine require certification of parts in order to be able to utilise them in their facilities. DNV GL will support us in helping establish certification covering the whole value chain, from powders to parts, certifying the technical performance of our technology, and independently endorsing our processes and products.
The independent certification will provide us with enhanced credibility when speaking to potential customers and will be a big step forward in recognition of the technology we have developed.” Brice Le Gallo, Regional Manager for SEA & Australia, DNV GL – Oil & Gas, added: “While additive manufacturing is raising more and more interest in various industries, the adoption level in the oil and gas and maritime industries is still slow due to challenges in qualification and certification. We are pleased to partner with Aurora and believe that our collaboration will help advance the use of AM for the oil and gas and marine industries.” www.auroralabs3d.com
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RMIT Centre for Additive Manufacturing – Printing biomedical implants Additive manufacturing (AM) technology offers opportunities for the manufacture of a range of new products. For example, lattice structures lend themselves perfectly to AM and show promise in particular for biomedical implants. By Darpan Shidid, Martin Leary, Maciej Mazur, Eric Yang, Matthew McMillan, Bill Lozanovski, Ma Qian and Milan Brandt. AM refers to methods that generate threedimensional structures layer by layer. Each AM technology is compatible with the specific form of the raw input material, which may be in liquid, powder and sheet form. AM processes are not subject to the constraints associated with traditional manufacturing methods and provide significant opportunities for the design of novel geometries and complex structures, such as cellular structures in particular. Cellular structures possess a number of properties compared to solid structures. For example, the design freedom offered by AM may be used to enhance the strengthto-weight ratio of structural components by transforming solid geometry into a cellular structure or space-filling hollow sections of the model with a cellular structure. The cellular structure within the model may be useful in distributing the loads evenly compared to a hollow model while conforming to the geometric boundaries of the object. This article discusses some of the basic concepts behind the metallic lattice structures manufactured using selective laser melting (SLM) technology and their application to biomedical implants in particular at the RMIT Centre for Additive Manufacturing.
Cellular structures Cellular structures are categorised as aperiodic (or stochastic) and periodic. Aperiodic cellular structures are characterised by random orientations of structural elements and can be found in nature in abundance, observedin bones, sponges, bird beaks and animal horns, for example. Such cellular structures are often surrounded by a thick plate structure, such as cortex bone, and hence are referred to as sandwich structures. Periodic structures, on the other hand, consist of a plurality of a single unit cell arranged in a specific pattern such as honeycomb structures and engineered lattice structures. A lattice structure, from a structural engineering context, is an array of struts that may be pin-jointed or rigidly bonded at their intersection and have been shown to have up to 300% greater strength compared with aperiodic cellular structures under similar circumstances.
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Cellular structures shown in an SLM build plate showing a range of Titanium lattice and lattice-solid structures.
The generation of periodic lattice structures is computationally efficient as it involves the repetition of predefined unit cell configurations. Furthermore, local and global properties of the lattice structure can be tailored by using applicable unit cells from a large unit cell library. This enables greater user-control over lattice configurations and density, making periodic lattice structures ideal for functionally graded materials. Additionally, the structural optimisation of periodic lattice structures is computationally efficient compared with aperiodic structures.
Structural performance of lattice structures The failure of a lattice structure is a complex phenomenon that can be attributed to several associated failure modes and loading conditions, including yield and buckling failure modes. Structurally, lattice structures can be broadly classified into bending-dominated and stretch-dominated structures. In both cases, the lattice structure undergoes plastic consolidation initially, after which the load starts to increase rapidly.
In stretch-dominated structures at peak load, the struts start to yield plastically and failure occurs either by buckling or fracture, resulting in a steep drop in load carrying ability. In bending-dominated structures, however, the collapse of the structure occurs at nearly constant stress, making bending dominated structures more suitable for energy absorbing applications and for the emulation of trabecular bone whereas stretch-dominated are desirable for high-load carrying applications. Lattice densification occurs after the structure is fully crushed and the structure behaves as a solid material.
A femoral implant for a patient with osteosarcoma. Here the implant is conformal to the bone’s geometry, has periodic lattice configuration with functionally gradient lattice structure, and is optimised for manufacturing and bone loading constraints.
Additive Manufacturing A femoral implant design manufactured at RMIT for a patient with osteosarcoma bone cancer. In this case the whole section of cancerous femur has been replaced.
Design and manufacture of lattice structures Generating lattice structures for regular geometries, including orthogonal, prismatic, or symmetric objects is relatively easy due to the object’s predictable geometry. However, irregular, free-form geometries such as orthopaedic implants are challenging to tessellate with periodic lattices, typically requiring the designer to trade-off structural integrity with associated lattice geometric conformity. Additionally, AM technologies make use of support structures to increase the scope of manufacturable geometries. In SLM, support structures are used as structural supports, as well as providing a thermal path for conducting heat of fusion from the melt pool, thereby increasing cooling of the part and managing residual stresses. Although support structures are useful for increasing AM manufacturability, they introduce challenges for part quality and cost. For example, in SLM, support structures are fused to the build part and are either frangible or removed by mechanical grinding, posing the risk of physical damage or deformation of the manufactured object. Secondly, support structures used within internal or hollow features (including lattice structures) cannot be removed with nondestructive methods, and thereby introduce further design constraints to AM. Thus, overhang geometries are considered undesirable due to the requirement of support structures and should be avoided. However, elimination of overhangs is not feasible, especially in complex structures such as lattice structures, and may result in structural instability if critical structural elements are eliminated. Thus, designing geometries that are manufacturable without the use of support structures either results in extended modelling time or structurally unstable components. Hence, it is complex to determine the internal structural configuration for space filling conformal lattice structures that are manufacturable using SLM as well as being structurally appropriate for the
intended application. Research as RMIT University has shown that support-free manufacture of lattice structures is feasible with identification and accommodation of manufacturing constraints of the applied SLM technology.
Lattice structures as orthopaedic implants Orthopaedic implants are required to reconstruct the natural form and function of a bone that may be compromised due to disease, deformity or trauma. Lattice structures that conform to a freeform geometry and are optimised for the manufacturing and loading constraints are desirable. The design and manufacture of patient-specific biomedical implant applications overcome several major limitations of conventional orthopaedic implants, includuing: • Standard implants are not customised to individual patients. • Heavy structural design of the implants for bone stability requires surgeon to remove significant amount of hard as well as soft tissue from patient. • The biomechanical engineer has to work according to the implant design to decide on placement strategy instead of the anatomical function of the bone. This results in significant rehabilitation and recovery time for the patient • Stress shielding due to stiffness mismatch results in bone resorption (degradation) and subsequent implant loosening RMIT University researchers have demonstrated that use of lattice structures can overcome these limitations by optimising the structural configuration of lattices to not only recover load-carrying capacity of the bone but also could promote bone ingrowth to ensure rapid and rigid biological fixation. Implant geometry that is generated using this method also conforms to the resected tissue to ensure that robust surface contact is achieved at the bone-implant interface. Curvilinear
struts that conform to the natural contours of the bone avoid stress concentrations that often contribute to fretting wear, i.e. the loss of material owing to the rubbing or contact of components. Recent RMIT research builds on all the identified markers and constraints for design optimisation and manufacture of orthopaedic implants (Shidid, Leary, Choong, & Brandt, 2016). In summary, RMIT University’s patent-pending methodology ensures • The implants with periodic lattice configuration conform to the bone’s shape • Their geometry is optimised so that it is manufacturable without the need for internal support structures • Lattice configuration consists of functionally varying pore size and shape to simultaneously enhance bone-ingrowth and strength to weight ratio. • And is structurally stable to withstand patient-specific loading conditions Implant designs manufactured at RMIT for patients with osteosarcoma bone cancer were mechanically tested against the healthy bone geometry using synthetic bones. The results show that the implants designed using RMIT methodology not only recover the load carrying capacity of the bone, but they also mimic the stiffness of the substrate bone yielding a superior option to conventionally designed implants. The algorithms used in this methodology are computationally highly efficient and can yield optimised designs within minutes making iterative design feasible even with very tight design time schedules. The RMIT Centre for Additive Manufacturing is involved in a number of research projects with collaborators at Stryker South Pacific, St Vincents Hospital in Melbourne, the Peter MacCallum Cancer Centre and UTS, and supported by the IMCRC and ARC Training Centre in Additive Biomanufacturing to research and develop new biomedical products using AM technology. www.rmit.edu.au
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iOrthotics dips a toe in 3D printing with HP Brisbane-based iOrthotics has adopted additive manufacturing technology from HP 3D Printing Solutions to produce stronger orthotics devices faster and more sustainably. HP has expanded its HP Multi Jet Fusion 3D printing technology into Australia, announcing iOrthotics as the first commercial customer to purchase an HP Jet Fusion 3D 4200 Printing Solution in the country. Adopting HP Multi Jet Fusion 3D printing technology will allow iOrthotics to become one of the first orthotics manufacturers in the world to have completely transitioned from polypropylene milling to 3D additive manufacturing – a faster, more sustainable method producing custom-made orthotics devices that are significantly stronger. iOrthotics recognised the economic benefits that would flow from digitising their operations and shifting to the market’s most advanced 3D printing innovations to produce products faster, superior in quality and with almost zero waste. “Patients depend upon their orthotics for comfort and wellbeing, so it is only natural that they expect these devices to be strong, sturdy and dependable,” said Dean Hartley, founding Director and General Manager, iOrthotics. “The extensive research and testing we conducted with the University of Queensland provided the empirical evidence that devices manufactured by HP’s Multi Jet Fusion 3D printing technology are 40%-60% stronger than those produced using traditional polypropylene milling.”
Damian Vassallo and Dean Hartley of iOrthotics.
The dramatic increase in scalability, speed, and volume afforded by HP’s Multi Jet Fusion technology will enable iOrthotics to pursue rapid growth. A subsidiary of my FootDr – Australia’s largest podiatry group – the company supplies custom-made orthotic devices to over 50 clinics, and expects to extend its reach to 130 clinics over the next few years, with potential for international expansion. “As a rapidly growing business, we needed to innovate our manufacturing process to keep up with demand,” said Damian Vassallo, co-founder of iOrthotics and non-executive director of my FootDr. “It was impractical to continue scaling up subtractive milling, which could produce just 30 plastic devices per day. Using HP Multi Jet Fusion technology, our output has increased to 120130 devices per day. With the ability to extend our capabilities, we are now undertaking orthotic and prosthetic fabrication and offering a 3D bureau printing service for engineering and industrial clients. It has been a quantum leap in technology, and our final investment decision has been validated. “In addition, we recognised the economic and environmental impact of material wastage,” Hartley added. “Subtractive milling results in 95% of the polypropylene being wasted, whereas HP’s Multi Jet Fusion technology has reduced wastage to less than 1% of the material.” HP’s ambition is to disrupt the $12 trillion global manufacturing market, and to make 3D printing a core part of the Fourth Industrial Revolution. HP and its partners are accelerating the end-to-end digital reinvention of the manufacturing industry, and transforming every step of the value chain – from design to workflow to materials to fabrication to post-processing to supply-chain to recyclability. In Australia, 3D printing represents a significant opportunity to reinvent the local manufacturing industry. Transitioning Australia’s manufacturing sector to a highly skilled, advanced industry has been identified by the Federal Government as an economic priority. “The world is going through a major economic and industrial transformation that impacts everything – from the cars we drive, to the clothes we wear, to the education and jobs our children will have in the future,” said Rob Mesaros, Managing Director, HP South
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The new machine will allow iOrthotics to transition from polypropylene milling to 3D additive manufacturing.
Pacific. “All industries will go through change in the Fourth Industrial Revolution, but perhaps none as dramatically as the manufacturing sector. Australian manufacturers like iOrthotics are truly leading the way – transforming their business and positioning themselves for growth by taking full advantage of this technological shift.” HP is moving fast to ramp up the availability and delivery of its Jet Fusion 3D Printing Solutions. Globally, HP is working with companies such as BMW, Nike, J&J, Jabil, Jaguar Land Rover, ETH Zurich and Danfoss Group, as well as manufacturing service bureaus like Materialise, Proto Labs, Forecast 3D and Go Proto. In August, HP announced a global alliance with Deloitte, combining HP’s leading 3D printing platform with Deloitte’s unrivalled digital transformation capabilities. HP Jet Fusion 3D Printing Solutions are now available in Australia. www.hp.com/au www.iorthotics.com.au
Delivering solutions for additive manufacturing
Renishaw’s metal powder bed fusion is an advanced additive manufacturing process that builds complex metal parts direct from 3D CAD data in a variety of metals. Benefits of the additive manufacturing process include: • Rapid design iterations • Bespoke or customised items • Reduce tooling costs • Build complex geometries such as thin walls, lattices and internal features • Increased design freedom - AM is not constrained by traditional design rules We offer a range of solutions for metal additive manufacturing, from systems, metal powders, ancillaries and software through to expert advice and support service.
For more information visit www.renishaw.com/additive
Renishaw Oceania Pty Ltd Unit 4, 6 – 7 Gilda Court, Mulgrave, Vic 3170, Australia T +61 3 9521 0922 F +61 3 9521 0932 E australia@renishaw.com
www.renishaw.com
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UNSW selected for world-leading 3D printing technology from GE UNSW Sydney students and staff have been handed a unique opportunity to help further develop the application of additive manufacturing with the arrival of a sophisticated metal 3D printing machine under an initiative by global digital industrial company GE. The company’s GE Additive division formally unveiled the $350,000 Concept Laser Mlab Cusing 200R machine at UNSW’s School of Mechanical and Manufacturing Engineering (MME) in December. GE is investing US$10m globally over the next five years to create a pipeline of additive manufacturing experts to accelerate advanced manufacturing under its Additive Education Program. A handpicked team of GE specialists evaluated and selected eight universities to receive the 3D printing equipment, with UNSW the only recipient outside the US. “This is a wonderful opportunity for GE to partner with UNSW and continue to grow the design possibilities for Australian engineers,” said Max York, GE’s CEO for Australia. “This collaboration will help UNSW and GE to take the lead in fostering the next generation of additive manufacturing technology in Australia.” Tom Gleeson, General Manager for Global Sales at GE Additive added: “That UNSW would be selected from 250 college and university applications under the GE Additive Education Program worldwide shows that Australian university students are punching above their weight when it comes to advancements in additive manufacturing.” The Concept Laser Mlab Cusing 200R machine is a laser powder-bed fusion system designed to manufacture metal components with elaborate structures and parts made from reactive materials like titanium. It is ideally suited to fine detail, high-quality surface finish, and precision component structures. It will be used for the following research areas at the frontier of additive manufacturing: • Final part production and improvement of tolerances and surface finish. • Design and development of new materials, including light-weight and low-cost materials, suitable for additive manufacturing. • Design, optimisation and fabrication of various metal parts with functional gradient microstructure, complex geometry or optimised topology design. • Simulation of the additive manufacturing process to understand and improve the manufacturing process.
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GE Australia CEO Max York, with Professor Brian Boyle, Deputy Vice-Chancellor - Enterprise at UNSW, Tom Gleeson, GM – Global Sales at GE Additive, Professor Mark Hoffman, Dean of UNSW Engineering, and Professor Chun Wang, Head of the UNSW School of Mechanical and Manufacturing Engineering.
The Mlab will be housed in a designed-forpurpose environment, due for completion in early 2018, and forms MME’s foundation technology for a host of research and education initiatives. In the second half of 2018, UNSW will offer one of the first university-level courses in additive manufacturing in Australia. Its priority is to address the gap in printable-design thinking. Professor Chun Wang, Head of the UNSW MME, said the new Concept Laser Mlab Cusing 200R machine would greatly enhance education and research in additive manufacturing at UNSW.
“MME has a great track record in additive manufacturing research and a strong vision of future research associated with a manufacturing process that will both disrupt and complement traditional manufacturing processes,” addedWang.
“Students will be able to use this machine in a newly created course in additive manufacturing technology,” said Wang. “In research, this machine will enable collaborative research between Engineering and Medicine to develop novel spinal fusion devices to overcome the current clinical problem of poor bone ingrowth into fusion devices, for example.”
UNSW Deputy Vice-Chancellor Enterprise Professor Brian Boyle said: “The development of this kind of technology has created huge potential for the manufacture of a wide range of components and devices in different industries and UNSW is pleased to be able to work with GE in this rapidly expanding field.”
How manufacturers might use multiple lasers within the same printer for optimising the quality of 3D printed products is a question MME hopes to address with a research grant from the Australian Government’s Defence, Science and Technology Group. The UNSW team is also partnering with Stanford University to investigate nano-structure and micro-scale defects in critical products such as medical devices and aviation components.
Professor Wang envisages Australia ultimately as an exporter of additive engineering know-how: “If we develop in-country novel technologies in terms of processes that deliver better properties, and new technology to interrogate 3D structures for quality assurance, these can be exported as engineering services.”
GE is set to open its second round of applications, inviting universities to put revolutionary 3D thinking into practice in the first quarter of 2018. “We want a pipeline of engineering talent that have additive in their DNA. This education program is our way of supporting that goal,” said Mohammad Ehteshami, Vice-President of GE Additive. www.ge.com www.engineering.unsw.edu.au
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DMP at the tipping point? 3D Systems’ On Demand Manufacturing service has proven the viability of direct metal printing (DMP) for missioncritical satellite applications with Thales Alenia Space In his best-selling 2000 book, Malcolm Gladwell defined ‘The Tipping Point’ as “the moment of critical mass, the threshold, the boiling point”. By that definition, direct metal printing (DMP) is standing on the precipice, as it moves rapidly from prototyping to production for mission-critical, risk-averse applications in defence and aerospace, where nothing is left to chance. An example of this mainstream acceptance is a long-term partnership between 3D Systems and Thales Alenia Space to leverage DMP for aerospace components. Based in Toulouse, France, Thales Alenia Space is one of the leading aerospace suppliers in the world, with revenues topping €2bn in 2014. The company has 7,500 employees in eight countries, specialising in space telecommunications, navigation, Earth observation, exploration and orbital infrastructures. The collaboration between Thales Alenia Space and 3D Systems can be seen in the production of antenna brackets (190mm x 230mm x 290mm) for a geostationary telecommunications satellite. DMP is now qualified and fully available for Thales Alenia Space’s titanium aerospace applications. Today, for certain products like the satellites, 80% of metal parts are produced using 3D printing, replacing traditionally manufactured parts.
Quick and efficient expertise Thales Alenia Space worked with the 3D Systems’ On Demand Manufacturing Solutions team in Leuven, Belgium, to design and print the Ti6Al4V brackets and guarantee that all quality aspects and tolerances were met. On Demand Manufacturing, a 3D design-tomanufacturing service, is the world’s leading provider of unique, custom-designed parts, offering instant online quoting, expertise in 3D design and printing, and proven postmachining support in order to be able to deliver validated flight parts. Thales Alenia Space and On Demand Manufacturing worked together to apply topological optimisation to the 3D printing process following a design for manufacturability approach. Topological optimisation determines the mostefficient material layout to meet the exact performance specifications of a part. It takes into consideration the given space allowed, loads that need to be handled, boundary conditions and other critical engineering factors.
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The topologically optimised large brackets were printed by a 3D Systems’ ProX DMP 320 printer.
better conservation of powder quality, no micro oxidation of parts during printing, fewer oxide interstitials during printing, and improved mechanical properties for O2sensitive alloys such as titanium.
Better parts in half the time The combination of 3D Systems’ On Demand Manufacturing expertise and the advanced capabilities of the ProX DMP 320 delivered exactly what Thales Alenia Space needed in about half the time it would have taken with traditional manufacturing. The DMP-produced titanium brackets are 25% lighter than brackets manufactured by traditional means and feature a better stiffness-to-weight ratio.
Each of the four brackets for the satellite required an individualized design, as they are mounted on the antenna’s reflector edges and screwed onto a shaped surface.
Proving its worth The antenna brackets were produced by On Demand Manufacturing on a beta version of 3D Systems’ ProX DMP 320 machine. While already in use within 3D Systems’s manufacturing services operations in Europe and the US, the printer was announced and made available for sale to end users at the International Consumer Electronics Show in January. The ProX DMP 320 is designed for heavyduty metal parts production. It uses a totally new architecture that simplifies set-up and provides the versatility to produce all types of part geometries in titanium (grades 1, 5 and 23), nickel super alloy and Stainless 316L. Exchangeable manufacturing modules deliver increased applications versatility and less downtime when moving among different part materials. A controlled vacuum build chamber ensures that every part is printed with proven material properties, density and chemical purity. Extremely low O2 levels in the ProX DMP 320 deliver several key benefits, including
Production costs have been reduced considerably and total time from order to shipping—including file preparation, 3D printing, heat treatment, finishing, CNC milling, quality-control analysis, cleaning and data traceability—was four to five weeks, compared to 10 weeks using traditional methods.
Accelerating DMP adoption Antenna fixation brackets for satellites are just the beginning of the DMP collaboration between 3D Systems’ On Demand Manufacturing and Thales Alenia Space. In 2015, 3D Systems produced more than 50 different space components for three Thales Alenia Space geostationary satcoms. Thales Alenia expects to double the production in 2016 using DMP from 3D Systems, according to Florent Lebrun, an additive manufacturing specialist for antenna applications. The collaboration between 3D Systems’ On Demand Manufacturing and Thales Alenia Space is emblematic of the accelerating adoption of DMP by defense and aerospace organisations worldwide. It appears to be just a matter of time before DMP takes its mainstream place alongside the traditional metal manufacturing processes that it complements. au.3dsystems.com
3D Systems’ On Demand Manufacturing DMPprinted brackets mounted on a Thales Alenia Space satellite antenna.
Cutting Tools
Aiming for global markets Any Australian manufacturer with aspirations as a global supplier needs to carefully analyse its business. It’s not enough to have the best product if it is not supported at multiple levels of the enterprise, where every part of the operation performs a key role for a predictable outcome. It also offers advanced super-abrasive regrinding that provides high accuracy and quality. The service is Australia’s only facility that will regrind special tools and apply a hard coating, along with a nitriding and heat treatment service. The regrinding service is popular with users who are looking to significantly reduce their tooling costs
How does a manufacturer, once considered too small to be regarded as a competitor by larger businesses, become the only major cutting tool manufacturer in Australia, competing globally with the world’s best? The pursuit of excellence has paid off for Sutton Tools, a multi-award winning Australian manufacturing icon that now exports 50% of its Australian manufactured products globally and is the preferred brand for the IPH Group, France’s largest distributor of industrial tools. The company also supplies Rolls Royce in Romania, Triumph Motorcycles in Thailand, Moog Aerospace in the Philippines, and Foxconn in China. Sutton Tools is typical of successful Australian companies that understand the challenges faced when market demand or conditions change, or when opportunities are presented and decisive action is needed. The business is a textbook case for study by any manufacturing business that wants to stay ahead of the competition, while developing a global market. Embedded in Sutton Tools’ DNA is the philosophy of a totally integrated approach that ensures customer satisfaction. Adoption of the latest technologies, recognition of the value of experienced, highly skilled employees, nimble, yet well-informed decision making as well as welcoming and meeting competitors’ challenges has been its success formula. “Today’s metal working industry faces the relentless challenges of producing product faster, better and cheaper than before,” says Commercial director Robert Sutton. “Meeting these challenges requires innovative technology and customer service to world standards.” Continuing the approach of its founder one hundred years ago, the company chases every technological advantage its management can find. It recognises the importance of constant improvement, selfexamination and never failing to ensure customer satisfaction. On top of this is a solid commitment to the importance of building ethical relationships with all its stakeholders – critical in building global strategic partnerships.
Surface Technology Coatings, the company’s own (and Australia’s first) PVD coating facility, extends tool life by applying the latest generation of thin film PVD coatings, increasing hardness, abrasion resistance and impact strength.
Customer service
Tools’ strategy. Just one example of its innovative approach is its ‘Harmony’ range of endmills, which recognises that the key to successful milling is to minimise or eliminate the vibration produced in the cutting action. This build-up of harmonics in the workpiece can be detrimental to the tool’s life. Often this vibration has been rectified by slowing down the cutting speed and feeds, altering the size of the cut, and/ or increasing the rigidity of the set-up. Through a combination of tool design, micro-geometry, material and coating, the Harmony endmill overcomes vibration without the need to sacrifice productivity.
Special tools and services Sutton Tools also operates a special tools division that provides a valuable express service on non-standard taps and other cutting tools. State-of-art CNC tool grinding equipment and manufacturing processes are used to manufacture specialised tools that exclusively use the very best European grades of materials, such as powder metallurgy, HSS cobalt and ultra-fine grain carbide.
Robert Sutton says customer service plays a critical role in cementing customer satisfaction by building confidence in product availability: “Customers know they can rely on our order processing thanks to our automatic delivery and order confirmation and rapid response backorder reporting. The needs of customers across different industries varies enormously. To enable us to provide the best service, we have designed and implemented adaptive and seamless ordering systems that allow us to efficiently receive, process and fulfil in the minimum time. “Our international distribution centre uses RF scanning and the latest stock replenishment systems for accurate stock control. We employ the latest freight management systems for rapid and accurate order fulfilment, electronic data interchange and online systems.” Despite having more than 20,000 stock keeping units (SKUs), the company consistently averages 98% stock availability. Every day a computerised despatch system manages in excess of 1,000 daily consignments and are despatched within the same day of order received. www.suttontools.com
Meeting needs through innovation Finding solutions for common machining productivity challenges is typical of Sutton
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New strategies for orthopaedic component machining Numerous factors are driving growing demand for orthopaedic replacement and repair devices such as artificial joints as well as plates, rods and pins used to repair or reinforce areas of the body after accidents or disease. Amid intense competition, device manufacturers are continually seeking ways to make the parts more quickly, cost-efficiently. By Jan-Willem van Iperen and Ruud Zanders. Demand for the parts is expanding as lifespans lengthen and aging results in arthritis and osteoporosis. Worldwide trends towards higher body weight and obesity put additional strain on skeletal joints. Changing lifestyles, from a lack physical activity for some to increased sports participation for others, further fuel demand for renewed body parts. Growth of emerging economies is giving greater numbers of people the resources to afford orthopedic devices. The Global Market Insights consulting group predicts that the global orthopaedic devices market will grow to â‚Ź50bn by 2024.
Competition prompts tooling development Orthopaedic devices include hip and knee replacement components, artificial elbow and ankle joints, trauma repair instruments, spinal bone plates and various repair pins, rods and fasteners. Joint reconstruction makes up over 40% of the market, with the majority of that in hip and knee replacement. The key requirements for these parts are strength, reliability, light weight and biocompatibility. Approximately five major suppliers claim 85% of the highly competitive orthopaedic component market, with more than 200 other companies vying for the rest. In the light of such intense competition, device manufacturers continually seek ways to make the parts more quickly, cost-efficiently. By applying new materials, implants are stronger and lighter and able to perform in the human body for up to 25 years. In addition, orthopaedic devices are part of the overall consumer goods trend towards personalisation; medical device manufacturers seek ways to tailor their products to individual patients’ physiognomy and other preferences. Product diversity has become a key competitive edge. As a result, machine tool makers are under pressure to develop ways to machine complex contours quickly, and toolmakers are focusing cutting tool technologies on speed and flexibility. Advanced manufacturing technology initiatives include 3D printing and advanced cooling technologies for machining operations.
Machining challenges Orthopaedic components are typically machined from bar stock, castings or forgings and then ground and polished. For hip and knee implants, the most common workpiece material is cobaltchrome alloy, with the use of titanium on the increase. A typical cobalt chrome alloy is similar to CoCr28Mo6, and the Ti6Al4V titanium alloy is most common. Both materials are biocompatible and very strong and stiff, making them excellent for application in orthopaedic components. However, those same properties also make the alloys difficult to machine. Cobalt chrome is hard and abrasive, has high elasticity and conducts heat poorly. The alloys may contain hard, abrasive elements that cause severe abrasive tool wear, and the chips produced are tough and continuous, requiring special attention to chip control and cutting edge geometries. Titanium is very light and strong. It also work-hardens when machined and is a poor conductor of heat. The heat concentrates on the cutting edge and the tool face. The combination of high temperatures, high cutting forces and friction from the passage of the chip causes crater wear and tool failure. The material’s low modulus of elasticity, a benefit in some implant applications, causes material to spring back from the cutting edge, demanding close attention to cutting tool sharpness.
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Because machining the materials used in orthopedic implants typically generates excessive heat, use of coolant is required. However, in many cases use of traditional coolants is either prohibited extremely limited to prevent contamination of the parts. Otherwise, time-consuming and expensive post-machining cleaning processes are needed. In addition, coolant itself poses environmental issues in regard to employee health and safety and disposal policies. An alternative coolant technology involves the use of super-critical carbon dioxide (scCo2) dry-cutting technology. Super-critical carbon dioxide acts as a vehicle to deliver dry and enhanced lubrication to a cutting zone. Developed by Fusion Coolant Systems, the process provides the capability to machine parts without oils, emulsions or synthetics. When carbon dioxide is pressurized above 74 bar (1,070 psi) and 31 degrees Celsius, it becomes a supercritical fluid. In this state, it fills a container like a gas, but with a density similar to a liquid. When delivered to the cutting zone, scCO2 expands to form dry ice, though it does not create a cryogenic substance like liquid nitrogen. The end result is an incredibly effective coolant solution that often outperforms existing systems that incorporate high pressure water/oil, minimum quantity lubrication (MQL), liquid CO2 and liquid nitrogen.
Cutting Heading Tools
3D printed components Another non-traditional manufacturing technology is seeing increased application in orthopaedic device production. The process of 3D printing uses titanium and cobalt-chromium alloy powders to produce complex, near-net-shape parts. In the medical industry, selective laser melting (SLM) melts the powders to build components layer by layer. The process allows medical manufacturers to generate special part contours and dimensions custom-tailored to individual patients. The process can also produce consistent micro-pore surfaces that expedite bonding between the part and living bone. For finish machining, parts produced via 3D printing maintain most of the machining characteristics of the metals they are made from. However, parts may have to receive post-printing treatments to relieve uneven stresses generated during processing. In addition, for post-machining, fixturing can sometimes be a challenge due to the parts’ near-net shapes and complex contours.
Replacement parts A total knee replacement typically consists of three basic components: A contoured metal (cobalt chrome or titanium) element called the femoral component is attached to the knee end of the femur, the large upper leg bone. A metal component called the tibial tray is affixed to the top of the tibia bone of the lower leg and consists of a short shaft or keel that supports a flat surface with raised edges. A plastic bearing insert between the metal parts permits motion of the joint. Similarly, a hip replacement has three main parts: a metal femoral stem topped with a femoral cap or head is inserted into the top or hip end of the femur. A metal acetabular cup or socket set in the pelvis accepts the ball. The new alinea bearing insert in the knee and the plastic cup in the hip typically are machined in Ultra High Molecular Weight Polyethylene (UHMWPE).
Combining manufacturing methods The metal alloy components of orthopedic implants must possess excellent surface finishes to minimise wear of any plastic parts and permit the joint to function for its projected lifetime of 20 years or more. In a knee replacement, for example, both the femoral component and tibial tray must be absolutely smooth to protect the plastic bearing insert against wear. Accordingly, manufacture of orthopaedic components typically requires that grinding operations follow the milling process in order to achieve a sufficiently fine finish. Grinding, however, is time-consuming and impacts overall manufacturing efficiency and flexibility. Equally important, grinding generates high temperatures and stress in the ground components, leading to component dimensional errors and affect the product’s strength and performance. Grinding can be supported or in some cases replaced with the application of advanced cutting tools and high-speed milling strategies. The goal of the milling operations is to achieve a burrfree outside profile and a superior surface finish that offers the exact required surface quality, integrity and dimensional accuracy. If there is a post treatment such as polishing, the time for that task can be minimised because of the defined surface roughness and structure
achieved in the milling process. On the tooling side, parallel goals are long, reliable tool life and maximum productivity. In a representative application, a cast cobalt-chrome femoral component was finished using a ball-nose end mill on a five-axis milling machine. High-speed copy milling strategies and use of a high-performance end mill enabled elimination of a grinding operation. The resulting cycle time of 11 minutes per part represented a 50% time reduction compared to prior method. The change from grinding to milling the condyle surface eliminated the generation of scrap parts. The solid-carbide end mills employed featured a dedicated tough solid-carbide grade and a hard, polished TiAlSiN coating and were engineered to provide high metal removal rates and smooth cutting action to achieve superior finish and minimise polishing time. The complex contours of orthopaedic components often necessitate use of specific sequences of specialised tools. The tibial tray, for example, typically can require up to seven separate machining operations. Those operations can include roughing, tray base roughing, tray base finishing, chamfer milling, t-slot undercut machining, wall finishing/chamfering, and undercut deburring. The challenge is to achieve superior surface finishes with minimal manual intervention as well as reliable tool performance with the best combination of productivity, cost and quality. Traditionally, carrying out these sorts of multiple operations dictated the use of separate special tools developed to produce each required contour, dimension and surface finish. Special tools require investment in design and development time and expense, and due to their low production volume may have extended lead times and availability constraints. A new approach involves the development and use of tools that are standardised for productive use in these applications but retain flexibility that enables enable them to be used in a variety of similar parts in the orthopedic industry. Global demographic and economic trends strongly indicate that the demand for sophisticated orthopedic components will grow. At the same time, consumer desires and the determination of medical parts manufacturers to differentiate themselves from competitors are combining to promote development of orthopaedic components that are personalised to meet the requirements of individual patients. Surprisingly, variable part specificity can be achieved with tools that are less specialised, more flexible and more cost-efficient than the custom tools previously applied to produce the parts. Jan-Willem van Iperen is a Medical Applications Engineer and Ruud Zanders is Product Manager (Jabro) at Seco Tools. www.secotools.com
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Cutting Tools
The LogIQ of machining intelligently in the era of Industry 4.0 Iscar has launched the LogIQ campaign to introduce a new standard in cutting tool excellence. As a longstanding industry leader and innovator in the world of metalworking, Iscar has taken the IQ concept of machining intelligently even further by applying logical improvements to tool development. The result is the LogIQ range of tooling solutions that both predicts and fulfils customer needs. LogIQ represents a smart logical progression in a series of strategic moves to implement Industry 4.0 standards while ensuring continuity and stability. Industry 4.0 directives – to integrate interoperability, technical task assistance and decentralised decision-making into factory practices – challenge machining centres to review their operations and adopt procedures to meet these objectives. Machining logically responds to this need. Iscar provides the tools to make it happen. LogIQ applications have created new tool families, upgraded existing lines, and inspired innovative product ranges to maximise equipment utilisation and optimise performance. Listening to customer concerns and staying ahead of market developments, Iscar’s product managers, research & development (R&D) engineers and designers have combined their expertise and experience to develop highly effective and logical tool solutions that meet today’s machining centre demands. In an industry where every second makes a difference and every movement counts, logical strategic design and tactical enhancement of even the most basic cutting tool can contribute to increased productivity, less wastage and lower costs. LogIQ’s unrivalled, out-of-the-box tool innovations include new cutting geometries and locking mechanisms for stable, vibrationfree machining with higher repeatability. The indexable inserts are equipped with sophisticated chip formers and contain geometries that facilitate soft cuts at high feed rates. Solid carbide tools are enriched with new designs that feature substantially increased anti-vibration strength – a key factor for boosting productivity in unfavourable cutting conditions. The latest cemented carbide grades reflect Iscar’s forward-looking knowledge and know-how in powder metallurgy and coating technologies. The toolholding line includes new heat-shrink-fit and vibrationdampening devices, which significantly improve performance when tool rigidity is critical. The new LogIQ milling solutions include strong, durable inserts and milling heads with enhanced capabilities. The LogIQ turning applications offer new solutions to decrease machining loads, produce thinner and wider chips, and resolve vibration issues and coolant flow capabilities. The LogIQ drilling tool concepts provide
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Cutting Heading Tools
advanced productivity solutions for high accuracy and repeatability, to reduce machine cycle time and produce high-end machined components. The LogIQ lines feature LogIQ3CAM to significantly improve drilling productivity; LogIQ4TURN for enhanced performance in generalduty turning operations; LogIQ4FEED, which enables rough milling at high metal removal rates; LogIQ8TANG, a new 90-degree square milling shoulder; LogIQ5GRIP, a versatile and high-efficiency solution for parting and grooving, and other tool families comprising hundreds of new products; each designed and developed to
perform essential tasks in the most efficient possible method. From concept to realisation, LogIQ-inspired tools reflect Iscar’s commitment to create and deliver high-quality products that contribute to increasing productivity and profitability. The fourth generation of the Industrial Revolution has unveiled new standards and requirements for machining metals. Iscar is at the forefront of this important industry trend, developing relevant technologies and implementing methods of effective machining to reflect and respond to the dynamic needs of the metalworking industry. www.iscar.com.au
Tooling assemblies: Adaptive trends in complex projects in order to study and interpret customer needs and provide appropriate and effective solutions. These comprehensive schemes save time and cut down on the workforce required for start-up procedures, especially for larger projects.
The challenging installation schedules and time constraints demanded when delivering turnkey projects; the need to quickly bring installed systems to the required levels of production; and the requirement to prove the quality of manufactured parts: all these factors place a range of pressures on the world’s machine tool builders (MTBs). When working with MTBs involved in turnkey projects, each partner is deeply involved in the installation, adjustment and start-up work for technical and tooling equipment that is intended for the end-user. Efficient functioning of complete and often complicated technical systems to meet customer requirements – integrating the supply, mounting, adjustment and initiation of all interrelated elements while concurrently ensuring that all the elements work as a single cohesive system – is a fundamental need not only for project management but for project completion and success. Although metal cutting tools are always a vital part of each project, it often happens that minimal time is allowed for the balancing and tuning of the tools. As a result, additional human resources are required to complete these essential tasks, meaning that experienced tooling assembly specialists need to be on hand to perform complicated procedures in a short time space and in unfamiliar environments. Sometimes essential supporting equipment is not supplied, and may even be missing when needed for adjustment procedures. In addition, the tools and their accessories are often packed in different containers, causing unwelcome time losses when searching for necessary components.
Each proposed turnkey package integrates distinctive features to maximise efficiency and simplify project implementation. Tools are fully assembled and adjusted, and all individual tools are supplied with assembly and tooling layout drawings. If needed, each assembly can be equipped with electronic sensors for data management.
Each assembly can be equipped with electronic sensors for data management.
Iscar supplies complete assemblies of rotating tools for complex turnkey projects. Iscar MTB specialists work in constant cooperation with MTB companies involved in the management of large turnkey projects,
For projects using tools intended for high-speed machining (HSM), Iscar is able to perform tool or assembly balancing by employing appropriate technical equipment and software for theoretical analysis and correction. The instruction guide includes an assembly drawing containing data related to balance characteristics and relevant data from balancing test results.
An often overlooked aspect of cutting tool supply with turnkey schemes is quality, secure packaging, which ensures safe delivery of tools and assemblies to customer sites.
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Cutting Tools
New possibilities in the field of tool dispensing Mapal’s Unibase-M tool dispensing system is configured for the optimum storage and management of tools, components and accessories, with a focus on ease of use that applies to all new variants in the range. If large, heavy tools are already assembled in the production area but are not yet needed on the machines, they should be stored away. Cabinet drawers with a maximum load-bearing capacity of 75kg are not ideal for this. They often reach their limits when loaded with several completely assembled tools. Sometimes, on account of its length, the tool can only be stored horizontally and this presents a risk to the cutting edges. With situations like these in mind, Mapal has introduced the new Unibase-V expandable cabinet, with up to four electronically lockable vertical drawers. Each of the automatically opening drawers has a maximum load-bearing capacity of 600kg and is equipped with loadable tool holders designed according to the customer’s specifications. The vertical drawers are compatible with existing Unibase-M systems and are controlled via the master unit. The new Unibase-C cabinets for controlled individual tool dispensing complete the storage module. A large number of small and single parts can be stored in a Unibase-C cabinet in a relatively small area. When an item is selected, only its individual compartment opens, helping reduce risk of theft. Unibase-C is available in standard versions. It can be used as a stand-alone solution or can be incorporated into existing Unibase-M systems. Mapal has also developed new software for the Unibase-M tool
dispensing system. The software connects the tool dispensing system to existing ERP systems, carries out permanent, automatic inventory monitoring, and offers user-specific and comprehensive evaluation features. Possible actions available to the user will be displayed for each item, if permitted. Retrieval of the item is just a few clicks away. Moreover, the software runs on tablets and external computers. In the new version, the search logic has been completely revised, significantly increasing the ease of use. Previously, the search function was transaction-based and often required several selection criteria to access the item sought. Now, instead of a transaction, the sought-after item immediately appears. The search function is now considerably faster and more convenient – simply enter one or more keywords. The second major innovation of the new software is the open web interface. The software is compatible with the Internet of Things and is remotely accessible. It can be controlled by any end device and operating system. Master data and movement data can be exchanged via the open, cloud-based c-Com platform without restriction. Since October the new software has been delivered with all tool dispensing systems in the Unibase series, and customers’ existing systems can be updated to the new software if required. www.mapal.com.au
Making the grade in milling Dormer Pramet has launched a new milling grade for general machining applications in a variety of engineering materials, particularly steels. Suitable for finishing to roughing applications, even in unfavorable conditions, the new M8330 provides a highly reliable and versatile option when machining either with or without coolant in steels and cast iron. It is also suitable for stainless steel, super alloys and hardened steels. The M8330 replaces the existing 8230 grade and features a nanolayered PVD coating. This offers both improved productivity and tool life through increased resistance to thermal cracks, improved toughness and greater impact strength. Added to more than 90 different types of existing Pramet milling inserts, the M8330 grade is also available in a completely new range of inserts for copy milling. The RCMT10 inserts offer high metal removal rates, with up to 5mm depth of cut and strong durability. Designed to allow a high feed per tooth, RCMT10 is available in three geometries to support operations in a wide range of materials. Geometry F is for stainless steels, super alloys and low carbon steels, geometry M for steels and stainless steels, while geometry R is for cast iron and hardened materials. To support this addition, Dormer Pramet has expanded its current line of versatile SRC copy milling cutters. The SRC10 is a range of small diameter cutters available in sizes from 25mm to 66mm and in a variety of types, including end mills, modular and shell mills. Its
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double negative design provides a stable cutting action even during roughing and is suitable for a wide variety of operations including face milling, helical interpolation, ramping, progressive plunging and high feed cutting. All SRC10 cutters incorporate through coolant, a high number of teeth and feature a pocket design which gives maximum support to inserts with eight surface facets. www.dormerpramet.com
Cutting Heading Tools
Success in the tap market is all about attitude Taps are notoriously complex to manufacture but that isn’t deterring Thai manufacturer SK Precision, which is building its capabilities to be the first domestic supplier of taps to the domestic market in Thailand. The Thai Government understands that manufacturing will be a key driver of the country’s long-term economic growth and has been encouraging companies to establish facilities in their territories through tax and other incentives. As a result, the country today has flourishing automotive and aerospace sectors that require suppliers.
Tibordee Srikul, President of SK Precision.
SK Precision has around 50 people working two shifts servicing their traditional market of cutting carbide tools and PCD tools. “We have been operating for over 20 years and know the local Thai market intimately,” says Tibordee Srikul, President of SK Precision. “We saw an opportunity in the tap grinding segment as until now companies could only source taps from overseas suppliers and that means longer lead times of up to three months and higher cost. Our customers want just-in-time products so they can reduce stock and inventory costs. Having a local supplier who can deliver taps in a short period of time helps them achieve a more efficient supply chain. “Taps are a difficult tool to manufacture. A complex application, the geometry and tolerances requirements take a lot of skill and knowledge to produce. At SK Precision we like a challenge and saw the combination of a gap in the market and a new application as something we could make a success.”
Single set-up tap manufacturing Srikul did not want to be restricted to producing just one type of tap, so after extensive market research, the company purchased a Tap X Linear from ANCA Tools. ANCA was the first machine manufacturer to deliver to market a single set-up machine for complete tap manufacture. Continuing this tradition of industry firsts, ANCA now offers the TapX Linear range of machines – the first single set-up tap grinding machine with LinX linear motor technology on X, Y and Z axis. TapX Linear finds the perfect balance between proven designs combined with ANCA’s newest technologies. The rigid bisymmetrical column design on the solid polymer concrete base has been the foundation design of ANCA machines over the years. Now, in addition, ANCA’s new LinX cylindrical linear motors and linear glass scales are fitted as standard on X, Y and Z axis for proven and unsurpassed long-term reliability and accuracy.
The result is a superior machine that ensures customers will meet ever-increasing market demands of precision tap grinding. TapX machines are purpose built, with tooling, coolant delivery and automation specifically for production grinding of all types of taps, from M3 up to M50, whether in high-speed steel or carbide. Clever tooling design means change over from one tap type to another can be done in minutes, not hours. This delivers greater flexibility in tap production and results in increased productivity and reduced costs. “Our investment in capabilities, both in technology and experience, means we can now produce special and standard taps locally,” says Srikul. “But that is only the beginning, in the future I want to produce spiral tap, point taps and hand taps and forming taps. “For me and my team it is all about attitude. We are always looking to the future to keep up to date on what technology and market trends are emerging. I like a challenge and I knew that there was great opportunity I could take advantage of. My philosophy is to take on a challenging market and develop it. Attitude is everything and that is how I make sure I am successful – I believe I can do it!” www.anca.com
The TapX Linear machine from ANCA Tools
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one-on-one
Michael Grainger is the Chair of the Brand Tasmania Council. He is also the Managing Director of Hobart-based Liferaft Systems Australia (LSA). He spoke to William Poole. AMT: Let’s start with Brand Tasmania. When was it established and what are its aims and objectives? Michael Grainger: The Brand Tasmania Council was formed in the early 1990s. It was established by a group of like-minded individuals who were exporting and promoting Tasmanian product all over the world. It became affiliated with the State Government not long after that and has grown over the years to represent Tasmania in many different aspects – for example, food & beverages, tourism, manufacturing, education and the arts are all pillars of our organisation. We share a fairly broad and equal range of promotion. AMT: What sort of activities does it engage in to achieve its objectives? MG: We engage really with the Tasmanian companies that are represented by Brand Tasmania to promote what they do, encourage and stimulate growth in the economy, create employment and just promote all things that are Tasmanian. We attend trade shows, we have our eFriends mailing list, a very big subscription for our Tasmanian Stories newsletter, we have the website obviously. And we work pretty closely with Government on promotion in speciality areas – for example if the Tasmanian State Government is promoting various events, we will assist them, we’ll do videos and so on. But it’s basically all to do with living and working and visiting Tasmania I guess. We have approimatley 700 members companies – or partners, as we call them. And again that’s across a very diverse range of industries all in Tasmania. The website and eFriends are probably the key areas that we’re promoting. We send out Tasmanian Stories once a month, and that goes out worldwide. AMT: It’s an interesting initiative – I think all states should run something similar. So what proportion of Brand Tasmania’s member companies would be in manufacturing? MG: Probably around 20-30%. Certainly the food & beverage sector is probably the biggest – that would encompass agriculture, aquaculture, wine, and so on. So food and beverage is the biggest, followed by tourism, and I think manufacturing would sit under that pretty closely. AMT: What does your role entail as Chair of the Brand Tasmania Council? MG: Really, it covers anything that’s strategically focused, having that advice and strategy in place for the executive team, and making sure we cover all the different sectors as evenly as we can. And it’s making sure we are working closely with Government to make sure that the funding the Government provides is spent properly and just keeping up those levels of diligence and governance. AMT: You’re also a manufacturer in your own right – tell us about Liferaft Systems Australia. MG: We started the company 25 years ago in September 1992. We’re a designer and manufacturer of marine evacuation systems, which encompasses inflatable evacuation slides and large-capacity inflatable liferafts.
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When we started the company in 1992, it was primarily to supply Incat with a new generation of evacuation system. We were the first company in the world to have a system that evacuated people directly from a vessel dry shod into an inflatable liferaft. We were the first company in the world to have an inflatable liferaft designed, manufactured and internationally approved that was larger than a 50-person capacity – our first product was a 100-person inflatable liferaft. No-one had done that before. We were also the first company in Australia to have the system approved by the EU in accordance with the Marine Equipment Directive. And we’ve grown from Incat being our only customer, to a situation today where Incat makes up just 5% of our business and we export all over the world. We have service agents in 27 countries. The UK and US Navies are good customers. Primarily our market is medium-to-large passenger ferries, naval ships and mega yachts. AMT: That’s impressive. It’s interesting in that, given Tasmania’s separation from mainland Australia, you’re kind of a case study of how Australian manufacturers more broadly need to find ways to overcome that “tyranny of distance” and crack global markets. MG: Well, Tasmania seems to have that inherent capability I guess. It probably comes from just our very nature of being an island state and having to work things out for ourselves, so to speak. But there are some very good niche manufacturers in this state who punch well above their weight from similar-sized sectors in mainland Australia. We’re just one company, but there are many many other companies involved in manufacturing who are doing that lowvolume, high-margin sort of niche manufacturing, Incat probably being the highest profile. Advanced manufacturing is very big in Tasmania, as is marine manufacturing. Precision, low-volume, high-margin stuff... really that sort of niche manufacturing is what Tasmania seems to do very well. And there are a lot of world-beating products being manufactured in this state. And it’s going very well. The economy is positive at the moment. The global economy and the Australian economy being where it is have been a big driver of success in a state the size of Tasmania. So all those exporters – particularly to the US – are doing well because of the foreign exchange rate at the moment. We’re in a good space right now. AMT: What are the big trends affecting the manufacturing sector there? MG: The foreign exchange rate would be helping. Tasmanian manufacturers are really not as diverse as their counterparts in other locations are, but they target specific markets. Particularly in marine. There’s not only us. There’s a company called CBG Systems for example, who have a very specialist structural fire protection business, which again they developed through Incat, but they now sell their systems and install them on vessels all over the world.
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Elphinstone is another one, in the north of the state, which manufactures specialist mining equipment and export their products, such as specialist mining trucks and things like that. So it’s really those niche markets that we seem to do well. I think the foreign exchange rate drives these exports, plus the innovation that comes out of Tasmania drives it as well. AMT: You mentioned how there’s been a significant shift into advanced manufacturing. What has driven that transition? MG: Mainly innovation, just being world-leaders in those niche markets. The Tasmanian Maritime Network is a classic example. The members of the network were bumping into each other at international airports on a regular basis, and we thought: ‘Why don’t we get together and form an association?’ Which we did. We called it the Tasmanian Maritime Network and again we promote all the maritime businesses that Tasmania has to offer through that network, which goes internationally. We exhibit as a group in international trade shows, defence shows and things like that. Because of the size of Tasmania, everyone knows what everyone else is doing. It’s a small community. You can get a lot of assistance from your neighbours to achieve the common goal.
AMT: You’ve got a strong brand in that sense, I think that applies to manufacturing in Tasmania in general. What are the other key strengths of Tasmanian manufacturing? MG: I guess it’s that collaborative approach and that mentality – the island mentality – which sees us build great relationships in all parts of the world, and that very high-level brand of quality, niche manufacturing in particular. The whole Brand Tasmania thing is globally recognised as being very high-quality and very responsible, which stands us in good stead all over the world. With communications the way things are today, it doesn’t take long for all the good news stories to reach all corners of the globe. The flip-slide is if there was a less than positive story, it reaches the same audience, but the response that Brand Tasmania gets from eFriends and from all over the world is always very positive. We just need to continue to build on our reputation. www.brandtasmania.com www.lsames.com
AMT: So having a very good collaborative culture among local manufacturers has been important?. MG: Absolutely. AMT: Do you think Government has been effective in helping promote the sector and encouraging innovation and collaboration? MG: They’re certainly trying. They’re being proactive. The State Government has set up a number of initiatives to assist SMEs in particular to achieve their export goals. I think the existing Government has been proactive in promoting that capability, but like any Government I guess they commit to a lot, but at the end of the day I’m not sure how much real assistance they provide. But there are certain products through Government that will assist SMEs in particular to expand and employ more people and things like that. So I guess the short answer is yes, the Government is proactive and they do assist a lot of companies in Tasmania. AMT: What are the biggest challenges facing manufacturers in Tasmania at the moment? MG: I guess the geographical location could be a challenge, however it doesn’t really challenge us as such. We have 20-foot and 40-foot containers picked up in our carpark once every four or five weeks, and those containers are full of our products which are exported all over the world. And I mean to all parts of the world, even the extreme Northern Hemisphere, northern Alaska, northern Norway, into Asia and North America. There is a cost to that I suppose, and our mainland counterparts probably don’t have the same sort of burden. We have to get our product to the mainland. It’s rare to ship directly from Tasmania although there has been some improvement over the last few years. I guess there are some challenges in getting the product to the major ports – it’s an additional cost that our mainland counterparts don’t necessarily have. Looking at the bigger picture, apart from Asia, Australia is a long way from our predominant markets, so that’s a bit of a disadvantage, but we make it up in many other ways. We have the quality of the product and the customer base we have and the reputation we have for making a decent product in a good, clean, green state that’s renowned for quality.
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State Spotlight
Partnerships makes unique learning available When Caterpillar decided to reduce its operations in North-West Tasmania, a huge amount of work was dedicated to transitioning and retraining employees, skilling up the supply chain businesses so they could compete internationally, and providing confidence to the people of the North-West that new opportunities would come their way. One such opportunity became apparent as Productivity Improvers, a Lean consultancy and training businesses, were coming to terms with the loss of the Simulated Work Environment (SWE), a unique training facility that was owned and housed at Caterpillar’s facilities. The SWE had traditionally been used by Caterpillar to teach the Lean manufacturing principals that underpinned its productivity across the world. Productivity Improvers had only recently developed a three-day, nationally accredited training course in Competitive Systems and Practices (Lean) that utilised the SWE. The course had seen attracted demand from industry, and delivered amazing results. “We had to find a practical way to keep the SWE here in the North-West,” says Productivity Improvers Director Clynton Jaffray. “The potential for it to positively contribute to improving the culture and productivity of business in our State was obvious.” One of the biggest advocates for the SWE was Lee Whiteley, Executive General Manager at the local manufacturing giants Elphinstone Pty Ltd. He approached Jeremy Rockliff MP, the Deputy Premier and State Minister for Education and Training, as well as the Department of State Growth, the Elphinstone Group and industry leaders to explore how the asset could be retained Productivity Improvers directors Clynton Jaffray and Michael Bonney.
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and housed. These stakeholders could see that retaining the SWE would clearly be of benefit to all types of industries across Tasmania, and indeed – given that it is only one of three such facilities in the Southern Hemisphere – across the Country. An agreement was reached for Elphinstone to purchase the SWE from Caterpillar, for the State Government to allow the relocation of the 500 square metres of equipment to a vacant government building, and for Productivity Improvers to manage and deliver the training. While the relocation of the facility was a massive undertaking, it was completed without incident and on-time by a dedicated team from Elphinstone, Productivity Improvers and the staff from the newly established Tasmanian Minerals and Energy Council’s Manufacturing Centre of Excellence in Burnie. The centre was officially opened by Rockliff on 3 March last year, in a ceremony also attended by Kelly Elphinstone, Managing Director of Elphinstone. Local newspaper, The Advocate, quoted Ms Elphinstone as saying: “To have this in Burnie is a testament to what’s actually going on here. This is a hands-on, interactive way of learning Lean principals, and how to improve not just manufacturing, but your everyday life. The things you learn
in this SWE facility you can apply to just about anything.” The well proven training tool actively demonstrates the benefits of Lean methodologies such as: Put Safety First, Chase Waste, Make Value Flow, Drive Standard Work, Go See Act, Stop To Fix and Make It Visual. While based on Lean Management Principles, it is not necessary to have completed any prior training in Lean to benefit from the full range of learning outcomes generated by the SWE. Internationally renowned Lean expert and author Paul Akers was also at the opening and was impressed by the partnerships that came together to keep such an amazing training facility in a regional area of Australia’s island State. “Nothing happens without courage,” said Akers. “Unless you have the courage to try something new, nothing is ever going to change”. Akers challenged Tasmania’s industry leaders to have the courage to take Lean to a level that would make Tasmania, not only the most productive state in Australia, but in the world. “Why not?” he asked. Productivity Improvers manages and runs the operation of the SWE, which requires 17 students and five facilitators to operate,
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targetted audience 8000+ contacts
impact 20.02% The Simulated Work Environment.
and is keen to see more industry and Government departments using it to assist their staff to ‘See Waste’. Since the opening, almost 400 participants from Tasmanian and mainland businesses including Hydro Tasmania, local government, Elphinstone Group businesses, and the Hobart-based Nekon Group’s food speciality companies have used this training facility. A key to Productivity Improvers’ success to date is the partnerships that they can broker due to their connections with industry, community groups, learning institutions and now their own registered training organisation People Improvers. The facilitators who operate the SWE with the students are themselves Lean fanatics who come from a range of businesses across the North-West Coast area. Their employers demonstrate a commitment to the training by allowing them to work at the facility in turn.
each week,” says Director Michael Bonney. “It’s going to be a big ask of the team leaders and administrators but increasing the volume of people exposed to Lean principals in this fabulous facility is the only way to achieve the productivity that is needed to be globally competitive. “It has taken courage from everyone involved to get to this point and it’s going to take more to push on when the going gets tough. But we are pretty good at that in Tassie.”
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The Simulated Work Environment – FAQs • Can the SWE be booked for private team-building session? Yes. In fact, it is encouraged (Groups of 17 participants are required). • Who is the training suitable for? Anyone and everyone.
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www.productivityimprovers.com
What does success look like for Productivity Improvers, the SWE and its partners? “Our goal for 2018 is to have a class of 17 students from across the Country, and from every sector, going through the SWE
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AMTIL PRODUCT E-BLASTS call anne samuelsson on 0400 115 525 or email asamuelsson@amtil.com.au for all enquiries.
• Are there any prerequisites? A wilingess to learn. • When can I start? Tomorrow seems like a great choice.
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• How do I book? Just email swe@elphistone.com
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State Spotlight
Tasmanian advanced manufacturing rides a wave Tasmania’s advanced manufacturing sector enjoyed a good year in 2017, with major projects coming to fruition, and contracts signed for significant work going forward. Four new deals worth a total of more than $80m are expected to generate nearly 50 new skilled jobs. Tamar Hydro in Exeter was selected in November to build hydro turbines for Indonesia, while Taylor Bros in Hobart will build two high-powered Antarctic landing barges for Australia’s new icebreaker RSV Nuyina. Meanwhile Liferaft Systems Australia (LSA) has signed a contract to build inflatable marine evacuation systems for a new class of warship being built in Britain, and Penguin Composites is working on its first major Defence-related contract and putting on 15 new employees. Tamar Hydro will create 20 new positions after signing the contract to build turbines for an extensive mini-hydro network in Indonesia; the deal is expected to bring in about $45m over three years. General Manager, David Hillier, said it was a significant coup for the Exeter-based business, which is now looking for a larger factory in the Westbury or Bell Bay areas. “This contract will bring us into the modern age with new machinery,” he said. “A lot of our equipment is fairly old – 30 years – so we need to re-tool.” Tamar Hydro has built more than 200 turbines for Asia-Pacific projects after starting life in the 1970s in a small shed on the banks of the Tamar River. Work will be undertaken across about 16 sites in Indonesia and will include the refurbishment of existing turbines, deploying new ones and constructing dams. Prominent Tasmanian Polar Network business, Taylor Bros, is scheduled to have two barges completed by 2020 when RSV Nuyina begins operations, replacing the long-serving Aurora Australis. Designed, engineered and built locally, the barges will carry 45.5-tonne trucks from ship to shore, giving the icebreaker unprecedented unloading and reloading capacity. Damen Schelde Naval Shipbuilding is building RSV Nuyina in Romania for the Australian Antarctic Division. It will be 156 metres in length, with a beam of 25.6 metres and will be able to break ice up to 1.65 metres thick at speeds of 3 knots. RSV Nuyina will supply Australia’s research stations in East Antarctica and Macquarie Island with cargo, equipment and personnel.
GP Glass – Can-do glaziers Spreyton-based glass manufacturer GP Glass landed a national award in October for a machine cobbled together from a
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University of Tasmania Deputy ViceChancellor (Research) Professor Brigid Heywood.
Launceston gets sensor hub State-of-the-art sensors for international markets will be manufactured in Launceston following the launch of a new advanced manufacturing hub last March. State and Federal governments have supported the joint venture involving manufacturing business Definium Technologies and UTAS’s Sense-T project. The university’s Deputy Vice-Chancellor, Brigid Heywood, said: “This is smart, future-facing manufacturing. This will position Launceston and Tasmania as an innovative provider of advanced circuit board components and electronic hardware design.”
mechanic’s engine crane and a boat winch. GP Glass is one of Tasmania’s leading manufacturers of glazing solutions, producing high-quality aluminium windows and doors, framed and frameless balustrades and shower screens, sliding wardrobe fronts, security doors and window screens, for residential and commercial markets. It also offers cut-tosize glass and glass replacements for your existing windows and doors. Faced with the mammoth task of installing 2,500 double-glazed windows weighing 100kg each in a new nine-storey student residence building for the University of Tasmania in Hobart, the GP team came up with its prize-winning window-lifting device that has piqued the interest of other glaziers around the country. The machine won a design award from the Tasmanian Glass and Aluminium Association and subsequently took out the National Safety Award at the Australian Glass and Glazing Association. Company Director Brian Imlach said his team had to find a way to safely install the large glass panels: “It needed to be simple. It needed to be light. It needed to be strong and transportable and disassembled quickly, so we could lift it from floor to floor.” The device was engineered to lift up to 200kg and it eliminated the need to use a harness while working on a building site edge, as a safety gate could be used. “It’s safe, efficient and we can install a lot more windows because there’s not as much strain on our workforce,” Imlach added.
The hub will allow Definium to design and build sensors for local and international applications. Definium Chief Executive Mike Cruse said: “We want to start monitoring and sensing the environment to help make decisions about the environment and create jobs.” Definium employs three full-time technicians as well as casual staff but it’s expected the hub will increase employment to about eight full-time workers.
Incat ships fourth Sydney ferry In August, Incat Tasmania completed delivery of the fourth in an order of six vessels to Sydney. Incat’s Hobart Shipyard has been awarded a contract to build six new ferries to operate on Sydney’s Inner Harbour. The Sydney Ferries will service commuter and tourist travel on the inner harbour routes from Watsons Bay in Sydney’s east to Cockatoo Island in the west, stopping at the new Barangaroo wharf. The new vessels have a traditional exterior design intended to look similar to the Sydney First Fleet vessels. However the 35-metre, 400-passenger craft have greater capacity than the current fleet. The interiors are more spacious, with comfortable inside seating, outdoor viewing areas, a large walk-around deck and additional features for passengers. Tasmania’s Deputy Premier, Matthew Groom, said the presence of Tasmanianbuilt ferries on Sydney Harbour would strengthen the state’s boat-building reputation: “This is an important element of securing other advanced manufacturing and defence-related contracts of significance, especially in the maritime sector.”
Tasmania A graphic representation of the RSV Nuyina with the two barges that will be built by Taylor Bros. (Photo: AAD/Damen).
In May, Incat also secured a $109m contract to build a 109-metre high-speed vehicle-passenger ferry for Naviera Armas, in Spain, with delivery scheduled for 2019. The wave-piercer will be able to travel at 35 knots) and carry 1,200 passengers and crew, along with 390 cars. Incat Chairman Robert Clifford said the Hobart shipyard’s 550-strong workforce was expected to deliver up to two large high-speed catamarans each year. A month earlier in April Incat’s newest highspeed car ferry, the $100m Express 3, was launched and sailed for Denmark after sea trials on the River Derwent. Incat is the world’s leading producer of high-speed, multi-hull ferries, but its fortunes have waxed and waned with the global ship market. Late last century it was Tasmania’s largest private employer with a 1,000-strong workforce, but the global financial crisis flattened demand and the workforce dwindled to 190. Now it’s all hands on deck again – the shipyard is spending $500,000 to raise the roof of its main construction shed by two metres so that more work can be completed under cover on its largest ships, while recruitment plans include doubling its team of apprentices to about 40.
Incat Tasmania’s high-speed car ferry Express 3.
Liferaft Systems Australia (LSA) has signed a contract to build inflatable marine evacuation systems for a new class of warship being built in Britain.
The company’s founder and Chairman Robert Clifford said: “Over the next six months we will be putting on up to 200 extra people bringing us up to the 700, 750 mark.” Reprinted courtesy of Brand Tasmania. www.brandtasmania.com www.tamarhydro.com.au www.taylorbros.com.au www.lsames.com www.penguincomposites.com.au www.gpglass.com.au www.sense-t.org.au www.definium.net www.utas.edu.au www.incat.com.au
Scan this code to visit Brand Tasmania’s YouTube channel and see a video of the world’s fastest ship, Incat’s wavepiercing catamaran ‘Francisco’.
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Company Focus
Penguin Composites – Perseverance the key to success Diversification, innovation, reinvestment and skilled recruitment have enabled Tasmanian manufacturer Penguin Composites to succeed and grow in both Australian and global markets. By Carole Goldsmith.
Penguin Composites’s owner, CEO and founding director John van der Woude in the company’s workshop, including its recent acquisition, a Multicam CNC routing machine.
In October Penguin Composites had a major win for the business and for Tasmanian manufacturing when it signed an three-year, $8m contract with Thales Australia to produce bonnets and other components for the Hawkei protected mobility vehicle. The deal represents the company’s first major defence related contract and it is expected to create around 15 jobs at its factory in the town of Penguin. Christopher Pyne, the Federal Minister for Defence Industry, congratulated Penguin Composites on the contract and said it would provide a significant boost to Tasmania’s share of the nation’s defence investment.
someone to get it done quickly and they had a short lead time. It took three months to get the contract and nine months to sort out the details and sign it.”
“This contract will not only create new jobs in Tasmania, it will also involve the upskilling of existing personnel to help deliver this work,” said Minister Pyne. “This is a textbook example of how Australian small-to-medium enterprises are building their capabilities and contributing to our sovereign defence industry capability.”
“Recently, we’ve also had to upskill our administration for our entire plant; that is where the biggest changes are occurring. An enterprise resource planning (ERP) software was implemented around five years ago, and now we are refining that to the n-th degree. That system runs the entire business, and it’s a big learning curve for any business that goes from being a simple jobbing shop to move on to become a well-run enterprise.”
Thales signed a $1.3bn contract in October 2015 to supply 1,100 Hawkei vehicles and more than 1,000 trailers, and is now ramping up for low-rate production. Penguin Composites was engaged after Thales identified a number of Australian suppliers who could provide components it required. Penguin Composites’s capabilities include design and engineering of moulds and plugs, fibreglass and composite component manufacturing, in addition to specialist composite product manufacturing. Penguin Composites’s owner, CEO and founding director John van der Woude is very excited about winning the Thales contract: “We have been working on the manufacturing moulding process for the Hawkei parts and are manufacturing the bonnet and the 18 other parts, including the guards, sidesteps and rear guard for the Hawkei protected vehicle. These components will be made of a fibreglass composite using Light Resin Transfer Moulding, a vacuum-assisted closed moulding process.” Van der Woude explains how his company secured the contract: “We tendered to Thales for the project as they were looking for
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The Hawkei project is expected to add 15 more employees to Penguin Composite’s current workforce of 40 people. Van der Woude adds: “We will need a couple in management, engineering and drafting, a couple of painters, and around eight process workers. Some employees will be new and some will be taken off the current manufacturing work, so we will need to replace them to do our existing projects.
According to van der Woude, involvement in the Hawkei project will help the company’s business growth: “It will open up other doors for future defence projects. Once we have ISO 9001 in place, other Defence Primes will be interested. We are still working on the ISO 9001 implementation.”
From making kayaks to diverse manufacturing Penguin Composites has been progressing in leaps and bounds since van der Woude started out in business just over 40 years ago. At that time, he was building kayaks and surfing gear at Penguin beach, on the picturesque north coast of Tasmania. “I was also paddling kayaks, heavily involved in surf lifesaving, and living on the beach,” he recounts. “I expanded the fibreglassing into a watersport and surf retail shop. Then we diversified, establishing kayak shops in Devonport, Burnie and Launceston, and ended up having just the one big shop in Devonport, which we sold four years ago.”
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The Hawkei protected mobility vehicle.
John van der Woude, at the company’s premises in Penguin, on Tasmania’s north coast.
In 2003, the business changed its name to Penguin Composites. Located in Penguin’s industrial area, the company’s factory and office space of 3,500 square metres spreads over two sites 100 metres apart. The business specialises in manufacturing composite components from various polyesters, isothalics, vinylesters and epoxies, combined with composite products of various fibres and core materials. “In the early days, we were a jobbing industry and people would come along and ask if we could build this or fix that, and we still get these requests today,” says van der Woude. “Over the last few years we have been getting more people with specialised skills. Five years ago, we employed our first engineer and recently recruited two draftsmen/programmers. As we are getting into CNC routing, we’ve acquired a large Multicam CNC machine. Now we can cut out panels like the joinery shops do, with the computer-controlled patterns.” As well as busily preparing for the Thales contract, the company’s product range is highly diverse. It has two subsidiaries. Composite Poles Australia makes power and telecommunications poles. Meanwhile, after the most recent downturn in the mining industry, the company diversified and took on Islander Campers, which produces a range of campervans, caravans and motorhome vehicles. The team at Penguin Composites has been redesigning the Islander Campers range over the last three years to cover many vehicle options. “Within our own product range, we want to expand sales of Islander Campers within Australia,” says Van der Woude. “If someone buys one they usually come down for a holiday and pick it up.” In addition, the company product portfolio ranges from CNC router panels for architectural projects and chairlift components bound for airports worldwide, through to heat shields for underground mining machinery, and igloo accommodation units for polar field operations. “Initially, our main industrial products were for the mining industry,” says Van der Woude. “We have been making engine heat shields for Elphinstone underground mining vehicles for many years now. These engine heat shields are also now exported to global Caterpillar clients.” Made out of fibreglass, the igloo accommodation units are mainly used in satellite camps away from main bases in Antarctica. “We ended up building Icewall One igloos for Antarctica and other places for our client Wallhead and Associates (Malcolm Wallhead & Associates, a local manufacturer of polar field equipment), and that work is ongoing. We have also made them for mining sites, and for Google’s offices in Zurich. There’s four in Europe used for interview booths in Google colours. New York University ordered a couple recently and I think that they will be used for research areas.”
Van der Woode voices particular pride regarding some of the architectural projects his company has been involved in: “We have just supplied large louvre covers for windows in Hobart’s Parliament Square. We also made panels for under a building’s balcony at Barangaroo, Sydney’s new waterfront destination.”
Building the business Van der Woude says that he has grown the business through innovation, perseverance, a commitment to the best technology, and the recruitment of key staff: “We are always trying to invent new products and improve production. Perseverance is the key to success. “The engine heat shield for Elphinstone underground mining trucks is probably the innovation that we are most proud of. We worked on that for a while, to determine the best composites for the job. Eventually we developed the stainless shield heat shield, for the underground mining trucks. The shield encases the turbo and manifold and lowers the engine’s external temperature. You can service the engine while it is running with the heat shield on it, as it was originally designed for fire control.” Regarding Penguin Composites’s commitment to technology, van der Woude explains that as things improve in the fibreglass industry, new technologies have been employed, such as Light Resin Transfer Moulding and drafting. He adds that reinvestment is the key to a business’s survival: “You don’t take money out of the business; you borrow safely and invest in the business’s cashflow.” Penguin Composites has always done marketing through businessto-business networking and via its website. It also uses Facebook for news and promotions. The company has been involved with the Australian Industry & Defence Network (AIDN), the peak industry association for SMEs in the defence and security sectors, over the past ten years, and is part of the Tasmanian Polar Network, a group of businesses and scientific organisations based in Tasmania that serve commercial and scientific activity in the Antarctic, subAntarctic and Southern Ocean. Van der Woude believes manufacturing in Tasmania is going very well: “All the guys I am speaking to, are very busy. “The State and Federal Governments have been very active supporting Tasmanian businesses over the past few years. The national Government’s defence projects are being tapped in Tasmania now and we are getting a lot more exposure to the defence project opportunities. Speaking on Penguin Composites’s future business plans, van der Woude says: “We want to improve technical skills, business processes, drafting and the engineering side of the business. Production control needs improvement and once you have that in place you can cope with any work that comes along. “Our company has a very solid diverse clientele, great contacts and a secure skilled workforce. We will be around for a long time.” www.penguincomposites.com.au
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Forming & Fabrication
Yawei HLE fibre laser brings multiple benefits to Wildcat Industries Yawei’s new HLE & HLF fibre lasers are gaining a reputation for outstanding performance coupled with value for money. Wildcat Industries is the latest in a line of customers who have seen the multiple benefits they bring. Following many years working in the sheet metal industry, Jon Flynn founded Wildcat Industries around 10 years ago. Based in Dandenong, Victoria, the business now employs 20 people across four divisions: high-tolerance sheet metal work; architectural facade work; the manufacture of high-tech wood and gas flue systems; and most recently, Wildcat wood-fired pizza ovens. While the architectural division services clients throughout Australia, the sheet metal work is predominantly Melbourne-based. Wildcat offers custom perforated panels to the architectural, building, construction, interior design and landscaping industry. Flynn already had extensive experience dealing with Applied Machinery having, in his own words, “virtually bought every single piece of equipment to date” from them. “The Applied Machinery people look after me as though they are part of my business,” says Flynn. “The service, support and warranty are very important for me and Applied excel in this area. So the decision to buy a Yawei fibre laser from Applied Machinery was both a logical and easy one. Already well known as one of the world’s leading manufacturers of CNC pressbrakes,
turret punch presses and guillotines, Yawei’s entrance into the laser cutting market comes off the back of years of R&D and refinement of the machines in its domestic market in China. The Yawei HLE comes equipped with an extensive range of high-quality componentry including an IPG fibre laser source with 2kW capacity, a Swiss Raytools cutting head, and a German Beckoff CNC control system, all housed within a rigid, robust frame. “The Yawei has enabled us to redesign products to make them perform and look better, and produce parts of a much higher quality,” adds Flynn. “Plus of course, given the speed and accuracy of the fibre laser, we are saving huge amounts of time; you can just do so much more with it. You don’t get any burn marks or blemishes on the material either. “The Yawei has been an absolute game changer for me; I really can’t stress that enough. It’s allowed us to replace one of the turret punch presses and also replace the plasma. Crucially this has enabled us to bring all our laser cutting in-house. In addition, the acquistion of the Yawei machine has made Wildcat more competitive in the marketplace. “There’s no tooling set-up for short runs, we can forecast more accurately and cut
more out of a sheet, resulting in further cost efficiencies,” Flynn explains. “Plus we can now cut a wider choice of material including titanium and stainless steel.” One other thing that the Yawei fibre laser has given Flynn is the confidence to quote on work that he wouldn’t have previously targeted, thereby increasing his volume of work. Just one example is a new customer Wildcat picked up as a direct result of having the fibre laser, which will provide a significant lift in work for the company over the next five years. Without the fibre laser Flynn and his team would not have been able to get the yield and the speed required to be competitive. “Quite simply the Yawei HLE has far exceeded my expectations – it really is that good,” Flynn concludes. “Yes, there are cheaper models out there but none of those have the quality, robustness and longevity that I am looking for; many also don’t meet Australian standards. Let’s face it, you get what you pay for. “The way things are going I can definitely see a need for a second fibre laser in the future.” www.wildcatindustries.com.au www.mypizzaoven.com.au www.appliedmachinery.com.au
Left: Wildcat Industries founder and Director Jon Flynn with his company’s new Yawei HLE fibre laser. Below: Wildcat Industries’s premises in Dandenong, Victoria.
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Technology investments help TW Woods set new benchmarks New high-definition plasma cutting technology is helping the TW Woods Group to optimise efficiency and quality in the production of chutes, bins, loaders, tanks and silos at its plant in Tomago, New South Wales. The new Lincoln Spirit 400 machine – now operating in the company’s 400sqm plate-processing facility – was specified to deliver industry-best standards of cut quality on standard and specialty steels, including stainless steels and heavy-duty chromium carbide protective plates up to 60mm thick. According to TW Woods’ Managing Director Tom Woods, highquality, wear and impact-resistant materials are now in high demand as coal and mineral processing plants place new emphasis on long-life products that avoid delays and breakdowns as mines step up production. The same quality, traceability and accountability standards are being required by private and state organisations involved in the energy, marine, oil & gas and defence sectors, where safety and durability are paramount. The investment in state-of-the-art plasma cutting technology has also been complemented by the installation of a new Truflow spray booth and bake oven to deliver best-quality protective finishes for customers in industries including defence, energy, manufacturing, mining, minerals-processing, materials-handling, metals, process engineering, and water and wastewater. Truflow technology – the same type used by industry leaders including Siemens, Bombardier and Veolia – is used by TW Woods to apply quality finishes ranging from camouflage patterns for defence projects, to protective coatings for mining, energy and bulk handling equipment used in aggressive, marine, chemical and mining environments.
The new Truflow paint finish facility The new investments are part of an ongoing multi-million dollar expansion of TW Woods’ two-hectare facility to expand the range of tasks it handles on the one site from start to finish, enabling it to maintain strict quality control and to meet tight deadlines. Production efficiency and quality control when producing such designs is further enhanced at the TW Woods plant by the integration of its plate processing area. This contains a new Spirit 400 machine with an 800sqm paint and blasting facility incorporating a sand blast chamber with 10m-high ceiling to handle large jobs. This facility feeds directly to a state-of-the-art 720sqm industrial paint shop with a 12m entry door to handle major projects such as coal and ore train load-out facilities, complex piping, recirculation tanks, shaker screens, storage bins, hoppers, silos, chutes, ductwork, bridgework, steel structures, tanks and mobile water tankers. The paint shop is immediately adjacent to the new Truflow facility, in which painted products can receive specialised finishes, all on the one site.
Optimised work flow “The optimised work flow and range of production facilities available on the one site means even the most complex jobs can be handled efficiently and expeditiously, without elements of the work having to be sent off-site with the attendant delays and potential lack of uniformity of quality standards,” says Woods. “We are also able to fully utilise the skills base of our staff team, which we have built up over 50 years and three generations of family ownership. We have a tremendous asset in our staff loyalty, great staff skills and our investment in comprehensively equipping ourselves to handle complete projects on-site.” Materials handling system efficiencies are further enhanced by
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Tom Woods with the new plasma cutting technology at the Tomago site.
innovative designs from TW Woods’ partner engineering group Chute Technology, which uses advanced engineering technologies, including discrete element modelling, to optimise and translate into reality materials handling configurations that minimise problems such as impact and abrasion zones, and smooth the flow of material within such systems. “We are finding that quality and safety-conscious clients are requiring increasingly higher standards of design, construction, finish and quality control to ensure the best lifespans and least maintenance achievable in their industries” adds Woods. “Companies and utilities are increasingly aware of the high costs of lost production and safety hazards involved in systems that are prone to wear and breakage. Failure-prone systems can entail high labour costs and significant hazards involved in having to continually clear stoppages and install new materials handling facilities to tight production deadlines.”
High-tech facilities Housed on the company’s two-hectare site with Hunter River frontage, the new facilities complement 4,000sqm of workshop area in which the company undertakes medium-to-heavy steel fabrication, plate rolling and pressing, and manufacturing of materials handling equipment including chromium carbide-clad, plate-hardened steel products. The company’s services (including specialised shaping, fabrication and welding technology for metals including carbon steel, stainless steel and aluminium) are used by organisations such as Delta Energy, Incitec Pivot, water and waste water authorities, Integra Coal, Laing O’Rourke, Xstrata and surface and underground mining companies throughout Australia, including iron ore producers in the Pilbara and coal companies in Queensland. The company has also become a valued supplier to the water treatment and materials handling industry because of its expanded capacity to process specialised metals and manufacture complex shapes required for special-purpose tanks, silos and pressure vessels. www.twwoods.com.au
Forming & Fabrication
TruLaser 5030 maximises productivity at Laser 3D Founded in 1992 with only two employees, Laser 3D now employs over 60 staff throughout Australia, operating 11 machines across Victoria, Queensland and SA. The laser cutting and fabrication specialists service a diverse range of industries, including automotive, transport, aerospace and shop fitting, among others. With a strong focus on company culture, Laser 3D place high importance on attracting and retaining great staff, with an aim to build upon their knowledge and training where possible.
Fibre Laser Systems Sheet/Tube/Coil 24/7 Operation • Swiss Design 3 Year Warranty
Laser 3D’s CEO Bruce Thomas says that there are three main factors that contribute to the company’s success: technology, customer relationships, and dependable suppliers. Ten years ago, Laser 3D used four different machines from four different suppliers. The company now uses one supplier, Headland, and Trumpf machinery only. Consequently its processes are fully streamlined where possible as all staff members can operate all the machinery in the factory. Technology is critical to automating processes and ensuring quick turnaround times for customers.
Systems from $75,000 and powers to 8kW IPG 2kW - twin table $240,000+GST
“We use technology wherever and whenever we can in order to streamline processes,” says Thomas. “We make sure that we fully understand each and every customer’s individual needs. We place high value in our customer relationships and we have been servicing some of the same customers for 25 years. “We also take our relationship with our suppliers as seriously as with our customers. We stick with them through thick and thin, which is why we believe our business succeeds.” Laser 3D recently purchased a TruLaser 5030 6kW, a highly automated Trumpf laser, from Headland. Trumpf machinery was chosen due to its quality and dependability. Renowned for high productivity and efficiency, the laser machine achieves high-quality results using any type of sheet metal, in a variety of thicknesses. High processing speeds and minimal operator involvement mean that non-productive times are minimal, and the complete machining process is more reliable than ever. Thomas reiterates the importance of their relationship with Headland: “Having a strong supplier relationship is imperative to our business because we sell time. If one of our lasers goes down, we’re losing time that we can’t get back. “It’s crucial to have as much up-time as possible, and the service team at Headland does a fantastic job across the country. There are no words to describe how good they are. We spent a long time looking for a reliable supplier, and the high level of support and service from Headland means that they are so quick to get us back up and running as best as they can.” www.laser3d.com.au www.headland.com.au
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Joining dissimilar materials Combining lightweight, dissimilar materials—particularly metals and polymers—is increasingly prevalent in the manufacture of lightweight assemblies in industries such as aerospace. Hence, suitable joining methods are necessary to integrate them. By Paul Kah. Polymer materials have become increasingly prevalent in structural applications because of their low weight, high specific strength, elasticity and low cost, spurring research into the combination of polymers and metals in manufacturing. Parts made with metal-topolymer joints now are in high demand.
However, adhesive bond joints can be problematic as the bonded joints cannot be disassembled without damage and can emit harmful environmental emissions. In addition, joints are prone to degradation from moisture, humidity and temperature, with low resistance in a chemically reactive environment.
One of the goals for using dissimilar joints is to enhance product design flexibility so that differing materials can be used in an efficient, functional manner based on their specific properties. Metal-topolymer assemblies combine the strength and ductility of metal with the physical-chemical resistance and light weight of polymers. Metal is used in sections where high stiffness and strength are needed, whereas plastic provides unique chemical properties.
Bonding demands extensive surface preparation. Surface properties in an adhesive bond play a vital role, and bond strength and joint durability can be significantly improved by surface treating workpieces before bonding. During pretreatment, the workpiece’s surface tension increases, but the contact angle of water decreases. Typical surface pretreatment techniques include solvent cleaning, surface chemistry alteration, and abrasion and other topographical changes.
Therefore, it is important to maximise the joint contribution of each material to ensure optimal operational performance while still maintaining a weight- and cost-effective approach. However, joining dissimilar materials is often difficult. The behavior of such joints is rarely fully understood, particularly when using bonding and heating techniques.
Current metal-to-plastic joining methods Techniques commonly used for hybrid joints between metal and polymer workpieces include adhesive bonding, mechanical fastening, and welding. Each technique has advantages and disadvantages. The most appropriate method will depend on application and service: Mechanical Fastening. Originally used for metal-to-metal joining, mechanical fastening is now used for metal-to-plastic joining too, employing clamping components such as screws and rivets for joint formation without fusing the joint surfaces. Different mechanical joining techniques exist for metal-to-plastic joints, but the emphasis currently is on riveting, because it establishes a reliable joint. Some types of riveting need a heating cycle, where rivets are heated before fastening so they shrink upon cooling, clamping the component tightly. Test results showed that in rivet joining between a metallic and polymeric material, the process depends on sheet thickness and the rivet’s geometric parameters, such as tool design and the riveting force. Because the bottom material undergoes the greatest deformation, the polymeric material should be placed under the metallic sheet. Joint configuration often depends solely on service conditions, such as whether it must be leakproof. In some cases, the joint may be designed to tolerate mismatches in the coefficient of thermal expansion during assembly. A joint can also be made to allow freedom of movement in the plane perpendicular to the clamping member. Mechanical fastening remains the most common joining method because of its simplicity. However, it has limitations, such as increased component weight and stress concentration around fastener holes, which degrade strength and eventually create corrosion. Adhesive Bonding. Adhesive bonding is a solid-state joining technique that involves the use of a polymeric adhesive, which undergoes a chemical or physical reaction, for joint formation. The use of adhesive-metal joining has grown substantially in recent years with the development of very strong and tough adhesives that can withstand both static and alternating loads. Also, adhesives generally weigh less than mechanical fasteners, affording considerable weight reduction. In addition, stress distribution during loading is homogeneous.
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An additional limitation is that bonded joints often fail instantaneously instead of progressively. The most important limiting factor for bonding is uncertainty in forecasting the long-term durability of this kind of joint because of difficulties in reliable non-destructive testing. Both mechanical fastening and adhesive bonding require an overlapping joint configuration to achieve the necessary joint strength, which increases the structure’s weight, thickness and stress concentration. This restricts the use of these joining techniques, leading to the pursuit of joining techniques that have greater design flexibility and fabrication rates — and to the development of welding approaches. Welding. Conventional welding processes such as shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), and submerged arc welding (SAW) have been used to weld dissimilar materials in metal-to-metal joints. However, the high energy inputs of these processes result in material metallurgical distortion that hinders this application, as well as metalto-polymer joints. The melting temperature of metals is extremely high compared to the melting temperature of polymers. Hence, polymers tend to degrade before metals melt. Polymer welding can be done only on thermoplastics, because the processing of thermosets and chemically cross-linked elastomers is characterised by an irreversible cross-linking reaction that results in degradation; therefore, they cannot be reshaped by heating. Thermoplastics and thermoplastic elastomers can be melted and softened by heat because of the weakening of the secondary Van der Waals and hydrogen bonding forces among interlocking polymer chains. This makes it possible for thermoplastics and thermoplastic elastomers to be remoulded upon application of heat, so they can, consequently, be fusion welded.
Emerging techniques Several promising techniques for joining dissimilar materials have been developed to solve problems related to traditional joining techniques. The effective application of these processes necessitates an understanding of their capabilities and limitations and the behaviour of metals and polymers: Ultrasonic Welding. Ultrasonic welding is a solid-state joining technique that initiates coalescence via simultaneous application of localised high-frequency vibration energy with a moderate clamping force. This welding technique is characterised by low energy input and requires the clamping and positioning of the workpieces between the welding tool (sonotrode) and an anvil by static force. No microstructural changes occur in the metal.
Forming & Fabrication
The workpieces can be two thin sheets or a thick and a thin sheet in a simple lap joint or a butt joint, depending on the direction of the energy supply of elastic oscillations to the welding zone. Ultrasonic vibration can be applied to welding both metals and plastics, but the welding process differs for each. The actual weld achieved depends on how the ultrasonic energy is delivered. In ultrasonic metal welding, the direction of ultrasonic oscillation is parallel to the weld area. When the ultrasonic metal welding is realised, the frictional action of the workpiece surfaces initiates a solid-state bond without any melting action. In plastic welding, the case is reversed. For ultrasonic plastic welding, the direction of ultrasonic oscillation is perpendicular to the weld area. Researchers experimented with ultrasonic welding of aluminium sheets to carbon fibre-reinforced thermoplastic composites. Their experiment studied the weldability of aluminium alloy 5754 to carbon fibre-reinforced polymer with thicknesses of 1 mm and 2 mm, respectively. They observed a sound weld at amplitudes around 40 microns as a result of displacement of the thermoplastic matrix, yielding a better contact between the metal and the fibre. They also observed that intermolecular reactions in the weld zone formed when oxide layers on the sheet metal peeled off during welding. The polymer matrix was actually displaced from the welding zone, which allowed the ductile aluminium to adapt the carbon fibres. This enabled mechanical interlocking and consequently increased joint strength. Finally, it was observed that the carbon fibres surrounded the aluminium alloy because of plastic deformation of the aluminium sheet, creating a successful weld. Laser Welding. Laser welding offers unique opportunities. It complements the fabrication and processing of joints hitherto difficult or impossible to achieve by other welding methods. Laser welding of metals to polymers can delive stable metallic, chemical, and covalent bonds between metal and polymer hybrid components. Laser direct joining between metals and polymers, typically known as laser-assisted metal and plastic joining, has been proposed. The joint interface is heated by the incident laser beam, and the plastic’s melting temperature is attained in a narrow region adjacent to the interface. The high temperature initiates formation of bubbles in the melted plastic close to the interface, which spread and diffuse into the molten phase and consequently increase seam dimension between the plastic and the metal. Bonding occurs due to chemical bonding between the metal oxide film and the polymers’ carbon atoms, and physical bonding resulting from the Van der Waals force and mechanical bonding. The advantages are very fast welding times, small heat input, and high adaptability. High joint strength can be achieved in laser direct metal-to-polymer joining, and this is applicable to several metals, such as steel, titanium, aluminium and iron. It should be noted, however, that the metal does not melt in this process. The limitations are the many parameters, such as travel speed and welding power, that influence the quality and reliability of the eventual joint. Laser welding also has limited design flexibility and is suitable mainly for lap joints because of the need for effective absorption of the laser beam. Due to the low thermal conductivity of plastics, heat remains concentrated in the material interaction zone. Furthermore, the behaviour of the heat depends on the plastic’s optical properties, a function of its molecular composition such as colour, and the incident beam’s wavelength.
Friction Stir Welding. This process incorporates three distinct phases: plunging, stirring, and retracting. During welding, a highspeed rotating tool with a probe pin is plunged at a specific rate into the overlapping weld spot until the tool’s shoulder contacts the upper workpiece. This causes plastic deformation around the pin. Conventional friction stir welding encounters problems when welding plastics, related to the poor thermal conductivity and diffusion from the macromolecular structure of thermoplastics. Friction Spot Joining. Friction spot joining is a variant of linear friction stir welding except that there is no linear movement of the tool. During friction spot joining, the friction between the pin and the workpiece generates most of the heat energy for the joint. Friction spot joining of metals to polymers incorporates two distinct processes: the sleeve plunge and the pin plunge. In sleeve plunging, workpieces are initially overlapped and clamped between a backing plate and a clamping ring, with the metal on top of the polymer. The sleeve and pin rotational motion is then initiated, with both pieces rotating in the same direction. At some point, the sleeve touches down on the upper metal workpiece, causing frictional heating. Simultaneously, the sleeve is inserted into the metal workpiece, plasticising the metal, and the pin is retracted, resulting in formation of an annular space or reservoir. The plasticised metal is squeezed into the created reservoir as a result of the sleeve plunging effect. Upon completion of joining, the sleeve is retracted from the metallic workpiece surface and the pin extrudes the entrapped plasticised material back into the weld. The keyhole is consequently refilled. Tool plunging is set in such a way that plunging takes place only in the metallic workpiece, to avoid damage to the fibre reinforcement of the polymeric workpiece, which can reduce joint strength. The plasticised metallic workpiece is further deformed by the sleeve plunging, resulting in formation of a metallic nub on the surface of the polymeric workpiece. Friction spot welding has been feasible in welding dissimilar metals such as aluminium alloy and magnesium alloy. The feasibility of friction stir welding with metal-to-polymer joints is not fully understood, mainly because of differences between the method for metals and for plastics. The low thermal conductivity of polymers and their complex structure require changes in welding tools and tool design.
Conclusion Ultrasonic metal-to-polymer welding seems a highly promising method for hybrid structures joining metals to polymers. Friction spot joining presents similar results as ultrasonic metal welding, but has been successfully applied only to low-melting-point metals and is not applicable to very thick metals. Laser welding of metals to polymers can deliver stable bonds between metal and polymer hybrid components, but bonding occurs in the moltensolid interphase between the plastic and metal; the metal does not melt. Metal-to-polymer welding processes are promising, but still in the developmental stages; more studies are need to effectively understand their feasibility and durability. Reprinted courtesy of The Fabricator. This article has been adapted from the white paper “Techniques for joining dissimilar materials: metals and polymers,” Lappeenranta University of Technology, Lappeenranta, Finland, 2013. www.thefabricator.com www.lut.fi
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Business Management
Mass customisation: A pathway to success for SMEs The Federal Government’s Entrepreneurs’ Programme held a special learning event on 7-8 December in Melbourne, during which Professor Kjeld Nielson from the Department of Materials and Production at Aalborg University in Denmark gave a presentation entitled ‘Introduction to Mass Customisation’. Here, Mal Clark summarises the key points. In this report, certain generic words such as product and others are used. However it should always be understood that, while manufacturing terminology may be used, the ideas described are equally applicable to service organisations. They may also cover specific elements of a business process, rather than simply the whole business. Many people have the impression that mass customisation is about mass production, and through some magical process allows an unlimited number of variations to be offered to the customer. This is wrong. Mass customisation is about tailoring the offering to the customer, while retaining the lower costs per item that are offered by mass production. This allows SMEs to complete with larger enterprises.
costs per item achieved in mass production? This would effectively amount to a return to a “pull system” from the craft production period. The answer is mass customisation.
Modularisation The starting point for mass customisation is modularisation – breaking down the business process steps into modules that have common characteristics. When these modules are combined, multiple options for the customer arise. An example is Lego blocks. From just six items of one module comes over 915 million customer options.
Mass customisation is also highly data-driven. Consequently, it is relevant to the ongoing developments in the field of Industry 4.0.
From pull to push, and back again Before industrialisation, everything was craft production, where the customer specified what was required and this was provided, but the cost was high. It was a ‘pull system’.
Mass customisation is not mass production. The concepts can even be applied by businesses offering only a few items a year. The basis of mass customisation stands on three components, all of which must be developed, implemented and refined concurrently. The three platforms are: Solution Space Development; Robust Process Design; and Choice Navigation.
Then during the Industry 1.0, mass production started, costs were reduced, but the options for the customer were also reduced. This continued through Industry 2.0 and Industry 3.0, with ever-reducing costs per item, abeit accompanied by a requirement to produce higher volumes. This resulted in an ongoing decline in the potential for variations. The mass production phase was a “push system”, where the supplier pushed what they thought the customer wanted onto the customer. We have probably all observed cases of businesses who have adopted automation because labour costs were perceived to be too high. This approach foregoes the key component of ‘customer pull’, instead jumping straight into the ‘supplier push’ way of thinking and this will offer the way forward. However, because they often do not have the volume to justify the capital investment of automation, these businesses are forced into the relentless pursuit of lower costs and higher volumes, following in the footsteps of numerous businesses since the early 20th Century. With the advent of Industry 4.0, the question being asked is: can we achieve the ability to offer choice, while still retaining the low
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Solution Space Development Solution Space Development involves developing a deep understanding of the space the business wants, needs, or can operate in; and its customers’ current needs, and more importantly their future needs (which they currently do not even know they need). There is a requirement for a great overlap of these two – business capability and customer needs. In summary, what space is the business in, what space is the customer in now, and what space will the customer be in sometime in the future? This can only come from data.
Business Management
In considering the current and nascent needs of the customer, there is a requirement to develop an understanding of the benefit of choice. More choices do not necessarily leads to improved benefits. There is a limit to the value of providing more choice as the customer cannot differentiate available options. Obviously modularisation helps delay the increasing cost of variety.
Where things go wrong There have been multiple high-profile firms whose attempts to implement mass customisation have gone wrong. Here are two prominent examples: • Individualised Levi Jeans. In this example, the failure was due to choice navigation being too broad, with every size being offered in every style. There was no ability to modularise, and this was exacerbated by inefficient business processes – the jeans were still craft manufactured. • MyMuesli. In this case, customers were able to choose percentages of up to 80 individual muesli ingredients. The venture failed due to business processes requiring to go through every filling station no matter how many ingredients were selected, meaning volume was not scalable (i.e. modularised). Moreover, the reducing benefit of choice led to customer fatigue.
Why do it? And where to from here? If completed successfully, mass customisation offers the ability to reduce costs by standardisation, while increasing revenue by offering customers what they want, even when they do not know they want it and they are prepared to pay more for the product.
Robust Process Design Robust Process Design is all about flexibility, agility and changeability, to deliver variability coupled with standard work within the business process modules. These are all the hallmarks of employee engagement, and a culture of continuous improvement, or Lean Manufacturing. Successful employee engagement is datadriven with intimate knowledge of internal performance
Choice Navigation Choice navigation entails helping customers feel they have all the choices they desire, but this is constrained within your product offering. It requires subtlety to ensure that, while choice is offered with unbridled flexibility, the business does not degenerate into a “one-off” configurator with the inherent costs associated with craft production. There are several software vendors entering this space such as: • Shape Diver. www.shapediver.com • Sofon Guided Solutions. www.sofon.com/en • 3D Source Product Configurator. www.3dsource.com Choice navigation software options also exist for services.
In my opinion, when considering whether a business might consider mass customisation, the firm must have control of intangible assets, such as intellectual property (IP). Firms that are “build to print” or “service to order” have limited ability to embrace mass customisation. IP may be registered, such as design, trade secrets such as recipes, or knowhow such as service provision. The business needs to be willing to accept that it needs to review and analyse all of its products and services to consider how to modularise each component into reproducible elements that when combined create new offerings. The business also needs to be ready, if not fully capable, of being data-driven, from understanding customer needs, to having a full understanding of business processes and being able to implement an appropriate choice navigation process (generally software-driven). Mass Customisation is a holistic business process – the business must be willing to jump past mass production straight to mass customisation. Mal Clark is a Business Adviser with AMTIL under the Entrepreneurs’ Programme, a Federal Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. AMTIL is a partner organisation in the Entrepreneurs’ Programme. For more information about the Entrepreneurs’ Programme, please contact Greg Chalker, Corporate Services Manager at AMTIL, on 03 9800 3666 or email gchalker@amtil.com.au. www.business.gov.au/EP
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Business Management
Inventory – Understand it before you try to slash it! One of the biggest costs in a business and often the largest commitment of cash is inventory. In Lean thinking all inventory is also waste. So what is the right level of inventory for your business? A common mistake by businesses is to treat inventory as a driver of business performance. The theory goes, reduced inventory leads to reduced working capital, which leads to improved return on capital. Unfortunately what usually happens is that reduced inventory leads to reduced customer service levels and increased firefighting in the supply chain, which then leads to lost business, increased costs and reduced profits! The problem with attacking inventory in isolation is that inventory levels are an outcome of how you run your business, not a driver!
Good and bad inventory Of course all businesses have inventory they would rather not have. This “bad inventory” is made up of excess and obsolete inventory. Obsolete inventory is stock of products that you no longer make, while excess inventory is stock in excess of that required to maintain your target level of customer service (more about that later). Your business needs a process to manage excess and obsolete stock. The best approach is to prevent it by careful management of product run-outs and setting of target stock levels. Management of excess and obsolete stock is an ongoing process, not a one-off event. The reality is that unless your customer demand is constant every day of the year or you have a supply chain with infinite capacity, you will need to keep some inventory somewhere in the chain. The question is, how much? In an ideal world your average inventory will be equal to your safety stock plus half of your replenishment quantity. The replenishment quantity is the average amount of the product that your business consumes between deliveries. For example if you receive deliveries
every week, then your replenishment quantity will be equal to one weeks average consumption. Safety stock on the other hand is a function of how variable the supply and demand of the product is and what level of customer service you are targeting. The more variable the usage or demand, or the higher the level of stock availability you require, the greater the level of safety stock you will need.
So how do you reduce inventory? Many things drive your stock levels — the level of customer service you need, the level of variability in supply and demand, the replenishment frequency, and the lead time to replenish. Also, in distribution networks, the number of stock points has a large impact on stock. Frequently the first target is to attack suppliers to improve their level of service and beat up on sales-people to give better forecasts. While these activities are generally satisfying for the frustrated supply chain manager, they are usually not the biggest drivers of inventory. The biggest driver is replenishment frequency. Switching from monthly to weekly or daily replenishment will reduce the amount of replenishment stock and the need for safety stock by an order of magnitude. Look at ways to consolidate freight through regular “milk runs” to reduce the impact on freight costs. Shorter supplier lead times also have a significant impact. By increasing the frequency of replenishment you can also review the number of locations where you stock the product. You may have to slaughter some parochial “sacred cows” to achieve this, but if you can offer more frequent and more reliable replenishment the argument becomes a lot easier. www.txm.com
Managing everyday tasks with red-green tee cards Warehouses have lots of routine tasks that need to be completed every day. Using Red-Green Tee cards is a great way to make sure that every task gets done every day. How do you make sure that everyday tasks, such as forklift checks, cycle counts or cleaning, get done every day? According to the team at TXM, the red-green tee card board is one of their favourite Lean visual controls. Warehouses are busy places. In the rush to get out daily orders, put away stock, and keep systems up to date, it is easy to forget to do every day tasks. Tee cards are a simple and effective way to make sure you complete every task every day. Henry Technologies in Tullamarine, Victoria, has been using a tee card board in its warehouse for the last four years. The board includes typical routine warehouse tasks such as a forklift safety
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check, restocking packaging materials, and putting away items after QA checks, as well as regular 5S tasks such as sweeping. Red-green tee card boards make it easy to keep track of tasks, empowering staff to take control of their area without the need for constant direction. To view a video explaining how Henry Technologies gets the most out of its tee card board, scan the code at right:
Business Management
R&D without AI is not R&D According to the 2016 Australian Innovation System Report, every dollar spent on innovation by Australian businesses returns at least two dollars in earnings. With talk of innovation, digital transformation, and redevelopment of infrastructures infiltrating both the public and private sectors, research & development (R&D) initiatives to foster these future-thinking strategies is an ever-growing consideration. By Benjamin Pring. This is particularly applicable to Australia, where businesses are able to claim tax offsets for R&D activities undertaken within the country. The policy demonstrates the Australian Government’s commitment to fostering innovation on Australian shores through R&D. There is a catch, however. Without embracing artificial intelligence (AI) technologies, R&D is rendered pointless. True innovation comes from AI as businesses learn more about their industry and customers, and invest in research that will serve to create real business value. Since innovation is typically desirable but frequently hard to define, AI should be employed in R&D not simply to improve products and services, but also to expedite business processes, improve sustainability and customer experience, as well as prioritise customer-led efforts.
Why guess when you can know the answer? The major benefit AI offers R&D departments is the ability to access up-to-date data to justify decisions, which reduces risk and increases the chances of success. The ability to leverage continual insight into businesses, customers and the industry itself is crucial in a world ruled by data. R&D-based innovation without an AI platform could barely be considered R&D, due to the knock-on effects of guessing the key success factors without being positive of the outcome. Another advantage of AI is the ability to glean valuable insight into customers and industries. In R&D, having access to data and realtime analytics means organisations are able to estimate various metrics such as consumer confidence, which previously was only measureable retrospectively. The power of prediction will ensure organisations stay ahead of the curve. With a recent PwC survey finding that 83% of companies expect data and analytics will become increasingly important in decision-making over the next five years, businesses should embrace AI and data in order to streamline decision-making in R&D.
Change for the better Innovation shouldn’t be looked at as a hunt for the next great breakthrough. Instead, businesses should ask how the new digital technology adds the most value. It’s vital that organisations view innovation as a series of small steps, rather than a sprint. With the new technology growing in importance, R&D processes have the potential to be revolutionised through AI across multiple levels: • Product innovation: AI platforms may be used to help monitor a fleet of machines as well as recognise which components fail prematurely. This, in turn, would enable businesses to inform the next wave of engineering, technological advancement and field service operations. • Process innovation: AI can monitor workflows, recognise any bottlenecks and suggest alternatives. • Customer-led innovation: AI can assist with ongoing reviews of how customers are actually using products and services to inform product management and pricing schemes.
By encouraging small discoveries, businesses will be able to change the very basis of competition. With the traditional mentality that a singular breakthrough is best, we’ve seen major players across industries quickly look to neutralise by mimicking the breakthrough in question. With a consistent, long-term approach, businesses will be gifted the advantage of stealth, thus making them nearly impossible to replicate.
Prioritise discovery While taking a long-term approach has clear benefits for businesses when it comes to R&D, it is important to appreciate the power of discovery. Many businesses recognise that the future is uncertain, and that continuous discovery through a trial-and-error approach will serve businesses more than investment in singularly planned discoveries. For forward-thinking, successful organisations, this means that a portfolio of initiatives based on discovery should be established in a manner similar to successful venture capitals. A clear lifecycle methodology should be leveraged from inception to the final result, be that success or failure. But it’s not just venture capital that businesses can turn to for inspiration. Traditional businesses have also been seen to embrace this attitude to discovery, such as car manufacturer Toyota. It has been simultaneously investing in its conventional car models while at the same time working on innovative new driverless cars. Organisation-wide, innovation should be prized. By embracing a culture of discovery, businesses will be able to demonstrate to all stakeholders, both internal and external, that a ‘business-as-usual’ attitude is not present or expected within the organisation.
Winning the innovation race A recent Commonwealth Bank report suggested that Australian businesses investing in innovation are the future of our national economy, set to unlock an additional $44bn in value from the regional sector alone. Those that fail to innovate and adapt to changing preferences, expectations and technologies are the ones who’ll be left in the dust while their competitors speed ahead. Internationally, for example, we’ve seen streaming giant Netflix adapt to its customers and speed up its R&D processes to provide an offering that was previously unavailable, yet in demand by consumers. By leveraging innovation fuelled by AI, companies will able to disrupt their respective industries, much like Netflix, and move quicker to incorporate new learnings. Furthermore, businesses that effectively leverage machine-made insights will quickly develop a roadmap to navigate their ongoing expansions. With innovation constantly growing in value across industries and fields, R&D into new technologies and processes have never been so vital to success. Data and AI are helping businesses create new growth opportunities by inspiring long-term change, and without them, R&D becomes ineffective. Benjamin Pring is the Director of the Centre for the Future of Work at Cognizant. He is also the co-author of ‘What To Do When Machines Do Everything’. www.cognizant.com
AMT Feb/Mar 2018
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Business Management
Asset finance. Leave less money on the table… and more in your pocket. Whether you are in the business of manufacturing and selling equipment, or are a buyer of expensive equipment for your business, asset finance could play a key role in helping you achieve your business goals. Too often, banks are seen as one-stop-shops when it comes to finance needs, but the reality is that there are other, potentially better options. Anthony Roberts, Managing Director of specialist asset finance provider Eclipx Commercial, explains how the use of asset finance can have a far-reaching impact on the growth, and ultimate success, of your business. Eclipx Commercial recently commissioned independent research house East & Partners to delve into asset finance in Australia. Who uses it? Why do they use it? And ultimately, does asset finance offer any tangible benefits to businesses selling equipment or businesses buying equipment? We started by looking at small and medium businesses’ overall access to the funds they need to grow, both in terms of the availability of funds as well as the time it took for approval, and moved on to the specific pros and cons of asset finance. Some of the results, which can be accessed at Eclipx Commercial’s website, were surprising. Equipment manufacturers and vendors stand to benefit substantially if they offer equipment finance to their customers. Over 90% of equipment manufacturers said they sold more if they offered finance as part of their sales package, three-quarters (75.5%) said they could close larger deals, nearly 64% said they closed deals more quickly, and most importantly, 80% said they forecasted higher growth, compared with businesses which did not offer equipment finance. Moreover, the cash conversion cycle, a metric often used to give an indication of the health of a business, was significantly reduced, from the 210 days averaged without equipment finance, to 159 days – a saving of 59 days. In fact, our research revealed that equipment manufacturers and sellers offering equipment finance reported a significantly higher one year forecasted growth rate of 5.9%, compared with 3.3% for businesses not offering equipment finance. Over a period of three years, the gap grew even larger – 18.2% forecasted growth for businesses offering asset finance compared with 10.2% forecasted growth for those that don’t. For your customers, the arguments for asset finance are just as strong. Most small and medium-sized businesses who use expensive equipment, or technology that needs upgrading regularly, struggle to fund their requirements with upfront capital outlays. They have the option of going to
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the bank for a loan, but since the credit crisis, many businesses are reporting that banks are often unwilling or unable to help. Yet investing in your business is essential for growth. Again, the research bears this out – 87.4% of buyers say that equipment finance has been essential to their ability to grow their business, so it makes perfect sense for equipment vendors to give them what they need.
Three reasons you should consider partnering with an asset finance provider 1. Offering finance as part of your sales process reduces uncertainty, removes buyer complexity and differentiates you from your competitors. When buyers are doing their research, both online and via traditional methods, they will have access to endless information and advice, but will not have certainty of outcome. If you can offer finance as part of the sales package, you will be providing certainty of credit. 2. Offering finance can improve your margins. Discounting and price wars are just a race to the bottom, where no one wins. The reality is that your customers are far more likely to consider higher quality, better specified (and therefore expensive) options, when it comes to business-critical equipment, if you can offer a plan (which could include service) spreading the costs over several years. 3. Higher sales volume, business growth. The figures don’t lie. Equipment sellers offering asset finance report significantly higher forecasted growth than those which don’t.
The bottom line is that asset finance reduces wasted opportunities – on both sides of the fence. Our research showed very clearly that without asset finance as part of the sales process, both equipment vendors and their customers are missing out. Vendors are missing out on larger and more profitable deals as well as better overall business growth, and customers are missing out on the equipment they need to grow their businesses. The trick is to partner with an asset finance provider that is invested in your success. Choose a finance provider who focuses on long-term relationships rather than single transactions, has the sector and business knowledge needed to bring insight and professional advice to your conversations, and has a track record of productive long term partnerships. With the right asset finance partner, you can expect to see your and your customers’ businesses go from strength to strength. www.eclipxcommercial.com.au
Business Management
Varley embraces digital transformation with Epicor ERP Newcastle-based manufacturer Varley Group sought assistance from Epicor in implementing an eCommerce platform that would enable it to gain a competitive advantage in the electric vehicles market. needed to be paid to PayPal. We weren’t sure how to reflect that charge and ensure it was accounted for correctly, but BISCit came up with a solution that means PayPal transactions are actually the easiest ones we can put through the system.”
Established in 1886, Varley is one of Australia’s oldest, most advanced engineering and manufacturing companies. The group manufactures and sells worldclass custom emergency service, health, education and rescue vehicles; defence ambulances and arms storage facilities; and industrial and recreational electric vehicles. Its electric vehicles — sold under the EMC Electric Vehicles brand name — include golf carts, resort vehicles, industrial materials-handling vehicles, and utility carts, as well as parts and accessories for each vehicle type. Facing strong competition in the electric vehicle marketplace, Varley needed to find a way to differentiate its range of vehicles and related products. Following a market review that included researching competitors in the US, the company embarked on a digital transformation project — at the centre of which was the creation of an eCommerce option to help stay ahead of the competition. “Varley has five or six key competitors in Australia within the electric vehicle marketplace alone,” says Dean Wiggins, Marketing Coordinator at Varley Group. “So, it’s important to stay a step ahead in terms of delivering the products and services our customers need, as well as making it easy for customers to purchase from Varley.” After deciding to trial eCommerce with EMC Electric Vehicles, Varley needed to determine what technology solution would underpin it. The business considered a number of approaches before deciding to utilise its existing enterprise resource planning (ERP) solution — Epicor ERP. Varley already used Epicor ERP to manage daily operations across the entire business. The familiar interface and existing relationship with both Epicor and its local partner BISCit contributed to Varley’s decision to stick with Epicor ERP, which had already delivered results. Epicor and BISCit recommended Epicor Commerce Connect, a solution that integrates Epicor ERP with Magento, a leading eCommerce platform. Epicor Commerce Connect lets customers develop quickly, and they can be managed easily. It’s fully integrated with Epicor ERP, extending Varley’s existing investment in the solution.
One of the key benefits Epicor Commerce Connect has delivered for Varley is the increased speed of transactions. The new system has also improved customer satisfaction. Varley’s customers have adapted to the new online store, and transactions have received good feedback across the board. The purchase process is smooth, so Varley is now seeing more repeat business and increased customer loyalty.
“There are so many options out there for eCommerce—it’s almost an endless list of considerations and potential providers,” says Wiggins. “We were already using Epicor ERP and were big fans of the system. Using it to help power the eCommerce store meant Varley could tie in the eCommerce activity with the bricksand-mortar activity using the same system, giving us a single source of truth. This made accounting processes flow more smoothly — and so made perfect sense. “Varley chose Magento because it works so neatly with Epicor Commerce Connect. From implementation, the impact was immediate, and we found out just how powerful and easy to use it was.” Epicor and BISCit worked closely with Varley to ensure all requirements were met and all systems worked seamlessly together. The implementation was complete in just four months. “BISCit was absolutely superb, managing the nuts and bolts of the Epicor Commerce Connect integration with Magento,” Wiggins recounts. “BISCit did all the coding and back-end work to ensure Magento and Commerce Connect communicated seamlessly. The process took around four months, which was very quick — given the complexity of the task. “For example, managing payment transactions through PayPal included a complex calculation regarding the fees that
“Around 20% of our online purchases are followed up by a repeat purchase,” Wiggins adds. “The eCommerce store has enhanced our reputation in the industry, and we’re getting interesting feedback from dealers, suppliers, and even competitors saying this is a great step forward for the whole industry.” “Traffic to the Varley website is increasing daily, which is another positive outcome. While not all customers want to purchase online, having the option makes us more responsive to customer needs.” As part of its digital transformation project, Varley aims to increase the range of products available on its eCommerce store. The company will also build a vehicle configurator that lets customers choose options — including paint colours and optional extras— and purchase the entire vehicle online. It will be the first time Australian customers can purchase an entire vehicle online from the manufacturer. After that, Varley will expand the online store across the entire Varley Group. This is a long-term expansion plan that will offer significant benefits to the group and bring it one step closer to its digital transformation goal. “Many of Varley’s business units compete in industries where there is very little to differentiate the products,” says Wiggins. “Standing out by providing different purchasing options is a key part of Varley’s approach and sets us up for future growth.” www.varleygroup.com www.emcelectricvehicles.com.au www.epicor.com
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Material Removal
NUM Flexium+ CNC helps Star Cutter maximise productivity NUM’s latest-generation CNC systems are helping US manufacturer Star Cutter Company maintain its position as a world leader in cutting tool machines. Star Cutter’s new five-axis tool and cutter grinding machine – the NTG 6RL – is based entirely on NUM’s Flexium+ CNC platform, and fully automates the high speed production and reconditioning of complex cutting tools. Star Cutter Company specialises in carbide and preform manufacturing, cutting tools and CNC machines for tool/cutter grinding and hob sharpening. Founded in Detroit in 1927, the company today operates six manufacturing facilities at strategic locations throughout Michigan. Since 1998, Star Cutter has partnered with NUM in development of applicationspecific CNC hardware and software. During the course of this collaboration, the two companies have advanced cutting tool machine technology significantly – Star Cutter currently manufactures seven highly specialised lines of machine tools, six of which are based on NUM’s CNC systems. Star Cutter originally used Fanuc controllers for its machines. However, with a goal to bring its customers even more capability and ease in realising complex tool forms, as well as to gain more flexibility and speed in integration of third-party motors and simplify the development of control software, the company sought to transition from a proprietary control scheme to a more open CNC platform. According to Bradley Lawton, Chairman of Star Cutter: “NUM was an obvious choice. The company is renowned for the open-architecture nature of its CNC solutions, and has done much to remove the ‘black box’ mystique that is endemic to many CNC products on the market. The quality and reliability of NUM’s products is excellent, which is extremely important to us – over 99% of the machines that we have produced in the past 20 years are still in everyday use. On top of that, NUM’s customer support is superb and we enjoy very responsive and helpful technical help”. NUM and Star Cutter’s partnership has created dividends for both companies, and for their customers and machine endusers. Starting with its ETG and PTG series of tool and cutter grinders – which now have an installed base of more than 200 – Star Cutter has steadily migrated nearly all of its CNC machines across to NUM’s CNC hardware and NUMROTOplus software. Star Cutter’s latest NTG 6RL full linear five-axis tool and cutter grinder machine can handle fluting, tertiary grinding, relief grinding and automated wheel change. It is based entirely on NUM’s powerful Flexium+
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CNC platform. The NUMDrive X modules that form part of this high-end CNC solution provide the drive flexibility needed to accommodate a variety of third-party linear and direct drive torque motors, as well as high-frequency grinding spindle motors. As a consequence, the machines are capable of very high grinding and surface finish accuracies, combined with unprecedented grinding speeds, and promise to be the most productive that Star Cutter has ever produced. Steven Schilling, General Manager of NUM Corporation, points out: “The higher bandwidth of the NUM’s DriveX servo drive and improved internal processing of NUM’s Flexium+ CNC platform, which is now managed by double-precision IEEE 754 floating point, provides capabilities that extend down to sub-picometre accuracy. This gives manufacturers like Star Cutter the opportunity to create machines that can grind even the smallest tools with superb accuracy.” Another key attribute of the Flexium+ platform is that it can run grinding programs as large as 40MB directly from the NCK memory. For very complex grinding cycles, the CNC system can execute cycles directly from the system’s disc drive, via a high-speed data transfer protocol. This increased capacity and speed helps Star Cutter’s customers to expand their CAD/ CAM grinding operations. Application areas include the processing of advanced materials and aerospace components, in addition to medical devices and tools.
Star Cutter’s new grinding machine features a novel servo-assisted popup mechanical steady rest. This makes full use of the ‘detachable axes’ facility of Flexium+ systems equipped with NUMDrive X modules. It enables end-users to simply place the rest into the machine for the production of longer parts, and to quickly remove the full motor/mechanical assembly when it is not needed. Focusing on an intuitive user experience, the operator station features an entirely new design, which reduces button pushing, significantly simplifying machine setups and daily operations. The optional six-axis robotic part loader essentially programs itself from the NUMroto tool files, requiring minimal user inputs. Notifications can be set to alert shop personnel of process completion or of issues encountered during unattended production. The new machine is also designed for ease of integration with other forms of industrial automation and handling robots. NUM’s Flexium+ platform offers a wide variety of system communication busses, including EtherCAT, CAN and EtherNet IP. Measured process or post-process data can be fed back to the CNC system’s NUMRoto software to provide on-the-fly corrections, facilitating adaptive real-time control of the entire grinding process. Shop floor data can even be shared easily with the rest of the plant and to the cloud with NUM’s builtin MTConnect interface. www.star-su.com www.num.com
Material Removal
Lubricating, cooling and cleaning simultaneously – with CO2 snow By using carbon dioxide (CO2) as a process coolant, the cost-efficiency of machining can be significantly improved. With its quattroClean system, acp has developed a solution suitable for use in serial productions. Among other things, the new system from acp (advanced clean production GmbH) increases productivity by around a third when machining workpieces made from polyether ether ketone (PEEK) and aluminium. A further advantage is that components and machines stay much cleaner. In recent years, the use of CO2 as a coolant for machining processes has become much more popular as an alternative to conventional cooling lubricant concepts. One of the reasons for this is the higher rate of material removal, which increases productivity and also reduces tool wear and the associated downtimes. The so-called cryogenic cooling method with carbon dioxide therefore decreases production costs.
The patented jacketed jet technology ensures a constant pressure and consistently good cooling results, while only the quantity of carbon dioxide needed for the desired cooling effect is supplied.
With its quattroClean snow jet technology, acp offers a cooling system that has proved its worth in serial productions. It can also be integrated into CNC machines and machining centres at a later stage. The quattroClean system works with liquid carbon dioxide, which is generated as a by-product from chemical processes as well as from the generation of energy from biomass, thus making it environmentally neutral. It is transported at room temperature to the non-wearing circular two-component nozzle. The CO2 only transforms from a liquid to a solid state in the form of fine snow crystals as it leaves the nozzle. The crystals are then bundled by a circular jacketed jet of compressed air and advanced to the process zone at supersonic speed. The temperature of the medium at this point can be as low as 78 degrees Celsius. On the one hand, the patented technology with the jacketed jet ensures a constant pressure and consistently good cooling results. On the other hand, only the quantity of carbon dioxide needed for the desired cooling effect is supplied.
Dry, residue-free machining The fact that solid-state carbon dioxide sublimates at room temperature makes this a dry process. Consequently, chips are clean and dry as well as fully recyclable. Dry machining also means that workpieces and machines stay much cleaner. In many cases, there is no further need to clean workpieces after processing. Depending on cleaning requirements, a cleaning module
The quattroClean system is also used to simultaneously lubricate, cool and clean machined implants and medical components made from PEEK. This increased productivity by over a third.
can be integrated quickly and efficiently downstream of the machining process. A further advantage of cooling with CO2 is that parts, for example for medical products, are machined free of contamination. The low temperature also minimises the risk of a workpiece deforming. Finally, no costs are incurred either for maintenance, care or the disposal of cooling lubricants. In contrast with other solutions, cooling takes place externally with the quattroClean system rather than through the tool. The non-abrasive and non-toxic jet of snow and compressed air is easy to focus and can be directed exactly where it is needed in the defined process zone around the cutting edge, chips and tool. For this, the CO2 nozzle “travels� with the tool. Among other applications, the quattroClean system is used in serial productions to lubricate, cool and simultaneously clean machined implants and medical
components made from PEEK. Another serial application is in metal processing. Here, the system is used to cool tools when machining parts made from aluminium. In both cases, productivity could be stepped up by more than 30% by cooling with CO2 externally using the acp system. Thanks to its modular concept, the quattroClean system from acp can be easily adapted to customer demands and has a very small footprint. Process parameters, such as the volume flow for compressed air, or the quantity of carbon dioxide required, can be optimally adjusted to the application concerned. The duration of the jet for both process parameters can also be modified separately. This high degree of flexibility enables the system to be used for completely new applications, as well as for applications that were unsuccessful with standard systems. www.acp-micron.com
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Material Removal
The best tools for cutting, grinding and finishing stainless steel Because stainless steel is expected to yield specific performance characteristics, it is typically used on higher valued parts. When working with stainless steel, you should never cut corners when selecting or storing tools for the job. The wrong choice can damage the material and may end up costing you a lot more in the long term in rework, scrap, and lost efficiency in production. Using some of the tips here can help you narrow down the choices. By Tony Hufford. People use stainless steel for several reasons, including its mechanical properties and appearance. However, if you’re like most, the first thing that comes to mind is its corrosion resistance, which makes it very desirable for many uses in food, medical, construction, automotive and marine applications, just to name a few. Stainless steel is typically more expensive than carbon steel, so it is critical to choose the right abrasive and utilise proper storage. Doing so can significantly improve production efficiency, lower rework costs, and reduce material waste. The two most common grades of stainless steel used in the industrial market are 304 and 316. Both have a high percentage of chromium, which forms the protective barrier that gives stainless steel its name. However, 316 is more resistant to chlorides (sea water, salts) due to the addition of molybdenum. It also costs significantly more than 304, so it is primarily used in more niche applications or as needed where the value of it can be realised.
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Addressing the challenges of stainless steel
still considered to be contaminated and the anti-corrosion properties will be diminished.
Stainless steel is more difficult to grind than carbon steel, so it is critical to use the right tools and follow some simple guidelines to get the job done correctly. Choosing the right tool not only increases operator efficiency, but it can also reduce rework, improve finish, and eliminate the risk of cross or general contamination. In the end, that adds up to overall cost savings.
Cross contamination is avoidable. Marking tools to distinguish them can be valuable, as can splitting operations in the manufacturing facility between a carbon steel side and a stainless steel side. Limiting operator access to storage areas can also help. Remember to always avoid storing a carbon brush next to a stainless steel brush where they could come into contact with each other.
Many shops utilise both carbon steel and stainless steel in their manufacturing operations. One of their biggest concerns is the potential for cross contamination. Stainless steel can become contaminated in many ways, the most frequent of which is through exposing it to iron by using the wrong tool. For example, cleaning or finishing with a carbon brush on stainless steel may leave a residue because of the iron in carbon steel, leading to a rust colour (after rust) on the surface of those pieces. When that happens, the stainless steel itself may not be rusted, but the piece is
Similarly, do not use a stainless steel brush that has been previously used on carbon steel. It is important to note that contaminated stainless steel may not always immediately show it has been contaminated. Sometimes it isn’t until the material is exposed to moisture that the oxidation of surface contaminates begins to occur. This makes it all the more critical to take the extra steps to avoid costly cross contamination in the first place. Heat discoloration is another potential issue that can arise when cutting, grinding
Material Removal
or finishing stainless steel. If an operator builds up too much heat, it can result in heat discoloration in the metal that almost resembles an “oil spill”. When this happens, most of the time the heat discoloration must be finished out of the stainless steel, requiring an extra step that costs both time and money. To help mitigate this problem, there are abrasive grains and coatings that allow operators to either use less pressure, reduce surface friction or both.
Selecting a tool All of the same basic styles of abrasive tools are used when cleaning, finishing, cutting and grinding stainless as they are on carbon steel. There are, however, a number of differences in the makeup of those tools that make their use easier and more productive. For instance: • Coated abrasives designed for stainless steel typically have an extra coating layer or “top coat” that helps reduce heat build-up. • Cutting and grinding wheels (and other abrasives) will have a special formulation and be labeled contaminant-free or INOX, meaning they are manufactured with additives that contain less than 0.01% of certain elements such as iron, sulphur and chlorine. • Wire brushes will have stainless steel wires that do the cleaning. Wire brushes are often the best choice when cleaning of welds or material surface is required. Remember, wire brushes don’t remove base material, so the dimensions of a part remain true. Also, let the wire tips do the work, as excessive pressure leads
to premature wire failure and shorter brush life. Choose stainless steel wire brushes with a twisted knot design for more aggression and a crimped design for better surface area coverage. Abrasive tools are commonly used for cutting, grinding and finishing. Tools specifically designed for INOX and/or that contain ceramic grains are the best options for most applications. For cutting, 1.1mm-diameter wheels are still the most popular; however, 1mm wheels are gaining traction in the market. Because they are slightly thinner, these wheels help minimise heat build-up and waste during the cutting process. As a rule of thumb, the thinner the cut, the faster the cut and less material must be removed – an important detail when working with more expensive material like stainless steel. Also, utilising the proper technique, like a slight sawing motion with minimal depth of cut, can help to maximise wheel life and cut efficiency. Grinding wheels are a great tool for removing a lot of material quickly. They don’t typically leave as smooth a finish as other abrasive products, but they get the job done fast. If the application does not require a specific finish, this type of tool may be best suited for the application. Always start grinding with a pullback motion instead of a push to reduce the chance of gouging this expensive material. Flap discs are another popular choice for working with stainless steel, because they grind and finish the workpiece in a single step. This eliminates the need for product changeovers and saves time and money in the process. While flap discs may cost a little more upfront, they can typically add more value in the long term. These types
of discs are also more forgiving to less experienced operators, adding value and efficiency. At the end of the day, you need to find the right tool for your applications. Using some of the tips here can help narrow down the choices. Remember, when working with stainless steel, never cut corners when selecting or storing tools for the job. Given that stainless steel is expected to yield specific performance characteristics and is typically used on higher-valued parts, the wrong choice can damage the material and may end up costing you a lot more in the long term. Reprinted courtesy of Fabricating & Metalworking. Tony Hufford is the Category Manager – Welding & Fabrication at Weiler Corporation. www.fabricatingandmetalworking.com www.weilercorp.co
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Quality & Inspection
Hizeaero – Using laser scanner technology to ensure aircraft technology Before an airplane takes its first flight, it has to undergo countless inspections and certification procedures. The detail and processes required can be very demanding – even a tiny metal component for a window has to be thoroughly inspected before being fitted onto an airplane. These measures are necessary to ensure the safety of the passengers. One such company that exemplifies this is Hizeaero, a South Koreabased aerospace structure manufacturer, which utilises the Faro Edge ScanArm HD to conduct its safety inspections across its projects.
The ultrathin Ti-Foil that is used in the rims of aircraft windows.
Established in 1999, Hizeaero first started supplying aircraft wings to various domestic and international aircraft manufacturers. The company’s operations later expanded to include the entire aircraft manufacturing process, ranging from aircraft assembly to refurbishment maintenance, and the production of aircraft components – such as sheet metal machining and surface treatment. In 2017, Hizeaero set up its third factory, occupying a total area of 11,000 square metres in Busan. Some of the aerospace industry’s biggest names are Hizeaero’s customers. They include Boeing, AVIC International, COMAC, ShinMaywa, ACM, ST Aerospace, Korea Aerospace Industries (KAI), Korean Air and Asiana Airlines.
A new challenge In 2016, Hizeaero signed a supply contract with Boeing’s subsidiary, Boeing Tianjin Composite (BTC) – a Chinese aircraft manufacturer. One of the key components that Hizeaero had to supply was the Ti-Foil, a film that will be inserted into the rim of an aircraft window. The Ti-Foil is an ultrathin titanium film with a thickness of just 0.076mm, and this posed a major challenge to the team at Hizeaero, both in terms of production and inspection. This obstacle was a major push factor that led the company to invest in the Faro ScanArm.
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“While titanium is a very strong metal, it behaves very differently when it is just 0.003 inch thick,” explained Minkwon Yoo, a member of the Quality Assurance Team at Hizeaero. “It’s highly malleable and can easily be bent with the slightest pressure. The handling of Ti-Foil alone was a major challenge.” For these reasons, the team at Hizearo could not measure the Ti-Foil with the existing fixed coordinate measuring machine (CMM) that they had. As the material was incredibly thin, it was impossible to conduct inspections using conventional contact measurement methods. They came across the portable FARO ScanArm while sourcing for a suitable non-contact scanning device to measure the Ti-Foil.
Quality & Inspection Inspecting the holes on the Ti-Foil Check Fixture using the contact probe.
The FARO ScanArm can be manoeuvred effortlessly and freely, offering high levels of versatility.
Inspecting the Ti-Foil by using the FARO ScanArm laser scanner.
“It was an easy decision as the device came highly recommended by our client, BTC,” added Yoo. “We valued their input as they have had first-hand experience using several of Faro’s contact measurement solutions with great success.”
Using non-contact measurement for the first time The Faro ScanArm marked Hizeaero’s maiden experience with noncontact scanning equipment. One of Faro’s best-selling products, the Faro ScanArm offers contact measurements using a probe, as well as non-contact measurements through its integrated Laser Line Probe (LLP). With a seven-axis rotation and a human-like arm design, the device provides users with high levels of versatility and a measurement range of up to 2.7 metres. Capable of scanning at 560,000 points per second, the LLP captures even the most intricate components in fine detail. At Hizeaero, once the Ti-Foil manufacturing process is complete, the component is scanned with the Faro ScanArm to ensure that it complies with the specifications laid out at the onset. Measurements for the Ti-Foil are captured in seconds without direct contact. The information captured includes the length, R value, and angle. Hizeaero also uses the contact probe on the Faro ScanArm to inspect the check fixtures used in the Ti-Foil manufacturing process. Specifically, the team uses the device to perform a temperature compensation check. This is to ensure that the fixture (which is made of metal) maintains its original size and shape, so that it accurately measures 35.56cm of Ti-Foil. The team does this by measuring the holes on the check fixture.
Intuitive and easy to use Yoo appreciated the ease of use and the intuitiveness of the Faro ScanArm, features that the fixed CMM did not possess. As a result, less time is required to train his staff as well.
Reports are generated in real-time as measurements are taken.
As BTC required measurements of ten specific locations to ensure accurate inspections, the portability feature of the Faro ScanArm came in handy. This allowed Hizeaero to conduct high-precision measurements anywhere, and at any time. Reports are generated in real-time as measurements are taken. “Even when the surface plate is in use, the ScanArm can run inspections quickly in another part of our production facility,” said Yoo. “The automated report generation feature is very easy to use. The layout is neat and simple, and we no longer have to do manual data entry in Excel!” At Hizeaero, the FARO ScanArm is the only measurement device used in the manufacturing process of the Ti-Foil. With each batch of production, all sample tests are conducted by the FARO ScanArm. Without the support of the FARO ScanArm, measuring the Ti- Foil would be significantly more complex and time consuming. Hwajoon Cha, Assistant Manager at Hizeaero, has overall responsibility for the measuring equipment used by the Quality Team. On the possibility of further growth in measurement capabilities, Cha said that the company is looking to purchase additional sets of Faro ScanArm in the near future. Cha is optimistic that the use of Faro ScanArm will soon become the norm in the domestic aviation industry, and Hizeaero looks forward to building a brighter future in close partnership with Faro. “Currently, we are only using the FARO ScanArm to inspect the TiFoil,” said Cha. “However, after much success with the device, we are seriously considering it for a variety of other tests in the future. For instance, we can improve on how our tool inspections and sheet metal inspections are carried out. While it will take some time to seek approval, I think incorporating such advanced technology is necessary for us to obtain uniform and standardised results.” www.hizeaero.com www.faro.com
“The device was extremely easy to handle,” he added.
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Quality & Inspection
Why quality managers are the leaders that manufacturing needs Companies are becoming more aggressive in their financial goals, with cost cutting being the mantra for many years. Indeed, in some organisations, when all the obvious cuts have been made, making the less obvious ones can begin to jeopardise the smooth running of the business. By Jennifer Sillars. In manufacturing, we see an industry under pressure. An industry trying to do more with less. A more proactive approach is needed now to break out of this cycle of simply fulfilling demand. While it may seem unlikely to some, your quality manager or quality director is in the perfect position to guide this strategy.
Reason one – A focus that is principled and positive Quality leaders are focused on … quality. By this I mean customer satisfaction and reputation building are inherent in their goals. ‘Quality’ often means meeting the customer requirements or meeting safety objectives. They are high-integrity individuals who make analytical decisions based on fact and with no hidden motive. It is this type of input that is needed when difficult choices have to be taken. HepcoMotion, a manufacturer of linear motion systems and automation components, is an example of a company who lead with quality. As HepcoMotion manufacture everything in-house, no responsibility for quality can be delegated away. John Burrows, Group Quality Manager, defines his job as “ensuring that our customers get the best possible products”. In industries striving for blocked-out order books filled with repeat business, the quality department’s smooth operation can make this a reality. Quality departments are often unfairly profiled as the inspector who comes in looking for problems at the end of a project. The truth behind this is that quality leaders, like Burrows, believe the company can achieve greatness. So, if something goes wrong, there is a process or control that needs to be fixed. Burrows is trusted at an operational level as someone to turn to when an issue is found. Leading from the front like this allows issues to be addressed earlier in the manufacturing process, instead of hidden from the inspector.
Reason two – Business intelligence in nonconformances Quality managers understand how the business runs. They know the small details, the daily struggles as well as the big-picture strategic goals. They work beyond silos to understand the internal processes that take requirements and turn them in to commercial products. This gives quality managers a deep understanding of where things can, and do, go wrong. They see where the trends are that provide opportunities for improvement. Quality leaders track non-conformances and the cost of these issues. “The ability to cost Corrective Action Preventative Action (CAPA’s) allows me to highlight areas that require attention, where costs have been accrued from a variety of different reasons – work in progress, customer issues, final inspection issues for example,” continues Burrows. “This gives us a much better picture of particular products that may require different processes or additional inspections. We can easily add costs of rework, extra inspections etc. to an issue and so can get an accurate picture of what it has cost the business.” This is the kind of data-driven decision-making that all companies are striving for. Executives often overlook the quality department as a partner in business intelligence. HepcoMotion has made great efforts to improve reporting and analysis, keeping in mind the strategic needs of the company.
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Reason three – A stabilising force In many companies, each location operates within its own rules and business constraints with little sharing of best practices. Each location focuses on optimisation. In itself this is a worthwhile activity that can have significant cost-saving benefits; however at the public level it may not be enough to make an impact. In a competitive market, customers put a premium on suppliers that they can rely on. Reliability and repeatability are fundamental goals within the quality leader’s principled and positive focus. It is part of “ensuring that our customers get the best possible products”, according to Burrows. When every customer knows they will get exactly what they need, orders grow. The wider market notices and the effects are transformative. When sub-contracting a part of the manufacture to suppliers, a part of the burden of reliability is taken. This is fine as long as you have chosen wisely, set the requirements and been realistic with lead times. The situation is different where you are the sole provider. This is the position that HepcoMotion is in - as they do all their manufacturing in-house. In recent years Burrows’ day-to-day focus has shifted as HepcoMotion adapts to deal with demand. Downtime is minimal and many of its machines run 24/7. Its order books are full; its focus on quality is undoubtedly a contributing factor. Customers expect the “HepcoMotion” standard, not the standard of a particular site. Burrows understands that it takes more than a written policy to ensure success. For that reason, he spends increasing amounts of time at different manufacturing sites engaging people and establishing a true group-wide approach to quality. When the reputation for quality and reliability is built, the impact of failing to meet a customer’s expectation in a single instance can be devastating. It is for these reasons that quality managers are the leaders that manufacturing needs. Jennifer Sillars is a Product Marketing Executive for Ideagen. www.ideagen.com
Quality & Inspection
Scanning technology helps solve Dutch shipwreck mysteries Maritime archaeologists from Flinders University in South Australia have turned to 3D scanning technology to help shed light on the demise of Dutch ships wrecked off the coast of Australia 300 years ago. Using 3D photogrammetry, laser and CT uncontrolled treasure hunting. To address scanning, rare models of the last remaining this, analysis of the scale models will be 17th and 18th century scale model ships undertaken to furnish more information on in the Netherlands will be scanned to the design and decoration of ships. capture the highest possible level of “The models are also fascinating in their detail. The ‘Ship Shapes’ project has the own right as objects of art and incredible potential to shed light on some of the most craftsmanship, originating from the same famous Dutch shipwrecks believed lost in artistic period that gave us Rembrandt Australian waters. and Vermeer,” said The scans will be Laser scanning of a modern van Duivenvoorde. used to create scale replica of Batavia, “Each one was which was wrecked off re c o n s t r u c t i o n s built for different Australia in 1629. and animations as reasons and has its well as 3D prints own story to tell.” and even virtual Dutch ships reality simulations. dominated trade The ships at the in the Indian centre of the project Ocean for much are Dutch East of the 17th and India Company 18th centuries return ships, and made the first large specialised European sighting vessels built to of the Australian travel from Europe coast in 1606, to the East Indies some 150 years bearing cargoes of silver, returning laden before Captain James Cook. During the with exotic spices. Funded by the Dutch next two centuries, the powerful trade winds Embassy in Canberra, the program has the carried some ships too far east, leading support of several museums, including the them to their doom off the treacherous reefs Rijksmuseum and the Scheepvaartmuseum off Australia’s west coast. Their wrecks now in Amsterdam, as well as the Dutch Cultural provide some of the earliest archaeological Heritage Agency and leading Dutch ship traces of European presence on the expert Ab Hoving. Australian continent. Four have been found Flinders researchers John McCarthy in Australian waters, including the Batavia and Associate Professor Wendy van (1629), the Vergulde Draak (1656), the Duivenvoorde will apply the innovative Zuiddorp (1712) and the Zeewijk (1727), techniques to capture the highest possible with three more known losses yet to be level of detail for these intricate models. located. “Since their discovery in the 1960s and 1970s, these shipwrecks have been studied intensively but there are still many gaps in our knowledge due to the fragmentary nature of the archaeological evidence,” said PhD candidate McCarthy. “Less than 20 contemporary models of these ships are known to survive globally, mostly held in Dutch museums. Our aim is to survey as many of these beautiful models as possible and to apply cutting-edge techniques to do so with maximum detail and precision.” McCarthy and van Duivenvoorde said the ambitious program would help to uncover more secrets. A total of 50 Dutch East India wrecks have been discovered around the world, but most of the remains have been destroyed by natural decay or through
The Netherlands and Australia recently signed an agreement on joint management and research of shipwrecks, sunken relics and other underwater cultural heritage. This Memorandum of Understanding builds on collaborations undertaken since 1972 and seeks to encourage more joint projects and sharing of skills and resources, in line with the UNESCO 2001 Convention on the Protection of the Underwater Cultural Heritage. Dutch and Australian maritime archaeologists from the Western Australian Museum and Flinders University are currently undertaking fieldwork at the sites of the Dutch shipwrecks Zeewijk and Batavia as part of the ‘Shipwrecks of the Roaring ’40s’ project. www.flinders.edu.au
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Quality & Inspection
Olympus launches 3D laser measuring microscope with 4K scanning Olympus’ new LEXT OLS5000 3D laser microscope measures surface area roughness precisely and with ease for enhanced productivity, making it suitable for a broad range of applications. The OLS5000 microscope can be used in research & development and quality inspection in a variety of applications including: semiconductors, electronic components, automotive, medical devices, new material development, nanofabrication, advanced manufacturing and various additional engineering applications. “The new OLS5000 3D laser measuring microscope delivers highresolution imaging and highly accurate measurement at speeds four times faster than the previous model,” said Clare Kelly, Product Manager, Olympus. “Samples that were previously difficult to measure can now be imaged thanks to our expanded range of LEXT dedicated lenses and new range of OLS5000 frames.” Australia and New Zealand are leveraging the rapid expansion of nanotechnology, new material development and advanced manufacturing technologies. Accurately measuring the surface features of product components is an increasingly important part of quality management. To meet this increasing demand, Olympus developed the OLS5000 measuring laser microscope to perform accurate three-dimensional measurement of the surface shape of a wide variety of samples using a technique that is non-contact and non-destructive. Succeeding the well-established OLS4100 microscope, the
OLS5000 offers significantly improved measurement performance. The microscope scans laser light over the surface of a sample to provide enlarged images of micro-scale features and to perform highly accurate measurements of surface area roughness, steps, and other features. The OLS5000 features new 4K scanning technology and enhanced optics designed to enable the detection of near-perpendicular features and small steps at close to the nanometer scale. The microscope comes with intuitive software designed for usability with features including the ability to automate settings that previously had to be specified by the operator. “The new software functionality ensures that measurement variability between different users is significantly decreased while maintaining our high level of measurement accuracy and repeatability,” explained Kelly. In addition, large samples or samples with uneven surfaces can be measured without preparation, using an expansion frame that can accommodate samples up to 210mm tall and a long working objective lens designed specifically for the OLS5000. This provides support for sophisticated user requirements such as observations through data acquisition, analysis and reporting. www.olympus-ims.com
New cost-effective Equotip portable hardness tester Proceq’s flagship product the Equotip 550 is a complete all-in-one hardness testing solution, which combines Leeb with portable Rockwell and now UCI (Ultrasonic Contact Impedance) methods. Equotip became the industry standard in portable hardness testing when it was introduced in 1975. Still proudly Swissmade, the Equotip 550 outshines the competition with its full-colour, dualprocessor touchscreen unit jam-packed with features. The Equotip 550 also has enhanced software with interactive wizards, automatic verification processes, personalised options, custom report functions and much more. With its combination of Leeb and portable Rockwell methods, the Equotip 550 is ideal for a broad range of applications including but not limited to oil & gas, automotive, aerospace and steelworking. Nevertheless, for some single-probe users the fully-featured Equotip 550 sits outside of their budget and comes with more software elements than are needed for basic regular hardness testing. The Equotip 540 portable hardness tester sees Proceq reaching out to the cost-conscious single probe user who doesn’t require extensive
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reporting or extra accessories (no test block, surface roughness comparator plate and coupling paste). Equotip 540 is designed for a single probe, Leeb D for on-site testing of heavy, large or installed parts or in UCI HV1-10 format for fine-grained materials with any shape and heat-treated surfaces. However, it is important to note that probes are not interchangeable, and the operator must assign the impact direction prior to testing. Happily, the Equotip 540 can be upgraded at a later time to the Equotip 550 if requirements change. Both the Equotip 550 and Equotip 540 are designed for rugged environments and are rated IP54 with special protection for hardware connections (probe connector, USB Host, USB Device and Ethernet). Both the cost-effective Equotip 540 and the fully-featured Equotip 550 portable hardness testers are available from Russell Fraser Sales in Sydney. www.rfsales.com.au
Quality & Inspection
Creaform scanner creates opportunities for Simply 3D Simply 3D opened up a new market opportunity after purchasing a 3D hand-held scanner from Hi-Tech Metrology. Based in Kingston, Queensland, Simply 3D provides a range of end-to-end 3D scanning and 3D printing services. The company was recently engaged by Stangfever International, a local business importing and converting US cars, to perform a conversion on a left-hand-driven 2015 Dodge Challenger Hellcat to right-hand drive. Converting a car for right-hand driving can be quite a complex task – one which unfortunately does not merely involve switching parts to the other side! For one, there are a lot of parts involved: for this specific project, Simply 3D’s Director Brad Jack worked on 15 different parts, including the dashboard, AC system, glovebox and centre console. While some can be “mirrored” then fitted in a relatively straightforward manner, others need further adaptation. Moreover, while there is a demand for such work to be performed, the case-by-case and model-by-model needs will never justify such parts to be mass manufactured in the automotive industry, so the components for right-hand driving will likely never be readily available. The project therefore was conducted as a “proof-ofconcept” for Stangfever, one that could bring a digital solution to a very labour-intensive industry. The Simply 3D mandate was to scan, reverse engineer and print all the components needed to convert the car. The scanning task was performed using a Creaform portable 3D scanner, Jack describes the Creaform scanner as “a great product”, which has made it possible to “create an entire new market” for the tuning industry, one that “didn’t exist before… for custom and aftermarket automotive parts”. The project aimed to achieve three things: reducing the production lead time; cutting production costs; and improving overall quality. Needless to say, the finished Aussie-ready Challenger easily ticked all three boxes, revealing an interesting new market opportunity. According to Jack, the portable 3D scanner pulled everything together due to its ease of use and speed. “This project was not possible without the scanner,” he explained. “I simply couldn’t have processed the plethora of parts that I received in either a timely or cost-effective manner.” www.simply3d.com.au www.hitechmetrology.com.au
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Compressors & Air Technology
Compressed air contracting: Just buy the air you need! Compressed air is often considered the fourth utility and, like gas, electricity and water, it is possible to simply buy the compressed air you need without the requirement to invest in capital equipment. Peter Eckberg, Managing Director of Kaeser Compressors Australia explains how, and the benefits this method offers the end user. For the majority of manufacturers, like gas, electricity and water, compressed air will be an indispensable utility to their operation. However, unlike gas, electricity and water, compressed air is more often than not produced the conventional way – via a compressed air system that the manufacturer actually owns. Here, the manufacturer not only pays for the utility itself (the compressed air produced), but at some point in time will have had the capital outlay for the purchase of the compressed air equipment, as well as the ongoing costs to service and maintain the compressed air system. Compressed air contracting presents a viable alternative to investing in, and maintaining your own compressed air system. Here, the end user simply purchases the compressed air they use, in the same way they would purchase gas, electricity or water. And, they can immediately enjoy the advantages of a cost-effective, energy-saving compressed air supply with no need for the initial capital investment. Compared to operating a conventional compressed air station, contracting models also offer a number of further benefits. With contracting, the compressed air partner takes care of all aspects of planning, installation and operation in accordance with the end user’s requirements. This allows the user to save 100% percent of the investment cost of a compressed air station and removes the burden of having to allocate staff and funds for maintenance and servicing work. In addition, contracting models provide a key tax advantage – by obtaining compressed air at a contractually established price per cubic metre, fixed costs are converted into variable operating costs, which can immediately be claimed for tax purposes. Users who decide to purchase only the required volume of compressed air at the quality they require – instead of a compressed air station – allow their business to benefit from improved cost transparency. Instead of a composite calculation, they can rely on the fixed price per cubic metre of compressed air, which is contractually agreed well into the future, thereby serving as a reliable basis of calculation.
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As an example, with the Sigma Air Utility operator model from Kaeser, the basic price set for the entire term of the contract will cover system and operating costs, as well as consumption of a mutuallyagreed base volume of compressed air. Should consumption exceed that amount, the surplus air charge that has also been contractually agreed is applied. Precise measurements guarantee that users are charged only for the volume of compressed air actually drawn from the system. By having the compressed air system provider take care of operation and maintenance of the compressed air supply system, maximum dependability and energy efficient performance are also assured at all times. The provider of course has a vested interest in adapting the system to meet the needs of changing operating conditions and to incorporate the very latest technological innovations. There are also significant advantages when it comes to maintenance. As an example, the compressed air supply delivered via the Kaeser Sigma Air Utility operator model comes complete with a Sigma Air Manager 4.0 compressor controller. This allows Kaeser to constantly monitor the compressed air system, with a built-in connection to the Kaeser Service Centre. This effectively ensures maximum efficiency and compressed air availability whilst enhancing production reliability. As energy costs remain a key concern for manufacturers with higher input costs for electricity biting into margins, finding ways
to optimise energy usage has never been so important. Compressed air contracting represents a highly attractive option for compressed air supply where rapid energy efficiency improvements are desired: in this case and many others, outsourcing offers a sophisticated solution. The potential savings that can be achieved vary in each case. When a company changes to compressed air contracting, the contracting partner usually installs a completely new compressed air system to ensure full utilisation of any and all potential energy savings. The degree to which compressed air costs are reduced depends on the system being replaced; however it is certainly not unusual for customers to achieve savings of 30% and beyond over the long-term. Moreover, that is continuously over the long-term, since the contracting partner (who is providing the compressed air at a fixed rate) has the greatest interest in ensuring that the system operates as efficiently and cost-effectively as possible. Contractors therefore always use the most advanced technology, such as high efficiency compressors and intelligent, PC-based compressed air management systems. Together with efficient and smart 3D pressure control, these innovations enable maximum system pressure to be reduced, which in turn dramatically cuts energy consumption. www.kaeser.com.au
Compressors & Air Technology
Time for the next stage of compressed air energy savings and efficiency As energy costs continue to outstrip other business input expenses, it’s more critical than ever to find new ways to save power. Two-stage compressors may just be one of the answers. To put that into perspective, energy savings mean generally one size smaller compressor and in most instances a return of the difference in capital cost in only a matter of months. Combine this with a VSD controller, where demand varies significantly, and savings can be even greater.
“Many customers get fixated with the capital cost of an air compressor, and whilst those that want to save energy costs will look a little deeper and review service costs, very few understand the long-term total operating cost of compressed air,” said Southern Cross CEO, Mark Ferguson. “The largest cost related to producing compressed air is in energy, and this typically represents the highest energy usage in the plant. With continuously rising energy costs, it’s an area in which businesses can readily address to achieve substantial potential savings. Two-stage compressors really are low-hanging fruit.”
internal pressures and temperatures mean greater axial and radial bearing loads. This can limit airend bearing life which can lead to significant long-term maintenance costs.
A single-stage compressor typically used in industry is limited by the overall compression ratio across a single airend. This compression ratio in most industrial applications is around 9:1 according to Ferguson. High compression ratios, particularly as pressures increase, results in significant internal slippage which leads to loss of capacity and a reduction in efficiency. A high compression ratio also means higher bearing loads as the elevated
A two-stage compressor, on the other hand, allows the compression ratio to be split over two distinct rotary screw airends resulting in compression ratios across each airend of around 3:1. The outcome is less slippage, reduced bearing loads and, with intercooling, significantly higher outputs for the installed motor power. The output of a two stage compressor is typically around 20% higher than that of an equivalent singe-stage compressor.
As a division of one of the world’s largest and most innovative compressor manufacturers, Southern Cross offers the latest in two stage technology built on traditional heavy-duty design platforms with components produced to last. When combined with a structured service program, the Southern Cross range of two-stage compressors enjoys a five-year package warranty with a unique, lifetime warranty on the screw airends. From 75kW to 355kW, all Southern Cross two-stage compressors are available as fixed or Variable Speed Drive (VSD) controls. www.southerncrossaircompressors. com.au
Boge shapes the future of Industry 4.0 Boge Compressors has made it a development task to pave the way for the Fourth Industrial Revolution in compressed air technology. In the Smart Factory of the future, compressed air technologies automatically communicate with connected peripheral equipment. The foundation for this is laid down in the self-describing communication protocol OPC Unified Architectures. In cooperation with users, Boge is developing standards for intelligent component networking. The goal is to ensure that the system adapts itself to the requirements and operates with maximum energy efficiency. New components should also simply be able to integrate into the system by “Plug-and-Pressure”. “The intelligent networking of compressed air generators and consumers of compressed air opens up a wide range of opportunities to monitor, control and optimise the entire system topology,” says Peter Boldt, Head of Development at Boge. As one of the first manufacturers of compressed air solutions, Boge is working on an integrated networking approach
Unified Architectures offers the possibility of establishing a vendor-neutral standard. The plant technology automatically undertakes the technical configuration to adjust the defined parameters to the demandoriented design for the production of compressed air.
which takes the process technologies connected to compressed air into consideration. “The communication protocol from OPC Unified Architectures is, as an open standard interface for Industry 4.0 applications, one of the most promising solutions in Europe,” adds Boldt. In contrast to the usual market and manufacturer-specific bus protocols, OPC
An easy commissioning of complex compressed air systems and flexible reconfiguration are key benefits of the Smart Factory. This is opening up new potential for users and plant designers to save energy. Boge has laid the technological foundation for intelligent system networking with the the German Federal Ministry of Education and Research’s leading-edge cluster known as ‘it’s OWL’ (short for Intelligent Technical Systems OstWestfalenLippe). Since 2016, Boge developers, together with manufacturers and users of consumables, have been working on the development of a future-oriented networking standard. www.boge.com.au
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Forum IP
Powerhouse and pirates - Protecting your intellectual property in China David Bennett offers useful advice for Australian companies on IP protection in China. China is Australia’s largest trading partner, export market, and source of imports. In recent years China has become an intellectual property (IP) powerhouse, receiving a record 1.38 million patent applications in 2017. China is now the world’s largest filer of patents, trade marks and designs. Local companies ZTE and Huawei have overtaken Qualcomm to become the world’s top filers of Patent Cooperation Treaty applications. There have also been marked improvements in IP protection, as China recognises that this is essential for its shift to a high-value economy. Is it possible for foreign companies to protect their IP in China? Data show that foreign and domestic companies enjoy similar win rates in Chinese civil IP cases. There are specialised IP courts and IP tribunals to hear complex IP cases, and multiple other enforcement options. The World Bank ranks China fifth best place to enforce a contract out of 190 economies, based on time, cost, and quality of judicial processes. Australian companies can protect their IP in China if they prepare appropriately and actively engage with the Chinese system.
IP powerhouse - register IP rights in China Australian manufacturers must ensure they register their IP rights in China. IP rights are territorial; an Australian patent, trade mark or design provides no protection in China. These rights have to be applied for and registered in China in order to be protected in China. Without these IP protections in place it’s perfectly legal to reverse engineer or reproduce a product. Any global IP strategy should include filings in China and relevant territories. Note that Hong Kong, Macau and Taiwan have their own legal systems, with separate registration procedures. An Australian patent or trade marks attorney can manage a global filing strategy that includes China. Chinese law firms can also be approached directly. Trade mark pirates - register trade marks in China Brand protection is important for manufacturers in all industries. A brand is protected in China through a registered Chinese trade mark. China has a first-to-file trade mark system, which means the first person to apply will generally own a trade mark. This is why it’s so important to file for trade mark protection in China early. Trade mark pirates register legitimate companies’ trade marks in order to extort money – this is the single biggest IP issue facing foreign companies in China. The only effective way to avoid this is to register trade marks in China as early as possible. In addition to an English brand name and a logo mark (if applicable), consider developing and registering an appealing Chinese language trade mark. A sword and shield - register patents and designs in China Chinese patent law provides protection for invention patents, utility models and design patents. In addition to filing invention patents in China, a good filing strategy may use utility models and design patents to provide extra protection. These rights are granted quickly without substantive examination, and can be enforced just like an invention patent. Furthermore, they prevent others from filing applications to monopolise your improvements and designs. In this way, they act as both a sword and a shield. Don’t forget that in order to be granted, patent and design applications need to be filed before the product is disclosed anywhere in the world.
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Monitoring and enforcement – ecommerce and physical markets Protecting IP in China requires proactive monitoring and enforcement. Monitor for IP infringements on ecommerce platforms, and use the provided IP protection portals to take down infringing listings. Monitor for infringements in physical markets, investigate and gather evidence. The case can then be taken to local authorities (administrative enforcement), to the courts (civil enforcement), or to the police (criminal enforcement, if criminal thresholds are exceeded). In addition, recording IP with Chinese customs allows them to seize infringing goods destined for export from China. Specialist firms provide online and off-line investigation services.
Contracts – draft specifically for China It is critical to ensure that any contract or agreement with a Chinese party is drafted to be enforceable in China. China does not enforce foreign court judgements, so contracts should provide for dispute resolution either in a Chinese court or via arbitration. A judgement from an Australian court can only be useful if the contracting party has significant operations in Australia to enforce against. Contract provisions that conflict with Chinese law will be invalid. Trying to adapt an Australian contract to China is unlikely to work, so contracts should be drafted specifically for China. Nondisclosure agreements should also consider non-competition and non-circumvention clauses. Ensure contracts are signed with the relevant company, not a shell company. Having an enforceable contract, and the credible threat of being able to bring litigation in China, reduces the likelihood of problems arising. Seek expert Chinese legal advice.
Trade fairs – for the world to see Exhibiting product at a trade fair will mean your brand, inventions and designs are on display for the world to see. Be sure to file for trade marks, patents and design registration in China well ahead of the trade fair. Trade fairs are also a good chance to identify potential infringers – plan how to collect and notarise evidence, and file an IP complaint. Start preparing at least three to six months ahead of the trade fair. David Bennett is IP Counsellor to China, IP Australia Find IP Australia’s guide to protecting IP in China, further China IP resources, and contact details of the IP Counsellor to China at www.ipaustralia.gov.au/china. Disclaimer: This article is not legal advice - you should seek your own legal advice as required.
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The Australian innovation patent – A powerful tool to be used while it lasts Ben Mott illustrates the ease with which innovation patents may be obtained, what this type of patent covers and the future for the Australian innovation patent. The writing is on the wall for the Australian innovation (eight year) patent. There is a good chance that Parliament will pass legislation abolishing the innovation patent during its 2018 Winter sitting. If the legislation is passed in its current form, no new innovation patents will be allowed after a deadline of a little over one year after the legislation passes. Most likely the deadline will be about July 2019. Up until the (estimated) July 2019 deadline, innovation patents should be considered for all new products and processes if an investment to guard against copying is warranted. Whilst new innovation patents won’t be allowed after the deadline, the current draft of the legislation allows innovation patents linked up to earlier patent applications to remain in force until the end of their eightyear terms. Innovation patents are being abolished in no small part because they are too advantageous for those who hold them, because they are too easy to get, too easy to make enforceable and can validly cover too much. Innovation patents are typically granted as a matter of routine within a few weeks of filing. As such, patentees can promptly market their products as ‘patented’ (as opposed to merely ‘patent pending’) albeit that in this context ‘granted’ is a misnomer. A ‘granted’ innovation patent cannot be enforced until it has passed the additional (and usually optional) step of substantive examination. Substantive examination entails a patent examiner (government official) testing the validity of the patent’s coverage. More often than not, innovation patents are not substantively examined. It is usual to request examination only if and when there is a need to enforce the patent. This approach defers the examination costs and preserves the deterrent value of having a granted patent which might be lost if examination is unsuccessful and the patent is revoked. As such, typically modest annual renewal fees are the only fees to be paid after the patent has been granted. During examination the coverage of the patent can be amended and if the examination is successful, a further related patent application can be filed. This creates a great deal of uncertainty for competitors because the patent coverage can be redefined after the competitor has released a product. By carefully choosing the wording of the initial patent application, the range of permissible amendments, and in turn the uncertainty for competitors, can be maximised. An Australian innovation patent can validly cover an obvious combination of well-known features. Whereas standard (20 year) patents require an inventive step, innovation patents only require an innovative step. This is a much lower threshold. Essentially any functional variation will suffice1 (as Fig.1 demonstrates). Indeed, even an inventive step is a much lower threshold than many imagine it to be. Given the lower innovative step threshold, typically an innovation patent can validly cover more (i.e. be harder to design around) than a corresponding standard patent directed to the same invention. The coverage of a patent is defined by the wording of the patent’s ‘claims’. How, and how easily, the patent coverage can be avoided depends on the choice of wording. This comes back to what has
been invented and the skill of the patent attorney. Popular myths such as ‘a 10% change avoids infringement’ are nonsense. Despite being easier to get and being able to validly cover more than standard patents, innovation patents provide the same scope of rights as standard patents. The owner of an innovation patent has the right to stop their competitors making, using, selling and/or importing (etc.) the technology covered by the patent.
Outlawing innovation patents You might think from the above that innovation patents are too good to be true … and you would be right! The Government agrees with you and is taking steps to outlaw innovation patents. Whilst those steps are underway (and most likely up until about July 2019) innovation patents will remain available to provide easycost, efficient Australian patent protection for new products and processes.
Granted without examination In 2001 Australian patent attorney John Keogh famously tested the innovation patent system by securing a granted innovation patent for a wheel in his innovation patent no. 2001100012 “Circular transportation facilitation device”. Whilst this patent never had a chance of passing examination and being made enforceable, it demonstrates just how easy innovation patents are to get.
No need for an inventive step A Court decision dating back to 2009 remains the leading authority on what it takes to qualify for a valid innovation patent. The decision relates to spring steel roadside posts that differed from earlier spring steel posts by the inclusion of: • a marker hole (e.g. item 135 on Fig.1) useful as a depth gauge during installation and a gripping point during removal; • a barb (e.g. item 137 on Fig.1) for anchoring the post into the ground; • a tapered end (e.g. item 132 on Fig.1) to make it easier to drive into the ground; • lengthwise ribs to resist buckling; and • specific dimensions. Any one of these variations was considered sufficiently innovative to qualify for protection. The proposed changes may be further examined and explained by contacting Wadeson patent & trade mark attorneys. Wadeson provides a wide range of IP services, combining engineering and IP experience across a wide range of technologies. Ben Mott is Principal, Mechanical Engineer & Patent Attorney. ben.mott@wadesonIP.com.au Ph: 03 9819 3808 www.wadesonIP.com.au 1. From what was already publicly known when the initial patent application was filed
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What it takes to be a dogged safety champion Colston Vowles of Courtenell WHS Training recently came across the true story of a courageous safety champion who refused to be diverted from his commitment to carrying out his responsibilities to those in his care. The events in this inspiring story took place during the devastating October 2017 bushfires in California. The harrowing and deadly California bushfires were the setting for a noble sacrifice. But the surprise is that the safety champion is a dog and what he did is somewhat aligned to the duty of care of a Worker under the WHS Act. The story may be a useful analogy or inspiration to managers and supervisors about their WHS duties.
(d) co-operate with any reasonable policy or procedure of the person conducting the business or undertaking relating to health or safety at the workplace that has been notified to workers.” We can’t say that what Odin did aligned exactly with the WHS duties of a Worker. He did go beyond taking “reasonable care” but he was certainly outstanding in taking care that his actions or omissions did not adversely affect the health and safety of others.
The Safety Champion The Safety Champion in this story is a Great Pyrenees Mountain Dog called Odin. The Great Pyrenees is a breed that has a centuries old history that goes back to being trained and used to guard flocks of sheep and goats from wolves and bears in the French Pyrenees. The breed is well known as a committed protector of small animals and young children.
Odins’ Safety Culture and Leadership Shared perceptions of a group or a flock about the nature of hazards in their workplace, the magnitude of risks, and the practicality and effectiveness of preventative plans are necessary to obtain agreement and willing cooperation with safety practices. The adventures of Odin and the goats show that Odin and the goats had achieved agreement and cooperation and so had created a positive safety culture.
Odin lived and worked on a small property in California and his job was to look after a flock of goats. When the October 2017 bushfires in California reached the property, the owners realised they would have to abandon their farm. They wanted to take Odin with them but had no way to take the goats as well. But Odin simply refused to go with them and abandon the goats. Very reluctantly the owners had to leave him even though they realised they may never see him alive again. The bushfires were devastating and claimed 40 lives including one of the owners’ neighbours. It destroyed many homes and caused billions of dollars in damage. As soon as the bushfires had subsided somewhat, the owners managed to get back to their property. They found their buildings were ruined and they had suffered millions of dollars in property damage. Suddenly the flock of goats appeared. They were under the charge of Odin who had also adopted several baby reindeer into the flock under his safety protection. One goat had a minor burn. Odin’s fur was singed, his whiskers had melted and he was limplng. Odin and the Duties of Workers – Section 28 of the WHS Act The WHS Act does not apply to Victoria or West Australia. However workers in these States have health and safety legal duties that are similar to section 28 of the WHS Act.
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“Odin has lived up to his namesake,” said Roland Hendel, Odin’s owner. “Pray for him and his charges. He is our inspiration. If he can be so fearless in this maelstrom, surely so can we.”
The WHS Act requires that; “While at work, a worker must: (a) take reasonable care for his or her own health and safety, and (b) take reasonable care that his or her acts or omissions do not adversely affect the health and safety of other persons, and (c) comply, so far as the worker is reasonably able, with any reasonable instruction that is given by the person conducting the business or undertaking to allow the person to comply with this Act, and
Leadership is a key element in improving the safety culture of an organisation. Senior managers need to demonstrate safety leadership through commitment to safety programs. But it is not only the senior managers who need to lead the way. line managers, supervisors and team leaders can also create a strong influence on the culture of an organisation. trust between workers and management is essential for a strong positive safety culture to develop. Odin’s qualities and performance as a leader and in building trust were exceptional. Committment, courage, leading by example, concern for the health and safety of others, and getting the job done with the minimum risk to others, all come easily to mind when considering what Odin did. And we have used the word dogged in the title of this article as it nicely descibes Odin. He was dogged because he was resolute, strongwilled and tenacious in achieving the safety of his flock. Courtenell is a WHS training provider which specialises in developing and delivering workplace health and safety training to help employers deal with their legal and corporate requirements for providing a safe, healthy and productive workplace. www.courtenell.com.au ph: 02 9516 1499
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Keeping pace with IoT: How to maximise operations across the Australian manufacturing industry Despite the well-publicised closure of some Australian manufacturing sectors, it isn’t dying. Instead, the industry is undergoing a time of digital disruption as new technologies and monetary realities grow, Pete Wood explains. Recently, CSIRO identified major growth opportunities and what the manufacturing sector needs to do to capitalise on these. Top of the list was Internet of things (IoT) adoption, offering rapid return on investment, through increased efficiency, automation and data insights. This has enabled manufacturers to realise the benefits of digital transformation across its value chain.
Agree to a clear problem statement Deciding whether IoT adoption is right for your business should be based on whether it will address a specific problem inhibiting growth. By defining the underlying needs of your organisation and customer, a prospective IoT solution can be selected to address the issue. Problem statements should cover fundamental questions including, “Why does this matter?” and “How will this benefit customers in the long run?” Next, you should define a prospective solution’s functional requirements and the core competencies required to support that solution. You want to be sure you have a good understanding of any possible limitations, affiliating the things your company does best with the needs of a solution modified to your market.
Learn from research and user actions As IoT technology advances and integrates further into the manufacturing process, businesses need to adapt. Mass adoption isn’t far away and there will be many more devices offering us data and asking for our attention. Australia’s R&D sector can play a critical role here and some agencies have already identified the technology gaps that need filling across manufacturing. In turn, businesses want to use these insights to differentiate themselves, monitor real-time developments and drive future-thinking decisions. It’s not just research providing new insights. As user actions evolve, we will need to develop different approaches to interfaces. Just as touch screens introduced the pinch, finger scroll and swipe, we can expect more natural movements controlling our environments in the future, such as hand gestures and voice recognition.
Leverage what you know Demand for more expensive bespoke products is replacing mass-production, meaning goods of the future must cater to evolving customer expectations. Businesses must strike the right balance between new and familiar user interfaces to ensure a smooth transition and deliver improved production requirements. This shouldn’t be difficult - companies can make efficient changes by leveraging what they already know. IoT is about enterprise asset intelligence after all, something the manufacturing industry is familiar with when addressing and making important decisions. For example; when considering questions like “What do I need to find out at a given point of activity?”- whether it happens on your property, at a vendor or elsewhere in the supply chain. From picking, to trailer unloading, to equipment service calls, you need that information in a timely manner. Instead of hoping materials will arrive in time, or waiting for a stock out to indicate replenishments, a manager with IoT visibility can leverage what they know from IoT insights and prepare or adjust proactively before small problems become big ones.
Prepare for ‘machine thinking’ In an “Industry 4.0” world, production will become more networked until everything becomes interlinked. This potential for a move towards predictive or proactive maintenance is one of the most alluring promises made by analytics and data capture technologies to the manufacturing industry. For example; technologies such as IoTdriven cloud service management platforms will enable manufacturers to make the leap to “predictive maintenance” and fix problems before they even occur. Now businesses have insights into what might happen, they will be better placed to spot and diagnose potential issues remotely. These will be able to be fixed without the need to dispatch field technicians or work out how to manage unplanned downtime. Now, the question becomes how do we find an architecture steady enough to keep everything networked together? I think it will initially entail new algorithms, synchronised across the entire value chain.
We should also consider interdependencies among machines. This includes production components, the manufacturing environment, and the IT infrastructure that connects it all, so the technology controlling the machines merges with the technical data of the components. This requires a high degree of standardisation, but we will continue to develop processes that govern themselves, where smart products can take corrective action to avoid damages and where parts are automatically replenished.
Security and privacy Governments, businesses and data protection authorities are trying to anticipate the possible impacts of the IoT; the chief concern is privacy. Any device that connects to a business network creates risk. They capture everything from conversations, to videos and locations, while tracking and accessing company financials and customer data. Cybercriminals see that as immensely valuable, making connected devices a prime target for attack. When advancing and implementing IoT applications, it’s critical that organisations build security testing into development. Everyone wants to be quick to market and save on costs, but security should be just as important as functionality. Organisations should encrypt not only communications, but also commands and values, from device to infrastructure and remote-control elements. This reduces risk and maximises protection against cyber-attacks.
Looking to the future Australia’s manufacturing industry must transform into a cohesive and exportfocused ecosystem to contend with global supply chains. It should concentrate on becoming a key player in Industry 4.0, to realise the benefits of reduced costs, increased productivity and commercial opportunities in emerging markets. Pete Wood is Head Technology Evangelist, RS Components. RS Components is a leading high-service distributor of electronics, automation and control components, tools and consumables, serving over 1 million customers globally. With operations across 32 countries, it has a global network of distribution centres worldwide. Ph: 1300 656 636 www.au.rs-online.com/web
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Yellow & Black This is a light-hearted return to the New Year from me. I know it is 2018 but I am still celebrating the grand final victories of the mighty Richmond Tigers and Melbourne Storm. I remember every minute of the day when “It’s Tiger Time” became the catch cry of the month. Having a beer before the game, waiting with anticipation in the top deck of the Southern Stand, feeling my heart skip a beat when we went up by 40 points in the last quarter and thinking “maybe we can win this” and walking down Bridge Road after the game singing the song and admiring the Yellow & Black stretch limo. Unlike some real Tiger Tragics (like a mate of mine who reckons he’s watched the AFL Grand Final over 20 times), I have only seen it half a dozen times since that glorious day in September. Mind you, my wife had some disagreement with the game being replayed on Christmas Day and New Year’s Eve. I tried explaining to her that these days were all about rejoicing in life’s great moments but she didn’t see it that way. She kept telling me that these days are about spending time with family and socialising. Needless the say the TV stayed on anyway. So my two teams are reigning premiers in AFL and NRL. Can they go back to back? With the Chinese New Year about to call 2018 the Year of the Dog, what does that say about the chances for the Western Bulldogs and Canterbury Bulldogs. Both teams missed the finals in 2017 and would need massive increases in team performance to challenge this year. I don’t think either can. What do you think? The AMTIL Footy Tipping Competition is on again this year. We have not had enough interest in doing an NRL tipping competition so we are only doing an AFL one this year. Entry is free to AMTIL members and costs $50 for non-members. First prize is $1000, second gets $500 and third wins $300 so get your registration in by emailing lbarnes@ amtil.com.au
Go Tigers….. Cheers
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Learnings from the Entrepreneurs’ Programme, so far AMTIL is a partner organisation in the Federal Government’s Entrepreneurs’ Programme (EP), focused on helping companies raise their competitiveness and productivity. Michael Fetherstonhaugh, an EP Business Adviser with AMTIL, reflects on what he has learnt in his time with the Programme. Having now worked directly with over 200 businesses from all over South Australia, I have learnt that “while every business is different, they are the same”. They are different in what they do or what industry sector they operate in, but they are exposed to the same issues that will define their success or failure. I now predominately work in the food & agribusiness sector, with a tendency to lean toward food and wine producers. Wine producers are a good example of the above statement. I have worked with wine producers from all of our amazing wine regions in South Australia and I have found that not one business is the same as another. While in the same industry and producing similar products, they are all different. Some may be family-owned boutique wineries, while others are large bulk wine producers with public ownership structures. Some are blessed with ideal soil and climate conditions to produce their own grapes and have the winemaking skills to produce super premium wines that have high demand from customers on a global scale, while others may outsource production and sell their range of products via a “wine club” marketing strategy. Other producers may utilise modern winemaking techniques to create wine styles that meet the demands of specific market sectors, led through market intelligence supplied by distributors and/or consumer feedback. No matter where the firm is located or what its business model is, I have learnt that the key elements that are likely to support success are: • A Strategic Plan that has genuine goals, vision and mission statements that are shared with employees. Ideally employees will have had input into the development of these statements; if so, it is more likely to empower them to support the plan and achieve its goals. The Strategic Plan tends to achieve the goals of the business if broken down into a 12-month Action Plan with KPIs that are regularly monitored for performance. • A Marketing Plan that ensures the business is producing a product that is in demand among customers and consumers, and enables a selling price that is profitable to the business. This may also look at new product development to ensure the business is continually evolving to meet market demands.
• Strong business systems (HR, Quality and WH&S), backed up with a reliable, efficient IT system that will aid monitoring and management. Good business systems that are implemented and adhered to, particularly at management level, tend to showcase strong leadership, which transforms into a positive working culture within the business. • Cash flow – while a marketing plan will assist with gaining sales, a business will often find itself “at risk” if it runs out of cash. Growing a business can be very exciting; however, funding that growth can create anxiety within the business. Other issues that impact on cash flow can be seasonal or contract-aligned revenue. Marketing Plans should be linked to accurate budgeting and forecasting systems, which can identify likely periods when the business may need extra financial support. I find that a “good business” usually has realistic plans in place, with employees who are empowered to support management to achieve them. Strong leadership will encourage employees to join the team and ride the success train. A strong leader will understand that making an unpopular decision is better than making no decision at all. The Entrepreneurs’ Programme has assisted many of these businesses by offering the Business Growth Grant to bring in outside expertise to implement any of the above actions. Often businesses have the knowledge or expertise to undertake such actions, but due to working in the day-to-day operations they struggle to implement new strategies. For more information about the Entrepreneurs’ Programme, please contact Greg Chalker, Corporate Services Manager at AMTIL, on 03 9800 3666 or email gchalker@amtil.com.au. www.business.gov.au/EP
At your service. AMTIL supports its members through its select range of AMTIL Service Partners. 1271AMTIL
www.amtil.com.au/Membership/Service-Partners
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Results in from AMT readers survey AMT Magazine conducted a survey of its readers towards the end of 2017. The results have now been collated and assessed. AMT surveys its readers on a regular basis to obtain your views on the magazine, its strengths and its weaknessees. With the invaluable feedback from our readers, we can continue to shape AMT into a source of news and information about your industry that is relevant to you. First up, the survey results showed that the majority of readers find the material that appears in AMT to be valuable and helpful to them in their businesses. A total of 21,200 readers found content in AMT either Very Useful or Extremely Useful. Meanwhile, more than 75% ranked AMT as their preferred industry magazine ahead of other publications. When it came to what you want to see in the magazine, the most popular of the editorial or industry features covered in the magazine was Defence, with 52.9% of survey participants saying this was of interest to them. Industry 4.0 came second with 50.0%, while Aerospace and Renewable Energy also figured strongly. Cutting Tools/Toolmaking was the clear frontrunner among the technology categories, with over half of respondents saying this was of interest to them; there were also strong showings for Additive Manufacturing and Robotics & Automation. One of the key objectives for AMT is exposing readers to the opportunities that the latest manufacturing technology can offer their businesses, and helping to guide them in their investment decisions. The survey found that magazines in general compared well in this area, recording similar scores to trade shows and direct mail, while rating a little behind the Internet – which is understandable. Some 11,813 readers found the advertisements in AMT were Extremely or Very Useful in sourcing products. In terms of the reach of AMT, it’s often been observed that many of the companies who receive the magazine pass it around the staff. This was corroborated by the survey, which showed that on average, between four and five persons read each copy of AMT that is sent out. This suggests that the readership for the print edition of AMT is approximately 31,500 per issue.
One interesting detail that arose from the survey was a resounding endorsement for the printed edition of the magazine, despite all those predications that electronic media would soon see us all reading off screens. Three-quarters of the readership preferred the hardcopy of the magazine, with just 25% favouring the e-magazine. Of those that prefer to read AMT in electronic format, 80.6% prefer to read it on a desktop or laptop, 13.9% on a tablet, and 5.5% via a smartphone. “The survey results have given the team at AMT a great insight into what the readers really value about the magazine,” said AMT Editor William Poole. “It’s good to see that a lot of what goes into the magazine is useful to our readers. But where the survey will prove invaluable is in highlighting the areas where we can improve, and we’ll be working hard on that in 2018.”
And the winners are… Five lucky AMT survey participants got an early Christmas present in December, after their names were picked out of the hat to each win a Google Home smart speaker. The voice-activated speakers were available to the lucky respondents who had filled in the latest AMT surveys of its readers and of its advertisers. The winners in the Readers Survey category were: Mark Teague of Sandvik; Frank Taranto of Jenkin Bros; and Rudi Wasmuth of Bystronic. In the Advertisers Survey, the winners were Cliff Purser of 600 Machine Tools, and Abla Evangelidis of SICK.
Frank Taranto of Jenkin Bros with his new Google Home.
Stay ahead, with HotSpots What are the big opportunities out there in the industry? What government assistance is available to your business? Where can you access the latest market data? With these questions and more, help is at hand with Industry HotSpots. Designed specifically for AMTIL members, HotSpots provides information and resources concerning our industry and the various useful services available for your business. Many of the items featured are available exclusively to our members only. HotSpots are broken down into four categories, loosely defined as: • Industry – These are industry-wide notices that AMTIL feels are of import 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. • Networking – Here is where AMTIL provides members with notices of events and activities that offer chances to network
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with other like-minded business leaders and collaborate on strategic activities. • Workplace – AMTIL is able to provide information to our members that they really should be aware of 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 e-mailing info@ amtil.com.au with the subject line HOTSPOT.
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Could your company be eligible for a sizeable R&D tax incentive claim? Engineering locally made, high-quality audiovisual and storage equipment has been ‘business as usual’ for Wilson & Gilkes for more than five decades. To discover that the business qualified for the Research & Development (R&D) Tax Incentive was a pleasant surprise, one which means they can continue to invest even more in improving their specialised designs. By Dr Rita Choueiri. Like many sheet metal manufacturers, Wilson & Gilkes provides custom-designed solutions for applications as well as off-the-shelf products under their brand names Bosco, Boscotek, Lectrum, Gilkon and Argent. Improving their products to be stronger, safer and more efficient is an ongoing process in their business practice, so it’s easy to overlook as R&D because it’s simply second nature in innovative businesses like theirs. In conversations regarding its product development program, the company’s accountant and advisor William Buck identified the potential for an R&D Tax Incentive claim. Ian Wilson, Director of Wilson & Gilkes, contacted William Buck, which assessed the company’s business processes and projects and found it met the eligibility criteria of the R&D Tax Incentive program, enabling them to receive a sizeable R&D claim. So what constitutes R&D? And how would you know if you are carrying out R&D? Simplistically, an eligible R&D activity is an activity that requires experimentation to solve a technical challenge and to generate new knowledge. Possible indicators of R&D activities include: • Developing new or improving existing products. • Developing or improving processes (e.g. to improve efficiencies or energy output, remove bottlenecks, etc.).
“Now we can direct more resources to our R&D program knowing that we are eligible for R&D benefits.” – Ian Wilson, Director, Wilson & Gilkes. Claimable expenses for R&D cover almost all aspects of carrying out R&D and can therefore add up to a considerable amount to be claimed. These may include: • Contractors and consultants.
• Using plant or equipment in a new way other than how it’s intended to be used.
• Salaries and bonuses paid to staff plus on-costs.
• Developing new or improved IT systems or software, requiring – for example – the development of complex and unknown algorithms. Systems or software may be operational (for example to control or aid manufacturing or logistics processes or equipment) or customer-facing (for sales and ordering, or a software solution of any type that is saleable/licensed).
• A portion of company overheads such as utilities, rent, security, cost of various consumables, or anything that has a direct nexus to the R&D activity.
The pub test to determine if an eligible R&D activity has occurred is to answer yes to all the questions below: • Did you overcome a technical challenge when developing products, process or software? • Did you need to conduct a trial or experiment to investigate an outcome? • Were you uncertain that the trial or experiment would produce your intended outcome? • Did the R&D activity create new knowledge? If existing knowledge was utilised to develop a new product or no true technical challenges existed (i.e. designers were confident in the new design and were certain it would work without the need for testing) then those products would be excluded from the R&D claim. Some examples of eligible R&D activities undertaken by Wilson & Gilkes included the design and development of: • Storage cabinets with manganese plating lining the locking mechanism, allowing for greater security. • A knockdown enclosure with shelves capable of supporting large loads (where each shelf is capable of holding more than 300kg).
• Any relevant direct costs (tooling, travel, materials used, software/IP licences, etc.).
• Depreciation of tangible assets such as machinery and capital equipment used in R&D. • Trial costs if not captured in the categories above. “We are always working on how we can improve our products to maintain our high standard of quality,” says Wilson. “Now we can direct more resources to our R&D program knowing that we are eligible for R&D benefits.” William Buck’s R&D team assists in identification of eligible R&D projects, streamlining the process and maximising R&D Tax Incentive claims, so that companies can focus on developing the ideas and products and processes that Australia (and the world) needs. If you believe your business may have activities that could qualify for the R&D Tax Incentive, or if you would like to know more, then please get in contact with William Buck for a free consultation. For R&D undertaken during the year that ended 30 June 2017, the lodgement deadline to register R&D activities with AusIndustry is 30 April 2018. Dr Rita Choueiri is the Principal – Research & Development at William Buck. AMTIL has a service partnership with William Buck as an exclusive benefit to our members. For more information, contact AMTIL’s Corporate Services Manager Greg Chalker at gchalker@amtil.com.au. www.wilsongilkes.com.au www.williambuck.com
• Various prototypes of new products that qualified for R&D.
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Amtil Inside
Golf Day rescheduled after rain stops play AMTIL held its usual line-up of celebrations to mark the festive season, but there was one notable exception as our Corporate Golf Day & Christmas Lunch was postponed. The event has now been rescheduled, and you can still book a place to attend. The run-up to the holidays was marked with a series of successful, well-attended AMTIL events for around the country. Members in New South Wales met for dinner at Adria Bar & Restaurant in Sydney, while Queenslanders enjoyed a lunch at Breakfast Creek Hotel in Brisbane. However, the Golf Day was all set to go ahead in Melbourne on 1 December when the warning came through from the Bureau of Meteorology that a “vast, intense, highimpact weather event” was about to hit Victoria – at round about the time our golfers were due to start teeing off. Faced with forecasts of up to 150mm of rain and a significant risk of flash flooding, the unprecedented decision was taken to postpone the event. Immediately AMTIL set about contacting everyone who had booked to attend to notify them, as well as getting to work on rescheduling the event. The AMTIL Golf Day will now take place on the afternoon of Tuesday 20 February. The meal will be a Barbecue Dinner instead of the original lunch. Fortunately almost all of those who had booked in for the December event can still participate. There are, nonetheless, a few places still available, so book now if you’d like to come and play. “Postponing the Golf Day was not something we took lightly,” said AMTIL Events Manager Kim Banks. “We’ve never had to cancel in all the years we’ve been running the event, but in the end the weather was so bad the decision made sense. All we need now is good weather when it does go ahead in February.”
Book now for Golf Day The Golf Day will be a four-ball ambrose event with participants invited to nominate
teams of four. The event includes dinner and drinks plus trophies, prizes and giveaways. Golf will commence at 12.30pm, with dinner getting underway as the golf finishes – at around 5.30pm. • Date and Time: Tuesday 20 February 2018 12.30pm – 8.00pm • Location: Riversdale Golf Club, Cnr Huntingdale Road & High Street Road, Mount Waverley, Victoria 3149 Places are limited, and preference will be given to AMTIL members if demand exceeds availability. Any individuals who book will be placed in teams by the organisers. AMTIL would like to sincerely thank William Buck, the major sponsor of this event, for their generous support. To book your place at the AMTIL Golf Day, please visit the Events page on the AMTIL website or scan the QR code. For more information about AMTIL Golf Day or any of AMTIL’s upcoming events, please call 03 9800 3666, or email Events Manager Kim Banks on kbanks@amtil. com.au. www.amtil.com.au/Events
It’s back! Register now for Footy Tipping AMTIL is once again running its AFL tipping competition, with great cash prizes for first, second and third places! This year the big prize is $1,000, so register now for a chance to win it. The 2018 AFL Season is building up to be a big one! Now you can be part of the excitement by pitting your tipping skills against your fellow AMTIL members. For this year’s competition, prizes will be awarded for:
• 1st Place: $1000 • 2nd Prize $500 • 3rd Prize $300 The leaderboard will be updated regularly on the AMTIL website and will also be published in AMT magazine. The competition does not include the Finals games.
To register Step 1. Register to become a member on www.footytips. com.au – membership is free. If you are already a member from last year you will need to reactivate your account. The site looks a little different but is just as good. Step 2. Join the AMTIL AFL 2018 group (www.footytips.com.au/ comps/AMTIL_AFL_2018). The password is AMTIL_AFL. Step 3. If you are an AMTIL member, you are ready to start tipping. Entry is free for AMTIL Members, with a $50.00 fee for non-members. Contact Louise on 03 9800 3666 or email lbarnes@amtil.com.au for information on how to pay for your registration or if you have any further questions. Happy tipping and good luck. www.footytips.com.au
AMT Feb/Mar 2018
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Industry Calendar
Please Note: It is recommended to contact the exhibition organiser to confirm before attending event
INTERNATIONAL Inside 3D Printing Germany, Dusseldorf: 21-22 Feb 2018 Turkey, Istanbul: 15-16 Mar 2018 Brazil, Sao Paulo: 11-12 Jun 2018 South Korea, Seoul: 28-30 Jun 2018 USA, NY: 30-31 Oct 2018 A leading 3D Printing and AM conference. www.inside3dprinting.com FABEX Middle East Egypt, Cairo 1-4 March 2018 Machine tool exhibition. www.metalsteelegy.com Asiamold China, Guangzhou 4-6 March 2018 Machine tool exhibition. www.asiamold-china.com SIMODEC France, La Roche-sur-Foron 6-9 March 2018 Machine tool exhibition. http://en.salon-simodec.com Indonesia Metal Working Week Indonesia, Jakarta 7-9 March 2018 Sheet metal working exhibition. www.indonesiametalworkingweek.com Advanced Factories Spain, Barcelona 13-15 March 2018 Machine tool exhibitions, automation and Industry 4.0. www.advancedfactories.com GrindTec Germany, Augsburg 14-17 March 2018 Grinding technology exhibition. www.grindtec.de Techni-Show The Netherlands, Utrecht 20-23 March 2018 Trade Fair for Industrial Production Technologies. www.technishow.nl St. Petersburg Technical Fair Russia, St. Petersburg 20-22 March 2018 Specialised industrial exhibitions for metallurgy/metalworking. www.ptfair.ru Techni-Show Netherlands, Utrecht 20-23 March 2018 Trade fair for industrial production technologies. www.technishow.nl Konepaga Engineering Works Trade Fair Finland, Tampere 20-22 March 2018 Metalworking exhibition. Includes Nordic Welding Expo. www.konepajamessut.fi
AMT Feb/Mar 2018
MECSPE Italy, Parma 22-24 March 2018 Metalworking exhibition. www.mecspe.com/en
FEIMEC Brazil, Sao Paulo 24-28 April 2018 Machine tool exhibition. www.feimec.com.br
Mashex Siberia Russia, Novosibirsk 27-30 March 2018 Metalworking exhibition. www.mashex-siberia.ru
EMEX NZ, Auckland 1-3 May 2018 Engineering, machinery & electronics exhibition. www.emex.co.nz
INDUSTRIE Paris France, Paris 27-30 March 2018 Machine tool exhibition. www.industrie-expo.com MachTech & InnoTech Bulgaria, Sofia 26-29 March 2018 Machine tool exhibition. http://machtech.bg SIMTOS South Korea, Goyang 3-7 April 2018 Seoul International Machine Tool Show. www.simtos.org AI EXPO Japan, Tokyo 4-6 April 2018 Artificial Intelligence Exhibition. www.ai-expo.jp CCMT China China, Shanghai 9-13 April 2018 China CNC Machine Tool Fair. www.ccmtshow.com STOM-TOOL Poland, Kielce 10-12 April 2018 Machine tool exhibition. www.targikielce.pl MACH UK, Birmingham 9-13 April 2018 UK’s premier engineering/manufacturing technologies exhibition. www.machexhibition.com Die & Mould India India, Mumbai 11-14 April 2018 Machine tool exhibition. www.diemouldindia.org Intermold Osaka/Die & Mold Asia Japan, Osaka 18 – 21 April, 2018 Exhibition for die & mould technology. www.intermold.jp SIAMS Switzerland, Moutier 17-20 April 2018 Exhibition for microtechnology production tools. www.siams.ch
iMT Taiwan. Taipei 9-12 May 2018 Intelligent Machinery & Manufacturing Technology. www.mtduo.com.tw METALLOOBRABOTKA Russia, Moscow 14-18 May 2018 Machine tool exhibition. www.metobr-expo.ru Intertool Austria, Vienna 15 – 18 May 2018 Machine tool exhibition. www.intertool.at INTERMACH Thailand, Bangkok 16 – 19 May 2018 Metalworking & automation exhibition. www.intermachshow.com BIEMH Spain, Bilbao 28 May -1 June 2018 Machine tool exhibition. www.biemh.com Automation Conference & Expo 2018 USA, Chicago 22-23 May 2018 Automation exhibition. www.theAutomationConference.com ITM MACH-TOOL Poland, Poznan 5-8 June 2018 Machine and tool exhibition. www.itm-polska.pl IMTS USA, Chicago 10-15 September 2018 International Manufacturing Technology Show. www.imts.com Foodtech Packtech NZ, Auckland 18 - 20 September 2018 Food manufacturing, packaging & processing technology exhibition. www.foodtechpacktech.co.nz EuroBLECH Germany, Hanover 23-26 October 2018 International sheet metal working technology exhibition. www.euroblech.com/2018
Industry Calendar Heading local Australasian Oil & Gas Exhibition & Conference Perth 14-16 March 2018 Showcasing latest products &technologies for the Australian oil and gas industry. www.aogexpo.com.au WA Major Projects Conference Perth 21-22 March 2018 As WA’s economy is readjusting after the mining boom, this conference will feature presentations on sectors such as tourism, transport, education and health, and focus on important infrastructure projects. www.expotradeglobal.com Vic Transport Infrastructure Conference 2018 Melbourne Convention & Exhibition Centre 11-12 April 2018 With the Victorian State Budget allocating over $10.4bn towards public transport and road projects, this includes the latest updates on the largest transport projects shaping Victoria. www.expotradeglobal.com AusMedtech 2018 Adelaide, Adelaide Convention Centre 1-2 May 2018 Australia’s premier medical technology conference. www.ausmedtech.com.au National Manufacturing Week 9-11 May 2018 Sydney Showground Includes Industry 4.0 Theatre, Safety First conference, automation, AM, welding, plastics, advanced materials, supply chain, OHS, engineering. www.nationalmanufacturingweek.com.au MEGATRANS 2018 Melbourne Convention & Exhibition Centre 10-12 May 2018 Debut event involving the future of global multimodal freight, logistics & supply chain. www.megatrans2018.com.au
Advertiser Index
Workplace Health & Safety Show 2018 Melbourne Convention & Exhibition Centre 23-24 May 2018 A new event showcasing the cutting edge of the safety world and official exhibition of #SAFETYSCAPE Convention. www.whsshow.com.au Northern Australia Food Futures Conference NT, Darwin 2-4 July 2018 Seeks to enable effective policy action to maximise agricultural development in Northern Australia by influencing strategic policies and taking advantage of new and emerging markets. www.foodfuturesntfarmers.org.au QME (Queensland Mining and Engineering Exhibition) Qld. Mackay Showground 24-26 July 2018 Innovative products and demonstrations of the latest mining equipment and technology. www.queenslandminingexpo.com.au Innovation and Industry 4.0; The Future of Intralogistics, Materials Handling and Supply Chain. Melbourne Convention & Exhibition Centre 24-26 July 2018 Includes logistics, warehousing, supply chain and IT. Focussing on Industry 4.0 and how improved automation, machine-to-machine communications, IIoT and digitalisation is shaping the future of warehousing, manufacturing and intralogistics. www.cemat.com.au Australasian Waste & Recycling Expo Sydney 29-30 August 2018 Features Australia’s most comprehensive marketplace of recycling, manufacturing, waste collection and landfill professionals. www.awre.com.au
Alfex CNC
23
Amiga Engineering
26
Applied Machinery
15
Bystronic P/L
6-7
Complete Machine Tools
13
Emona Instruments
37
Hare & Forbes
4-5
Headland 116 HI-tech Metrology
97
IMTS 49 Industrial Laser
25, 81
Iscar 2-3 Machinery Forum
115
Magnum Machinery MTI Qualos
41 cover flap, 35, 99
National Manufacturing Week
21
Okuma
9
Renishaw Oceania
59
Seco Tools
39
SICK 51 Sutton Tools
17
Thinglab/Freedspace 61 Whitelaw Machinery
11
Australian Manufacturing Technology Your Industry. Your MagazinE
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Oct NOv
ology
AustrAliAn MAnufActur ing techn
Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asameulsson@amtil.com.au
53
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AMT Feb/Mar 2018
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history
Big wheels & little wheels – the story of Sir Laurence John Hartnett (1898 – 1986)
Part 23
“The sand in those dunes is bottomless”
UK-born Sir Laurence Hartnett arrived in Australia in 1934. The visionary Sir Laurence became known as Australia’s ‘Father of the Holden’ – and much more. In 1936 the plans were underway for the building of the new GM-H plant in swampy Fishermans Bend. But first Laurence had to prove that the foundation would not disappear beneath the sand.
I
n 1935 Parliament approved our application to buy one hundred acres of land at Fishermans Bend – a wasteland of sand dunes and swamps in Port Melbourne, only two miles from Melbourne’s GPO. The price was £800 an acre. Our decision to build a modern assembly plant in Melbourne was great news for the community. The project would provide jobs for a lot of men still unemployed. Above all, it demonstrated that a great international organization (GM) had faith in the future of the nation. With the country slowly emerging from the depression, that was a great morale-builder. Enthusiasm for the project spread quickly. Everyone wanted to help, and GM-H needed all the help it could get. There were no roads to the site, no water, gas or power. Even so, a lot of people thought we were crazy even to consider building a plant on the sandy wastes of Fishermans Bend. One of them, Callanan, the managing director of Vacuum Oil, told me during a lunch at Menzies’ Hotel, “Larry, I just hate to have to tell you this, but that land at Fishermen’s Bend is no good for building. It’s tidal, and the sand in those dunes is bottomless. We were thinking of building an oil-depot there, but we had to give it up because the ground’s hopeless. Why, Larry, they tell me that if you dig a hole three feet down, it will fill with water.” Well, that kind of comment doesn’t worry me until I’ve found out if there is truth in it. I felt he was wrong, because I knew that the Vickers plant at Crayford, alongside the Thames in the UK, was built on a muddy quagmire; yet it was a huge plant that employed eighteen thousand people during the First War. I told Eric Gibson, the consulting engineer who’d joined our staff to supervise and co-ordinate the new building programme, what Callanan had said. Gibby’s reply was, “Don’t worry, Larry, you must know that there’s nothing like sand, reasonably retained, for a good foundation. Ever had anything to do with a drop-forge shop?” “Yes, I have, and I know what you’re driving at: there’s no better foundation than sand for a good drop-forge plant.” “We’ll test it well beforehand, just to make· sure there is no movement, but I’m sure it will be perfectly suitable” added Gibby.
1936: Horse-drawn scoops carve the foundations for the GM-H plant in Fishermans Bend, Port Melbourne. It was the first factory built in the area, only 2 miles from Melbourne’s GPO.
Gibby sank concrete blocks into several points on the site, and a pressure of three tons to the square foot didn’t produce any movement at all. “We won’t dig deep foundations - no need for it in this ground,” he said. “We’ll just lay them out over the widest possible area-make them work like camel’s feet in the sand - there won’t be any movement.” He was right, all the way. Gibson was one of the finest construction engineers I have ever met or heard of and later became recognized as one of the most capable and brilliant construction men Australia had ever had. When the initial surveys of the GM-H plant were made, Gibby moved on to the site, in a small wooden hut, with a wash-basin, a bed and a portable lavatory. He lived at Fishermans Bend, day and night, until the buildings were finished. Inside GM-H, we set up a team representing every department to draw up the design and erect the new plant. We did not engage an architect, and we consulted no outside specialists on plant layout. This was a GM-H plant, designed by GM-H people. We knew what we wanted, and Eric Gibson, John Storey and I supervised it. One consideration which over-rode all others was that this plant eventually would be the production centre of a wholly Australian
car, and the layout of buildings was fixed accordingly. On 14 February 1936, Albert Dunstan, the Premier, turned the first sod on the site. This was on the third green of the old golf course. Then, when the hole had been enlarged, we wheeled along a barrow-load of cement, and it was poured in - the first foundation of the first building on Fishermans Bend. Mr. Dunstan spoke prophetic words at the foundation ceremony. He said, “This great project will provide employment, directly and indirectly, for thousands of people and give an impetus to business which cannot be calculated in terms of pounds, shillings and pence.” Only seven months and two weeks later, on 28 September 1936, PM Joe Lyons officially opened the plant, and the first car assembled there was driven off the assembly line, with John Storey at the wheel and me sitting happily beside him. What an incredible achievement it was: seven months from turning the first sod to production - in an area without services or roads to start with! The whole plant, designed and built by Australians, using Australian materials, cost less than £440,000.
This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.
AMT Feb/Mar 2018
To be continued…
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