AMT AUG/SEPT 2019

AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

AUGISEP19

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AUGISEP19

MINING & RESOURCES Industry 4.0 State Spotlight: Victoria

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04_AMTIL_150819

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TM

008

CONTENTS

Volume 19 Number 04 AUG/SEP 2019 ISSN 1832-6080

FEATURES MINING & RESOURCES The capital of mining technology innovation NEPEAN – Productivity & customer satisfaction Australia-made secondary mine ventilation John Hart assists ACIM to break ground worldwide AIMEX 2019 - Unearthing opportunities

44 48 50 53 54

FORMING & FABRICATION MFB products – Upgrading for the future FormFlow – Revolutionising sheet metal bending Next-generation tube-bending robots from transfluid The rationale behind ISO 9606-1 Qualification FAB9 – Melbourne’s newest Makerspace

56 58 59 60 62

STATE SPOTLIGHT VICTORIA Redline combines engineering with service APT boosts productivity with Lang Technik

66 68

INDUSTRY 4.0 thyssenkrupp – Alfred AI solution Intelligent tech for Oz manufacturers Improving the life of the line Harnessing Industry 4.0 for quality inspections World of simulation Restoring the human element – Mitsubishi Mid-sized manufacturers need to embrace IIoT

72 74 76 78 80 82 83

CUTTING TOOLS Digital way to make internal turning more efficient Tools for large part manufacturing Mapal meets the needs of automotive electrification Face milling for nickel-based alloys

84 86 88 90

QUALITY & INSPECTION What does ISO 9001 mean for customers?

Navigating automotive evolution with Mitutoyo Creaform launches HandySCAN BLACK

92 94 96

WASTE & RECYCLING Deakin - Recycling rare earths, plant waste Applied Machinery, FIMIC - Improved recycling

98 99

MATERIAL REMOVAL Tornos introduces new models

100

PUMPS & VALVES technotrans helps eliminate oil mist

102

ADVANCED MATERIALS & COMPOSITES Bringing graphene and new materials to market Can we bend it? The flexible technology challenge

104 106

REGULARS

The capital of mining technology innovation Digital technologies are having major impacts on the mining & resources sectors. We look at three companies aiding in the digital transformation of mining.

56 Upgrading for the future Victorian manufacturer MFB Products is maintaining its competitive edge with the latest state-of-the-art sheet metal technology and its focus on specialised, customised options.

64 Grant Anderson

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

36

ONE ON ONE – Grant Anderson

64

COMPANY FOCUS Bastion Cycles – Bespoke bikes, advanced manufacturing

44

The Executive Director of Industry Capability Network (ICN) Victoria speaks to AMT about the ICN’s role in helping companies build productivity and efficiency.

70

70

AMTIL FORUMS

108

Bespoke bikes, advanced manufacturing

AMTIL INSIDE – The latest news from AMTIL

112

MANUFACTURING HISTORY – A look back in time

118

Bastion cycles is the world’s first company to bring an international-standard, commercially available, 3D printed bicycle to market.

AMT AUG/SEP 2019

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AMTAUGSEP19

Demonstration Centre: Unit 20, 17-23 Keppel Drive, Hallam, Victoria Service Centre: Unit 8, 17-23 Keppel Drive, Hallam, Victoria

010

FROM THE EDITOR WILLIAM POOLE

Gen-Z set to stem the skills crisis

Editor William Poole wpoole@amtil.com.au

A few years ago I was interviewing the owner of an Australian manufacturing business when he made an interesting remark. Whenever the company had a major project, they would often bring in older workers to help, even coaxing them to come out of retirement.

The experience these industry veterans could offer had undoubted advantages, but the company’s owner conceded it was not a sustainable strategy in the long term; he cited skills shortages as the biggest challenge facing the industry in this country.

Contributors Dee Rudebeck Brent Balinski

Anyone close to Australian manufacturing will know what he means. Attend any industry gathering and, amid the sea of silver hair or bald heads, you’ll find that more likely than not the conversation will turn to the difficulty of finding talented young staff, for vacancies that urgently need to be filled. But Australia is no outlier here; manufacturers in many Western economies are struggling with the same issue, particularly in the wake of outsourcing so much of their production to lower-cost countries such as China.

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

Recently a report from software specialists Leading2Lean has revealed the extent of the problem in the US. Manufacturing in the US peaked in the 1970s as the Baby Boomer generation entered the workforce. Today, those Boomers are retiring, and they’re taking immense reserves of knowledge and experience with them. The report states there are now 522,000 open manufacturing jobs in the US (an all-time high), with 2.4 million jobs projected to go unfilled over the next decade.

Leading2Lean attributes much of this to enduring misconceptions about the industry. For example, the report found more than half (53%) of the US public assumed the average salary of a mid-level manufacturing manager was below US$60,000. In reality, that figure is actually close to double that, at US$118,500.

A big factor in this is education. The report found 75% of the public had never had a teacher or career adviser suggest attending trade or vocational school, and only 13% had been encouraged to consider manufacturing as a career option. Sounds familiar?

Who hasn’t heard stories of teachers warning pupils that if they didn’t apply themselves at school they’d end up working in a factory?

However, Leading2Lean also offers compelling evidence to suggest that attitudes are shifting, specifically among Generation Z (the cohort of people born between 1997 and 2012). One-third (32%) of Gen-Z has had manufacturing suggested as a career option, up from 18% for Millennials (those born between the early 1980s and the mid-1990s), and compared with 13% of the general public.

Moreover, Gen-Z were found to have more positive attitudes towards manufacturing, and towards careers in the industry. When surveyed about working in manufacturing, 43% of Gen-Z respondents saw it as an attractive option. Compared with the general public, they are 7% more likely to consider working in manufacturing, and 12% less likely to view the industry as being in decline.

Admittedly, these figures are from the US, so they shouldn’t be seen as indicative of what is going on in Australia. Nonetheless, given the similarities between the two countries, it’s no great leap to see similar trends here. Engaging younger workers is always a challenge in any industry. However, if manufacturing can find the right way, maybe Gen-Z has the potential to build a dynamic workforce for the future.

Head of Partnerships & Sales Anne Samuelsson asamuelsson@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 bi-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.

1464AMTAUG/SEP2019

LANG TECHNIK’S ZERO-POINT SYSTEM - REDUCES CHANGEOVER TIME, BOOSTS PRODUCTIVITY. Lang Technik’s zero-point clamping system allows for a one time installation. Once the base plate is mounted and aligned to the machine tool table and the zero point defined, you can build workpieces and fixtures quickly, providing a huge boost to productivity and reducing changeover time from 1-2 hours to five minutes. Combine this with a Makro-Grip 5-axis vise offering unmatched holding power, and you’ve got the ultimate workholder.

TURNING

AMT AUG/SEP 2019

MILLING

dimac.com.au ENVIRONMENTAL

ACCESSORIES

012

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Benchmarking your business’s health and safety Employers are required by law to provide a safe, risk-free work environment for all employees. This will include assessing and monitoring the workplace for risks, and listening to and consulting all workers. For organisations that are serious about mitigating workplace risks, the ISO 45001 Standard is undoubtedly the best option to benchmark an organisation’s occupational health & safety performances against their local and overseas competitors.

Despite businesses in Australia having a legal requirement to comply with their State’s workplace health & safety (WHS) laws, more than 100,000 serious workplace injuries still occur every year. These range from mental stress, to trips and falls, to collisions with objects. A leading auditing and training organisation in occupational health & safety is alerting organisations to commonly overlooked workplace practices that are risking the health and safety of their employees.

SAI Global is a global risk management provider that has audited and trained thousands of organisations seeking to meet the ISO 45001 international standard for WHS, in addition to the workplace health & safety acts and regulations in their own state.

SAI Global recently released a list of the seven workplace hazards commonly overlooked by employers: 1. Heavy workloads and high stress levels. Are employees stressed, working long hours or skipping breaks as they struggle to meet the demands of their jobs? Work-related stress is the second most common compensated illness or injury in Australia. It can lead to physical symptoms such as headaches and fatigue, psychological symptoms such as anxiety, sleep loss and depression, or behavioural symptoms such as mood swings. These can contribute to long-term health complications such as sleep loss and even diabetes. The ISO 45001 Standard requires top management to include all workers in their WHS decision-making, and implement ways to gather employee feedback.

2. Concealed bullying and harassment. We tend to think of managers as the main perpetrators of workplace bullying and harassment. But SAI Global auditors have identified the behaviour among junior-to-mid-level employees, contractors and even external suppliers. Bullying and harassment includes hurtful remarks, playing mind games, making one feeling undervalued, assigning pointless tasks that have nothing to do with a person’s job, giving impossible KPIs or jobs, changing work schedules to make it difficult for the employee, or being required to do humiliating things to be accepted in a team.

Being at the receiving end of bullying and harassment can cause emotional trauma and lead to mental health injuries.

3. Basic clutter. Do staff need to meander around stacked boxes, plants, artworks, bags on floors, or courier deliveries placed in access areas? These present trip or collision risks for anyone on the workplace, especially when they are distracted, carrying items or turning corners. It is recommended that employers organise regular workplace ‘housekeeping’ or inspections to identify potential obstacles that might create hazards. Implement a program to sort through workplace items,

ensure every item has a predetermined storage location when not used, have the workplace cleaned daily, keep all employees on-board on the new set of standards and ensure the new habits are adopted.

4. Blocking fire safety equipment. Are bookshelves or tall furniture pieces blocking fire exits, sprinkler heads, fire hoses or fire hydrants? These can obstruct the use or efficiency of fire safety equipment in the case of an emergency. Management should ensure fire safety equipment has one-metre clear zones marked by signage, workplaces have regular safety inspections, and there is preventative maintenance in place for essential services.

5. Non-adjustable desks, chairs and monitors. Think height adjustable desks are a bit of a fad? Not so. Desks, chairs and monitors that can’t be adapted to employee needs can lead to injuries. Research led by the University of Sydney found that lower back pain accounts for a third of all work-related disability.

While employers might be reluctant to incur the expense of ergonomic equipment, the cost of compensation claims can far outweigh the investment.

6. Extreme workplace temperatures. Are desks positioned beneath air-conditioning vents, or in draughts? Or is direct sunlight causing ‘hot spots’ in the office in Summer? Employee complaints related to temperature are common. Ideally, interior workplaces should be a comfortable, even temperature of 22 degrees in summer and 24 degrees in winter. Heat and cold stress can impact our health. An employee falling ill because they were forced to work in uncomfortable conditions can lead to days off work, and even a workers compensation claim.

7. An employer’s lack of commitment to safety. If you can’t remember seeing a company WHS policy, you have a major employee safety issue. You still have an issue if your company does have a WHS program, but not every person working under the organisation – including contractors, volunteers and interns – is included and consulted into it. SAI Global auditors have seen organisations with good programs in place, but which have not been taken on board by management. When staff are not educated about potential workplace hazards, risks and good safety practices, injuries and illnesses are more likely to occur. The relevant manager should take all staff through the company’s WHS policy and take practical steps to demonstrate that their safety is their priority. A safe culture is directly linked to productive workplaces. If a supervisor or manager does something unsafe, it’s likely that other workers will follow suit.

For more information visit: www.saiglobal.com.au/iso45001

FREDDY TAKES THE NIGHTMARE OUT OF COOLANT MANAGEMENT. Make your coolant last longer, lower your operating costs and extend the life of your equipment with a Freddy vacuum and coolant recycler. Freddy rapidly and safely removes coolant, swarf and oil and separates the particulates, returning the filtered coolant for re-use. Streamlining workflow, he works while your machine is in operation whilst also helping protect your employees from WHS issues.

TURNING

AMT AUG/SEP 2019

MILLING

dimac.com.au ENVIRONMENTAL

ACCESSORIES

HEADING

New

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014

FROM THE MINISTRY THE HON KAREN ANDREWS MP – Minister for Industry, Science and Technology

Fostering creative thinking in young people is vital for manufacturing Manufacturing needs to attract bright young people to secure Australia’s economic future. Not only are youth vital to renew the workforce, but intelligent young people brimming with ideas and energy are capable of transforming the way we do business.

Skills and knowledge, particularly in the STEM subjects – science, technology, engineering and mathematics – have to be learnt and continually upgraded, but what needs to be fostered more than ever are creative ways of applying these skills.

Building these skills is critical in preparing our manufacturing workforce. Advanced technologies and automation will change the way we work, allowing more time for creative, interpersonal and problem-solving tasks. We need to act now to build these capabilities for our future.

The Government sponsors initiatives to inspire young people to think creatively in ways that can have industrial applications and lead to careers in advanced manufacturing.

National Science Week, which takes place in August each year, is one of these. Fostering a fascination with the way things work is an excellent way of producing creative industrial thinkers. National Science Week features more than 2,000 events around Australia, including interactive workshops, discussions and demonstrations.

Projects that have received grants include chemistry in the kitchen and a quest to discover plastic-eating bacteria.

“Building these skills is critical in preparing our manufacturing workforce. Advanced technologies and automation will change the way we work, allowing more time for creative, interpersonal and problemsolving tasks. We need to act now to build these capabilities for our future.”

Our National Science and Technology Centre, Questacon, has done a great job of getting young people excited about science. Its renowned Science Circus tours the nation visiting schools, running pop-up science centres and professional development workshops for teachers. Our Government boosted funding for this program by $8.9m in the 2019-20 budget. A key aim of this program is increased collaboration with regional STEM providers and the promotion of job pathways.

The Government also supports grants for student science engagement. These grants help students to attend STEM events and competitions in Australia and overseas, developing their skills and exposing them to diverse career options.

Examples of events that students have participated in include the F1 in Schools engineering challenge, the FIRST Robotics League and the International Science and Engineering Fair.

Funded in the latest Budget, the Engineering is Elementary program will introduce teachers to the skills needed to increase student interest in STEM subjects. Questacon, in partnership with Defence Force Recruiting, will roll out this program over the next three years.

Finally, earlier this year I announced almost $5m in grants to universities in Victoria, Western Australia and Queensland to deliver the Automotive Engineering Graduate Program, which will place 107 post graduate engineers into industry-based automotive projects.

The program will develop job-ready engineers with the skills and experience our automotive industry needs and create high skill Australian jobs. As an engineer myself I’m well aware of the vital importance of engineering in supporting nearly every aspect of our lives. STEM skills are essential for our economic prosperity and the Australian Government is determined to encourage more students, particularly girls and young women, to study these subjects.

1391/2AMTIL

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AMT AUG/SEP 2019

’S APPLIED

“We have already seen the positive financial implications of the Yawei; it’s value for money.”

ED CUT

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SPE

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Shane Blewden, Owner - Alliance Metal Solutions, Kings Park, NSW.

nsistency of cut, combined with very low operating he perfect way to take your business to the next level.

ue of its own, opening up possibilities for companies tart-ups through to full production, 3-shift Launched at Austech, the HLX model is the latest precision fiber laser in the impressive line-up from Yawei.

The HLX series high speed, high specification fiber laser sits at the top end of the laser market and represents an exceptional value proposition for Australian manufacturers and contract cutters alike.

aluminium cutting and much, much more, the Yawei HLX series machine really has to be seen to be believed.

Dollar for dollar, the Yawei HLX, HLF and HLE series o-focus cutting head, IPG laser source, Siemens fiber lasers rival anything in their respective market ss-relieved fully annealed frame it really is a cutsegments aboveand the Applied sales and service network has Featuring a world class Precitec Pro Cutter autofocus cutting head (zoom also available), a high power 8kW IPG fiber laser source (up to 20kW available), Siemens 840D CNC control, Siemens servo drive and motors, remote diagnostics capability, 6 barrel DonaldstonTorit fume extractor, patented mixing device for brilliant

Australia covered – coast to coast. Yawei and Applied are slashing barriers to entry into laser cutting, along with offering established high end processors, a very attractive, value-packed alternative when it comes to replacing aging CO2 machines. Yawei Fiber Lasers – world class performance without the price tag.

That’s Applied thinking.

Connect with us socially

22/12/16 9:27 am

016

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Energy needs better regulation, no more no less The complexity and importance of energy sits awkwardly with simple regulation-versus-deregulation arguments. The energy markets need a lot of rules to work at all: natural network monopolies require regulation to protect consumers who are stuck with the bill; but successive State and Federal Governments have attracted immense private capital and reduced the drain on the public purse by promising a predictable and welcoming environment for energy investment.

That promise looks increasingly shaky. The broadly drafted divestiture powers proposed by the Federal Government are intended to frighten energy market participants into good behaviour, but in practice seem more likely to encourage them to sit pat and avoid investment.

Ad hoc interventions by all levels of government increasingly sideline the core design of the National Electricity Market. Decision-making around gas developments is often a political battleground rather than a disinterested process in which industry and the community can share confidence. The lack of a clear, credible and durable longterm emissions policy for energy is a major source of uncertainty for energy investment.

Not all is bleak. We are in the midst of a major burst of renewables investment, driven by a combination of the Renewable Energy Target, State policies, and the response of energy users and suppliers to high power prices and ever-cheaper wind and solar costs. There are multiple options for natural gas supply taking shape or seeking approvals – from Narrabri to pipelines to import terminals and more.

We need to do better, however. Electricity prices are high and supply is still tight in peak periods. New investment and reinvestment can help with both, but the current wave of capacity additions will soon break and what follows is completely unclear. Gas prices are high and supply and demand will be out of balance in the next five years without further action. New supply may not see prices fall below export parity, but its absence could easily see prices surge far above international levels. Households and businesses of all sizes are under pressure, with energy-intensive manufacturers at increasingly serious risk.

There is more to regulation than light touches, firm hands and big sticks. The steps that we need to take are largely not about having more or less regulation, but about doing it better.

Transmission lines can unlock the cheapest electricity resources or waste billions on wrong assumptions about supply options and demand growth. If developers keep too much risk, nothing gets built – and if energy users bear too much risk, they may be paying for a whole herd of white elephants. A regulatory test for investment is

AMT AUG/SEP 2019

meant to get the balance right, but the current version is far too slow and limited in the costs and benefits it can consider.

Smarter rules are needed elsewhere in the energy system: to provide more ways to reward demand response; to encourage the efficient provision of enabling infrastructure for distributed energy resources like solar, batteries and electric vehicles; to change pricing structures and incentives so those resources are used to create value for the whole system.

Gas development should face neither blanket bans nor a Wild West.

Strong science-based rules, clear, timely decisions, and credible enforcement are needed to earn community confidence and provide a workable environment for the gas industry.

The Big Stick of forcible divestment sounds appealing to some, and the Government suggests it would be kept in reserve – like Gondorians grasping for Sauron’s Ring, ‘not used, I say, unless at the uttermost end of need’. It is hard to believe this assurance.

Calls within and outside the Government to broaden the power belie it. The ACCC and the Harper Competition Review recommended against divestment as too big and risky a step, and they were right.

Financial assistance by all levels of government to new and existing generators is unlikely to stop, but it can be put on a more coherent and predictable footing. The States and Commonwealth should coordinate with each other and the Energy Security Board to support the Integrated System Plan and deliver market-wide outcomes for affordability, reliability and emissions.

Integrating energy and climate policy remains critical. To ensure we get the investment we need, it would be helpful to have a better guide to when old high-emitting assets may exit, and it is essential to know the specifics of how emissions and abatement will be treated over long asset lives. Market-wide policy is the gold standard, whether delivered at the national level or through collaboration among the States – who, after all, have the constitutional responsibility for power.

For more about Energy policy: www.aigroup.com.au/energy

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FROM THE UNION PAUL BASTIAN – National Secretary Australian Manufacturing Workers Union

Taking a lead in lithium Australian is very good at digging things up. Many proud AMWU members build and maintain the machines and facilities where we extract and refine the raw materials that have generated so much wealth for Australia over the years.

Those are important jobs and important skills, and as a resourcerich nation we will continue to rely on our extractive industries well into the future. As a country with a significant portion of the world’s lithium resources and the leading producers of lithium, Australia will be a key player in the future of this valuable resource. Demand for lithium is expected to increase ten-fold by 2030 as part of the global shift to electric vehicles and off-grid renewable energy storage increase the need for lithium-ion batteries.

At the moment, Australia only digs up lithium ore and sends it overseas to be refined and then turned into batteries or used for other industrial purposes. A report released late last year by the Federal Government stated that Australia currently captures only 0.53% of the total value chain made possible by our supply of lithium to the global market. To put that into dollar terms, we export $1.13bn in lithium ore, which – through electro-chemical processing, battery cell production and product assembly – is turned into $213bn of total value. This is simply unacceptable and we cannot allow it to continue.

However, things are changing – a $1bn dollar lithium refinery is being built in Kemerton, WA which will produce 100,000 tons of lithium hydroxide – a key precursor chemical for lithium-ion batteries. A $516m expansion of the world’s largest lithium mining project near Bunbury will also see significant volumes of lithium concentrate developed on-shore. Plans are also underway to build a low-cost lithium-ion battery manufacturing facility in Darwin.

These are welcome developments and will see Australia move further up the lithium value chain, but there is much more that we could be doing to encourage this growing industry in Australia.

One report suggested that we could generate more than $50bn in annual revenue and support about 100,000 jobs by developing a battery materials sector right here in Australia.

Establishing a lithium refinery and low-cost battery manufacturing facility in Australia are important steps in the right direction. There is significant value to Australian workers and taxpayers if we continue to move up the value chain and establish a broad-scale lithium battery manufacturing industry in Australia. Not only will this mean that Australia is exporting high-value goods rather than raw material, it will give us competitive advantages in other advanced manufacturing industries that will rely on these batteries, such as electric vehicles.

Australia currently captures only 0.53% of the total value chain made possible by our supply of lithium to the global market.

To put that into dollar terms, we export $1.13bn in lithium ore, which is turned into $213bn of total value.

A strong and successful lithium industry in Australia must deliver secure, well-paid jobs to well-trained local workers. We must equip TAFE and our universities to support lifelong learning for the domestic workforce that we will need if we want this industry to compete on the global stage.

The Government released a glossy 50-page brochure touting Australia’s potential role in the global lithium-ion battery value chain late last year. While the paper had lots of case studies, it lacked any commitment to growing the industry. The government is yet again sitting on its hands hoping that the global market will solve their problems for them. While other governments around the world are falling over themselves to attract these sorts of advanced industries to their shores, our Government is doing very little to attract them here or invest in the workforce that will be vital to the future of this industry.

Australia’s natural bounty has again presented us with an opportunity to build strong communities, supported by quality jobs and growing businesses. We have missed these opportunities before; we must not allow that to happen again.

Establishing a sophisticated new lithium manufacturing industry will also encourage investment in research & development. If Australia is to remain an advanced and prosperous economy, we need to continue to invest in new and innovative products that can be made here and integrated into global supply chains. Taking advantage of our natural lithium resources will allow us to do just that.

Australia’s resources belong to the Australian people and they are the ones who should benefit directly from the job opportunities that come with setting up a new local industry. When there are over a million workers in Australia either looking for a job or looking for more work, we must ensure that we grab on to the opportunity to develop new industries with both hands.

Like all new and emerging industries, we will not have all the expertise that we need from Day One, but it is important that as an industry we engage with international partners to transfer the knowledge that we need for a successful domestic industry.

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INDUSTRY NEWS

Industrial sentiment bounces, conditions confirm a loss of momentum The Australian Chamber of Commerce and Industry (ACCI) – Westpac Survey of Industrial Trends for the second quarter of 2019 showed a slowing in manufacturing business growth but a rise in sentiment post-election.

The Westpac-AusChamber Actual Composite Index declined in June 2019 to 61.5, down from 61.8 in March, and significantly below the 63.5 recorded in mid-2018. According to Westpac Senior Economist Andrew Hanlan: “This confirms that the loss of momentum from mid-2018 persisted over the first half of 2019.

While not a weak reading, conditions over the first half of 2019 were the softest since late 2016.”

The survey found that manufacturing new orders are rising, but at a slower pace than evident over 2017 and 2018. Exports maintained a modest uptrend, which is expected to continue with the lower Australian dollar providing some support at a time of softer global conditions.

“The manufacturing sector is being impacted by cross-currents,” said Hanlan. “The housing downturn and spillovers from the drought are clear negatives. Countering this is the boost from the lower Australian dollar and from the upswing in public infrastructure investment.” Conducted after May’s Federal election, the survey indicates that optimism among manufacturing firms has rebounded after faltering earlier in the year, though it

remains below the levels prevailing in 2017. In June, a net 28% of firms expected the general business environment to improve over the next six months, up from 12% in March. Respondents expected new orders to strengthen in the coming three months, rising from a net 25% to a net 36%.

Investment intentions have rebounded after a soft start to 2019 amid uncertainty ahead of the Federal election. A net 21% of firms plan to increase equipment spending over the next 12 months, up from 12% in March, to be back in line with the readings evident in 2018.”

ACCI CEO James Pearson said: “The survey indicated there had been some improvements, with rising output, growth in new orders and the backlog of orders, and an increase in overtime for workers. But this was not enough to stem the fall in the Composite index, which reflects recent signs of a slowing economy and flat employment growth over the past three quarters. It all points to the need to strengthen the economy and improve business conditions for the manufacturing sector and business generally.”

Research collaboration lays foundations for Speedpanel 2.0 A collaboration with Swinburne University of Technology and with co-investment from the Innovative Manufacturing Cooperative Research Centre (IMCRC) is helping Victorian manufacturer Speedpanel develop the next generation of its modular wall panel system.

Based in Bayswater, Speedpanel manufactures cutting-edge fire- and acoustic-rated non-load bearing wall systems. The company has partnered with Swinburne to research and develop new materials and manufacturing technology to further enhance its Speedpanel 2.0 system. Recognising the changing nature of Australia’s construction sector – particularly in light of technological advances and environmental pressures – Speedpanel is investing in the next generation of its proven lightweight, fire and acoustic rated wall systems, which are easy to install and widely used in the building and construction industry.

Under the leadership of Professor Jay Sanjayan, Director of Swinburne’s Centre for Sustainable Infrastructure, researchers will apply advanced manufacturing principles to develop and test the structural, acoustic and fire performance of new, lowcarbon materials, and incorporate them into Speedpanel’s existing production environments.

“Swinburne is proud to work alongside an industry leader like Speedpanel and other collaborators, with the help of the IMCRC,” said Professor Sanjayan. “This project provides a great opportunity for our team to go beyond the laboratories and use our groundbreaking research to develop new materials and technologies that have the potential to revolutionise the construction industry.”

Peter Bernhardt, Innovation & Technology Manager at Speedpanel, described the groundbreaking, world-first research project as a major shift in how fire and acoustic rated wall systems are designed, manufactured and supplied. The three-year project is worth more than $4.4m in research effort. “Speedpanel 2.0 will be a game changer for the building and construction market,” said

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Bernhardt. “New methods of manufacturing, combined with exciting, new, innovative and sustainable materials, are set to enhance our versatile range and further reduce our carbon footprint.”

The project will be a collaboration with industry Speedpanel Innovation & Technology Manager, Peter Bernhardt, and partners such as Independent researcher Sayanthan Ramakrishnan Cement Limited, Redox conduct tests on new materials as and Speedfoam to leverage part of the Speedpanel 2.0 project. synergies and adopt new approaches to delivering affordable, high-quality products and services that benefit the wider building and construction industry.

David Chuter, CEO and Managing Director of IMCRC, says that Australia’s building and construction sector presents a widespread opportunity for change and greater potential for the adoption of advanced manufacturing technology.

“As part of its commitment to business transformation and continuous improvement, Speedpanel has recognised the need to further develop and evolve production processes, components and systems used to increase efficiency, productivity and respond to market demands,” said Chuter. “Aligning its manufacturing capabilities, and investing in the development of new materials and technologies, will create a breadth of opportunity across the entire supply chain as it develops the next generation of Speedpanel products.”

INDUSTRY NEWS

Positive outlook for automotive manufacturing With the dust settling in the wake of car manufacturers ceasing vehicle production in Australia, the automotive manufacturing sector has had to recalibrate, but positive signs are emerging, according to the Australian Automotive Aftermarket Association (AAAA).

Although overall revenue and employment numbers are down from 2015 figures, business sentiment within the sector is positive; with reinvention, new ventures and innovation driving an increase in the number of manufacturing businesses operating in Australia.

In fact, research commissioned by the AAAA with ACA Research to evaluate the state of the market has revealed a total of 300 automotive manufacturing companies operating in Australia - up from 260 in 2015.

The increase is an encouraging sign and is a combination of OEM parts suppliers being able to pivot and diversify into other markets with new products, and skilled workers previously employed by vehicle manufacturers starting new ventures in more specialised/ niche areas. In 2019, the Australian automotive manufacturing sector employs nearly 10,000 workers and has a combined annual revenue of $4bn. This revenue predominantly comes from direct sales to consumers and trade, or sales to wholesalers and retailers.

With the popularity of the 4WD market in Australia and overseas from a parts and accessories perspective, it is unsurprising that 86% of businesses are engaged in this market. Diversification is widespread, however, with businesses most commonly producing parts for four types of vehicles – 4WDs, passenger vehicles, light commercial and performance vehicles.

While Australia remains the core customer base for most manufacturers, 70% of these companies are exporting overseas.

The combined export revenue within the sector currently sits at $640m, with the US remaining the key export market, ahead of Europe, New Zealand and the Middle East. Although export markets remain a key area for growth potential to the sector, external economic issues such as the fluctuating dollar, general economic conditions, plus rising power and fuel costs are the greatest challenges to the industry’s medium-term growth.

To mitigate these factors, investment in new technology, research & development and skills building are the main drivers for business development. And with nearly all manufacturing business forecasting revenue growth and the volume of exports to increase over the next 12 months, signs are positive.

“It has been a challenging time for us following Ford, Holden and Toyota leaving Australia,” said Lesley Yates, Senior Manager – Government Relations and Advocacy of the AAAA. “But this landmark research has now shed important light on the steady growth in the number of companies, and the increase in product innovation in our industry. We are still here, and we are encouraged by the increase in exports and business confidence. These findings are a catalyst for further optimism and growth within automotive manufacturing.”

ACA Research Director Steve Nuttall echoed the confidence in the industry that the research has uncovered: “The highlight of this research for us is the positive outlook for the future of the Australian automotive manufacturing sector, despite an uncertain economic environment. In our view, this confidence is justified, with our manufacturing firms focusing on investing in talent and innovation which will position them for success in Australian and international markets.”

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INDUSTRY NEWS

Top industry award for Australian rail innovation A world-leading technology to minimise passenger dwell time at rail stations has received the top Excellence in Innovation award at the Cooperative Research Centre Association’s annual conference.

Developed by the University of Technology Sydney (UTS), Downer and the Rail Manufacturing CRC, Dwell Track is a technology solution which can anonymously monitor passenger numbers and behaviour in real-time on rail station platforms.

“Chronic congestion on platforms can lead to extended dwell times when trains stop to put down and pick up passengers,” said Tim Young, Executive General Manager of Downer’s Rollingstock Services. “This in turn affects passenger safety, train path capacity, service delivery and reliability. Dwell Track enables station staff to make effective decisions when guiding passengers in real-time and also provides longer term insights into enhanced platform operations around dwell management.”

Detecting and tracking human movement is challenging, as people are dynamic and come in a variety of shapes, sizes and appearances. This is further complicated in crowded environments due to frequent visual blockages and the sheer number of people in proximity. Dwell Track leverages advances in 3D camera technology to extract relevant spatial and temporal information from the rail platform in real-time.

“This technology solution was developed by Rapido, a commercial R&D unit at UTS, translating and integrating fundamental research from the UTS Centre for Autonomous Systems, a specialist unit robotics unit creating positive change for government, industry and the community,” said Herve Harvard, Director of Rapido. The 3D cameras work by firing an irregular pattern of dots from an infrared

projector and sending it to a processor to determine depth from the displacement of the dots.

“Using this depth data, we developed several algorithms to identify the head and shoulders, the body parts most visible in a crowd,” said Dr Alen Alempijevic, UTS Centre for Autonomous Systems. “Dwell Track uses this detail, combined with an understanding of social norms, to track individual movements by determining train door positions, door status, platform occupancy, passenger counts and the direction passengers are moving.” The availability of dwell time data has the potential to improve service reliability due to insights used to stabilise dwell times at key stations and increase service numbers per hour. The data also assists in identifying which parts of the dwell time structure can be reduced or are extending beyond usual practice, while also identifying strategies or procedural changes that will reduce the impacts of dwell time on other aspects of train operations.

Dwell Track isn’t just relevant to rail businesses; there is clear opportunity to use the technology in transportation including buses and trams, as well as places where the movement of people in crowded places can benefit from autonomous monitoring and optimisation of how spaces are run.

“The greatest driver of success for this collaborative project is the strong range of stakeholders covering the whole research and supply chain, resulting in the successful conception, prototyping and commercialisation of Dwell Track,” said Stuart Thomson, CEO of the Rail Manufacturing CRC.

New partnership to accelerate WA defence innovation A $230,000 partnership between the Australian Mathematical Sciences Institute’s (AMSI) APR.Intern program and the Defence Science Centre (DSC) Western Australia will accelerate STEM PhDs into defence innovation.

Announced at the DSC launch on 12 June by the WA Defence Issues Minister, Paul Paplia, the agreement – the first for the DSC – will see 10 PhD students placed into short-term, focused SME-led defence innovation projects. With an emphasis on engaging small business in Western Australian defence innovation, eligible industry partners will receive $10,000 DSC subsidy.

These internships are supported by the Federal Government including a 50% rebate towards industry internship costs through its Supporting more women in STEM careers: Australian Mathematical Sciences Institute (AMSI)—National Research Internship Program (NRIP).

AMSI Director, Professor Tim Brown welcomed the opportunity to partner with DSC to provide WA STEM PhD students with the opportunity to develop industry skills while helping drive real-world defence innovation. “We are excited to open this powerful platform for Western Australian universities to complement specialist PhD training with defence industry experience while delivering real-world innovation solutions,” said Professor Brown.

Gary Hogan AM, APR.Intern Director and Melbourne Enterprise Professor, said the placements were a welcome boost for WA’s small business sector and a positive step towards realising the objectives of NRIP.

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“Contributing to the delivery of NRIP, the placements under the APR.Intern program will allow SMEs to cost-effectively tap into specialist research talent with unique skillsets to advance Western Australian defence innovation,” he said.

Minister Paplia said the partnership would contribute to the McGowan Government’s support for small businessled defence innovation and ongoing efforts to secure the state’s STEM future.

“This partnership will foster essential research-industry collaboration, accelerating WA defence innovation and building STEM capability to position the state as a global innovation leader,” said Minister Paplia.

WA Defence Issues Minister Paul Paplia; Federal Minister for Defence Industry Melissa Price; and Professor Tanya Monro, Chief Defence Scientist. Picture supplied by DSC.

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INDUSTRY NEWS

AVALON 2021 aiming to break records Set for 23 to 28 February 2021, the Australian International Airshow and Aerospace & Defence Exposition (AVALON 2021) is aiming to break attendance records as a cornerstone event of celebrations to mark the Royal Australian Air Force (RAAF)’s centenary.

With 78% of internal exhibition space already reserved by previous 2019 exhibitors and international pavilion partners, AVALON 2021 organisers are planning for unprecedented participation from exhibitors and trade delegates in what is expected to be the Southern Hemisphere’s largest single aerospace and aviation exposition. AVALON 2021 will comprise industry-only trade exposition days from Tuesday 23 February to Friday 26 February, with public airshow and entertainment days from Friday 26 February to Sunday 28 February.

AVALON 2021 CEO Ian Honnery said the RAAF milestone, together with the 2020 centenary of the formation of Qantas, meant that organisers were planning for an event that would eclipse even 2019’s record trade attendance.

“As an international aerospace industry exposition, AVALON 2019 was a record‐breaker in both exhibitor numbers and trade day attendances, with a host of major industry announcements and significant international participation from a total of 37 countries,” said Honnery. “AVALON 2021 will be the largest single event in the Air Force 2021 centenary calendar and will come just three months after the November 2020 centenary of Qantas.

That combination of civil and defence is already proving a magnet for industry, with both Australian and international companies committing to the event to display their contributions to this worldclass Australian aviation heritage.

“AVALON 2021 will be a celebration of 100 years of Australian innovation and leadership in military and civil aviation and aerospace.

“More than ever, AVALON 2021 will showcase Australian industry to the world, by bringing the world to Australia.”

Manufacturing hardest hit as SMEs face $115bn cashflow crunch from late payments A report from Xero has revealed the magnitude and impact of late payments to Australian small businesses, putting the value of outstanding, late payments at $115bn a year, with manufacturing SMEs among the slowest paid.

The research found that half of all trade credit invoices are paid late and that solving the problem would deliver a benefit of $4.38bn to Australian SMEs over 10 years. Manufacturing SMEs were found to have waited an average of 31 days to be paid by all customers – a 13-day lag compared with SMEs in accommodation, food services and financial services.

The report, Paying the Price: the economic impact of big businesses paying Australian small businesses late, is based on data from Xero Small Business Insights (Xero SBI). Prepared by AlphaBeta Advisors, it analyses more than 10m invoices issued by more than 150,000 SMEs. “Late payments are the scourge of small business, and being able to name the staggering figure of $115bn gives fresh urgency to solving the problem,” said Trent Innes, Xero Managing Director, Australia and Asia. “We call on big business and Government to prioritise this issue.”

The report finds that over half of all trade credit invoices to SMEs (53%) are paid late, being settled an average 23 days after they are due. With small business issuing $216bn in invoices each year, this equates to $115bn in late payments. If these invoices are paid on time, it would equate to transferring $7bn in working capital from large businesses to SMEs. The returned $7bn could be used

by SMEs to reduce debt or increase investment and output.

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The combined effect of lower financing costs and increased investment opportunities is estimated to deliver a benefit of $4.38bn over 10 years to the small business sector. Allowing for extra costs for large businesses, this would still deliver a net benefit to the Australia economy of $2.54bn.

The report also finds a direct link between payment time length and slower growth for small business. The study finds that SMEs that are paid more slowly than average have about a third lower revenue growth than those paid more quickly. Long payment times also have a domino effect across the economy, as SMEs that are paid slower than average pay their own suppliers eight days later than those paid faster than average.

“We can no longer accept it as the status quo that Australian small business carries billions of dollars of debt for big business,” added Innes. “The $115bn of late payments identified in the report equates to around $52,000 owed to each SME in Australia. That’s the value of giving every small business owner a Toyota Hilux 4x4.

It’s the value of two NBNs, or 23 Snowy Hydro 2.0s.

“Unlocking this capital for small business to use will give a significant stimulus to the economy. Faster, predictable payments will generate greater stability and confidence amongst the small business sector. Small businesses will grow faster, have better cash flow, employ more people and take on more business risk.”

INDUSTRY NEWS

RMIT’s Calum Drummond receives Order of Australia

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RMIT University’s Professor Calum Drummond was appointed an Officer of the Order of Australia (AO) in the Queen’s Birthday 2019 Honours List in June, for his outstanding service to science and innovation.

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Drummond, Deputy Vice-Chancellor for Research & Innovation and Vice-President at RMIT, received the appointment in recognition of distinguished service to chemistry and materials science research, commercialisation initiatives, and his exceptional contribution as a scientific leader and mentor. Drummond’s research achievements include advancing the fundamental understanding of materials at the nanoscale that have enabled high-performing products to be developed and commercialised.

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Having worked in his field for more than 30 years, Drummond said he felt humbled and honoured by the appointment.

“To be recognised as making a positive contribution to my country and to science is an absolute honour,” he said. “I think this appointment highlights that we, as researchers, are in a privileged position to make a positive difference to our local, regional and international communities.

“I am proud to have worked with so many inspiring researchers throughout my career. I have definitely benefited from good mentors over the years, and in the spirit of passing it forward I have always been delighted when I have been able to play a role in helping others to succeed in their chosen field.”

RMIT Vice-Chancellor and President Martin Bean CBE said he was delighted by the news: “It’s tremendous that Calum has been acknowledged as one of Australia’s outstanding leaders through his appointment as an Officer of the Order of Australia. He continues to work passionately to drive benefit and impact through innovation, research, engagement and collaboration and we are very privileged to have him at RMIT.” Drummond was commended for his contributions to the National Innovation System by creating direct value for many Australian companies and contributing to governance and advisory bodies.

Drummond’s research has identified many organic molecules capable of self-assembling in solvents to form materials with highly ordered 2D and 3D internal nanostructures. These materials have been used to enhance products from drug delivery vehicles to environmentally friendly off-shore oil drilling fluids, waterproof recyclable paper, household cleaning products and specialty chemicals for the construction industry. Drummond’s scientific advances have also resulted in two patented cancer drug delivery technologies.

Prior to joining RMIT University in 2014, Drummond was Group Executive for Manufacturing, Materials and Minerals at CSIRO. In both organisations, he led major reforms to improve productivity and efficiency, support for researchers, and impact delivery.

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INDUSTRY NEWS

Headland partners with SPEE3D Headland Machinery has announced a new partnership with innovative additive manufacturing start-up SPEE3D. Based in Dandenong, Victoria, SPEE3D specialises in bespoke 3D metal printing machinery. Displayed at the Austech 2019 exhibition in Melbourne in May, SPEE3D’s innovative 3D printing technology is able to create highly complex parts at very high speeds. The company’s co-founders Byron Kennedy (now its CEO) and Steve Camilleri (Chief Technical Officer) created the world’s first metalbased 3D printer that uses supersonic 3D deposition – also known as SP3D; hence the company name – SPEE3D. SPEE3D’s mission is to make manufacturing easier by improving three key elements of 3D metal printing – cost, speed and reliability.

Its technology manufactures fast, low-cost, near-net-shape parts suitable for commercial and industrial applications. Ideally suited for producing parts currently designed for sand or die casting, the end applications include automotive, HVAC and industrial.

SPEE3D rounds off Headland’s Advanced Manufacturing Division where it joins an existing line-up of high-quality suppliers such as Mimaki, TRUMPF, Voxeljet and VisiConsult. Headland Machinery’s CEO and Joint Managing Director Richard Kloé voiced his excitement about the new partnership.

SPEE3D’s innovative 3D printer.

SPEE3D CEO Byron Kennedy and Richard Kloé, CEO and Joint Managing Director of Headland Machinery.

“We are delighted to be partnering with Australian manufacturer SPEE3D, due to their superior technology and innovative outlook on the industry,” said Kloé. “Advanced manufacturing technology is the way forward as the landscape of traditional manufacturing changes within the Industry 4.0 era. Headland’s goal has always been to enable innovation and to provide our customers the highest quality technology solutions available, which is exactly what SPEE3D brings to the table. We’re delighted.”

Businesses urged to switch to smart fibre to keep phone numbers Australian telco Netmode is urging businesses to begin switching over to next-generation IP-based services or risk losing their telephone numbers when Telstra begins disconnecting traditional phone services later this year.

Many business owners are unaware that from 30 September, the old copper infrastructure that supports Australia’s traditional phone lines and the ISDN (Integrated Services Digital Network) will be removed, with the entire network expected to be decommissioned within a few years. Netmode is facilitating the transition for businesses switching from the old ISDN network to the latest technology for voice and data services. Netmode CEO David Stevens says the clock is ticking for businesses to implement a transition plan in time to migrate their all-important telephone numbers.

the latest fibre and microwave technology, through its own independent enterprise-grade core network and infrastructure. The company utilises a combination of business-grade fibre and microwave to provide internet connectivity and security anywhere in Australia. According to Stevens, businesses still using ISDN for their voice services would see a massive improvement in performance once they switched to a smart fibre solution running VoIP. Netmode CEO David Stevens.

“Businesses caught unprepared risk losing their voice service and phone numbers if they don’t start porting them to a reliable provider now, as it can take weeks for technicians to migrate phone numbers to a new network,” says Stevens. “As the country transitions from the old technology infrastructure to new carrier-delivered fibre or even wireless delivery, now is the time for businesses to adopt modern voice technology. “We are alerting businesses that the deadline is looming to switch their phone service to Voice over IP (VoIP) because if businesses leave their run too late they could end up losing their phone numbers for good. Companies that are still to establish a transition plan are being urged to do so now to avoid being caught in a communication ‘blackout’.” Netmode has been transitioning businesses from copper-based services to

AMT AUG/SEP 2019

“Business-critical technologies such as VoIP, video conferencing, digital applications, data storage, and cloud and co-location technologies require a robust communications network for successful implementation,” he says. “The ISDN shutdown is an opportunity for businesses to advance their digital operations and leverage all the benefits it offers, including substantial reductions to internet and phone expenses plus a higher level of employee productivity.

“We know that businesses switching to smart fibre through our network are experiencing major improvements to their internet, with speeds increasing up to 200% from 50Mbps up to 1000Mbps.

Netmode manages the telephone number-porting process in a seamless manner, but time is running out, so we urge businesses still on an ISDN network to begin the process now.”

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GOVERNMENT NEWS

Grants help drive automotive innovation Devices which pick up when drivers are getting tired and save on fuel consumption are among the projects to share in almost $2.5m dollars in funding awarded by the Federal Government.

The Automotive Innovation Lab Access Grants program will help businesses enhance the design and development of their products. Minister for Industry, Science and Technology Karen Andrews said the array of projects show how Australia’s automotive industry is transitioning.

“These grants are part of the Liberal National Government’s ongoing efforts to support the automotive and advanced manufacturing sectors, a vital part of our economy,” said Andrews. “These grants will help the businesses get their products to market sooner, which will grow the economy and create new Australian jobs.”

The successful applicants are: • Brown & Watson International (VIC) – $200,000 to help develop an automotive lighting project for 4WD enthusiasts and long-distance transport users.

• Disc Brakes Australia (NSW) – $107,100 to develop a new lightweight composite performance disc brake rotor to improve fuel efficiency and vehicle safety.

• Composite Materials Engineering (VIC) – $200,000 to help create and validate an advanced lightweight body panel.

• Optalert (VIC) – $168,302 to help develop an early warning drowsiness detection video system for driver monitoring.

• Impact Import Group (VIC) – $142,610 for help with a storage drawer system for restraint and security of loads for industry and recreational vehicles.

• Eurospares (VIC) – $200,000 for the development of disc brake systems to replace inferior drum brakes on a range of

popular SUVs and light commercial vehicles.

• Fitmycar (VIC) – $200,000 to further the development and prototyping of the new Bedrock floor liner product.

• Maxitrans Industries (VIC) – $200,000 to assist with an innovative suspension solution for truck trailers.

• TJM Products (QLD) $187,000 to help with the development of a canopy solution for various trade and recreational uses.

• HRDS Technologies (NSW) – $200,000 for development of a device for heavy vehicles to reduce harmful emissions by substantially reducing the fuel used.

• Lumen Freedom (VIC) – $200,000 for testing of a Wireless Electric Vehicle Charging System.

• Altair Aviation (VIC) – $199,540 for development of a new, stronger and more robust locking differential for 4WD and off-road vehicles.

• Battleist (VIC) – $175,000 to finalise development of a device that measures the side slip angle (also known as oversteer angle or drift angle) of a vehicle in motion.

• Total Ability (NSW) – $74,500 for development of a platform to allow people with quadriplegia and other severe physical disabilities to drive a modified vehicle safely and competently.

The Automotive Innovation Lab Access Grants program is a key element of the Government’s $100m Advanced Manufacturing Fund. Each of the grants will be matched by industry funding from the businesses. For more information, visit www.business.gov.au/ailag

New Business Growth Fund to create jobs in Victoria The Victorian State Government will establish a $250m Victorian Business Growth Fund for small and medium enterprises (SMEs) to help them access capital and create jobs to grow the Victorian economy.

Treasurer Tim Pallas has announced a $50m contribution towards the Fund, which will be developed with leading industry superannuation groups First State Super and VicSuper. The Fund will be the largest of its kind in Australia, seeking to create thousands of jobs by investing in established Victorian businesses with potential for growth and jobs creation.

“The Victorian Business Growth Fund will give some of our best small and medium sized businesses the incentive to take on new ventures and employ more Victorians,” said Pallas.

The State Government, First State Super and VicSuper are continuing to work together to finalise the design of the fund, which is subject to a formal agreement. An independent fund manager

AMT AUG/SEP 2019

will be appointed through a competitive process. Many Victorian SMEs find it difficult to access affordable capital, limiting their ability to expand their business. The Reserve Bank and the Small Business and Family Enterprise Ombudsman have repeatedly noted that the economy is being held back by a lack of access to finance.

“This Fund will help break down the barriers small businesses face in obtaining the capital they need to grow,” said Adem Somyurek, Victorian Minister for Small Business.

The Fund will complement the Victorian Government’s existing programs to support businesses, such as the Victorian Jobs and Investment Fund and payroll tax cuts announced in the Victorian Budget 2019/20.

1465AMTILEPGROUP

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Business Management By providing access to a national network of experienced business advisers and facilitators, this element helps you to improve your business practices, become more competitive, and take advantage of growth and collaboration opportunities.

•

Innovation Connections Experienced innovation facilitators will work with your business to identify knowledge gaps that are preventing your business growth.

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Accelerating Commercialisation Help is provided for small and medium businesses, entrepreneurs and researchers to commercialise novel products, services and processes.

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Incubator Support This element assists new and existing incubators in improving the prospects of Australian start-ups achieving commercial success in international markets, by helping them to develop their business capabilities.

To find out what the Entrepreneurs’ Programme can do for you, contact Greg Chalker 03 9800 3666 or email gchalker@amtil.com.au

www.amtil.com.au Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Are subscription business models being overlooked as we enter the Fourth Industrial Revolution?

While technological advances dominate the media coverage of Industry 4.0, there are equally significant changes coming in how we think of business models, with the rise of the subscription economy. By Iman Ghodosi.

We’re in the early stages of what is widely regarded as the Fourth Industrial Revolution – or Industry 4.0. As the name suggests, this is a period of momentous (as well as complex) change, but also of extraordinary opportunity, especially in the field of manufacturing.

The tectonic shifts brought about by the preceding revolution – the digital revolution – has led us to a new world of industrial possibility.

If you’ve ever read one of the thousands of articles, explainers or opinion pieces on the subject, you’ll know that this fourth era encompasses sensor technology, data analytics, artificial intelligence, machine learning, advanced automation, robotics, human-tomachine communication, the Internet of Things and more.

What you probably haven’t heard so much about, though, is the similarly radical transformation that could – and I think must – accompany these much-talked-about changes: a shift in business models.

Indeed, many already do. And they should. In Germany, the heartland of mechanical and plant engineering, 80% of revenue is generated by the sale of new equipment and 20% by services. But that 20% accounts for 60% of profits.

The future is here already.

What about the Subscription Economy?

Are we missing a manufacturing trick?

What do I mean by business models in the context of Industry 4.0?

It’s the way that organisations are reacting to the world’s movement away from products and towards services. You might think of it as the ‘Spotification’ of industry. It’s the advent of the Subscription Economy, encompassing a profound reimaging and reorganisation of business-to-customer and business-to-business relationships.

The future is here, but not everybody is talking about it. Or, more precisely, not everybody is talking about it in its entirety.

Let me use some examples to make the whole concept clearer.

• Adobe – Adobe saw the writing on the wall almost a decade ago. In 2012 the company stopped selling software – its famous Photoshop application, for instance – in boxes, forever.

The share price has risen by around about 800% since it set out its subscription strategy in 2011. Five years ago, it moved everything to the cloud and its share of recurring revenue has jumped from 19% to 70% from then to now.

• Caterpillar – What about an example more specific to manufacturing? Caterpillar Inc. is almost a century old – an icon of the Second Industrial Revolution. The company has embraced Industry 4.0 in many significant ways, none more important than in its use of sensors on its new generation of excavators, dozers, trucks and loaders. These sensors provide vital data on everything from safety and equipment management to sustainability and productivity. And through CAT Connect, Caterpillar offers this data as a subscription service.

Today Caterpillar has the largest connected industrial fleet in the world, incorporating more than 500,000 machines.

• Volvo – And what about something that seems, at first glance, to be the epitome of an individualised, status-symbol product that could never be sold as a service – the car? Well, Volvo recently announced that they’re aiming for 50% of their cars to be driven on subscription by 2025.

As Gary Brooks, Chief Marketing Officer at Syncron, predicts in a recent article for Manufacturing Global, in the future many OEMs will no longer report on the number of new products sold, or even service parts revenue. In fact, they will follow the path many Software as a Service (SaaS) companies have taken, reporting on recurring revenue from subscription-based services.

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Take the recently released research report from Swinburne University of Technology, PwC, Siemens and the Australian Manufacturing Workers’ Union, titled Transforming Australian Manufacturing: Preparing Businesses and Workplaces for Industry 4.0. This is an outstanding and timely piece of work that I would recommend to anyone with an interest in the field of Australian manufacturing.

However, it’s notable for the absence of any mention of business models.

I wonder whether the relative lack of focus on business model innovation in the Industry 4.0 conversation has meant that companies like Adobe, Caterpillar and Volvo are in an exclusive minority.

According to a recent PwC report, only 14% of manufacturers say they have created go-to-market Internet of Things strategies. And according to Stephan Liozu, Chief Value Officer of Thales Group, despite a high level of interest and investments from some deeply engaged companies, the reality is that most companies are just getting started [with their digital business models].

It doesn’t need to be this way. As our just-released white paper Reaping the Recurring Benefits of Industry 4.0 outlines, if executed successfully, business model innovation can unlock new value pools, while enabling new recurring and predictable revenue streams.

Zuora’s biannual Subscription Economy Index (SEI) demonstrates that Australian subscription companies grew revenues at ten times the rate of the ASX sales-per-share index over the past seven years.

In that same period, companies across North America, Europe and the Asia-Pacific region, have grown their subscription-based sales by more than 300%.

Yes, business model innovation in the Industry 4.0 age is fraught with complexity. But when subscriptions and services have the power to change many things we’ve long taken as a given and upend economic conventions, untangling complexity may be a small price to pay when the alternative is obsolescence.

Iman Ghodosi is Vice-President & General Manager of Asia Pacific Region for Zuora. www.zuora.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Manufacturing an energy strategy that defies the economy Despite energy costs hitting record highs, Australian manufacturers can still gain a competitive edge by finding smart ways to make energy savings. By Lachlan Jacobson.

Australia’s manufacturing industry is one of the nation’s most energy-intensive.

It accounts for close to one quarter of Australia’s total energy consumption and around 40% of natural gas consumption. Historically, manufacturers have benefitted from low energy costs but in recent years, costs have increased. According to the Australian Energy Market Operator’s (AEMO) first quarterly report of 2019, prices are at a record high. While this has impacted manufacturers’ bottom lines, energy still has the potential to offer a competitive advantage.

Australia’s shifting energy market is creating new opportunities for manufacturers to generate savings in the energy category, from taking on portions of Australia’s growing pipeline of renewables, to investing in future-ready energy strategies that leverage marketready tech to deliver savings. If manufacturers are able to engage with how they use energy, they can move beyond being simply price takers.

Plan for the long term The energy market is changing. Coal-fired generation is leaving the market and being replaced by renewable energy. This is pushing new retailers to deliver more innovative offerings and impacting how users engage with energy.

At the forefront of this shift is the rise of the Power Purchase Agreement (PPA). First pioneered by large corporates like Telstra and Coca-Cola Amatil, PPAs allow businesses to push past the traditional retail model and lock in long-term agreements directly with renewable generators.

This model, when treated as more than just a financial tool, enables manufacturers to contract energy directly from wind and solar plants, supporting Australia’s development of renewable energy. It is a low-cost strategy that reaps the most benefits when implemented for a long-term period, and allows businesses to fulfil sustainability commitments. For one leading food & beverage manufacturer, the decision to enter a PPA delivered savings of 18% on its energy costs in 2018, compared with what it would’ve paid on a standard fixedrate retail contract.

Knowing the hows and whens Taken alone, PPAs deliver low-cost renewable energy, but if treated as part of a broader energy strategy, they create more opportunities on price.

The concept of peak and off-peak is familiar to many energy users – most fixed-rate contracts charge based on this pricing model. But these contracts don’t give transparency into the actual highs and lows of the market, which shift every 30 minutes. Manufacturers who buy from the wholesale market should look at how and when they use power, to maximise the opportunities to tap into low-cost pricing periods. Demand management, specifically load shifting, encourages manufacturers to move operations in-line with the highs

and lows of the market. This can be as simple as shifting energy-intensive processes to earlier in the day to reduce consumption during the more expensive late afternoon and early evening period.

These small daily movements, which can account for just a handful of hours over a year, drive down total energy expenditure. Aside from the costbenefit, demand management connects manufacturers to how they use energy, allowing them to uncover potential areas of improvement.

For businesses, especially those buying power on the wholesale spot market, it can deliver savings of up to 33.3% on energy costs, in addition to savings generated by a PPA.

ANCA: Leading the way Founded in 1974, ANCA has established itself as a leading manufacturer of CNC tool grinding machines, motion control systems and sheet metal products, exporting 98% of its product while remaining based in Melbourne.

Faced with a changing energy market, ANCA knew that it would need to make a change to how it bought energy if it was to keep costs down. When the power contract came up for renewal, its incumbent offered a quote of a 100% price increase, while another power supplier quoted an increase of almost 150% from the existing spend.

ANCA approached Flow Power for an energy solution that was reasonably priced and offered greater transparency on costs.

Looking at ANCA’s energy usage, Flow Power was able to connect the manufacturer to low-cost wholesale wind power through a Corporate Renewable Power Purchase Agreement.

The renewable energy can be used in real time to offset grid electricity consumption, saving thousands of dollars in electricity costs and reducing overall emissions. ANCA buys a fixed percentage of wind power under a ‘take or pay’ arrangement, meaning that the business only ever pays for what it uses.

ANCA’s cost saving potential doesn’t stop there. Data assessed from a 12-month period (Q2 2017 to Q1 2018) has shown that using a demand response strategy would deliver a further 2.3% in savings. This is on top of those savings already achieved from buying wholesale power with a PPA.

Defying the economy The time is right for manufacturers to act on energy, and the market is ready with tools to drive them.

Taking a holistic view of energy that encompasses how it is sourced, managed and consumed is the avenue that will power a low-cost energy future for Australia’s manufacturers. Once manufacturers are able to do this, it becomes clear where energy expenditure lies and its impact, including the all-important end cost to the customer.

Lachlan Jacobson is a Senior Business Development Manager at Flow Power. www.flowpower.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Peak human potential: preparing workers for the digital economy Australia’s workforce – and, by extension, its economy – is on the precipice of massive change. Digital technologies are displacing human labour at an accelerating rate, and job insecurity is on the rise. By Dr Sean Gallagher.

Up against artificial intelligence (AI) and automation, workers need to adapt. The question is: how? Swinburne’s Centre for the New Workforce set out to answer this question by surveying 1,000 working Australians across the economy, to understand how they expect to succeed in the future of work. The research revealed two remarkable trends that challenge orthodox approaches to educating and training workers.

The first trend is that the more an industry is disrupted by digital technologies, the more that its workers value ‘social competencies’ like collaboration, empathy and entrepreneurial skills. Social competencies are uniquely human; they are less vulnerable to being displaced by AI and automation.

Right now, the industries most disrupted by technology are those in the knowledge sector of the economy, such as information, media, telecommunications and finance. The traditional expertise that is required to do jobs in these industries remains fundamentally important. However, knowledge sector workers place almost equal importance on social competencies.

By contrast, workers in the least-digitised, asset-intensive industries like mining, construction and utilities value traditional expertise three times more than social competencies. In the middle – both in terms of degree of digitisation and how much its workers value traditional expertise – lies the service sector, which employs four of five Australian workers.

Why are knowledge sector workers’ views important? They align with the balanced skillsets forecast by the OECD and McKinsey, and are well described in a 2019 World Economic Forum paper Leading in the Fourth Industrial Revolution: “To be truly successful in new roles, workers need unique ‘combinatorial skill sets’ at the intersection of innately human skills, functional skills, know-how and experience, and technology skills.”

Employers, especially in the technology-trailing sectors of the economy, must take heed of the growing importance of social competencies for workers in digital environments.

The second trend relates to how workers want to prepare for the future of work. Overwhelmingly, all Australian workers – regardless of education background, income level, industry or age – prefer ‘learning on the job’ as the best way to prepare to work in digital environments. And the more digitally disrupted their industry, the more workers prefer to learn on the job.

This makes sense. Work is where disruption is taking place, not in the classroom. Formal, structured education’s ability to simulate the transforming workplace decreases as the leading edge of technology advances. We must reverse this disconnection by bringing learning and work together.

We propose a new approach called ‘learning-integrated work’, where learning is increasingly taken off-campus and immersed in disruptive work environments – for students and workers alike.

For instance, in agile environments, in co-working spaces, on freelancing platforms, or in Industry 4.0 settings.

In learning-integrated work, the goal is less about producing results and more on learning how to create new value by nurturing workers’ combinatorial skillsets and developing tacit knowledge.

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Value creation – work that enhances an organisation’s competitive advantage – will distinguish the ‘learning worker’ alongside technologies that are increasingly sophisticated at producing.

Some examples of learning workers in Australia: • The factory floor worker who optimises the manufacturing processes they oversee.

• The designer who uses virtual reality to improve the design process.

• The medical specialist using AI’s diagnostic ability to free up their time to focus on bespoke patient care.

• The agile team of cross-functional experts developing a new product.

The Federal Government invested in building the National Broadband Network, the national infrastructure for the digital revolution. Now it’s time for Australia to invest in our workers – with the skills and competencies required to thrive in the digital, automated future – and build a national learning infrastructure.

We need to lift all workers into the digital economy by providing them basic digital training. Many of these future skills are best provided through vocational education, especially within a more coherent tertiary education system. However, for learning and work to converge, we need a learning infrastructure that brings education providers and employers together, too.

We need to shift learning into future workplaces by trialling new learning approaches delivered through partnerships of education institutions and employers. These learning partnerships would form the foundation of the infrastructure, and focus on developing learning workers, integrating learning into work, and reimagining accreditation. There will be many successful formulas. The AiGroup, Siemens and Swinburne University’s Industry 4.0 Higher Apprentice Program is an early case study.

Only the Government has the policy levers and resources to support digital training, and to co-ordinate and network this new learning infrastructure across the economy. In a world ever-more hyperconnected, this infrastructure must drive deep connections between educators, employers and government – ultimately enabling all workers to reach peak human potential.

Dr Sean Gallagher is director of the Centre for the New Workforce at Swinburne University of Technology. The national survey report ‘Peak human potential: preparing Australia’s workforce for the digital future’ can be accessed at: http://tinyurl.com/yy7lqztj www. swinburne.edu.au

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TECH NEWS

USA: New manufacturing process for aluminium alloys

Prof. Afsaneh Rabiei, the inventor of CMF The ShAPE™ process combined with a unique aluminium alloy produced high-strength, high-ductility rods in a single process

An advanced manufacturing process to produce nanostructured rods and tubes directly from high-performance aluminium alloy powder in a single step has been demonstrated. The process eliminates multiple steps typical in conventional extrusion. Using a novel Solid Phase Processing (ShAPE™), several steps were eliminated while also achieving a significant increase in ductility. In this process, an aluminium alloy powder is poured into an open container and a rotating extrusion die is then forced into it, which generates heat at the interface between the powder and die.

The material softens and easily extrudes, eliminating the need for canning, degassing, hot pressing, pre-heating, and decanning.

High-performance aluminium alloys have historically shown excellent strength but poor ductility. However, in this process, ductility of two to three times compared to conventional extrusion products was found – and with equivalent strength.

Pacific Northwest National Laboratory

Australia: World’s first thermal battery launched in SA Thermal energy could hold the key to cheaper, more sustainable electricity, with South Australian company CCT Energy Storage unveiling the world’s first working thermal battery. Known as TED (Thermal Energy Device), the battery accepts any form of electrical input to convert and store energy as latent heat – making it versatile, affordable and long-lasting, potentially changing the global energy market by providing the most affordable and environmentallyfriendly alternative power source. TED stores electrical energy as thermal energy by heating and melting a unique phase change material. The energy is stored at more than 12 times the density of a lead acid battery, before being extracted by thermic generator to provide electricity when, and where it’s needed. TED’s scalability means it can be used in small scale 5kW applications to large scale applications of hundreds of megawatts of instantaneous power.

CCT Energy Storage

USA: Metal foam stops bullets at half the weight of steel Researchers have demonstrated that vehicle armour using composite metal foam (CMF) can stop ball and armour-piercing .50 calibre rounds as effectively as conventional steel armour, yet weighs less than half as much. This will allow the development of lighter military vehicles without sacrificing safety. The hard armour system consists of a ceramic faceplate, a CMF core and a thin back plate of aluminium. This was able to absorb 72-75% of the kinetic energy of the ball rounds, and 68-78% of the kinetic energy of the armour-piercing rounds. CMFs are also very effective at shielding X-rays, gamma rays and neutron radiation – and can handle fire and

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heat twice as well as the plain metals they are made of and hold promise for a variety of applications. It was previously demonstrated that CMF could block blast pressure and fragmentation at 1,500 metres per second from high explosive incendiary rounds detonated only 45cm away.

North Carolina State University

US: RoCycle robot gets a feel for paper, metal and plastic MIT researchers have developed RoCycle, a robotic recycling machine that can differentiate between paper, metal or plastic. Said to be compatible with any robotic arm, RoCycle was 85% accurate at detecting materials when stationary, and 63% accurate on a simulated conveyer belt. The advance includes a soft teflon hand that uses tactile sensors on its fingertips to detect an object’s size and stiffness. Computer vision alone will not be able to solve the problem of giving machines human-like perception, so being able to use tactile input is of vital importance.

The Engineer

Australia: RMIT technique makes MOFs in minutes Researchers have An acoustically-created MOF, used sound waves to with the microchip that produced precisely manipulate the high-frequency sound waves atoms and molecules, used in the process. accelerating the sustainable production of breakthrough smart materials. Metal-organic frameworks (MOFs) are incredibly versatile and highly porous nanomaterials that can be used to store, separate, release or protect almost anything.

Scientists have designed more than 88,000 MOFs - with applications ranging from agriculture to pharmaceuticals - but the traditional process for creating them is environmentally unsustainable and can take several hours or days. Now researchers from RMIT have demonstrated a clean, green technique that can produce a customised MOF in minutes by harnessing the precision power of high-frequency sound waves. The process can be easily scaled up for efficient massproduction. At the nano-scale, sound waves are powerful tools for the meticulous ordering and manoeuvring of atoms and molecules.

Some have predicted MOFs could be as important to the 21st Century as plastics were to the 20th.

RMIT

TECH HEADING NEWS

Sweden: Sandvik creates first 3D printed diamond composite Sandvik AM has created the first-ever 3D printed diamond composite, potentially revolutionising the way industry uses the world’s hardest natural material. It will now be possible to print anything, in any shape – in diamond. Synthetic diamond has been produced since 1953, but because it’s so hard and complicated to machine, it is almost imposs-ible to form complex shapes. By using additive manufacturing, Sandvik has 3D-printed diamond composites which can be formed in almost any shape – potentially using it in applications that were considered impossible. The difference between Sandvik’s diamond and natural or synthetic diamond is that Sandvik’s is a composite material. Most of the material is diamond, but to make it printable and dense, it needs to be cemented in a very hard matrix material. Using stereolithography, a slurry containing diamond powder and polymer was used. After printing, Sandvik developed a proprietary post processing method that is able to produce the exact properties of the diamond composite.

Sandvik

UK: World’s fastest jet-powered suit, 3D printed In 2017, the Gravity Jet Suit set a world record for fastest speed in a body-controlled jet engine powered suit at 51.53 kph.

However, Loughborough University student Sam Rogers has since flown his redesigned, 3D printed version at more than 80kph, climbing to 3,000 metres. The five-turbojet engine race suit, 3D-printed entirely in aluminium, steel and nylon was developed as part of Sam’s degree and is composed of five kerosene-fuelled turbines placed around the body, two on each arm, one on the rear, one larger one on the back-pack, each with 22kg of thrust, with the controls located inside the grip handles; allowing a human to fly by accelerating gas downwards.

“I redesigned the suit from traditional materials to being entirely 3D printed in aluminium, steel and nylon, which reduced the time and cost of building the suit” said Sam. Loughborough University

Sweden: Mimicking wood’s ‘ultrastructure’ with 3D printing Researchers have 3D-printed with a wood-based ink in a way that mimics the unique ‘ultrastructure’ of wood, potentially revolutionising the manufacturing of green products by emulating the natural cellular architecture of wood. This will allow green products to be developed from trees, with unique properties (clothes, packaging, furniture, healthcare products etc). Unlike metals and plastics,

wood cannot be melted and easily reshaped, and instead must be sawn, planed or curved. But the new technology allows wood to be effectively grown into the shape desired. By previously converting wood pulp into a nanocellulose gel, the researchers had already succeeded in creating a type of ink that could be 3D-printed. Now, they have successfully interpreted and digitised wood’s genetic code, so that it can instruct a 3D printer. Those products which today are forest-based can now be printed in a much shorter time.

And the metals and plastics can be replaced with a renewable, sustainable alternative.

Chalmers University of Technology

Germany: Sliding along on water Machine bearings are usually lubricated with various oils. But large quantities of these oils still end up in the environment. Researchers have developed a method which will in the future make it possible to lubricate slide bearings using water, a much more environmentally friendly approach. But until now, the fact that metal parts corrode when they come into contact with water has been a major obstacle.

However additives have been used to change water (mixing ionic liquids into the water) in such a way that it could be used as a lubricant. There were two advantages: the lubrication achieved is much better, since water is not as viscous as oil; and corrosion is prevented. The research team has already demonstrated the viability of the process and are currently looking for partners in industry with whom they plan to further optimise the ionic liquids.

Fraunhofer

Australia/India: Making graphene from gum trees Researchers have developed a cost-effective and eco-friendly way of producing graphene using one of Australia’s most abundant resources: eucalyptus trees. Graphene is the thinnest and strongest material known. It’s also flexible, transparent and conducts heat and electricity 10 times better than copper. The new approach by researchers from RMIT and the National Institute of Technology, Warangal (India), uses Eucalyptus bark extract and could reduce the cost of production from $USD100 per gram to a staggering US50 cents per gram. Chemical reduction is the most common method for synthesising graphene oxide. This method however relies on reducing agents that are dangerous to people and the environment. When tested in the application of a supercapacitor, the ‘green’ graphene produced using this method matched the quality and performance characteristics of traditionally-produced graphene without the toxic reagents. This ‘green’ chemistry could open the door to the application of graphene not only for electronic devices but also biocompatible materials. In their experiment, researchers used a eucalyptus polyphenol solution obtained from a eucalyptus bark extract to trigger the reduction of exfoliated graphene oxide to soluble graphene under reflux conditions in an aqueous medium. That led to effective removal of the oxygen functionalities of graphene oxide.

RMIT/pv magazine

“Even now we are just starting to grasp the possibilities and applications that this breakthrough could have” - Anders Ohlsson, Delivery Manager at Sandvik Additive Manufacturing regarding 3D-printing complex shapes in a diamond composite material. This material is three times stiffer than steel, with heat conductivity higher than copper, the thermal expansion close to Invar (a nickel–iron alloy notable for its uniquely low coefficient of thermal expansion) – and with a density close to aluminium.

Considered a true innovation, this means that diamond may be used in applications and shapes never conceived before.

AMT AUG/SEP 2019

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PRODUCT NEWS

Sigma Air Manager 4.0: Tomorrow’s technology today Industry 4.0, the Internet of Things: the Sigma Air Manager 4.0 (SAM 4.0) makes it all possible, offering the ability to make predictions far in advance, know today what the future holds, network components, and exploit much larger data volumes than ever before, while also ensuring significant energy cost savings and delivering a reliable, consistent and efficient compressed air supply.

The latest generation of SAM 4.0, Kaeser’s master control system for all a user’s compressed air production and treatment components, optimises pressure values, automatically adjusts compressor system air delivery to accommodate fluctuating pressure demand and maximises system efficiency based on control losses, switching losses and pressure flexibility. With the SAM 4.0 the end user can take advantage of services such as Sigma Smart Air, for predictive maintenance. All of these features not only boost operational reliability and efficiency, but also significantly reduce energy costs.

This is in no small part made possible by Kaeser’s adaptive 3-Dadvanced Control, which takes into account additional factors, aside from switching losses (start/stop), that affect compressed air system energy efficiency. These include control and idling losses, frequency converter operation and pressure flexibility (average increase above required pressure). The patented optimisation method predictively calculates the optimum achievable configuration and adjusts the connected components accordingly – all based on the specific pressure required by the user.

The SAM 4.0 supports operations in 30 languages, while the easyto-use 30cm colour touchscreen shows at a glance whether the station is operating in the ‘green zone’ from an energy management perspective. Operating status, pressure history, free air delivery, power consumption, as well as maintenance and any error messages can be easily displayed and analysed – both in realtime and retroactively. Using a PC and network connection, this data can be accessed conveniently from anywhere, not just at the machine itself. This not only gives users peace of mind and lays the foundation for digital products in the pipeline, it also enables energy management in accordance with ISO 50001.

The far-reaching benefits of the SAM 4.0 are expanded even further when users take advantage of Kaeser’s Sigma Network. Based on Ethernet technology, the powerful Sigma Network is a closed and secure network that has been specially developed to support optimal monitoring and co-ordinated control of compressed air stations.

Moreover, the SAM 4.0 is versatile in other ways. An interface for plugin communication modules lends itself to flexible adaptation to accommodate future requirements. The SAM 4.0 is up to date with the latest trends and ensures the reliable, cross-system exchange of data and information. The SAM 4.0 is designed to accommodate potential future compressed air system expansion. A straightforward software upgrade allows for expansion with no need for additional investment in new hardware. www.kaeser.com.au

Tungaloy expands TungCut turning range Tungaloy has expanded its market leading TungCut series of multi-functional grooving tools with the introduction of the new AH7025 universal PVD grade and the high-performing DTM style chipbreaker.

The enhanced TungCut range incorporates a unique insert clamping mechanism to improve insert rigidity during machining.

This provides extended insert life and stability when conducting a wide range of grooving applications on everything from compact Swiss-type machines through to heavyduty CNC turning centres.

The impressive AH7025 insert grade is Tungaloy’s first-choice grade for grooving applications. It features a high aluminiumcontent multi-layered Nano PVD coating with strong coating adhesion and a dedicated carbide substrate that creates superior fracture toughness as well as impressive resistance to wear and chipping. The result is an exceptional grade that ensures unparalleled machining efficiency, insert reliability and longevity when grooving steel, alloy steel, stainless steel, and heat-resistant super-alloys. The new DTM style chipbreaker is a multi-functional geometry that has been

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designed to create a smooth chip flow in grooving and turning. The combination of the DTM chipbreaker and the AH7025 grade provides machining stability and efficiency when conducting everything from external, internal and face grooving and parting as well as external facing and profiling. The combination of the DTM chipbreaker and the AH7025 insert grade now sees a total of 22 items added to the extremely diverse series of Tungaloy’s turning, parting and grooving portfolio.

The new insert designation is compatible with Tungaloy’s extremely diverse range of toolholders and boring bars, making the DTM and AH7025 grade combination available to a vast range of turning, parting and grooving applications on everything from the smallest and most compact sliding head turning machines through to large CNC turning and mill/turn machine tools. www.tungaloy.com/au

PRODUCT NEWS

Versatile clamping for automated machine loading spraying system with a low level of mist

Schunk has developed the Vero-S NSE-A3 138 automation module specifically for automated machine tool loading as well as for applications in handling, assembly and automation technology.

The clamping module is part of the extensive Schunk Vero-S modular system, which enables more than 1,000 possible combinations for efficient workpiece clamping. For process-reliable workpiece and clamping device changes, the automation component is equipped with a powerful blow-off function, which carefully cleans the bearing surface during the changing process. In addition, a spring-actuated cone seal prevents chips or dirt from penetrating into the changing interface.

An enormous pull-down force of 8,000N, or 28,000N with activated turbo function, and a high dimensional stability of the module body benefit the rigidity of automated quick-change solutions. Thus, even high tilting moments and shear forces can be reliably absorbed.

Depending on the application, the modules can be combined in any quantity. Centering inserts with flexible elements ensure positional orientation with a high repeat accuracy and maximum process reliability in automated operations. The repeat accuracy amounts to < 0.005 mm. Due to the conical fitting, the clamping pins can also be joined into the modules eccentrically, making this process incredibly easy.

The actual clamping is done without any external energy supply via spring force; it is form-fit and self-retaining. This means the workpieces remain safely clamped in the case of a sudden drop in pneumatic pressure. A pneumatic system pressure of 6 bar is enough for opening the module.

If the modules are used individually, a standard integrated antitwist protection device ensures a stable position. By means of the integrated media transfer unit, fluids with permissible system pressures of up to 300 bar can be transferred, for example, to control clamping devices using Plug & Work or to supply components for automated monitoring. As a part of the Vero-S modular system, the automation module benefits from a variety of combination options â&#x20AC;&#x201C; from standard plates to Schunk Tandem clamping force blocks, to mechanical vises from the Schunk Kontec series. www.romheld.com.au

spray.xact COMPRESSED AIR-FREE SPRAY LUBRICATION Precise and economical oil application without annoying spray mist and without suction! spray.xact is an easily adaptable solution for the exact application of oils, emulsions and corrosion protection agents to blanks, coils or moulded parts. www.technotrans.com

technotrans technologies pte ltd | Unit 7 / 111 Lewis Road Wantirna, Victoria 3152 Phone +61 3 9887-5049 | Fax +61 3 9801 1945

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PRODUCT NEWS

Yale UX forklift range delivers simple efficient solutions A world leader in forklifts and warehousing solutions, Yale is introducing its new UX Series of lift trucks to Asia-Pacific, for clients seeking cost-effective material handling solutions with reputable service backup.

The Yale UX series of counterbalance lift trucks, in six different capacities from 1.5 to 3.5 tons, provides an attractive option for customers across many industries who require quality materials handling equipment but don’t need advanced functionalities for their tasks. They provide affordable, reliable and cost-effective handling solutions in applications where they are required to work intermittently as required over a working week, typically up to 4,000 hours a year.

“The new Yale UX Series has been developed for low-hour applications and is priced accordingly,” says Tony Fagg, Managing Director of Hyster-Yale Asia-Pacific. “Its uncomplicated design results in easy operation and service that eliminate non-core features that add complexity and unnecessary maintenances costs for particular applications.

world, having been in the lifting business for over 140 years.

“The Yale brand – with its ‘People, Products, Productivity’ tagline – prides itself on helping customers solve materials handling challenges with solutions that individual organisations need, when and how they need them,” says Fagg. “This requires the type of backing provided with the UX Series throughout Asia-Pacific.”

The Yale dealer and service network extends across Australia, New Zealand, Thailand, Malaysia, Vietnam, Indonesia, Singapore, Philippines, Korea and Taiwan.

“The rationale of this ‘Yale - Simply Efficient’ range has at its core the understanding that, if your forklift usage is only around four hours a day, you don’t need a more expensive forklift that has been designed to handle all day, every day applications. But what such users do want – and which is provided by the new UX range –is a strong global brand backed by a professional dealer and service network across Asia-Pacific.”

“What differentiates the UX Series from other offerings on the market today is that these trucks are backed by a network of specially chosen, experienced, independent distributors, professional dealers and service providers who offer a wide range of support services to their customers,” Fagg adds. “With a keen appreciation for the varying needs of customers, Yale’s network offers peace of mind, delivering fast support whenever it is needed. This support includes rapid response to maintenance requirements, comprehensive parts availability and comprehensive applications surveys. All of these commitments are key to keeping materials handling operations on track and within budget.

The Yale dealer and service network is backed by the global Hyster-Yale Group, with a full product line of lift trucks in operation across hundreds of industries worldwide. Yale is one of the oldest original manufacturers of lift trucks and warehouse equipment in the

“Offering a solution which reliably meets productivity targets, while keeping operating costs low, the Yale UX range has been designed to be easy to operate and to maintain, delivering a solution to individual user needs.” www.yale.com

Seco Mini End Mill series adds big precision to tiny tools Shops that struggle to machine micro-sized workpiece surfaces can now achieve superior surface-finish quality, accuracy and precision with the new Seco Tools JM100 Mini end mill series, part of the wide and continuously expanding Jabro range of solid-carbide end mills.

In micro-machining operations with zero visibility of workpiece and cutting tool, the JM100 Mini delivers longer tool life, stability and guaranteed surface quality thanks to its extremely precise geometries, virtually zero runout, advanced coatings and tight radius tolerances.

Targeted to achieve precise surface finishes on mould and die components, the JM100 Mini helps shops minimise secondary benchwork that can increase part processing time. The end mill’s special coating reduces tool wear to help lower overall tool costs and eliminate the need for frequent tool

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changes. It also ensures smooth and consistent surface finishes that yield exceptional part performance. Tight radius tolerances of ±0.005μ on the tool reduce runout virtually to zero, increasing output and contributing to lower cost per part with high process precision, stability and reliability.

The JM100 Mini is available in tool diameters from 0.2mm to 3.0mm, corner radii ranging from 0.05mm to 0.3mm RE = ±0.005, and overhang lengths from 1.5*DC to 20*DC, with two- and three-flute versions. www.secotools.com

QUALITY With worldwide energy efficiency classes in mind, the DRN series offer interface of gear unit combinations, whilst meeting global legal and standard motor requirements.

With optimised weight, dimensions and performance, the DRN series easily integrates into any application to ensure efficient operation.

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PRODUCT NEWS

BOC unveils new Beacon IIoT technology BOC has launched its new Beacon technology, an Industrial Internet of Things (IIoT) solution that will transform the way its customers can check, track, monitor and order gas.

The new telemetry system will connect BOC bulk tanks and cylinders to an advanced network of smart devices that will send real-time data collected by sensors to the new Beacon customer app. Theo Martin, Head of Sales and Marketing at BOC South Pacific, said the launch of Beacon is part of the organisation’s commitment to developing tailor-made digital solutions that improve customer experience and productivity through better scheduling and stock management.

“The Beacon technology and network will allow BOC and our customers to make smarter decisions, faster – with gas levels and location tracking for each vessel visible through the app anytime, anywhere,” said Martin. “This will benefit any manufacturer from small welding workshops with a CRYOSPEED and Mixonsite system, right through to a large manufacturer with hundreds of gas tanks and cylinders onsite.”

BOC has been at the forefront of innovation in the industrial gases industry for over 80 years, from being the first company in Australia to put barcodes on cylinders in 2006, to unveiling a world-leading robot cylinder automation system at its Sydney Operations Centre in 2018.

“Suppliers and manufacturers need to work together to fast-track advanced technology solutions that will transform the way we work and leverage the connected world we live in,” Martin added. “As we embrace this new era of advanced manufacturing and continue to invest in digital technology, we will ensure our customers can make smarter decisions, faster to position Australia as a global leader.”

BOC is currently rolling-out Beacon technology across its national network of bulk gas and CRYOSPEED liquid tanks, with cylinder packs and cylinders to follow. www.boc.com.au

Hypertherm – XPR rotational torch sleeves for bevel, robotic cutting Hypertherm is introducing three new torch sleeves for XPR plasma cutting torches and lead sets.

The sleeves allow the torch and lead sets to remain axially fixed while the torch holding device rotates 360 degrees in either a clockwise or counter-clockwise direction.

This capability greatly enhances torch lead life in high-flex applications.

The new sleeves — available in short, medium, and extended lengths — are ideal for bevel or 3D/robotic cutting applications when using either an XPR170 or XPR300 X-Definition Plasma system. The sleeves include several engineering advances. An outside diameter of 76mm allows for an increased wall thickness and eliminates compression caused by clamping. Presealed, high precision bearings reduce axial play by 90% and radial play by 81%.

This keeps out dirt and other particulates associated with plasma cutting and greatly extends the life of the sleeve and lead system.

When used with Hypertherm’s specialised robotic/bevel lead sets, the rotational sleeve will afford customers an especially robust industrial solution in applications requiring frequent rotational flexing when cutting with an XPR170 and XPR300, the only two X-Definition capable systems in

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the world. A combination of engineering advances and refined high definition plasma processes help X-Definition class plasma deliver unmatched plasma cut quality on mild steel, stainless steel, and aluminium. Laboratory testing shows ISO9013 Range 2 cut quality on thin mild steel and extended ISO Range 3 cuts on thicker metals.

Both X-Definition systems contain patentpending processes like Vented Water Injection (VWI), plasma dampening, and Cool Nozzle technologies for squarer cut edges, markedly less angularity, and excellent surface finish on non-ferrous metals like aluminium and stainless steel. At the same time, the systems cut faster and use power more efficiently than earlier Hypertherm systems like the HyPerformance HPR260XD. “Hypertherm is constantly working to advance the capability of our products by devoting extensive resources to research & development,” said Phil Parker, Product Manager for Hypertherm’s heavy industrial plasma products. “By listening and incorporating feedback from our partners and customers, we are able to

deliver products like our X-Definition Plasma and these new torch sleeves that help customers increase the efficiency of their cutting operation.” www.hypertherm.com/ plasmaprecisely

PRODUCT NEWS

Kemper extends CleanAirTower series Delivering clean production air for all employees, even in small companies, Kemper has expanded its CleanAirTower series, especially for air pollution control for sporadic welding.

With the CleanAirTower SF 5000 and SF 9000 models, Kemper has brought two new general ventilation systems with storage filters onto the market. Thanks to Cloud connectivity on the Kemper Connect portal, all parameters can be monitored from anywhere at any time. Kemper recommends the systems as a supplement to source extraction.

“Clean hall air for all staff in the entire production area is a real benefit for employers in the context of the shortage of skilled workers,” says Björn Kemper, CEO of Kemper GmbH. “General ventilation systems as a supplement to source extraction protect not just the welders themselves. They are therefore an important component for effective air pollution control.”

With the extension of the CleanAirTower series, Kemper now also offers a room ventilation solution for low fine dust loads. Kemper is expanding its filter tower series with two variants.

Both variants are particularly suitable for air pollution control in small welding companies with sporadic welding and low levels of welding fumes. Whereas the CleanAirTower SF 5000 has an extraction capacity of 5,000 cubic metres per hour, the CleanAirTower SF 9000 is capable of cleaning 9,000 cubic metres of air per hour. Thanks to their comparatively low height, they can also be installed in plants with low ceiling heights.

The use of replaceable storage filters results in lower investment costs for businesses than cleanable filters. Because different filter media can be integrated in the systems, the new CleanAirTowers from Kemper are also suitable for production environments beyond metal processing, such as those in the logistics sector.

Both room ventilation systems function according to the layer ventilation principle. They capture welding fumes in a 360-degree radius at a height of 2.70 or 3.40m respectively and separate even

ultra-fine dust particles to more than 99.9%.

Employees can switch on a new TurboBoost mode if the concentration of hazardous substances is extremely high at times.

This temporarily increases the extraction capacity by around 30%, which allows the towers to capture more contaminated air for a limited period of time and reduce welding fume ceilings more quickly. Even at the highest power level, the noise level is only 76 dB(A).

TOTAL SOLUTION PROVIDER

OF AMEC TOOLING

Thanks to the simple connection to the Kemper Connect portal, the manufacturer realises energy- and process-efficient operation.

The general ventilation systems network with the Cloud in just a few moments via a mobile wireless-based connection.

All relevant data flows into the Cloud in real time. Users can intuitively put together individual dashboards and user interfaces.

The portal is able to control the CleanAirTower automatically – for example, when the AirWatch air monitoring system from Kemper measures high concentrations of hazardous substances that threaten to exceed legally prescribed limit values.

The permanent recording and evaluation of relevant process parameters also enables predictive maintenance – and even paves the way for Smart Maintenance. In the web-based IoT solution, service employees have full control over their general ventilation systems anywhere and at any time.

The CleanAirTowers are suitable as a supplement to source extraction during welding. They protect welders and employees at nearby workplaces – especially in cases where welding fumes are not completely captured or source extraction is practically impossible. The general ventilation systems also help ensure that companies act in accordance with the law within the framework of increasingly stringent legal regulations. www.kemper.eu

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PRODUCT NEWS

BOGE marks anniversary with S 111-4 Decorated with the image of its founder Otto Boge, BOGE has released the S 111-4, a special exclusive version of its popular S-series compressor range as the company marks its 111th anniversary.

The S 111-4 machine comes with a range of unique features. The S 111-4 anniversary compressor lets users know its operating condition at a single glance, and they can even do this remotely: For the first time, BOGE has integrated the traditional status notification into the body of the machine as an easily visible light strip.

The LED bar at the upper edge of the compressor reliably and conveniently indicates any anomalies, even in vast production halls. BOGE has also equipped its anniversary machine with numerous efficiency improvements as standard: the IE4 motor ensures the current possible maximum degree of efficiency for the drive. The specific power consumption of the S 111-4 has also been improved. The machine is available with direct drive and frequency control.

The compressor has been fitted with super-soundproofing as standard too: it works at a sound level of 67 dBA, making it the best in its class compared with competitor products.

This means normal conversation is possible next to the running compressor, and adjoining office spaces or production workplaces do not require any additional noise protection.

With a drive capacity of 110kW, the anniversary machine is in a higher power range for deployment in medium-to-large industrial plants. A direct drive, very few builtin maintenance parts and a low speed of 1,500rpm make the S 111-4 low-wear and low-maintenance, and therefore also extremely durable. Besides this, the compressor is impervious to dirt and dust particles from the ambient air thanks to its design. www.boge.com.au

Balluff – Rugged sensors for small-scale process technology

Kennametal Mill 4-12KT – Next-gen tangential shoulder milling

Balluff has expanded its range of sensors for mediacontacting temperature detection, in hydraulic power units for example.

Kennametal has released its new Mill 4-12KT, the next generation of tangential shoulder mills, producing highquality floor surface finishes for nearly all steel and cast iron applications.

New additions to the range include a temperature sensor with display, a temperature transmitter, as well as a PT1000 sensor. The version without display is especially compact and vibration-resistant, whereas the versions with the turnable and highly readable display offers high operating convenience and flexible installation.

Depending on the version, the BFT sensors provide PNP switching outputs, analog signals 0...10V /4...20mA, or work as a PT1000 sensor. They are simple to install by threading into the process using a standard process connection with G- and NPT threads.

Integrating them requires just a four-pin M12 plug on the sensor.

Continuous monitoring of process media on machines and equipment contributes greatly to process security. Values that need to be maintained are pressure, level and temperature. When for example in a hydraulic system you need to monitor the temperature of the hydraulic fluid, you can do this reliably using our BFT mediacontacting temperature sensors. Monitoring the temperature within the hydraulic loop guarantees correct fluid viscosity and thereby the best performance of a machine.

Critical process conditions such as a temperature limit can be controlled directly via the switching output. An analog output provides continuous measurement results. The BFT temperature sensors also stand out when it comes to monitoring the cooling water, lubricants and compressed air, making them ideal for a variety of applications. www.balluff.com.au

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“The Mill 4-12KT uses 15% lower cutting forces, an important consideration with today’s lighter duty, 40-taper machine tools,” says Tim Marshall, Senior Global Product Manager at Kennametal.

“That allows customers to feed faster without putting additional stress on the spindle. And in long overhang situations or where the part fixturing is less than optimal, lower forces equate to less chatter, reduced edge chipping, and smoother surface finishes.”

Mill 4-12KT has tangentially mounted inserts with four cutting edges per insert for reduced tooling costs. Seven corner radii from 0.4mm to 3.1mm are available, along with coolant-through, medium and coarse pitch cutter bodies 50mm to 200mm in diameter. With an axial depth of cut range from 0.5mm to 12mm, Mill 4-12KT covers most shoulder milling applications.

Multiple factors contribute to significant performance increases, even in aggressive cutting conditions. The tangential, “on-edge” insert design also allows the insert to take advantage of the strength of the carbide thickness more so than radially mounted inserts found on traditional milling cutters. A shallow pocket design allows the core size of the cutter body to be very robust. The axial and radial seating surface designs provide exceptional stability.

The Mill 4-12KT is the perfect complement to Kennametal’s existing shoulder milling portfolio. This includes the Mill 4-11 and Mill 4-15, cutters known for their ability to generate shoulders with high quality wall surface finishes. www.kennametal.com

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MINING & RESOURCES

THE CAPITAL OF

MINING

TECHNOLOGY

INNOVATION Digital technologies are having far-reaching impacts on the mining & resources sectors – as with all industries.

Brent Balinski spoke to three very different companies, each aiding in the digital transformation of mining.

The resources sector plays a big role in Australia’s economy. Iron ore, coal and natural gas were ranked first, second and fourth respectively among the country’s exports by value for 2017-18. The sector that is key to extracting these and other resources – mining equipment, technology and services (METS) – is another source of national strength. Dating back to 1859 in Australia, it has not stood still and its technical leadership is globally renowned.

An Austrade paper from 2016 notes that while Australia may not design and manufacture big capital items such as draglines and earthmovers, its METS companies “lead the world” via “time and effort in the area of innovation”. The sector is valued at $90bn, based on research in 2013 by industry body Austmine. Exports totalled $15bn, R&D spend amounted to $4bn, and the workforce numbered 386,000.

“The Australian METS sector continues to develop its reputation on a global scale and is of vital importance to the domestic economy,” says Austmine CEO Christine Gibbs Stewart.

“We believe the figures in 2013 are still roughly accurate. We plan to conduct another survey this year.”

Gibbs Stewart believes digitalisation is unavoidable for the sector: “Whether it be through product development, supply chain management, accounting, customer interface or communications, digital has completely transformed our sector. This has been embodied in a number of solutions from ‘traditional’ mining suppliers. They have used sensors and data to provide greater services to their clients and to differentiate from competitors. For example, we have a member that is a wear-liner maintenance company that now offers a software application to monitor the health of wear-plates.”

Developing and delivering globally relevant technology is not easy, but it’s something Australian companies have successfully done. Groundprobe, Roobuck and Southern Innovation are just three pioneering companies whose focus is on bringing digital insights to miners.

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Christine Gibbs Stewart, Austmine’s CEO

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Groundprobe – Acting like a start-up to keep a cutting edge “I think that Australia is the capital of mining technology innovation,” says Lachlan Campbell, Vice-President, Marketing & Innovation at Groundprobe. “It’s the sort of thing that Australians should be immensely proud of. I think that the general public may not be aware of this, [but] we are global leaders in mining technology.”

Named Australia’s most innovative company by the Australian Financial Review last year, Groundprobe has its origins in the Cooperative Research Centre for Sensor Signal and Information Processing (which operated from 1992 through to 2006), and promising work detecting rock movements through radar. Since forming in 2001 and achieving its first sales in 2003, it has remained a fast-growing technology provider, improving on wire extensometers, and saving property and lives.

Neil Cordon joined Groundprobe five years ago as Manager of Technical Support & Development, as the company looked to sharpen quality and tech support. It has been an eventful period, including an acquisition by blasting services leader Orica in 2017.

“We went from a single-product company to eight products in the last five years,” says Cordon, now Senior Manager – Supply & Reliability.

Beginning with its original slope-stability radar invention, the company now has three different radar technologies and two different lidar-based technologies, with associated software. Headquartered in Brisbane, the company’s products are in 32 countries, yet it has kept manufacturing here. Cordon estimates 80% of its componentry is Australian.

“The 20% would be small, strange, specific stuff that we can only get from single sources because it’s a technology solution,” he says. “We stretch as far as Finland, the UK, Germany, some stuff from the United States.”

Metal work such as cutting, welding, powder coating and galvanising is carried out by Kilner’s Engineering of Morningside, which has grown through Groundprobe’s progress.

“We’ve given them a large portion of our work from our supply chain, and they’ve used that as a lever to get government grants for new laser cutters and new technologies,” adds Cordon.

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MINING & RESOURCES GroundProbe provides a range of advanced hardware and software solutions to the mining industry.

Contined from previous page

Despite its acquisition

by Orica, Groundprobe has stayed in touch with its start-up roots. At the AFR’s Most Innovative Companies awards last year, it won Best Overall Innovation for its Geotech Monitoring Lidar (GML), as well as ranking #1 in the paper’s Top 100 List of Most Innovative Companies.

“When we have a big project, we actually pull out a dedicated team and we put them in a small shed with camping chairs and bad coffee and keep them really hungry for that success with a limited budget,” says Campbell. “That way they really focus on making money as soon as they can, rather than staying in a big, corporate, tinkering environment.”

Current projects involve safety solutions for tailings dams, as well as a platform for aggregating and making sense of different types of monitoring data.

According to Cordon, development work sees the reliability and manufacturing team get involved in product design early, “to make sure that it’s designed for manufacture, and that we’ve got the most lean and economical use of materials and labour to assemble the product”.

Groundprobe aims is to triple or quadruple in size over the next four years through demand for its lidar products in civil tunnelling and underground mining, as well as through new customers via Orica.

Cordon says this is likely to yield greater efficiency, rather than a lot of new assembly roles.

“My team’s only 13 people, it’s a very small team,” he explains.

“Most of the guys are doing technical work: configuration and calibration, that kind of testing stuff. So [we’d] go from 13 to 18 instead of 13 to 50.”

Groundprobe also aims to maintain and grow its local supply base, and Australian producers will remain important.

“It was a conscious decision to lean on an Australian-dominated supply chain because we believe in advanced manufacturing in this country,” says Campbell. “Our future is based on the bright ideas that are coming out of university research and innovative companies that can maintain advanced manufacturing in Australia.”

Roobuck – Small, stringent, and ready to collaborate For dangerous work environments down mines and elsewhere, certification and quality systems are vital. Based in Brookvale, NSW, Roobuck’s focus is on these, through its supply of lighting, personal protective equipment (PPE), and – more recently – electronic tracking technology.

Roobuck’s flagship

“It’s a complex area, there is product range is its not much competition, and cordless miners’ cap-lamps for the products are very, very underground mines. stringently manufactured,” explains David Forshaw, Head of Business Engagement at Roobuck, which manufactures both in Australia and China. “These are designed and manufactured to stringent standards; and our IECEx certification is performed by the independent Test Safe Laboratory here in Sydney. Test Safe engineers travel to our China factory each year to audit factory quality assurance (QA) systems and production processes to ensure that all product builds meet Australian IECEx standards.”

Roobuck’s products are in an estimated 70% of Australian mines, including BHP Olympic Dam, and about 40% of its business is exports, to 20 countries including the USA, Chile, Brazil and the Middle East. The company supplies products for underground coal mines, hard rock mines, tunnels, above-ground operations and the petrochemical industries. Roobuck’s flagship product range (including wireless innovation) is its cordless miners’ cap-lamps for underground mines. The company is a small team of 12, covering design, manufacturing, certification, R&D, imports, exports and system integration. “We operate to a Lean business mode,” explains Forshaw. “We outsource and engage expertise project by project.

We’re also looking for new requirements feedback from mines so we can custom-build their solutions.”

Collaboration with outside help, including engagement with grant projects and universities, is important in driving product development. A recent successful application with the METS Ignited Project Fund is supporting development of collision detection technology on Roobuck’s OVERwatch platform, which tracks the location of people and assets underground.

Forshaw, who is also the OVERwatch Projects Manager, says: “The OVERwatch platform is now a key focus for the company to drive further innovation into the mining sector, which is gearing up for the digital mine, by offering connected devices, sensors over wireless connectivity providing rich data to broaden our market offering.”

Roobuck aims to keep expanding the range of applications for the platform over time, which will again require partnerships.

“We aim to keep expanding our range of applications for the OVERwatch platform,” Forshaw adds. “To this end we are always keen to partner with other suppliers and integrators where a mutual benefit is evident, and we are always looking for new underground mines which may wish to partner with us to deliver business solutions matched to their operation needs and future plans.”

Lachlan Campbell, Vice-President, Marketing & Innovation at Groundprobe.

AMT AUG/SEP 2019

MINING & RESOURCES Southern Innovation – Catching rays In June a small Melbourne company specialising in sophisticated digital signal processing products announced it had formalised and expanded its partnership with BHP. Through the agreement, Southern Innovation would provide “technical expertise to uncover solutions to specific challenges” faced by the mining giant. The technology provider would also double its workforce over the next two years.

Southern Innovation seems to have arrived, but the path there looks nothing like a straight line. As Managing Director David Scoullar puts it: “It involves mistakes and bruises and rabbit burrows that you run down and then have to turn around and run back out of.”

Scoullar and brother Paul grew up overseas, with their father employed by the United Nations Food and Agriculture Organisation.

Living in locations including Nigeria and Pakistan, they saw the effects of landmines – rendering areas off-limits for farmers and others – and had friends employed in mine clearance.

Back home, at the University of Melbourne, David studied commerce, while Paul studied electrical and electronic engineering.

The young engineer’s research focused on detection of antipersonnel landmines, developing an algorithm to vastly improve gamma ray-based methods during his PhD. This decodes “pulse pile-up”, where radiation signals overwhelm the ability to process them and accuracy suffers.

Paul started Southern Innovation in 2004 to commercialise this technique, which he brands SITORO Accelerated Analysis.

Early work was in improving gamma logging of oil wells. An oilfield services business saw SITORO’s merit but wanted all the IP rights, so no deal was made. It wasn’t until 2011 that SITORO was licensed to US technology firm XIA for pulse processors, enabling much faster and better x-ray processing for scientific applications.

It was finally an application that stacked up.

“That’s a market that’s important to us and growing,” says David.

“This financial year we expect gross revenue there to be probably just under a US$1m. [But] it’s not going to pay for the wages of 20 people working full-time on our product development pathways.”

The next market it targeted was air cargo screening, forming a joint venture with Little Group and eventually being bought out. Southern Innovation returned to mining, starting its relationship with BHP in late 2015. The first project was developing tools for real-time characterising of iron ore, coking coal and potash on conveyors.

“At the same time, one of their technical experts said ‘Listen, if you can do that on a conveyor belt, do you think you’d be able to analyse the cuttings coming out of a reverse circulation exploration drill rig in the field?’” recalls Scoullar.

“The cost to buy a single channel of SITORO-enabled FalconX processing from XIA is about US$25,000,” says David. “A single channel of processing from other providers that use traditional techniques [is] as low as US$1,000 a channel. We need to find really high-value use cases where an increase in speed, an increase in accuracy and potentially a reduction in radiation dose are valued over and above the cost of integrating.”

DrillScan went through a stage-gated process. First was discriminating between iron ore and waste samples at the Synchrotron. Then there was being able to do this for slurry passing through a pipe, and then building a device mounted on a rig. Then came improving the resolution from just ‘ore versus waste’ to grading. Field tests began last August. These have revealed lessons about modularity, so a faulty part can be swapped out in the field while the unit is still mounted on the rig.

The Australian Synchrotron was able to see the value. David says an x-ray fluorescence beamline had 400% demand for its available time, and a signal-processing capability offering 10 times the speed of analysis was compelling. Other facilities have followed; Southern Innovation is now top provider of signal-processing equipment to synchrotrons in the world.

Southern Innovation has now moved from prototyping to manufacture. It recently completed two DrillScan units, expected to be sold to BHP for use in a field trial before the end of the calendar year. David predicts the company could sell between five and ten units in the next 12 months.

“Our preference is probably to work with product partners in the industry that have that manufacturing capability, but more importantly who have channels to market it and existing distribution capabilities, sales, and business development capability,” he adds.

David believes the most important thing for any METS innovator trying to commercialise interesting but complex technology is perseverance. It’s your job and not your customer’s job to figure out how to solve problems associated with getting to market.

“A thing that you can do to ensure that you don’t succeed with each of those mining houses is to get angry and begin to secondguess their decision-making processes,” he says. “Maybe take a step back and try somewhere else, and then when you’ve got a more well-developed offering, come back to those mining houses and say ‘Is now the right time?’ And then sometimes the answer will be ‘Yes,’ as it was with BHP in 2015.” www.austmine.com.au www.groundprobe.com www.roobuck.com.au www.southerninnovation.com

David and Paul Scoullar, Managing Director and Technical Director of Southern Innovation.

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MINING & RESOURCES

NEPEAN – Generating productivity and customer satisfaction gains Over the next five years, the Australian mining industry is set to increase its level of maintenance activity by nearly 60% as companies endeavour to maintain a competitive edge. As a sector, the mining space is particularly complex as businesses must navigate fluctuations in resource prices and availability, as well as the introduction of new technologies and automation processes.

Controlling costs throughout the entire mining product lifestyle across exploration, construction and operation to retirement is a challenge. As a result, mining businesses need to maintain control of their financial components, embracing technologies that enable a full view of equipment and operations to remain competitive and profitable.

One example is NEPEAN, Australia’s leading privately owned engineering, mining services and industrial manufacturing organisation, with operations in six continents and more than 1,200 employees. Founded in 1974, the company supplies mining equipment and fabrications to more than 65 countries and manufactures building products in Australia for the local construction industry.

Boosting efficiency by streamlining processes Due to its expansive network, NEPEAN needed to streamline its reporting and business management processes to create efficiencies, increase profitability and strengthen competitive advantage. The company leveraged Pronto Software’s flagship enterprise resource planning (ERP) solution, Pronto Xi, to build a strong foundation for consolidation and insights. NEPEAN started using Pronto Xi in 1999; however, the company still opted to run much of its business on Excel spreadsheets. As a result, financial accounts took weeks to reconcile. As a large and complex organisation with many different business units including mining, steel fabrication, machinery and construction, it was facing significant challenges when it came to managing and streamlining its operations. One of the major frustrations for the leadership team was that the company’s disparate systems made unified financial reporting and analysis challenging.

This impeded the gathering of the critical business-wide insights that are needed to support strategic decision-making.

Inventory management was also a concern for the organisation.

NEPEAN was often unable to tell customers if the item they wanted was in-stock and when delivery might take place.

Andrew Honnibal, CIO – Technology & People at NEPEAN, explains: “We realised that there were a range of issues in how we had set up and used Pronto Xi. Fundamentally it was a good solution, we just needed to find a way forward by integrating ERP, financials and reporting.”

Conveying a focus on efficiency and customer service According to Honnibal, the decision to upgrade to the latest version of Pronto Xi was taken for several reasons, including the fact that employees found the system easy to use.

“For any new system, adoption rates are critical for success and this often depends on how quickly users can become confident and complete their key tasks,” he says. “I knew with Pronto Xi our employees would see a familiar tool they trusted.”

NEPEAN completely reimplemented its Pronto infrastructure, beginning with one of the more demanding units.

“A recent acquisition meant that our conveyor business expanded rapidly and we had to support about 65% more IT users,” Honnibal adds.

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The upgrade to a later version of Pronto Xi and the integration of previously separate business entities delivered instant improvements.

“We were able to automatically report a P&L on a project-by-project basis, something that was not possible in the past,” says Honnibal.

“This is significant because since the mining downturn in Australia margins have been tighter than ever. The real-time insight we receive from Pronto Xi enables us to ensure we do not deviate from plans and budgets, which helps us remain profitable, even with lower margins.”

NEPEAN’s building and infrastructure lintel business, Galintel, was the next to upgrade. This has enabled the business to respond rapidly to customers enquiries with accurate inventory availability, product lead times and quotes. NEPEAN also gained clear insight into the profitability of different stock keeping units (SKUs).

“We went from managing businesses using hundreds of errorprone spreadsheets to having a fully integrated system containing all pricing, materials and inventory in one system – Pronto Xi,” says Honnibal.

NEPEAN’s Weldlok business has also reported strong gains from the Pronto upgrade. Honnibal remarks: “We used to do monthly stocktakes in this area but we now do them annually and the last stocktake showed zero variance.”

The company has also benefited from improved Business Intelligence (BI): “We now have clear dashboards and can see all our open orders, and details show if we are on track to meet the commitments we have made to customers. The right people also receive alerts and can extract the information they need to identify trends and make better decisions for our business.

BI has also really helped NEPEAN with critical financial reporting after acquisitions.

MINING & RESOURCES

“When we acquire a business, especially those offshore, we can now produce consolidated financial results from day one,” Honnibal comments. “It used to take us a week to do this and now we do it with a single button press. This is a tremendous time saving and of significant value to business leaders who require timely insight.”

In addition, NEPEAN utilises the Pronto Xi Payroll and HR module, and Honnibal notes that this is delivering significant benefits: “Most other Australian ERP providers do not offer payroll and it’s a great addition that Pronto provides. We are able to very efficiently bring timesheets straight across from the manufacturing module, improving project costing.”

“Overall, Pronto Xi gives NEPEAN measurable productivity and customer satisfaction gains, which is a phenomenal achievement as it directly impacts our revenue.”

Empowering mobile teams to seal the deal Pronto Mobile CRM is another key feature of the upgrade, enabling NEPEAN’s field-based sales staff to better service customers with faster quotes, more accurate pricing and inventory information.

“Our sales teams can visit a customer, take an order and check to see, with absolute certainty, how much stock we have of that item,” says Honnibal. “They can then provide quick quotes, which are all automatically integrated back into the core Pronto system – reducing the chance of error. Shorter lead times and accuracy are critically important in our business. Pronto Xi enables us to give our customers reliable information, quickly, as it’s needed.”

NEPEAN chose a hybrid cloud infrastructure, and according to Honnibal this has given them an added layer of assurance.

“Having access to Pronto Cloud’s technical expertise to manage the server is important,” he says. “With Pronto Cloud monitoring and managing the machine, we know we have better uptime and faster results.

Today’s leading manufacturing companies operating in the mining sector need the ability to control their financial components and consolidate disparate business processes. Through access to real-time, actionable insights and a comprehensive inventory management process, companies like NEPEAN are enhancing productivity and boosting customer satisfaction. By deploying resources like Pronto Xi, businesses can enhance the scalability of their operations, and also leverage predictive monitoring and accurate financial reporting to support smarter business decisionmaking.

“Pronto Xi is an excellent solution, especially when it comes to managing the complexities of a business like ours,” concludes Honnibal. “Pronto does what it says it can do. The total cost of implementation is low, the ongoing costs are low – therefore the return on investment is very good.” www.nepean.com www.pronto.net

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MINING & RESOURCES

Australian-made secondary mine ventilation brings cost savings, compliances A new technological solution for mining ventilation, engineered and manufactured in Australia, categorically offers power savings and control not yet seen in the underground mining industry.

Minetek’s patented secondary mine ventilation system, based on a High Output Axial Fan system uses a patented mine air control (MAC) system to maximise return from its performance on demand (POD) units, which automatically sense how much air is needed in any one heading at any time. Each solution is engineered and manufactured in Australia specific for the end user.

Whilst these secondary underground fans strategically optimise air flow, they eliminate much of the power traditionally wasted in such applications while performing across a very large operating range and meeting broad regulatory compliance parameters.

Compared to the common standard twinstage axial fan ventilation systems found on the market, the Minetek High Output Axial Fan system is modular and provides: • Vastly reduced energy costs.

• Adequate air at the face.

• High levels of control.

• Sensor tracking to automatically adjust to real-time demand.

• High volume compliance.

• Blast dust removal rapidly.

• Reduced noise output.

According to Remy Bourcier, Engineering Manager at Minetek, the company’s High Output Axial Fan has been designed and manufactured in Australia completely with the underground mining industry in mind.

He added that the MAC control system brings the mine’s fan system together with complete automation.

“Until now, the market has to a certain limit used high-maintenance Variable Speed Drives to provide some level of control to the air flow in secondary ventilation systems,” says Bourcier. “But our patented system works on high-pressure, steelfabricated impeller technology, allowing operation at temperatures and conditions previously thought impractical for an axial fan – and we achieve this in seriously harsh environments.

“It’s in the area of energy costs where the real savings are found, and this is very tangible too. Various studies point out that between 42% and 49% of a mine’s energy costs are consumed by mine ventilation, with the figure of about 27% attributed to the cost of secondary ventilation alone.

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“Typically, a fan consuming 190kW with an electricity price of 15 cents per kilowatt will cost $249,660 per year to run and may not even be properly compliant. Considering the average mine uses about 15 secondary fans, the total annual consumption costs around $3,744,900.”

Key to its high cost efficiency is the POD system – an electronic controller on the fan that allows the fan to be regulated from very low flow requirements right through to more than double the duty point of a traditional vane axial fan.

With the use of the MAC System RFID trackers, it constantly remains aware what items of underground mining equipment are moving into the heading, so the POD controller will automatically adjust the air volumetric flow required to provide sufficient air volume to disperse the gases and ventilate the area.

It will sense what specific truck has entered the tunnel and it will be aware of the size of its engine and the number of people it will be carrying, so it will automatically adjust to meet the demand for sufficient ventilation for the people in accordance with industry regulation.

Considering temperatures at the rock face can be up to 50°C, it is critical to ensure adequate ventilation is providing fresh and cool air reliably. Being a

modular solution, mine managers can add or take away things such as silencers or adapters, booster fans or even boost the system further through control options. In normal underground mining conditions, the Minetek systems will operate significantly quieter, providing a noise level 8dB less than a twin 1400 twin 110kW for the same volume flow.

Richard McAlpin, Sales Manager at Minetek, says the big benefit to the global mining sector is that they are no longer hamstrung by not being able to control the volume of air within the headings, and that mine owners are able to save substantial money through this control.

“What we have designed is not just a top performer, but something that is also very durable without loss of performance,” says McAlpin. “The fact that our POD system can be controlled accurately, means that the re-entry times to the mines are shortened significantly, meaning downtime is significantly reduced.

“We have spent several years developing this solution and are proving already that underground mining sectors around the world are finding it hard to ignore the cost savings it can deliver”. www.minetek.com

MINING & RESOURCES

Repair by cladding â&#x20AC;&#x201C; from the small to the very large Cladding as a repair process is making a significant contribution to industries such as mining and oil & gas, where metal components are subject to huge stress in daily operations. Laseline diode lasers have been installed in workshops across Australia to meet this demand.

As experts in thermal spray technology, QSP Engineering specialises in the reclamation, repair and resizing of worn components, with the company servicing clients come from a wide and diverse range of industries including the mining, construction, earth-moving, marine and industrial sectors. QSPâ&#x20AC;&#x2122;s large workshop in Bethania, Queensland, allows the team to repair small items such as respraying household irons to repair and reclamation of very large parts worn and corroded through excessive and heavy usage â&#x20AC;&#x201C; for example, pivot shafts.

Over 40 years of successful operations, the company has built a range of services to meet the needs of its clients, resulting in a highly trained team with expertise in spraying techniques. QSP offers highvelocity oxy fuel spraying (HVOF), arc spraying, ceramic and plasma spraying.

The latest laser technology has now been added to this mix, with a Laserline system that allows QSP to offer reliable finished workpieces. With a laser, exposure time

is short and the cooling is very quick, allowing the material to be metallurgically connected, pore-free and crack-free, in a single operation, while keeping postprocessing to a minimum. This process results in laser cladding being particularly tough, well suited to large items such as oil & gas drills and tanks. These can be repaired with long-term stable linings to reach required safety standards.

For customers engaged in oil extraction, mining, metal and paper industries, where part replacement is costly or can take months to replace, the use of cladding to repair large expensive equipment is seen as an economic, time-saving solution.

Additionally, coatings by laser-based high-speed powder cladding provide maximum impermeability combined with a long lifetime, making them superior to other coating techniques such as thermal spraying.

Australia boasts a number of oil & gas fields where high-performance drilling operations put tools under tremendous stresses.

A QSP Engineering employee setting up the Laserline laser for cladding a large rotor.

When presented to a workshop using a Laserline LDF or LDM diode laser for repair, economic and dependable results can be achieved, in most cases even extending the original projected life of a part. www.raymax.com.au www.qspengineering.com.au

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MINING & RESOURCES

Safescape launches prototype electric vehicle for mining industry Bendigo-based company Safescape has unveiled the Bortana EV, a prototype electric vehicle for the mining industry.

Designed specifically to face the tough conditions of the mining environment, the Bortana EV is a robust and rugged vehicle equipped with advanced electric technology. The Bortana EV is built using the chassis from an Agrale Marruá, a resilient four-wheel-drive utility vehicle from Brazilian manufacturer Agrale, traditionally used in the Brazilian army and mining industry. Safescape selected the Marruá chassis for the new Bortana EV due to its corrosion-resistant body and ability to withstand the harshest of conditions.

The Bortana EV is the result of a collaboration between Safescape and 3ME Technology with support from METS Ignited, the Industry Growth Centre for the mining equipment, technology and services (METS) sector. METS Ignited provided $500,000 toward the project under its Collaborative Project Funds in 2018.

3ME is a Newcastle-based company dedicated to developing heavy-duty e-mobility solutions. The electric technology for the Bortana EV features a battery with advanced opportunistic on-board charging capability.

According to Safescape Managing Director Steve Durkin, the Bortana EV is a newage, advanced vehicle that will change the way mine fleets operate: “The Bortana EV will offer the right mix of capability and longevity in the mining environment. The transition from diesel-powered vehicles to battery electric vehicles in underground mining provides considerable benefits, not only because of reduced maintenance and higher operating efficiency”.

Underground mines in particular will benefit from the Bortana EV, says Durkin. “Electric

vehicles have no tailpipe emissions and have considerably less heat emissions than diesel powered vehicles,” he explains.

“This has a positive impact on the working environment underground. We believe that the Bortana EV will have a lower total cost of ownership than any other comparable production vehicle in the mining environment.”

The Bortana EV will begin a three-month trial at Kirkland Lake Gold’s Fosterville Gold Mine in Central Victoria. www.safescape.com

Cyanide-free gold goes into production Australia is leading the charge towards greener, safer gold production with an environmentally superior gold recovery process technology, dispensing with toxic cyanide and mercury currently used in most gold production processes.

Clean Mining Managing Director, Jeff McCulloch, says the technology is suitable for new greenfields mines, locations where cyanide cannot be used or is banned, as well as in existing mines looking to upgrade and transition to the new technology.

After successful industry trials and the first gold pour last year, CSIRO will transfer its ‘Going for Gold’ process technology to Australian company, Clean Mining.

CSIRO Research Program Leader, Dr Chris Vernon, believes the technology not only overcomes a significant environmental hazard, but opens the door for gold miners and end-users to capitalise on demand for sustainable processes and products.

“Cyanide is used in about 75% of global gold production, and while the industry works to manage the associated risks, there have been recent toxic spills overseas that have caused great concern to communities,” Dr Vernon said. “An alternative process, which eliminates hazardous chemicals while maximising gold recovery, meets industry and consumer demands for more sustainably-produced gold.”

CSIRO’s ‘Going for Gold’ process replaces cyanide with a reagent, known

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as thiosulphate, creating a relatively costeffective, non-toxic and safe alternative to conventional cyanide-based gold recovery.

Clean Mining will deliver the new solution to a global market of gold producers, offering technology products and licences as well as turnkey processing plant options, plus equipment and product support throughout the mine life.

“This technology provides gold miners with an opportunity to proactively evolve their environmental, social and governance (ESG) standards,” McCullloch said. “This new technology literally delivers a new gold standard for the global gold industry. The technology is scalable and cost-effective, and the process has been tested and proven at an industrial-scale to deliver commercially viable results.”

Clean Mining is currently in negotiations with ICA Mining Services in the Northern Territory of Australia to commission the first commercial plant to process gold using this technology, and with Nu-Fortune Gold to commission a plant in the Goldfields of Western Australia. www.csiro.au

MINING & RESOURCES

John Hart helps ACIM to break ground worldwide ACIM’s products regularly outperform more established competitors, and the Melbourne-based company says one reason for this success is investment in Mazak CNC machine tools.

Managed by husband and wife team Anthony and Lisa Coleman, ACIM designs and manufactures inflatable packers, hydraulic fracturing systems, tools and data loggers for the geotechnical, mining, and oil & gas markets. Established in 1990, it has grown from humble beginnings servicing the Australian market, to a company that now sells into international markets such as Chile, South Korea, Italy, Russia, America and Indonesia.

In 2013 when ACIM decided to bring manufacturing in-house, it gave John Hart the opportunity to offer a solution to suit its requirements. As a result, ACIM invested in a Mazak Quick Turn Smart 350M multifunction lathe with milling capability. The machine combines productivity, accuracy and reliability handling parts up to 420mm in diameter and 1,250mm in length.

Anthony explains: “Programming was the main reason we selected a Quick Turn Smart. It has proven easy to learn, and being a small business we were under pressure to make good on our investment and produce parts straight away. John Hart showed us how to get jobs started and we became comfortable using the machine faster than expected. “Bringing manufacturing inhouse also enabled us to respond quickly to our client’s customisation needs. The Quick Turn Smart has driven our development further, improved our designs, enabled testing, and allowed us to do it all in-house.”

The business growth brought about by the Quick Turn Smart investment resulted in a further purchase in 2019, of a Mazak VTC-530/20 - a high-speed, high accuracy travelling-column vertical machining centre.

Ian Swan, Victorian Branch Manager for John Hart, commented: “The VTC-530/20 was not only an innovative solution but also an alternative solution to the one originally considered by ACIM. The new machine facilitated the move of a majority of milling from the Quick Turn Smart to the VTC530/20 for improved machine utilisation and increased production.”

The 2,300mm x 530mm table provides exceptional versatility. An optional centre partition allows the VTC-530/20 to be used like two separate machines. Part set-up can be performed on one side of the partition while workpiece machining is being performed on the other.

WORLD CLASS

COORDINATE MEASURING MACHINES

Anthony Coleman of ACIM in front of the Mazak VTC-530-20.

A compact machine footprint was another important factor for ACIM. The VTC530/20 boasts a footprint 50% smaller than conventional machining centres with a similarly large X-axis stroke of 1,950mm.

The two Mazaks have enabled ACIM to further enhance production processes, cut down production costs and reducing overall manufacturing time. Anthony describes one recent job that showed the advantages of the Mazak machines. “A customer requested a custom mining tool, with a tight turnaround,” he explains. “The product needed to be designed from scratch, manufactured, tested and delivered to NSW in less than two weeks.”

BRIDGE CMMS

HORIZONTAL ARM CMMS

Achieving such a tight delivery requirement had historically not been possible, but with two world-class Mazak machine tools, the job was done and the customer happy.

At the time of considering the Mazak VTC530/20, ACIM also evaluated the feasibility of using a CAM solution to make programs directly from the CAD software. The CAM system would complement Mazatrol programming by accessing the information and intelligence built into a 3D model and make programming faster, easier and less error-prone. A CAM system was also required to generate 3D toolpaths. Anthony looked into the leading CAM software options and selected hyperMILL due to its cutting-edge technology and high the level of support provided by John Hart.

“The people at John Hart work hard to provide our company with world-class technology and world-class value, backed by world-class service,” adds Anthony. “It is clear to us that they tie their success to our success.” www.aciminflatablepackers.com www.johnhart.com.au

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MINING & RESOURCES

AIMEX 2019 - Unearthing opportunities Australia’s mining industry is gearing up for what will be one of its most important events when the Asia-Pacific region’s largest and longest-running mining exhibition and conference opens in August.

Registrations for Asia-Pacific’s International Mining Exhibition (AIMEX) 2019 edition are now open, with more than 6,000 mining industry professionals and an additional 2,000 exhibitor personnel set to take over Sydney’s Showgrounds across three days from 27-29 August. More than 500 exhibitors are expected take part, with the likes of Contitech, ESS Engineering Services, Alfagomma, Cummins, Hitachi and Volkswagen already signing up to participate in an event that brings together mining industry leaders and decisionmakers from across the world.

Steve Cummins, South Pacific Director of Mining, Oil and Gas Business, will be taking part with one of those exhibitors: global technology leader Cummins. He believes involvement in AIMEX during Cummins’ own 100th anniversary year was very important and that they are proud to be involved in the exhibition as a major player in the mining industry around the world.

“A pioneer in power systems technology for 100 years, Cummins has the total power solution for the mining industry,” he added.

“High horsepower Quantum engines to ensure lowest cost-per-ton, CustomPaks for mine dewatering, and power generation systems ranging from single gensets to turn-key power stations. At AIMEX 2019, Cummins will introduce its innovative HSK78G gas generator series, a completely new design from the skid up, providing reliable power regardless of the natural gas source or climate.”

For the second year, a free-to-attend multistream mining conference will be embedded within the exhibition, providing visitors with a unique opportunity to hear from mining innovators and disruptors at the same venue where the technology is on show. Brought to the public by Davey Bickford Enaex, the AIMEX Conference will focus on key themes surrounding the changing of mindsets and how to survive the impact of future technological, social and environmental changes. The conference will also look at the rise of automation and robotics and the use of AR and VR to enhance safety training for staff amongst other topics.

In a first for AIMEX, five of Australia’s biggest mining companies will also come together to create the AIMEX Mining Pavilion.

Centennial Coal, Glencore, Mach Energy and Whitehaven Coal will join Yancoal Australia to outline their own enterprises, connect with suppliers and drive their own recruitment strategies.

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“AIMEX is the most important mining industry event in 2019,” said Ward.

“During these changing times it is vital that AIMEX provides a platform for suppliers to showcase their latest innovations and to give the industry a chance to come together, explore new technologies, and embrace the wider mining family.

Katie Brassil, Centennial Coal’s Executive General Manager – Approvals, Sustainability & Corporate Communications, said involvement in the AIMEX Mining Pavilion allows the company to promote its initiatives and engage with industry and suppliers more broadly.

“We think it is a perfect opportunity for us to tell our story,” Brassil said. “Not just our story in terms of Centennial and what we do and that we are loud-and-proud coal miners, but also the story of our communities and our most valuable assets: our workforce.

“Our people look forward to AIMEX. As a company, we encourage and promote innovation and more recently have been on a digital transformation journey. AIMEX provides a fantastic opportunity for our people to experience the latest products and equipment up close and to network with suppliers and industry peers.”

AIMEX Event Director Brandon Ward said the newly launched Mining Pavilion, along with the conference component of AIMEX, adds significant weight to encourage mining professionals to attend the biennial event this year.

“We are delighted to welcome five mining companies onboard this year as part of our first AIMEX Mining Pavilion, and excited to bring together our second free-to-attend conference, which will again give attendees the chance to hear from industry experts and challenge them on what the future holds for the sector. Every two years, delegates from across the globe continue to make Sydney and AIMEX their home for three days in Sydney in August, and this year’s event is certainly one to lock into your diary now.”

Registrations for AIMEX are now open with full details of topics and speakers for the conference to be announced once they are confirmed. www.aimex.com.au

Materials Services

Reducing material cost through waterjet technology

Waterjet technology Waterjet cutting is a process of precision cutting that utilises high pressure water.

We can process a wide array of materials. Heavy gauge plate, thin sheet stock and composite materials (i.e. carbon fibre, phenolics etc.).

It is not uncommon for 6+ inch aluminium and titanium to be cut on waterjets to near final shapes.

Edge quality of the parts can vary depending on customer requirements.

We can process anything from a very rough cut for hog-outs, to a very fine edge for precision, finished parts:

Cut up to 6 m x 3 m (20 ft x 10 ft) Thickness up to 254 mm (10 in)

Improved yield and less waste material Supplied close to net shape reducing customer machine time Shorter lead times Zero heat effected zone Processing of customer supplied materials

Contact thyssenkrupp Materials Australia Pty Ltd Unit 2, 7â&#x2C6;&#x2019;10 Denoci Close Wetherill Park, NSW 2164, Australia

T: +61 2 9757 7777 F: +61 2 9757 7700 sales.tkmaterials.au@thyssenkrupp.com www.thyssenkrupp-materials-australia.com

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MFB Products – Upgrading for the future As it approaches its half-century, Victorian manufacturer MFB Products is maintaining its competitive edge with the latest state-of-the-art sheet metal technology. By William Poole.

MFB was established by Brian and Faye Bilston in April 1970, taking its name from Faye’s initials: Margaret Faye Bilston. While they remain involved in the business, these days they’ve largely handed the reins to their son David Bilston, now MFB’s Managing Director.

“They started the business 50 years ago, and the driver behind it was providing precision sheet metal for the electronics industry,” says David. “And that’s still basically how the business operates today. Our core business these days is data enclosures, but we still offer jobbing shop services.”

Over the years the company moved from site to site around Melbourne’s eastern suburbs, before settling at its current base in Wantirna in 2002. Today MFB employs 50 people, with a couple of staff running a sales office in Sydney and the remainder in Wantirna.

Its main product range is in electronics enclosures, ranging from the cabinets widely utilised in data centres, to more rugged models for outdoor environments.

The company’s customer base is varied, encompassing the data electronics, communications and IT industries, as well as clients in defence and security, through to specialist engineers requiring radio frequency (RF)-shielded enclosures. Apart from occasional exports within the South Pacific region, MFB’s products are largely destined for the Australian market.

According to David, the business’ strength largely stems from its core product range of standard 19-inch rack technology. However, growing competition from China is increasingly pushing the company to seek new ways to differentiate itself.

“That’s forced us to kind of reset and focus on more specialised product,” he explains. “I love it when a customer comes and says ‘I want 500 of these’, but the reality is that doesn’t happen often enough. It’s more about the bespoke, specialised, customised option. Or a customer says: ‘I want that cabinet, but I want it wider, I want it higher, I want it deeper. I want it to do different things.’”

To meet those demands, MFB boasts a diverse array of capabilities.

Most sheet metal processes can be performed in-house, in a workshop equipped with turret punches, press brakes and panel benders, plus five welding bays. The company can perform light engineering, inserting and finishing, with a dual powdercoat line and a batch oven for larger objects. Final assembly is further complemented by the capacity to even incorporate low-level wiring. All this means MFB can offer an extensive set of options to its customers.

“It’s much more specialised, and to do that we have a fairly sophisticated CAD design centre,” adds David. “Customers can come to us and say ‘Here’s our drawings’. They might just give us a sketch and we’ll develop something from that, there’s this process of discussion and finetuning, and then it goes into production.”

Underlining MFB’s capabilities are a growing list of certifications. The company is Australian Security Intelligence Organisation (ASIO)approved to supply Class B and Class C enclosures. It has also held ISO 9001 quality management accreditation since 1997, and earlier this year, it was accredited with ISO 14001, the international standard for effective environmental management.

“It’s new, something we’re still working our heads around, but it’ll extend further,” David adds. “It’s an important aspect to the business: our carbon footprint’s minimal, and we’re careful in how we manage our waste. When we tender for government work, or even commercial, they’re all looking for companies that can tick those boxes. As a preferred defence supplier, we are conscious

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MFB’s Managing Director David Bilston with the new RAS MultibendCentre panel bender.

of having the right accreditations to ensure we are a centre of excellence in everything we do. It gives peace of mind to our customers that we have good policies in place. It’s a feather in our cap to develop these systems in growing the business. We want to be seen as an innovative, smart business – and a relevant business at that. So, this is very important to our operation.”

Crucial in making all this possible is MFB’s 6,000sqm purposebuilt facility in Wantirna. Designed with a clear, coherent sense of the company’s processes, the factory has an open layout that minimises congestion and bottlenecks while maximising productivity and efficiency. With three forklifts usually in operation, a traffic management system keeps operations running smoothly, while an enterprise resource planning (ERP) system handles stock control, inventory and production flows.

“This facility has workflows that are unique to MFB,” explains David. “And we’ve been able to develop that process, whereby raw materials go in one end, we process and assemble the work, and then finished work goes out the door at the other end. There’s a clearly defined system in terms of how we process our product.”

As well as optimising productivity, the site has also been designed to create a beneficial environment for its personnel. As well as recently installed LED overhead lights, all the walls are painted bright white, eliminating dark spots and improving visibility in the workshop.

MFB’s turret punches are situated in a dedicated room, separated from the rest of the factory by a noise absorption wall. While this shields the broader workforce from the noise from the turrets, the wall also prevents the noise reverberating within the room, making for a better workplace for the turret operators. That emphasis on building a workplace that supports staff welfare is indicative of the people-focused culture at MFB. With Faye and Brian still working a couple of days a week, the company remains a family business, which can also boast minimal staff turnover. For David, a workforce dominated by long-term employees brings significant benefits.

“Those guys who have been here, they understand the business, they understand what their part is in the operation of the business,” he says. “From a manager’s point of view, it self-manages; it really does help in terms of how things work. Everybody takes ownership, the guys really do take ownership of their job and push things through. And that’s a great thing, that we encourage. A concept developed by my father, that I am keen to see continue.”

FORMING & FABRICATION Left: MFB’s main product range is in electronics enclosures, ranging from the cabinets widely utilised in data centres, to more rugged models for outdoor environments.

Below: MFB Products’ facility in Wantirna.

Enhanced capability MFB recently acquired a RAS Multibend-Centre panel bender, supplied by Sheetmetal Machinery. The company had already owned an earlier model of the same machine for about 20 years, and it has served MFB well. However, it was starting to show signs of wear and tear: the machine’s accuracy was fading, making it harder to achieve the required tolerances; and on the occasions when it broke down, sourcing parts was becoming increasingly difficult. Nonetheless, events out in the wider world meant the new machine was a long time coming.

“To be honest, we’d been looking to purchase a new RAS in 2008; I was very close to placing an order, and then the GFC hit,” says David. “Holding off on the purchase was the prudent thing to do.

Things take their course and you just have to grin and bear it for a while. Our decision was to try and extend the life of the existing RAS. But now we’ve just come off two boom years for the company.

That gave us the opportunity to rethink investing in a new machine.”

Meanwhile, RAS had released a new scaled-back version of the Multibend-Centre, which is the model MFB bought. The old panel bender remains in service as a back-up for busy spells, but according to David, the new machine unquestionably represents a significant upgrade.

“I think they market this machine as an entry-level panel bender, but from our perspective it’s a perfect fit,” he explains. “It’s a really sophisticated bit of equipment. It suits our purposes hands down. For doing large panel work, it’s a no-brainer. There is more sophistication with the machine. It’s a lot faster. The way the machine works, it just has a sense of accuracy about it.”

The 20-year interval since MFB bought the first machine has seen the addition of numerous new technological features, including offline software and a more intuitive, graphical user interface.

Operators can program the machine and then see an animation of the actual folding sequence, so that if a part or fold is going to crash, it will be flagged up on-screen in advance rather than during actual folding operations. Despite these changes, the new model features many of the same logos and icons as on the original, easing the transition for MFB’s operators.

For David, the new machine brings enhanced accuracy and productivity, while also improving safety: “In our industry, with manual handling of parts, back injuries are a given, so it’s important that we

can reduce the risk wherever possible. With the new machine, the guys load a panel onto a table and it goes away and folds the part.

The alternative would be to have two people standing there holding that panel at a press brake; a lapse in concentration and the part is folded incorrectly. So straight away I increase my risk associated to injury, and I decrease my accuracy of folding.”

David was highly impressed with the service MFB received from Sheetmetal Machinery, both during the new machine’s installation and in terms of after-sales support: “I’d have to say they were ten out of ten. We’ve bought different machinery from them over the years. They’re knowledgeable. The technology that’s going into machinery that sheet metal fabricators are using is phenomenal, it’s amazing. And Sheetmetal Machinery is aware of that – they’re really, really good at promoting that idea and being able to provide support, which is really important. They’re hands-on; they’re responsive and very helpful.”

Looking to the future, MFB is concentrating on further diversifying its operations and branching out in new market segments. Amid increased competition from overseas, the focus is on high-end work where the company’s competitive edge is based on quality and advanced capabilities, rather than price.

“Competition from China forces us to look for alternative work.

We’re doing that. We’re diversifying with our product, moving into different types of product. This morning we had a truck leave here carrying big enclosures for the energy sector. That’s an area we want to explore further. We think there’s lots of opportunities with renewable energies, all sorts of things that can come out of it. And that’s potentially a huge area for us.”

With this in mind, David is excited about the possibilities which technology such as the new RAS panel bender could open up for MFB. “If we can promote this type of machinery through the business, we’re going to identify ourselves as a sophisticated manufacturer.

Someone who can design, and manufacture, and turn around product quickly, which I think is an important part of how we market the business and how we operate. That ability to turn things around quickly, accurately: That’s what customers are looking for, from local manufacturers.” www.mfb.com.au www.mfbmetal.com.au www.sheetmetalmachinery.com.au

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FORMING & FABRICATION

FormFlow – Revolutionising sheet metal bending Based in Geelong, FormFlow is a start-up formed to bring a unique and potentially revolutionary cold metal pressing process to bend corrugated sheet metal without cracking.

FormFlow was established in 2016 to commercialise a metal-forming technique that enables the creation of joined corrugated metal shapes with no gaps, offering significant potential in the $1bn sheet metal roofing sector, as well as in other industries. Developed in collaboration with Deakin University, the innovation keeps out moisture, dirt, animals and embers, with an air-tight seal that also provides increased insulation. The technology is a world-first.

“If you have two adjoining sheets of corrugated iron, either two walls or the two sides of a roof, rather than having to put a cap over the top of them, you can end it to match that bend and then slide another piece of sheet up underneath it,” explains Matt Dingle, a co-founder at FormFlow.

“You end up with a smooth transition.”

To move the concept to the production and services stage, ongoing collaboration has been essential. The Advanced Manufacturing Growth Centre (AMGC) came on board early, providing $250,000 in co-funding for a collaborative project between FormFlow, Deakin and Geelongbased manufacturing business Austeng.

Without that support, the technology would not be at its current stage of readiness.

A patent for the technology, named the FormFlow Bend, has been lodged. Cofounder Dr Matthias Weiss is a Senior Research Fellow at Deakin’s Institute for Frontier Materials, manages its sheet material testing facilities, and has built one of the world’s largest roll-forming research groups.

“Deakin is a strategic research and development partner,” says Dingle. “There are lots of things that Deakin do that are really important to us. The most obvious one is they have a real expertise in metalforming research.”

FormFlow is not the first Deakin offshoot Dingle has been involved with. He previously co-founded Carbon Revolution, which pioneered the world’s first one‑piece carbon fibre wheel and has now successfully commercialised its innovation in the global automotive industry.

“I’ve had a very strong connection with Deakin for years,” he explains. “I was an undergraduate student, I did my PhD there, and the Carbon Revolution program sort of grew out of things that we were doing at Deakin and then commercialised afterwards. And this is just another offshoot of that.”

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Matt Dingle, Co-founder of FormFlow.

FormFlow’s technology is currently at Manufacturing Readiness Level 5 (MRL 5), or pre-production. If successful, the collaborative project will raise this to MRL 8, the production implementation stage, at which point the FormFlow Bend concept will be ready to commercialise. This will ideally take place through the licensing of the technology to steelmaking companies.

Within five years it could generate over 100 jobs.

The company has two main areas of focus.

One of these is to establish partnerships and scale their innovation through a joint venture and/or licensing with a steelmaker, such as BlueScope or Liberty OneSteel.

“Otherwise we have to establish all of that infrastructure and supply chain ourselves, which makes no sense at all,” notes Dingle.

The other area is to establish a research & development entity to develop other new ideas. A licensing arrangement would create servitisation opportunities and enable international expansion, while keeping the intellectual property (IP) in Australia.

According to IBISWorld research, the metal roof and guttering manufacturing sector in Australia is worth $1bn and growing at 11.5%. Making reasonable inroads into this would create an estimated 100 direct and indirect jobs within three to five years,

according to FormFlow. Achieving this and also cracking international markets will be most feasible by having machines designed

by FormFlow installed in other companies’ factories and operating under license, with collaboration partner Austeng also gaining revenues through associated services.

Citing FormFlow’s reasons for joining the AMGC and its support through the $250,000 co-funded project, Dingle says a strong manufacturing sector underpins the economies of successful developed nations, and this should be fostered. He believes it is vital for the manufacturing sector to prosper in Australia and that collaboration between businesses and university researchers need to be encouraged.

“I think we want to be part of ensuring the manufacturing sector in Australia is strong and becomes stronger over the next decade,” says Dingle. “In Australia we don’t have large organisations that have the broad skills base that you might find in some of the huge multinationals overseas.

But if we pool our efforts collectively, we have an incredible knowledge base and capability in Australia, and if we learn to utilise that more effectively, then that’s our biggest strength.” www.amgc.org.au www.formflow.net.au

MATERIAL REMOVAL

Next-generation tube-bending robots from transfluid Utilising the latest generation of advanced robots, transfluid’s range of tube bending machines have been designed to deliver more efficient processing.

Robots that process tubes in an effective and flexible way have already been used for some time in transfluid’s production cells.

Since the beginning, these bending systems have been capable of taking isometrics data and using them to generate bending data, without the need for separate robot programming. The high-tech engineering company has now taken the development of its bending robots one step further and improved them again.

“We wanted a solution that was even easier to use. This applies to the programming, which has been reduced or completely eliminated,” explains Stefanie Flaeper, Director at transfluid. “And at the same time, we have managed to make the robots even more flexible. It was a very big challenge to significantly improve bending robots that were already working extremely well. That is why I am even happier that our team of experts has been successful.”

Synchronised and clear identification Tried and tested transfluid bending units with two robots can bend long tubes from both sides. This way the tubes can be supplied already with forming or connection systems. However, it is much easier to process straight tubes in forming machines, when a bending machine can start from both sides.

“The robots are synchronised when in use,” says Flaeper. “Additional fittings, like mounting and support devices, are automatically synchronized with the processing robots. The robots recognise the tubes thanks to the code on the components and they generate the bending sequence; they can also choose different radii and diameters.”

It is possible to work with up to six different tube diameters without tool changing.

Saving on time-consuming programming

Expanded processing, greater output

The latest generation of bending robots also offers safer handling. The position where the robot grabs the tube in the magazine and the position where it grabs the tube to remove and deposit it can be retrieved from pre-programmed settings. This means that the operator has to do almost no programming of the bending program or the handling process. It is simply retrieved from stored data.

With the new and continued developments from transfluid, each manufacturing cell with two robots can do more than just bending tubes from both sides: each of these bending robots can also work on their own different geometry. The system can therefore be used in a very efficient way and the output is significantly greater.

“With the software we have developed, we have set ourselves a new goal, which is to make the processes much simpler,” Flaeper explains. “The bending data will be generated automatically from the coordinates, without the need to program the robots.”

It is also possible to process components that have been bent and put aside by the robots without any problems, even if there are potential collisions, because of the long segments. This is because the last bend can be done on the ‘floating’ tube, just above the unloading position.

The whole system is managed through the bending machine controls. This has the advantage that you can work with X, Y and Z data, but also with lengths and bending angles, just like with the standard bending machines. It is not necessary to have special knowledge of how to program a robot.

To keep the set-up time as short as possible, the robots have preloaded settings that include the additional axes. This makes it possible for the operator to complete any tool changes in a very short time. The robots can be positioned next to each other in specific positions. By pressing a button, the system will return to the start position. www.transfluid.net

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FORMING & FABRICATION

The rationale behind ISO 9606-1 Qualification testing of welders — Fusion welding In the wake of the introduction into Australia of ISO 9606-1 ‘Qualification testing of welders—Fusion welding— Part1: Steels’, there remains a widespread lack of understanding within the fabrication industry about the rationale for adopting the new standard. Geoff Crittenden, CEO of Weld Australia, explains the reasoning behind it, and more broadly the need for ISO Standards.

I would like to begin with a brief overview of AS/NZS 1554 ‘Structural steel welding Part 1: Welding of steels structures’. An excellent standard, AS/NZS 1554.1 states that a welder must be qualified, by welding a coupon in accordance with the relevant acceptance criteria as outlined in the standard. For shutdown work, particularly where welders move from site to site, this can impose a significant cost impost (especially in time delays) due to the need to requalify every time they commence work on a new site.

Geoff Crittenden, CEO of Weld Australia.

While this is not so much of an issue for workshop-based fabricators, where the shop will have ready access to the welder’s qualification records, it is a major problem for organisations within the resources, power, defence, and oil & gas industries, who will often employ teams of specialist welders to undertake programspecific on-site maintenance work – usually where there may be minimal records available of either the welder’s qualifications, or maintenance of qualifications.

In this situation, every welder contracted to undertake programspecific maintenance work must complete a welding coupon. Each welding coupon costs between $2,000 and $5,000, depending on the complexity of the weld procedure to which the welder is being qualified. Unfortunately, the failure rate of welders attempting these coupons can be as high as 80%. Therefore, to successfully qualify 10 welders, an organisation may need to test as many as 50 welders, at a total cost of as much as $250,000.

While this type of cost is an unacceptable burden on many industries, I want to emphasise that this is not a criticism of AS/ NZS 1554.1.

To help alleviate this financial burden, Weld Australia looked internationally for an appropriate standard that would provide a benchmark for welder competency in Australia. We had two options: ISO 9606-1, or AS/NZS 2980 ‘Qualification of welders for fusion welding of steels’.

At the time of consideration, AS/NZS 2980 was known to be based on an old version of ISO 9606-1. In consultation with our members – particularly major asset managers in the resources, power, defence, and oil & gas industries – we settled on the current edition of ISO 9606-1 for several reasons.

Why Weld Australia opted for ISO 9606-1 ISO 9606-1 is the only standard in the world that is accepted in both Europe and the US, and is the minimum requirement for working on rolling stock, defence, infrastructure and pressure equipment projects. In fact, ISO 9606-1 is required under several international standards, including EN 15085 ‘Railway applications—Welding of railway vehicles and components’, and DIN 2303 ‘Welding and allied processes—Quality requirements for production and maintenance companies for military products’.

ISO 9606-1 utilises a simple test that assesses welding competency according to a specific weld procedure, based on a set of practical acceptance criteria. It can be used to test the competency of a welder to complete a variety of weld procedures, from a basic butt weld up to the most complex pipe joints, utilising various positions, processes and materials.

Under ISO 9606-1, welder competency testing is focused on the three key elements required of a welder, including the ability to: 1. Set up a welding machine.

2. Read a welding procedure.

3. Welding a coupon in according with the relevant acceptance criteria.

Welder qualifications are valid for two or three years, and are transportable across worksites and employers, avoiding the need to requalify welders where there is evidence of maintenance of qualification. In addition, a six-monthly confirmation process is used to verify welder qualifications to ensure maintenance of welder skills, without the need for additional testing. The confirmation process is similar to that required for welders qualified to other standards including AS/NZS 1554.1.

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FORMING & FABRICATION

Professional Measuring Instruments

Full range of industry standard measuring equipment with many popular sizes supplied with calibration certificates.

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ISO 9606-1 does not replace either AS/NZS 1554 or AS/NZS 1796 â&#x20AC;&#x2DC;Certification of welders and welding supervisorsâ&#x20AC;&#x2122;. Rather, ISO 9606-1 is complementary to these standards, working well alongside both.

The Australian Welder Certification Register Having decided on this strategy, Weld Australia acquired an online system to help us manage the process of qualifying and certifying welders to ISO 9606-1: the Australian Welder Certification Register (AWCR).

Under the AWCR system, welders complete a test that qualifies them to a welding procedure as set out in ISO 9606-1. Once qualified, the welder is provided with a test certificate to that procedure, becoming a Registered Welder, and the information recorded in the AWCR. The certificate is valid for up to three years, subject to six-monthly confirmations by a responsible person (such as a supervisor or an approved examiner).

The AWCR system is already proving to be enormously beneficial for many organisations. It enables asset managers and owners to check the competence level of any Registered Welder against an internationally recognised standard, minimising welder testing and reducing costs. By qualifying welders against a recognised and certified competency level, the risk of a welder failing a weld procedure is significantly reduced. In addition, asset managers can assess welders against current, rather than past, performance, and quickly and easily identify and contact Registered Welders for employment.

I encourage all Australian manufacturers to support the AWCR. You can register your business on the AWCR, and ensure your employees and subcontractors are registered and certified via the AWCR. Access to the AWCR is completely free of charge for all Weld Australia members. www.awcr.org.au

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FORMING & FABRICATION

FAB9 – Melbourne’s newest Makerspace You may not be familiar with the term ‘Makerspace’, but it is a term and a concept that is growing in popularity in Australia. Makerspaces have the support of governments, industry and manufacturers and are a way of empowering people with great ideas, but limited resources.

There are many ways to define a Makerspace, but essentially it is a place where people can come to use – and learn to use – equipment, develop creative projects, or simply gain experience. They are most commonly associated with offering technology to create, develop and design in an informal, non-traditional, environment. Becoming a member of a Makerspace enables you to access the resources (training, machinery, technology and materials) at times that are convenient to yourself, without the capital outlay often required for production.

FAB9 is a purpose-built space, located in the Melbourne suburb of Footscray, for hardware entrepreneurs, engineers, designers, tinkerers, craftspeople, artists, hobbyists and anyone who wants to experiment through the making of physical objects. Whether you’re an amateur working on a fun project, or an inventor set to create the next world-changing product, they are open for people of all interests and skill levels.

Architecturally designed, FAB9’s building houses an impressive array of equipment and facilities ranging from electronics labs, hand tools, power tools, 3D printers, laser cutters and CNC routing machines.

Because FAB9 has to be able to cater for nearly every manufacturing demand of its members, it is important that the equipment they provide is rugged, reliable and versatile. Particularly big-ticket items like the CNC router.

The CNC router that FAB9 decided to include in their suite of facilities is the Multicam Trident 3000 Series flatbed CNC router. The Trident combines three different cutting technologies to provide maximum versatility, by offering a choice of routing spindle and two knives, which can be either tangential, oscillating, or a combination of both.

The Trident machine is truly unique in that it has the ability to rout timbers, plastics, aluminium and composite materials, with a heavy-duty, automatic tool change spindle.

It can also knife cut flexible and semi-rigid materials, up to 120mm thick, with ease, using either the tangential or oscillating knife head. A host of accessories and features, such as creasing attachments, camera recognition and live vacuum zones, means that FAB9 members using the Trident CNC router can really let their imaginations soar.

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FAB9’s Multicam Trident 3000 Series flatbed CNC router.

Makerspaces such as FAB9 provide opportunities for people to learn to use equipment, develop creative projects, or gain experience in an informal environment.

The Multicam Trident 3000 Series flatbed CNC router is the most powerful piece of equipment at FAB9, and it has the potential to significantly enhance the making practices of many start-ups, small businesses, designers and individual makers. It was selected by FAB9 because of its larger-than-average cutting area, its flexibility, and the backup and support provided by Multicam’s office in Melbourne.

For FAB9 this means getting real-time support, and gives them the opportunity of having official Multicam technicians train both staff and members.

Phil Balzan of Multicam’s Melbourne office was instrumental in helping FAB9 choose the correct CNC router for their facility.

“Multicam has many different model CNC routers available,” says Phil. “During our discussions with FAB9 I realised that they

would need a CNC router that was capable of exceeding their demands in terms of flexibility and value, and the Trident certainly does that.

“Multicam has a long association with training facilities such as TAFE training colleges, universities and schools. Even though FAB9 is offering a rather different service, we feel that our experience in the education and training sectors give us the ability to offer unique and tailored solutions to them.

“We are excited to be working with FAB9 in presenting opportunities and fostering Australian innovation,” Phil concludes. “And we are confident that FAB9 has responded to a real need that will be of great benefit to everyone involved.” www.fab9.com.au. www.multicam.com.au

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ONE-ON-ONE

Grant Anderson is the Executive Director of Industry Capability Network (ICN) Victoria. He spoke to William Poole.

AMT: Tell us about the Industry Capability Network and its role.

Grant Anderson: ICN Victoria is a not-for-profit organisation that has been around since 1984 and our mission is to maximise opportunities for local industry. We play a key role in liaising with government agencies and bidders ensuring that local suppliers have an opportunity to register interest in upcoming government projects.

Another huge part of our role is to administer the Local Jobs First policy on behalf of the Victorian Government and that includes assessing projects for potential local content. Local Jobs First is about creating local jobs and opportunities for Victorian businesses and workers, whilst achieving value for money.

We also have two main product offerings - ICN Gateway and ICN Analytics.

AMT: For an ordinary manufacturing business seeking to win work on a project through the ICN, what sort of pathway would that take?

GA: Local businesses, including principal contractors and local suppliers of goods and services can use the ICN Gateway to register their business capability, access project opportunities and search for suppliers. We also run many events every year that facilitate an opportunity for businesses to connect with project owners.

Our Industry Advisers all bring with them many years of experience in multiple sectoral areas and similar to myself, aim to give back to industry by helping SMEs get major project work. From working with bidders to identify local suppliers to post-award support and Enhanced Services, our Industry Advisers are out and about in the marketplace every day working directly with SMEs. AMT: Tell us a bit more about Analytics.

GA: ICN Analytics is a secure online platform that provides for the collection and analysis of local content and jobs data over the life of a project. A couple of years ago it became evident that there was an opportunity to improve data collection and project reporting systems and processes. We designed and developed ICN Analytics to be deployed throughout the supply chain.

At the top level, a project manager can nominate their first-level key suppliers then the next level does the same, and so on and so on, throughout the supply chain. Once nominated in the system, it is up to those suppliers to regularly update their data within the system. The data is then aggregated and gives the project manager a dashboard of the key KPIs that they’re expected to achieve on that particular project. ICN Analytics is required to be used on all government projects worth $20m or more, including all projects deemed Strategic Projects. Projects that have a lower value can opt in to use the system at no additional cost. Departments, principal contractors and local suppliers can use ICN Analytics to enter data on local content, employment numbers and hours, and to track performance against commitments made under Local Jobs First.

AMT: What do you think are the biggest challenges for manufacturing businesses trying to secure work in these areas, both in Victoria, and across Australia more generally?

GA: There seem to be several issues within the Government space in particular. There have been a large number of projects sourced by the Victorian government in the last couple of years that greatly vary in length – some might last for up to five years in some cases. And that means it’s generating a lot of work in the marketplace, particularly in steel and concrete and those sorts of areas in construction. There’s

AMT AUG/SEP 2019

a huge amount of work going on, and what’s now being exposed is a lack a capacity in some areas. The challenge is to try and find alternate sources for the future – particularly around fabrication of structural steel structures for instance – and where else they can be found within the state. We have five regional advisers in Victoria who are now seeking out opportunities within each of the regions, and as projects in areas such as rail, road or renewable energy are sourced around the regions, we’re looking to engage local suppliers in that supply chain process. In the broader manufacturing segment, I guess now that the automotive industry has disappeared, I think we’ve seen the scale disappear in manufacturing in a large way.

However, it’s really encouraging when you get out there and have a look at some of the manufacturers who’ve got new technologies in new areas, but who are at the early commercialisation stage of getting those launched. Once they get embedded, they can eventually grow through export, but they need a lot of help and support. What we’re seeing is in some sectors is that those smaller businesses are not business-ready to support major government projects or major export projects for instance.

AMT: So where do you see the opportunities really lying for manufacturing at the moment?

GA: There are so many that it’s quite incredible. The cross section of the supply chain that we deal with in ICN is huge. It covers almost every industry sector that you can think about, and I think there’s opportunities if people want to go after it. But they have to show a will. Now, government projects do require additional paperwork.

That’s part of the process. If you’re prepared to deal with that, then there are opportunities for businesses to grow. But in some of these early commercialisation projects, you have to get the first significant customers to get you off and running. And that’s often the hardest part – to get somebody to take the risk to run with you on something new.

AMT: And that’s where ICN comes in and helps.

GA: Well that’s where we try and help: to engage, introduce and support. We run a significant number of events each year, our flagship so to speak is the Victorian Manufacturing Showcase, we also do four or five Regional Opportunities Showcases, industry events at Avalon Airshow and the Australian Grand Prix, and many project briefings.

AMT: You’ll be again holding the Victorian Manufacturing Showcase, in Wantirna this October. What can we expect to see this year?

GA: The Victorian Manufacturing Showcase 2019 is an annual event celebrating its sixth year. We have tried to do something a little different this year by branding the event VMS19. VMS19 is hosted by a partnership of the ICN, Victorian Government and six local councils in the eastern suburbs. The objective of this event is to provide opportunities for Victorian manufacturers to gain invaluable insights into successful Victorian businesses while networking with other manufacturers and Victorian industry.

This year’s theme is Engage. Innovate. Create. And it will take place on Tuesday 22 October at the State Basketball Centre in Wantirna South. Following on from the successful Victorian Manufacturing Showcase 2018 at the GMHBA Stadium in Geelong, the 2019 edition will be even bigger and better. We have sponsorship and exhibition opportunities available – if your readers would like to know more they can check out our event website (http://bit.ly/VMS_19).

HEADING AMT: Where do you see the industry in Victoria and in Australia in 10 or 20 years time? What would you like to see it look like?

GA: I think it will look like an industry where you have specific regions around specific technologies. We’re already starting to see some examples of that: around the Carbon Precinct down in Geelong for instance, around defence sectors, around electrification sectors. And I think there are businesses which are specialising in those. 3D printing is another area of specialisation. So there’ll be a number of segments, which will evolve in the near term. The world is changing and Australia has to change with it, and fast. And that brings with it a lot of opportunities. Electrification of motor vehicles, for instance, brings with it a lot of new technologies, a lot of new equipment investment, a lot of new people that need to become upskilled to deal with those issues. With AI and robotics, there’s a huge opportunity to automate a lot of things that we have done manually in the past. As you’re introducing new equipment and new people and new systems, it’s the ideal time to think about those methodologies to build productivity and efficiency into the future of manufacturing in Australia.

AMT: Tell us about your background and the path that brought you to ICN today.

GA: Well I’ve followed quite a tortuous path to get here. I started my life in South Australia; I was an apprentice at Chrysler; I joined a family company; and I went through various management roles including engineering, sales, marketing, supply chain management, manufacturing management, and eventually Managing Director of that business in South Australia. That business was taken over by various public companies and then returned to private; it was originally Rainsfords Metal Products in South Australia, which became Britax Rainsfords, which then became Schefenacker, and today is run as SMR, which is owned by an Indian company, so it’s seen lots of different owners. That was a great experience because we took that from quite a small business of $16.5m, to looking at a regional size of around $330m, exporting 90-odd percent of our output and operating plants across the region. In Australia we had three plants; in South Korea we had two; in India we had a joint venture; in Thailand we had a licensee; and so on. I then left there, came to Victoria and ran PBR Automotive, the international brake company, and then in my most recent role prior to ICN, I ran the ANCA Group for eight years. That was a great success story, taking it up to the next level of expertise and quadrupling the turnover of the business.

AMT: And how long have you been at ICN now?

GA: I’m just coming up to a year at ICN. I retired from ANCA at the end of June last year and decided I was going to take a bit of a holiday and then got approached to take this role of Executive Director for ICN Victoria. I have also recently joined the board of Sutton Tools. My goal in life now is to try and help companies evolve to be the best they can be in a global marketplace.

AMT: So when you say you’ve retired, you’re not exactly taking it easy. So, the retirement didn’t last long?

GA: No, I haven’t gone sailing full-time just yet. As I mentioned, the new goal is now to try and help companies evolve and I feel that I am achieving at ICN. AMT: Well one day maybe! And what’s the most satisfying part of the job with ICN? GA: We are the interface with connecting business to government projects and there are some challenges with the Local Jobs First policy that was legislated last August and the additional work coming from that, however there is a real comradery at ICN Victoria and it’s great to be a part of. I am also very pleased with the new software and product development, we don’t rest on our laurels that’s for sure.

AMT: Sounds like you’re keeping nice and busy.

GA: Absolutely. www.icn.org.au/victoria

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VICTORIA

STATE SPOTLIGHT

Redline combines ‘Engineering with Service’ with the latest technology

Based in Mordialloc, in Melbourne’s south-eastern suburbs, Redline Engineering has remained internationally competitive through a simple strategy of ‘Engineering with Service’ combined with investment in the latest technology.

A third-generation family company, Redline commenced operations in 1969 when the legendary record-breaking drag racer Eddie Thomas decided to turn his passion for designing and manufacturing automotive speed equipment into a business. He launched what has gone on to become a precision component manufacturing enterprise, and the drive, passion and highperformance commitment continues today through Eddie’s son Ken Thomas, now Redline’ Managing Director, and his sonin-law Ken Stuart, the company’s Director and General Manager. The two Kens lead a team of highly skilled and dedicated personnel.

With an eye to precision, Redline purchased its first Okuma machine in the early 1990s.

The company has subsequently developed an enduring, strong supplier relationship with the Okuma brand over the intervening period, with those early precision machines still in operation more than 20 years on.

The Redline Engineering team, from left: Andrew Bannan, Afternoon Shift Team Leader; Paul Robson, Operations Manager; Ken Stuart, Director; Darren Schindler, Business Development Manager; and Adam Burt, Sales Engineer.

“When reviewing the market for our next new machine, Okuma was the standout with their professional proactive approach,” says Stuart. “It is one of the few companies which has had a constant presence in Australia over many decades and is backed by a strong innovative parent company in Japan. Sales, service and technical personnel are outstanding as is their training support.”

The latest investment to complement Redline’s already-impressive machine lineup is an Okuma CNC Horizontal Machining Centre Model MB4000H, with an OSPP300MA Control and an Auto Pallet Changer for six pallets. This new machine is already reducing machine set-up times in Redline’s workshop, significantly increasing manufacturing flexibility while delivering consistent high-quality accuracy. It also occupies a relatively small footprint for its significant output.

“With the new Auto-Pallet changer we are able to adapt to our customers’ needs and change from one job to another quickly with ease and efficiency,” explains Stuart.

Today the company’s capabilities include: alloy steels, engineering plastics, aluminium alloys, stainless steels, exotic alloys, brass and bronze. The extensive range of services provided by Redline today are the result of the company’s ongoing policy of proactively searching for ways to ensure

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A Redline operator with the new Okuma CNC Horizontal Machining Centre Model MB4000H.

that customers are delivered complete manufacturing solutions, through valueadded services such as precision assembly, heat treatment, grinding, polishing, anodising, painting, plating, bending and fabrication.

Whilst direct export sales for the company are growing, a large percentage of the output from this engineering company ends up indirectly in the international market with components going into diverse markets such as aviation, defence, highend automotive, medical and transport, including trucks, trains and light rail.

“The new Okuma CNC horizontal machining centre allows Redline to retain a competitive edge and is opening up further opportunities with existing customers,” says Stuart. “It provides us with greater flexibility, especially with the pallets, which enable jobs to remain set up between runs.

The new Okuma machine has reduced set-up times at Redline, increasing manufacturing flexibility while delivering consistent accuracy.

It also ensures we continue to be at the forefront of our industry and our team see our investment in the latest technology as important for their long-term security and embrace the opportunities this brings.”

To ensure only quality components and assemblies are delivered to its clients the Redline facility has fully equipped metrology capabilities, including optical CMM measurement. These operate under extensive quality assuranwce (QA) systems supported by dedicated resources covering Redline’s accreditation to ISO 9001 standard.

“Ongoing success in manufacturing requires investment in technology to differentiate in a service-orientated business, and meet the broader requirements of our customers to truly provide ‘Engineering with Service’,” Stuart concludes. www.okumaaustralia.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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STATE SPOTLIGHT

APT boosts productivity with Lang Technik workholding products From starting out with a single machine manufacturing spectacle screws, Victorian manufacturer Australian Precision Technologies (APT) has successfully evolved into a leader in the production of precision components and assemblies, utilising the latest CNC technology and manufacturing software.

At one point APT was the preferred supplier for automotive components manufacturer Robert Bosch; its business with Bosch accounted for 86% of the company’s turnover. However, like many automotive suppliers faced with the imminent closure of the local car industry, APT needed to diversify into other areas. In APT’s case, the market it targeted was the defence industry.

“One of the key benefits of Lang Technik is their patented Quick Point zero-point clamping system,” explains Weinzierl.

“This allows for a one-time installation – once the base plate is mounted and aligned to the machine tool table, and the zero point is defined, you can build workpieces and fixtures quickly and accurately. This provides a huge boost to productivity reducing changeover time from one or two hours to five minutes.

To say the company has been successful in this transition is “The zero-point system is super something of an understatement. fast and accurate, which is essential given the nature of our Today APT’s key customers are The Makro-Grip five-axis vice from Lang Technik. work. We use Lang vices on all a veritable who’s who of leaders our milling machines – the quality in the defence industry, to whom APT supply a diverse range of specialised components. These is first class. Their Makro-Grip five-axis vices are the perfect solution include parts for the F-35 Joint Strike Fighter and components for all challenging clamping tasks and are simply unbeatable in fivesided manufacturing. for the Steyer rifle, radar systems, remote weapon stations, submarines and munitions. APT also supplies a variety of products “The flexibility of Lang vices are another key benefit. Because it’s an to customers in the electronics and security industries. easy-to-use modular system, we can swap vices around machines However, APT’s Founder and Managing Director Richard Weinzierl is quick to point out that it is the assistance of the Centre for Defence Industry Capability (CDIC) and its Supplier Continuous Improvement Program (SCIP) that has been a crucial part of their success.

“The SCIP program gave us the tools we needed to ensure we moved successfully into the defence arena,” says Weinzierl. “The business coaching, which included the development of a strategic plan and staff engagement programs, really has been the key to our success and transformed the business. We have also been fortunate to be the recipient of a number of government grants which has greatly assisted the transition and our continued expansion.”

For its part, APT has dedicated significant resources to ensure its processes and operations meet the stringent requirements of the defence industry, including increased security and putting a cybersecurity plan in place.

“My wife Nicola has also been a key driving force in our transition and success and my daughter (a project management graduate) has joined us recently in a support role,” Weinzierl adds. “This will ensure APT remains a family-focused business.”

The ‘one large family’ theme at APT is clearly evident with the commitment and support Weinzierl has for his team of 30 staff, and this ethos is reflected in APT’s core values of teamwork, honesty and value.

Getting to grips with advanced technology APT was the first company in Australia to purchase Lang Technik’s range of workholding products. These were initially acquired direct from the manufacturer in Germany, but more recently they have from been obtained from Dimac Tooling, which took over the sales and distribution of Lang products in Australia and New Zealand.

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easily and quickly knowing that the quality and accuracy will be the same.”

APT also uses Lang’s Makro-Grip stamping technology, Weinzierl adds: “This stamping technology, also called pre-stamping, involves the workpiece being stamped outside of the machine tool with up to 20 tons of hydraulic pressure, providing the highest holding power for five-face machining worldwide. Makro-Grip stamping technology provides tremendous material savings due to minimal clamping edge requirements.”

Another unique product in the Lang Technik range that APT makes use of is its Cleaning Fan. This fan automatically cleans the machine table, pallet and/or workpieces after the machining process is complete, saving time and reducing workload.

APT produces a diverse range of specialised components for clients in the defence industry.

VICTORIA Richard Weinzierl, Founder and Managing Director of Australian Precision Technologies (APT), outside his company’s facility in Berwick, Victoria.

– it’s fantastic,” says Weinzierl. “We can ring up and have stock delivered same day, and crucially they hold stock for us, which is very helpful. Without the support of Dimac our CNC machines just wouldn’t run. They’re a one-stop shop; everything that we need to support our production we buy through Dimac.”

APT has had a close association with Dimac for more than 20 years.

In addition to Lang Technik products, other products that APT has purchased through Dimac including the Mitee-Bite workholding tools, Dimac’s own Australian-made soft jaws, and high pressure coolant equipment. “Dimac’s service and advice is second to none

APT is currently working towards gaining ISO 9100D accreditation. This will open up new markets including the aerospace industry, and APT is already in discussion with a number of leading companies in this specialised sector. Given the expertise and knowledge that APT has, defence will continue to be APT’s main focus, but in the future other markets such as renewable energy are also likely to be part of the company’s portfolio. One thing’s for sure: APT will continue to be a leader and a dominant force in precision manufacturing far into the future. www.dimac.com.au www.aptengineering.com

Melbourne set for 2019 Australian Technologies Competition finals Australia’s premier platform to accelerate technology scaleups and SMEs with global potential – the Australian Technologies Competition (ATC) – is heading south this year, to Australia’s burgeoning tech centre – Melbourne.

Now in its ninth season, the ATC is a national competition to recruit, spotlight and promote commercially attractive SMEs to a global audience, providing a platform for recognition, mentoring and acceleration support and an avenue to meet potential partners and investors. This year 33 semi-finalists have been chosen from a pool of 206 entrants, comprising of high-growth potential companies from across Australia.

Victoria is represented by: AgriNous, Aspire, Navi Medical Technologies, Tournicare and Unpackaged Eco. Having been staged in Sydney for almost a decade, the 2019 national awards and finals will be held in Melbourne thanks to welcoming sponsors and hosts: the Victorian Government’s Department of Jobs, Precincts & Regions (DJPR) and Department of Environment, Land, Water & Planning (DEWLP).

Victorian Minister for Energy, Environment & Climate Change Lily D’Ambrosio remarked: “We have an international reputation for fostering innovation in new energy and environmental technologies here in Victoria. Chargefox electric vehicle charging stations are capable of delivering up to 400km in 15 minutes, and our Microgrid Demonstration Initiative supports nine projects that explore opportunities for new energy markets across the state. We’re proud to host the ATC and share our expertise and city with our guests.”

Patrick Mooney, Chairman of Impact Tech Ventures and organiser of the ATC, echoed these sentiments: “Victoria has always been a strong participant in the ATC, particularly in the fields of advanced manufacturing, new energy, smart cities, medtech and global social impact. This is a wonderful opportunity to spotlight Victoria’s enterprising tech scale-ups and the entrepreneurial ecosystem thriving here in Melbourne.”

According to InvestVic, Melbourne is now home to more than half of Australia’s top 20 technology companies. The ICT industry operating in Victoria generates more than $36bn in revenue each year and employs close to 140,000 people.

Last year, several Victorian companies reached the top of the Competition leader board as both finalists and winners. They included: innovative biotech company AdAlta (winner of the 2018 Medtech & Pharma Award); Geelong-based Capricorn Power (Winner of the 2018 New Energy Award); Anatomics, a medical facial implant manufacturer; Ynomia, an Internet of Things (IoT) company solving construction headaches; and Kesem Health, developer of a patented device to assess urinary issues.

The ATC will host a Partner Connect event in Melbourne on 28 October, introducing overseas corporate partners, investors, high net worth individuals and venture funds to ATC finalists and alumni.

On 29 October, the ATC national finals and Awards Ceremony will take place at the landmark Melbourne Cricket Ground (MCG), with more than 200 guests expected in attendance.

This year, entrants in the ATC compete across ten key industries, ranging from advanced manufacturing, cyber-security, food & agribusiness, to new energy, global social impact and circular economy. This year’s cohort of 33 semi-finalists were selected by a panel of 14 expert judges who earmarked those companies possessing technology/solutions with the greatest global potential.

“In addition to Australia’s high-value industries, we’re providing a platform to showcase innovative technology with global social impact,” said Mooney. “Australia is full of incredible innovators and problem-solvers with technologies that can be transformed into great commercial success stories.” www.austechcomp.com

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COMPANY FOCUS

Bastion Cycles – Bespoke bikes, advanced manufacturing Somewhere in the story of Bastion Cycles is a joke about how many former automotive engineers does it take to create the world’s first market-ready 3D printed bespoke bicycle? The answer is three, and the tale is even better when you learn they pooled their redundancy packages from Toyota to form a company now leading the field in advanced bike manufacturing only a few years after its launch. By Dee Rudebeck.

Bastion makes the bike frame from carbon fibre tubes with 3D printed titanium joints, with an internal lattice-like structure providing strength while minimising weight.

After the R&D specialists were handed their notice from Toyota in 2014, they sat down and nutted out a new business concept. Bastion Managing Director Ben Schultz recalls how he and his co-founders, James Woolcock and Dean McGeary, wanted to incorporate their three passions: cycling, leading-edge manufacturing and Australian-made production. All keen cyclists, it was a classic case of creating the bike they wanted to buy but which didn’t exist. Bastion empowers the rider to design their own adjustable bike that is a unique fit not only to their desired specifications and aesthetic preferences, but the physical capabilities of their own body with all its ticks and quirks.

Bastion shares the industrial warehouse it occupies in Fairfield, north-east Melbourne, with three other specialised bicycle-related companies. Schultz says they think of it as an advanced manufacturing bicycle hub because, though there are synergies between the businesses and they send each other work, they share the space because none of them could afford to be there independently otherwise. This cooperative approach is an intriguing part of their business model, and just one of the ways Bastion likes to do things differently.

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When a cyclist commissions a bicycle from Bastion, they should not expect the experience they might have purchasing a bike from one of the well-known larger manufacturers. They won’t enter a flashy retail store and view scores of factoryfresh bikes, choosing a few to test-ride and deciding which one they want to take out the door with them. At Bastion, after an initial chat with Schultz or Woolcock about their requirements, they will spend the next 2-3 hours at Riderfit, one of Bastion’s companion companies at the front of the building. There, they will be put on a physiotherapist’s table to address any injuries or asymmetries they may have before having their physical data measured and recorded.

a suit-tailoring analogy: “There is custom clothing where a tailor will measure your body dimensions and then take a pattern and size it, and then there’s the full bespoke suit service where they’d cut a pattern, pin it on you and do three or four fittings and checks, where they’d get you to twist and bend to make sure it’s not bunching up anywhere – that’s the level we work at.”

“We don’t just measure the customer’s arms, legs and torso length, then make assumptions about the bike size that will fit them,” Schultz says. “Two people who have the exact same body dimensions could need totally different bikes. That’s because of their flexibility or injury history, and asymmetries in their body that they didn’t even know they had.”

“The majority of the discussion is probably around the paint job – what colours and designs to choose,” he explains. “Some people like to keep it raw and let the materials shine and others paint the entire frame.”

So one leg might be shorter than the other or a rider’s hip rotation might mean one leg pedals differently to the other. Schultz uses

Riderfit will analyse how all the customer’s data comes together while watching them pedal an adjustable bike frame in the workshop. There is then further detailed discussion about component specifications and performance preferences, but Schultz admits that it’s often not the highly advanced technical manufacturing options that get some clients excited.

The paint job is done once construction is completed in the back of the building at another of Bastion’s companion companies: Bikes by Steve.

Bastion aims to arm the customer with as much information as possible to ‘precision

071 Bastion Managing Director Ben Schultz.

road or wind noise. Your brain filters it out – you can still have a conversation – but your brain is still processing it.

craft’ their bike. Based on their consultation, Bastion provides them with a four-page report that contains graphical representation of how the bike will handle, comparing it to other bikes on the market or bikes they’ve owned before to illustrate how a certain geometry or spec will make the new bike quicker or more agile, for example.

The tailoring service is not all that’s unique, Schultz adds: “We were the first company in the world to bring a fully internationalstandards tested, commercially available, 3D printed bicycle to market. People had used the technology in bikes before but purely at a design concept or universitystudy level. Although the price point is high, it’s been received by the market. There is literally no one else in the world making bikes the way we make them.”

Bastion uses carbon fibre tubes to make the bike frame, but with titanium joints created using 3D printing technology that enables a lattice-like internal honeycomb structure, allowing strength while minimising weight.

Bastion’s printer, a Renishaw AM250, is kept busy, running 24 hours a day, six days a week. It uses aerospace grade Ti6Al4V titanium alloy powder and a high-powered precision laser to weld layer on top of layer in a pattern governed by a CAD design to build three-dimensional shapes.

“The advantage of titanium is that it delivers a much nicer ride comfort and quality,” says Schultz. “So there’s a performance benefit for no weight increase. It’s got to do with the level of damping and compliance in the material.”

This is where the team’s automotive backgrounds come to the fore: “When you are in a car or a bike, there is road noise.

It’s a very small but high-frequency vibration as the tyres are rolling over the rocks in the asphalt. Titanium is much better than carbon fibre at isolating and smoothing out that vibration or lessening it.”

The science of smooth cycling So why does smoothness relate to feeling fresher at the end of a ride?

“It’s because after you’ve been on an allcarbon fibre bike for five minutes, you don’t notice the vibration any more but your brain is still processing it,” Schultz explains. “When you’re in a car, it’s the same if you have that

“It’s that constant processing of stimulus that tires people out. It’s been proven in studies in cars and aircraft. They try to minimise it so pilots don’t get tired. People in passenger seats get cranky because of this constant noise. So it translates to a bike. But we’re not Boeing or NASA; we haven’t done the peer-reviewed studies to prove it yet.”

That said, Bastion is in talks with RMIT University this year to design such a scientific study to quantify this anecdotal finding.

“I know from my experience at Toyota that it’s a very difficult thing to quantify but we’re going to try,” Schultz adds. “Subjective feedback from more than 100 customers, from ex-professionals through to beginner riders, is that Bastion bikes are smoother than their current bike. It’s definitely there, we just have to figure out how to measure it.”

For such a young company, there have been a number of milestones on the road to sustainability.

“The first sale in 2016 was pretty exciting,” says Schultz. “We had a 30% discount on the first five bikes and they sold in two days.

And none of those people had seen one.”

Apart from bringing the 3D printing inhouse earlier this year, the other key decision Schultz and his co-founders made was partnering with 16 bike fitters and retailers around the world, as 70% of their business is now exports.

There are a couple of other bespoke bike makers in Australia and while Schultz is confident of Bastion’s appeal, his main concern is that this small market keeps growing for all of the manufacturers here: “What we really want is for more people to not buy a standard production bike out of China and buy something locally made and bespoke. The more people who start to make that jump, then their friends will buy them and their friends. And some of them will come to us.”

There are only hundreds of people each year who buy bespoke, but tens of thousands of people buying bikes from the big brands, whose top-of-the-line models might cost $15,000 or $16,000. Bastion bikes start at around $13,000 but most customers spend around $18,000.

“So that’s only a 10% jump to get something from us that is tailored to you,” Schultz adds. “We just need to get in front of some of those people because we don’t have the

marketing budget that the big brands do.

We can’t sponsor a Tour de France team when they need 200 bikes every season.

We haven’t even made 200 bikes yet. We’re still only four years in, we’re still on that uptake of the early adopter curve, although sales have gone up this year.”

So what’s in the pipeline for the future?

Bastion has just received a grant from the Advanced Manufacturing Growth Centre (AMGC) to support development of their next model, which will be a lot more innovative – though Schultz isn’t able to elaborate more. To build the bike, they’ll have to come up with a series of new processes and technologies. It’s an exciting time at Bastion as the trio return enthusiastically to their R&D roots.

Bastion also operates a consultancy arm specialising in design for additive manufacturing and bespoke engineering solutions. This element of the business has been bolstered by the ability to print titanium parts in-house, and is already producing components for five other bike builders globally. Bastion is also producing custom high-performance parts that are used by the Australian Olympic track cycling team.

So it seems Toyota’s loss is the bespoke bicycle world’s gain.

“Yeah, I love it,” says Schultz. “I wouldn’t do anything else now. I just love it.”

He does it in family-friendly hours too, leaving at 3pm most days to pick up his child from school. Woolcock also works from home one day a week and looks after his pre-school-age daughter. The work often has to resume once the families are in bed, but nonetheless Bastion’s cofounders have built a successful business, created their dream jobs, and achieved a happy work-life balance to boot. If only all redundancies turned out so well. www.bastion-cycles.com

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INDUSTRY 4.0

thyssenkrupp ‘keeps calm and carries on’ with alfred AI solution Alfred Krupp founded his company in 1811. Now, he is the namesake and inspiration for an artificial intelligence (AI) solution built by thyssenkrupp Materials Services (tkMX) – one of German industrial giant thyssenkrupp’s strategic business areas, tkMX is the largest materials distributor and service provider in the Western World.

The alfred AI solution, powered by Microsoft Azure, helps the company analyse and process more than two million orders per year and better serve its 250,000 global customers. alfred is already helping tkMX optimise its logistics network – allocating materials to the right location much faster, minimising transport volume and enhancing usage of the company’s transport capacity.

Axel Berger, Head of Digital Transformation at tkMX

Axel Berger, Head of Digital Transformation at tkMX, discussed how alfred is changing the business.

AMT: Tell us about alfred and why tkMX developed it. What business challenges were you facing?

Axel Berger: We are a wholesaler, so data insights and data algorithms are possibly one of the strongest levers we have to improve our business. We had a lot of data that we weren’t using before, for three main reasons.

First, we didn’t really have the expertise to work on specific data science topics – we had the data, but it wasn’t always available.

Second, data quality was an issue. And third, we lacked the technology to store data in different formats to use it and make it available in one central location on a massive scale. We also lacked the related tools to really analyse it, visualise it and finally, build algorithms out of it that could be deployed in different scenarios.

There are many possible use cases for wholesalers, and it took us a long time to pinpoint the use case that we should implement first. The major topic we’ve focused on is network optimisation. How can we optimise, for example, transport costs or our supply network? How can we reduce the stock that is delivered from A to B without sacrificing our service levels?

So the first project that we’ve worked on is network simulations within our German trade network.

It’s important to note that alfred is growing through its use cases. We didn’t create a huge global platform that could do everything. The first use case requires a specific amount of data, computing power and certain tools. But with additional use cases that we are now implementing, alfred is growing.

AMT: You developed alfred internally. Can you tell us a little about that?

AB: alfred came to life in early 2018. The

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biggest challenge was definitely data availability. You can have the greatest technology, the best tools, but the biggest challenge is to get quality data. Another challenge is to have the domain knowledge, the expertise in the specific topic to really make it relevant.

Everybody’s thinking that if you just use data and artificial intelligence, in the end this artificial intelligence will give you the insights that you don’t know yet. But that’s not happening. It’s about having the right data of the right quality, the expertise and the domain knowledge on a specific topic, and the technology to run it. Technology is the easy part, because nowadays there is someone like Microsoft with the technology.

But to bring data and domain knowledge into the project and to understand the use case and the questions you are trying to answer, that is the hardest part.

AMT:: What might alfred do over the course of one day?

AB: There are so many things that alfred can do! alfred dynamically tells us from which site we should ship which material to which customer. alfred optimises our stock levels. alfred tells us what the perfect price for a specific customer for a specific product is. alfred visualises and tells us which customers are profitable, and which customers are not.

alfred can help us build a predictive maintenance model for our machinery, and tell us which machine is about to break. alfred also helps us to optimise our supply network in terms of physical sites – where should we open the next site or close it down, and which materials should be subbed somewhere else. It helps us to get better purchase prices because it helps us in negotiations and the bundling of materials that we want to purchase. These are all current or potential use cases.

AMT: Obviously it’s still evolving, but what is the biggest benefit alfred has had on your business?

AB: We handed over decision-making to alfred (a machine) that relies on data.

One of the taglines that we use for alfred is “intelligence in each transaction,” which means that we want to build decision engines. alfred already delivered the first decision engine: the system tells us from which location the customer is to be supplied, taking into account all relevant frame data. That was our first decision engine, you could say.

AMT: What has been the employee reaction to alfred? Have they embraced it, or was there some resistance?

AB: People weren’t resistant to alfred, because right away we could show them

INDUSTRY 4.0 and decision-making capacity to machines?

I studied mechatronics some 25 years ago. With mechatronics you were already talking about cyber-physical systems and programming and automising machines. So IoT is nothing new. It’s just the technology has evolved and that gives us new opportunities.

When you look at artificial intelligence, the methodologies are out of the 1940s, 1950s – neural networks, for example.

It’s nothing new. It’s all about cheaper storage, more computing power and better connectivity, but also about standardisation and harmonisation of data. And if you come back to that point, you realise it’s feasible to cope with it, because we’ve been able to cope with it for many years. how alfred would help them in their daily work, and the benefits we’d gain. With the use case we’ve been working on, alfred doesn’t imply any layoffs or redundancies. It is purely optimising the way we are working, and helping to enhance the impact our employees are driving. So alfred is seen positively.

AMT: Did you do any training to prepare employees for alfred?

AB: Yes, absolutely. We helped them, trained them, involved them in the process very early. We trained them in the tools.

What we are also planning is to deploy data labs, small versions of alfred, so people working on a specific data problem can use alfred to solve their own problems with just a push of the button. We teach them how to do this – how to use Microsoft Power BI, for example, to visualise their own data. That helped a lot because they started to work with data and to better understand what it’s all about and how it can be utilised.

AMT: How else has alfred helped your employees achieve more and optimised their work?

AB: alfred has helped employees by enabling them to simulate tkMX’s network setup, which was extremely difficult before because our network is extremely complex.

It has helped with data availability – the employees have much more data that they can now access themselves, without involving anybody from data warehousing.

And obviously by increasing data transparency.

AMT: Have new roles or opportunities opened up to support alfred?

AB: Yes, of course. Roles like data engineering, data architecture, data science, solution designers – these are all new roles that we staff now.

AMT: What advice would you give other companies that are considering launching an AI initiative?

AB: I’d like to shift the focus away from the buzzword “AI” and better discuss

what’s behind it. I don’t believe that there is an artificial intelligence as such. We have focused algorithms.

AMT: You talked about what alfred is doing now. In 10 years, where do you want the platform to be?

In other words, what I would recommend is to calm down and don’t be afraid of AI, because the methods are 60 years old.

What has changed are the opportunities that advanced technologies such as cloud and edge computing provide and the pace at which they evolve. So, businesses need to get used to these new technologies, and use technology that is easy to handle – like Microsoft Azure. With Azure we can quickly launch applications that can be used for data aggregation, manipulation and analysis with the click of a button, with only a few people in the beginning.

AB: Technology is evolving so fast, it’s hard to foresee. Do you know the saying ‘The appetite comes with eating’? It’s like when you’re working on a project, you’re finding new data insights, new data points that give you the motivation to go to the next step.

So I am convinced there will be so many more use cases in the future that I cannot foresee right now.

To start, I would recommend taking data, searching for your first use cases, and just building them without engineering them forever. Clarify the questions you want to answer. Don’t believe in overarching algorithms that will solve the problem of finding the question, the use case. Because otherwise everybody is expecting results for something that you don’t even know is a problem.

AMT: Based on your experience, what concerns or rewards do you see for society as AI becomes more ubiquitous?

AB: Again, I would say calm down and get in touch with the methods and technologies behind AI. People are fearing things they don’t know. If you get in touch with it and understand what’s really behind AI, then I think it’s easier for people to understand that we are far away from real artificial intelligence. We see specific use cases, specific technologies to solve specific problems, but nothing like a mastermind.

It’s important to talk about AI and engage in the public debate, because with the evolving technology around machine learning and AI, there are questions to answer, including both ethical and legal questions. For example, the much-used example of an autonomous car. How do we cope as we give more and more autonomy

I will learn, we all will learn, the machine will learn. We will get more and more data created out of the data that we already have – other data sources, third-party data and so forth. So right now, I cannot foresee all the use cases we will see in the future. We will work under one paradigm, which is ‘Intelligence in each transaction’.

Over time alfred will also take decisions in our ERP system automatically. In average transactions that we do, we would like to have more intelligence, and alfred will help us with that.

I’m a great believer in removing the mystique of buzzwords like AI and focusing on what’s behind it instead – helping people and companies understand the technologies and methods that help us make our businesses as well as our personal lives easier and better. It’s part of my role, but I also believe that digitalisation is a bunch of buzzwords. If you ask someone at a conference what you really mean by digitalisation, most people will get very thin in their answers. Why? Because they don’t really know, because they are looking at digitalisation from a huge height.

I think if you really want to go beyond the buzzwords, you really need to go into the use cases and the business, and you really need to redefine the opportunities. So I am trying hard to get out of these buzzwords and really get down to the use cases. www.microsoft.com www.thyssenkrupp.com

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Unlocking the benefits of intelligent technology for Australian manufacturers Industry 4.0 is in full swing and Australian manufacturers can benefit significantly from intelligent technology, if integrated into their business in the right way. By Greg O’Loan.

Industry 4.0 refers to advanced manufacturing technologies including the Internet of Things (IoT) and artificial intelligence (AI). It also facilitates new ways to apply old concepts such as automation and robotics, both of which have long been used in manufacturing (with outstanding results).

Embracing emerging, intelligent technology is essential for Australian manufacturers to compete effectively in a tough globalised environment. While the manufacturing industry in Australia has recently returned to growth, strong competition from overseas manufacturers remains a concern for local firms. Manufacturers in this country tend to have higher costs in terms of energy, labour, materials and logistics, compared with overseas competitors.

One of the ways to potentially overcome this disadvantage is to embrace smarter technology, such as IoT or AI. For example, one manufacturer has used cloud-based analytics and IoT to reduce equipment inspection times by 100%. This helped the company avoid a potential cost of $361 per second for downtime caused by manual inspections. This illustrates the enormity of savings that could be delivered by this type of technology.

Lower fault rates can mean manufacturers spend less time on corrections and more time on producing saleable products. The data provided by IoT sensors can help manufacturers identify bottlenecks or inefficiencies and remove these for a more streamlined process.

It is even possible to identify new revenue opportunities and offer customised, unique products that further set the manufacturer apart from its competitors.

Many manufacturers are already aware of the potential presented by intelligent technology. Epicor research indicates that manufacturers believe the industry is either on the verge of large-scale IoT adoption or at least experimenting with the idea. According to the survey, 79% of manufacturers already have IoT sensors on their machines and 42% are using IoT technology to control and work with robots. Asia Pacific manufacturers are savvier than those in other parts of the world, with 73% saying they’re well informed about IoT, compared with 43% in Europe, the Middle East and Africa (EMEA).

One barrier to implementing this type of technology, however, is that measuring the benefits isn’t always straightforward. Almost three-quarters of the manufacturers surveyed by Epicor said they hadn’t yet measured a real return on IoT investments. Numbers like these can make manufacturers nervous about investing in intelligent technology, since a strong business case and demonstrable return on investment are key factors.

To maximise the benefits offered by intelligent technology like IoT and AI, manufacturers must pair them with enterprise resource planning (ERP) systems developed specifically for the manufacturing industry.

This pairing can help manufacturers extract deeper, more meaningful insights from the data provided by IoT sensors, for example.

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Real-time business intelligence systems, built into modern ERP solutions, can help manufacturers gain a microscopic view of their operations.

This can help them extract every single last opportunity for improvement and deliver an outstanding customer experience that sets them apart from competitors. Getting that same level of insight using older reporting tools simply isn’t feasible.

Furthermore, modern ERP systems are far more capable of integration with emerging intelligent technologies than their older predecessors. This reduces the risk of adopting new technologies and increases the speed with which manufacturers can start to see results.

Consequently, running pilot programs can get quick wins on the board, which can then scale to the broader business.

When IoT is effectively integrated with ERP systems, manufacturers can realise significant benefits beyond speed, accuracy, and customer experience. For example, they can effectively measure the daily performance of their operations down to each individual machine. This can let manufacturers understand how well their equipment is being utilised and it can provide opportunities for predictive maintenance, which reduces the amount of downtime in a production facility.

The vast quantities of valuable data that can be collected by IoT sensors can only be useful when it’s analysed and the insights are used to determine actions that will deliver results. While most manufacturers already rely on an ERP system of some kind, it takes a modern, preferably cloud-based ERP system to fully leverage the benefits of intelligent technology.

A modern ERP solution with business intelligence built in can more effectively manage the onslaught of data triggered by IoT sensors, turning data into insights, and insights into actions. Importantly, modern systems can provide these insights in near real-time instead of as part of a batched report at the end of the month or the end of the quarter—when it’s too late to see any benefit from changes.

Cloud-based solutions are also valuable because they eliminate the cost and burden of managing on-premise solutions that can be challenging to upgrade. This means manufacturers can access the latest functionality without the cost and risk of a monolithic solution upgrade.

By combining IoT and ERP, manufacturers can unlock significant benefits to help them compete more effectively in an evolving landscape and continue to grow their business. Importantly, the addition of ERP overcomes return-on-investment challenges associated with emerging technologies, resulting in measurable improvements for the business.

Greg O’Loan is the Regional Vice-President, ANZ for Epicor Software Corporation. www.epicor.com/australia

INDUSTRY 4.0

Seven reasons to choose manufacturing control software With the advent of Industry 4.0, manufacturers are increasingly investing in advanced technology to achieve their smart factory ambitions. A game changer in this area, manufacturing control software is having a big impact on processes and easing workloads.

Are you considering implementing manufacturing control software but are unsure of the applications? Or have you just heard about it and want to learn more? Here are Headland Machineryâ&#x20AC;&#x2122;s top seven reasons why you should choose manufacturing control software:

1. Improved planning processes While the product is being manufactured, the materials used are tracked to allow you to order materials in advance instead of realising too late, creating a smart manufacturing process.

2. Reduced cycle times Through the use of manufacturing control software, manufacturers have greater visibility and control of the order process from step one right through to completion and the final shipment. By having all steps in the process automated, scheduled and with materials in full supply, there is less chance for scenarios to crop up that would delay the manufacturing process, hence reducing the cycle times.

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3. Improved product quality Every part produced is done so via a formal build plan comprising a set of digital work instructions at each stage of the manufacturing process. By sticking to this plan, optimum quality is ensured.

4. Shorter lead times How many production delays have there been as result of parts not being available at the assembling station? Manufacturing control software tracks parts automatically throughout the manufacturing process, putting an end to a cycle of poor organisation.

5. Minimised waste Keeping waste to a minimum is a common challenge for project managers. By controlling production, manufacturing control software can identify occurrences of waste and implement a strategy to reduce the amount of waste produced. In addition, the software can also keep track of machine downtime and maintenance, ensuring that a steady flow of output is achieved, and eliminates any areas of wasted productivity.

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6. Cost savings Operating costs are undoubtedly one of the largest costs in the manufacturing process, in terms of running equipment, hiring employees, maintenance, and countless other factors within the factory. By utilising manufacturing control software, you can reduce many of these costs by eliminating reasons for error, maximising materials, and operating in a smart way.

7. Advanced planning & scheduling You can efficiently optimise production within your factory through the use of the technology available. This can also be taken a step further by integrating your software with your enterprise resource planning (ERP) systems, solving bottlenecks in the process, improving delivery performance, reducing inventory, and more. www.headland.com.au

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Improving the life of the line Eckhart, a US-based leader in advanced industrial solutions, has positioned itself at the forefront of Industry 4.0 through its application of cutting-edge technologies such as additive manufacturing.

Based in Warren, Michigan, the company is committed to improving the lives of factory-floor workers through safety, reliability and efficiency in manufacturing, for industries ranging from medical devices to automotive.

This 3D-printed lug nut starter is a lightweight solution that improves ergonomics and assembly speed.

“Industry 4.0 is really the ecosystem that is a smart factory,” says Andrew Storm, Eckhart’s CEO. “It takes all of the systems in a factory, ties them together to help not only those who manage the process, but also to help the employees on the factory floor become more informed on the health of the system.”

“Ninety percent of Fortune 500 manufacturing CEOs believe adopting Industry 4.0 technologies is imperative,” adds Dan Burseth, Vice-President of Eckhart. “And we build technology implementation plans with some of the largest manufacturers in the world, designing tools, equipment and automation that truly improve the life of the people tasked with running the line.”

Customised, proven additive solutions Eckhart develops customised factory floor solutions to address the specific needs of each client, walking the floor to see exactly where ergonomics, line of site or bill of materials can be improved using autonomous guided vehicles, collaborative robotics and additive manufacturing.

“Our customers want proven solutions, durable solutions; the assembly environment is harsh,” says Bob Heath, Additive Manufacturing Applications Engineer at Eckhart. “These tools are being used 60 times an hour for an eight-hour shift, three shifts a day, six or seven days a week. With Stratasys engineering-grade materials, Nylon 12 with carbon-fibre and ULTEM 1010 resin, we are able to produce durable, lasting solutions that can hold up and withstand the rigours of an automotive environment.”

When working to streamline production for their leading industry clients, from Ford to Mercedes to Airbus, Eckhart has shown how additive manufacturing with Stratasys materials greatly improves the way things have always been done.

“Traditionally, we had to design our parts around the way we were going to manufacture them,” says Heath. “Whether it was manually machining or CNC machine, our part design was limited to our manufacturing capabilities. But with additive manufacturing, the complexities and capabilities are limitless.”

Many of Eckhart’s clients have seen great benefit from small tweaks to their processes, adopting 3D-printed jigs or fixtures for applications such as a lug nut starter, badge alignment tools and wiper alignment set fixtures.

“Pressing on badges, emblems on vehicles – these things are repetitive tasks,” Heath explains. “When we go into plants and we pick up a badge tool, and it’s heavy, it’s either above or right at that ergonomic limit for the operator to be able to pick up 60 times an hour. So we’re alleviating the repetitive injury strain on the operator.”

“We provide solutions that are not replacing operators but are making up for the operators they can’t hire, or projecting the ability of one operator so that one can be the same as five,” adds Drew Morales, Director of Business Development and Engineering Systems at Eckhart. “And additive manufacturing is one of the tools that we have to facilitate that.”

Partnering for a streamlined future Eckhart recognises time and innovation are top priorities, and all businesses are under an extreme amount of pressure to iterate faster. Eckhart sees this across the board, from heavy truck manufacturers like Caterpillar, to medical device manufacturers such as Medtronic and Boston Scientific, to aerospace manufacturers including Boeing, Airbus and Lockheed Martin.

“We feel very strongly that 3D printing is the catalyst that allows businesses to test hypotheses much faster than they’ve ever been able to before,” concludes Storm. “Speed and customisation ultimately is empowered through the use of 3D printing.” www.eckhartusa.com www.objective3d.com.au

Eckhart’s Advanced Technology Centre in Warren, Michigan.

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Eckhart uses jigs and fixtures for GrabCAD Print software to design new tooling with speed and ease.

Explore your unlimited possibilities additively The Additive Manufacturing Hub is a $1.85m programme that will grow and develop additive manufacturing capability and investment in Victoria. The vision of the AM Hub is to provide an industry-driven network of users, suppliers and supporters that will foster and grow the use of Additive Manufacturing technology in Australia. + Promote and market additive manufacturing sector capabilities. + Expand the knowledge base of additive manufacturing technologies. + A grant programme for Victorian businesses to encourage adoption of additive manufacturing technologies. + Support the creation of high quality additive manufacturing jobs. + Be a voice to Government on additive manufacturing sector development.

Companies looking to explore the potential of additive manufacturing, or further expand their use of the technology should register interest via email at amhub@amtil.com.au

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Harnessing Industry 4.0 for quality inspections and assembly ‘Industry 4.0’ is quite possibly the manufacturing world’s most frequently used buzzword of the 2010s. While it is clearly more than just the flavour of the month, the phenomenon still has some ways to go before it gains complete acceptance across the globe. By Jutta Mayer.

For most people, Industry 4.0 mainly refers to the Internet of Things (IoT) — the fact that every piece of equipment is interconnected, and how they have the ability to ‘talk’ to each other. True as that may be, the other principles that characterise Industry 4.0 are just as definitive – if not more so.

The increased connectivity that modern technology brings enables information transparency, which allows the collection and sharing of vast amounts of data. Industry 4.0 is also characterised by decentralised decisions, where cyber-physical systems act as autonomous agents within its dedicated scope, performing tasks without the need for human intervention, and where humans are still required, Industry 4.0 has shifted their role — from operator of machines to problem-solver — through the use of technical assistance systems.

What constitutes technical assistance anyway?

Designed to aid operators in their role as decision-makers, assistance systems typically offer either physical support on dangerous, strenuous tasks, or they provide crucial information to enable better decision-making.

Examples of physical support systems include collaborative robots that take on the heavy-lifting parts of a task; exoskeletons to eliminate fatigue and injury; and headsets that optimise order-picking routes to save time and cost. On the other hand, informational support systems include wearables that alert operators to machine faults; tablets or glasses that offer step-by-step guidance on installation or assembly processes; and carriers that provide instructions on assembly, and transport the tools and components required.

In the context of the manufacturing environment today, both types of technical assistance systems play a vital role in alleviating production challenges. While Industry 4.0 may seem like a daunting endeavour to undertake, exploring and implementing technical assistance systems is one relatively uncomplicated way for companies to enter these unchartered territories, and to leverage technology benefits.

Streamlining tool and fixture building One such instance of technical assistance is in virtual inspection, in particular for tool and fixture building. Often, in early phases of prototyping, companies would be developing tools, fixtures, or assemblies where not all the components of the whole are in place just yet. However, quality inspection early on in the process is still necessary, in order to ensure that everything eventually fits in its allocated position. Otherwise, any changes that may be required in later stages can incur additional costs and cause delays with prototypes and pilot lots, with the risk of pushing back production timelines for final inspection, approvals, and series production.

To circumvent that challenge, manufacturers can employ augmented reality software to conduct virtual inspections using CAD data. Advances in mixed reality technology have made it possible for an assembly, a tool, or part to be virtually examined in detail, even with an incomplete set-up. Missing elements — such as the prototype for which a tool will be used — can be represented by a virtual instance based on its CAD data. Through an overlay, the virtual object can be inserted into the software to see how it fits with the existing elements.

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FARO Visual Inspect AR enables the intuitive viewing of complex 3D data for (virtual) quality checks of parts and assemblies – even in early stages of an assembly process.

This way, any difference between the actual and the intended, targeted set-up can be identified, documented, and fixed early on.

The information gathered by the system can also be documented and shared with team members and stakeholders located anywhere in the world, which enables better collaboration.

Manufacturers who choose to rely on such technical assistance systems stand to gain time- and cost-savings, as any problems with quality can be identified and fixed early on in the process, even before the first prototypes arrive for physical ‘real-world’ testing.

By eliminating transfers to-and-fro, companies can ensure a quick transition from the first prototype phase to pilot lots, and series production.

Simplifying templating and positioning Another scenario where manufacturers can easily introduce technical assistance to embark on their Industry 4.0 journey is in welding assembly and verification. Most basic welding jobs will see technicians rely on blueprints, tools, and tape measures to join and build the parts. While these traditional methods have worked well in the past, companies have also lived with the high levels of error and its associated costs — owing to rework, scrap, and lost time.

Originally used in the aerospace and defence industries, laser projection has since been made available to automotive, heavy equipment, and machine shops. The system utilises 3D CAD data to generate a series of specific points and create a projection outline on a surface. Using advanced optics, galvanometers and high-precision mirrors, the laser beam “draws” images onto a surface (which need not be flat) and the high-speed motion of the laser beam creates what appears to be a continuous line to the human eye.

INDUSTRY HEADING 4.0 Jutta Mayer

Innovative laser imaging and projection solutions such as the FARO Tracer SI Imaging Laser Projector help welders increase throughput by accurately guiding the placement of each part.

This means that manufacturers can evaluate placement and adjust alignment as the project progresses, not just afterwards when the welding has already been completed. For technicians, the ability to assess their work and take appropriate corrective action before investing further effort is invaluable, as it prevents a situation where the end result becomes a flawed assembly.

Using 3D laser projection or 3D laser imaging systems, manufacturers can achieve significant improvements in efficiency and accuracy, while eliminating physical templates all at once.

Instead of blueprints, operators can simply follow a sequential guide through the welding process. Such systems provide clear instructions to users each step of the way, and are capable of indicating where to place each component and feature â&#x20AC;&#x201D; down to the detail of each weld bead or hole. This eliminates the risk of less experienced employees welding onto incorrect positions, allowing manufacturers to ensure alignment accuracy every single time.

As Industry 4.0 continues to unfold in the years ahead, most businesses will recognise the need to roll with the punches and not be left behind. Technical assistance systems offer manufacturers tangible benefits of better quality, improved efficiency, and cost savings, and those that choose to adopt suitable solutions will stand to gain an edge over their competitors in this new era.

A virtual templating solution removes the need for physical templates, and also the time and expense associated with the usage, including design, build, maintenance and storage. In addition, an advanced 3D laser imaging system enables in-process verification (IPV) to be performed after any step of the welding and assembly sequence.

Jutta Mayer is a Product Marketing Manager (3D Manufacturing) with FARO Technologies. www.faro.com

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World of simulation Simulations and digital twins are revolutionising the way we think about the development and deployment of products.

By Marek Florkowski and Daniel Szary of ABB Corporate Research, and Andreas Moglestue of ABB Review.

The phrase “all is number”, attributed to Pythagoras, is more pertinent now than ever before. Numbers enable us to capture and process physical magnitudes, be they positions, temperatures, flow rates, field strengths and many other quantities.

A vast inventory of ingenious methods exists for measuring – or describing – the physical world using numbers. The age of computing has added a new, highly versatile tool: simulation.

Simulation permits the inference of data that is not directly available for measurement.

It is possible, for example, to gauge the temperature deep inside an object from measurements of the surface temperature combined with physical understanding of what is happening inside the object. The inaccessibility of a measurement point must not be strictly spatial. The data of interest can also be in the future, or even in a system that has not physically been built.

Compared to physical testing, simulation can deliver huge savings in time and costs, as well as avoiding waste and potentially dangerous situations. Physical laboratory testing incurs a considerable time latency due to the need to prepare and build test samples and set-ups, constraints imposed by the capability and capacity of the lab, not to mention inflexibility should developers request a last-second modification. In a design process requiring numerous iterations, each having to await the results of the previous test, such a time penalty can be immense.

Time and cost advantages apart, simulations permit a far broader range of variants to be studied. Product developers have more scope to be innovative, can test a far greater number and combination of variants, and can experiment with unorthodox approaches. The result is a more optimised solution. In some cases, simulations are the only viable way to verify a design because physical tests are not realistically feasible – for example large-scale seismic tests. Today, almost all aspects of a product’s lifecycle can be simulated: manufacture, virtual testing, transportation, regular operation, aging, harsh environmental conditions, and so on.

ABB makes broad use of simulation in product development, across a wide range of fields including electromagnetics, thermodynamics, mechanics, fluid dynamics and material science.

Increasingly, simulations combine several of these domains and capture not only the sum of their effects but also the coupling

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and interactions between them, in what are called multi-physical simulations.

Progress in simulations The field of simulation has advanced significantly in recent years. Capabilities quite recently considered wishful and futuristic are now tested and proven components of the simulation toolbox.

Major drivers in advancing the capability of simulations have been growth in computing power and speed as well as affordability, but also ease of use. What would have been a major, processor-hungry job 25 or 30 years ago can now easily be completed in less than half an hour (plus preparation of the model). Besides the overall increase in speed, today’s simulations can take a larger number of variables into account, adding to the overall accuracy of the simulation.

Further to the hardware and cost aspects, there have been considerable changes in the roles of simulation engineers. In the early days, experienced engineers would typically have invested a lot of time in creating models and setting up simulations.

Such is the advancement of knowledge and computer literacy, but also improvements in automation and the tools themselves, that today many such tasks can easily be performed by junior staff or students. Far from implying a de-skilling, this shift means simulations experts can now concentrate on the interpretation of results and on guiding and advising design decisions.

Year by year, simulations are becoming

simpler to use. This “democratisation” is enabling the adoption of simulation in more and more areas.

Feedback from the physical world The most sophisticated simulation is of no value if the results do not adequately reflect what happens in the physical world.

Confidence in simulations is improved by comparing simulation results with physical tests as well as field experience. It is the hallmark of a good simulation method that results do indeed prove a good match to laboratory tests.

A simulation must digitally mirror phenomena occurring within a physical object or system. As in the real world, multiple physical effects act on an object simultaneously. For example – looking at an installation purely from the electrical point of view – it is relatively straightforward to determine an optimal cable cross-section.

But taking into account other phenomena, such as thermal effects or mechanical vibrations, this optimum may need to be reconsidered. Simulations must thus reflect effects in different physical domains (electrical, mechanical, thermal).

Often, the interdependence of these effects needs to be considered. For example, simulation of an arc requires simulation of the dynamics of the plasma, as well as of its electromagnetic behavior and heat generation and cooling. These phenomena are all mutually linked as, for example, the

INDUSTRY 4.0 High-performance computers are required for processor-hungry simulations.

local conductivity of the plasma influences the heat generated, and the resulting temperature feeds back into conductivity.

The heat also affects the spatial movement and redistribution of the plasma, which in turn affects changes in local conductivity, and so on. The chain of influence is thus highly meshed and the respective calculations of the individual domains must run concurrently and exchange information.

Before simulations were available, design decisions of this type were often based on experience, backed up by observation.

Simulations enable a far more detailed understanding of what occurs within a phenomenon such as an arc than was previously possible.

Digital twins A simulation requires, as a starting point, basic data about a device or system. With different simulations being performed on the same product, computational efficiency can be gained by relevant data being shared between simulations rather than totally separate and incompatible inputs being generated manually in every case.

This data can also be used for myriad other purposes in different phases of the product’s lifecycle, including system integration, diagnostics, prediction and advanced services.

A virtual image of the physical device or system is created that simplifies the accessibility of data and verification of properties. This structured collection of data and algorithms forms the device’s digital twin.

A digital twin can provide a unified repository serving all relevant data associated with a device. This can range from CAD information and documentation to lifetime and service history, operating hours and a wealth of other pertinent information. It can also embed simulation algorithms that can, for example, advise a system configurator or operator whether a planned operation will overload a device or take it outside a specified envelope.

Allowing, for example, a temperature to rise above a critical value may shorten the device’s service interval or lifetime, but an informed operator or plant manager may choose to do so nevertheless for operational reasons. Such data can be provided with a one-click query. The usability of such a tool can be improved with augmented reality (a technician looks at objects through the camera of his or her mobile phone and the

pictures are automatically annotated or overlaid with interactive information).

In addition to being available on workstations and hand-held devices, querying tools of this type can be embedded directly into the next generation of control-system interfaces so as to be constantly available without requiring any manual transfer of data.

Besides individual devices, larger processes and systems (such as for example a group of collaborating machines in a factory) can also have digital twins comprised of the individual digital twins of the components plus data on their configuration and interaction. Digital twins can also capture the interfaces between devices and thus support system configuration, testing and troubleshooting.

Tools and methods of simulation In its simulations, ABB uses a mix of commercial, open-source and selfdeveloped tools. The choice depends on the precise problem, and part of the skill in simulation lies in knowing how to select the best tool.

The model for simulation is prepared based on information from the design (such as CAD data), taking into account factors such as boundary conditions, loads and so on. The process of preparing this data is already supported by a certain degree of automation. Such tools becoming easier to use has led to a “democratisation” of simulation.

The computing power required depends on the simulation type. For example, in the electro-thermal analysis of complete medium voltage switchgear (approximately 50 million cells in a finite volume mesh), a high-performance computer might be needed. In case of simpler models or different applications, a good laptop is sufficient. For example, a calculation of electric field emissions around a power station was completed on laptop in two hours. For network calculations, a single run can take a few seconds while returning a result of reasonable quality.

Artificial intelligence (AI) is playing an increasing role in simulations, for example in creating the models and in recognising and interpreting phenomena. One great strength of AI lies in the optimisation of data correlation. AI can, for example, recognise which parameters have the greatest effect on optimisation and suggest design variants that come closer to a design optimum.

Simulations and 3D/4D printing Since the simulations described so far are typically performed well ahead of or independently of manufacture or application, they are not considered real-time operations. An example where simulations may have to run in realtime occurs in 3D and 4D printing (fourdimensional printing uses the same techniques of 3D printing, but adds the dimension of transformation over time).

A simulation running concurrently to printing can be used to correct parameters during printing. For example, temporary temperature gradients caused by the printing process can be compensated.

Simulation is about more than replacing lab tests or speeding up product development.

Because it is so much easier to run a simulation than set up a test, it is possible to run a far larger number of simulations and thus explore a broader range of variants, including out-of-the-box thinking and “what if” ideas. By not artificially restricting users to a given solution from the beginning, simulation is opening new avenues, not only in product design, but in manufacturing processes, business decisions, testing and verification, and service. Staff can play with different geometries and ideas and refine parameters in multiple iterations. Simulation removes barriers to creativity.

Reprinted courtesy of ABB Review. www.abb.com/au

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Restoring the human element – Mitsubishi Electric’s e-F@ctory in action Mitsubishi’s Electric’s e-F@ctory concept at its Kani manufacturing facility in Japan has delivered hugely beneficial outcomes, with the productivity of each square metre of production space increased through greater utilisation.

Part of its Nagoya Works, Mitsubishi’s Kani factory, which produces motor starters and contactors, was facing a number of significant challenges, not least the sheer number of product variations and possible configurations in its product range – some 14,000 in fact. Customer demand for greater choice had diluted the volumes of each particular product, despite overall product quantities increasing substantially.

Manual production at Kani had given way to totally automated assembly lines, which were ideal for mass production with few product variations where high yields could be realised at high speed. However, many individual components were required in stock and ready for the manufacturing process – without which the lines would not be able to run for any appreciable length of time.

For various reasons, substantial numbers of assembly lines had been optimised to produce a limited range of products, and these would stand still when components ran out. In such a scenario it became difficult and uneconomical to produce small batches.

The solution was to employ engineering know-how built up over many years and combine this with a vision of integrated manufacturing – known as the Mitsubishi Electric e-F@ctory concept. In tandem, existing technology and third-party relationships were utilised through the e-F@ctory Alliance, CLPA and other collaborative engineering groups. Put simply, the objective was to perfect the ‘art of manufacturing’ – or ‘monozukuri’, as it is known in Japan.

The major challenge was to find the root cause of any inconsistencies. This involved several approaches, from analysing existing data or collecting new data sets for fresh eyes to review, to looking for links between data that on the surface could appear unlinked. This factor is related to the first principles of Industry 4.0.

Studying existing processes, as well as the methodology, revealed that natural, normal, organic growth in the production process had inadvertently led to inefficiencies.

Resolving this issue at Kani led to a reevaluation of the need of 100% automated lines, which were not necessarily the most efficient. Restoring some human elements could potentially reduce manufacturing anomalies.

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The introduction of a human element to previously automated assembly lines has helped the Kani factory react to changes in product demand.

Further observations revealed that the automated parts feeding of some larger components not only created bottlenecks but led to the parts feeders consuming large volumes of space. This could result in minor damage to components – not enough to cause an issue, but enough that engineers were dissatisfied with the quality level being achieved.

Conversely, automation of some tasks which had, in the past, seemed impossible, now looked possible through a combination of technologies. An example of this thinking concerned the misalignment of certain screws during the assembly process.

The automation system, unaware of the misalignment, would try to insert the screw and cause damage to the entrance of the hole.

Two technologies helped to overcome this problem: the automatic alignment of robots; and combining rotational drives for inserting screws using torque sensors.

As a result, the hole can now be located easily and aligned correctly every time.

Moreover, the torque sensor confirms the absence of misalignment and that the screw is tightened to the correct level. The increased use of vision systems, checking for correct assembly and alignment, has also helped to increase the number of rightfirst-time products.

A further, simpler idea was to etch a matrix code on the body of each product and track it through the various stages. Now,

as the product arrives at a workstation, its code is read and the appropriate processes and parts applied. At the end of the manufacturing cycle, each product then has a traceable manufacturing history, making it possible to track the history of individual issues.

By redesigning the process and reintegrating the human element, a single line occupying some 280sqm has been reduced to a cell of just 44.1sqm. This 84% reduction means the productivity of each square metre of production hall has been increased through greater utilisation. Even though a single new cell cannot produce the same volume and speed of units as the original fully automated line, it is now possible to deploy up to 6.3 cells in the same space. In turn, total productivity density is much higher thanks to three key factors: a wider variety of products can be manufactured in smaller batches; one stoppage does not halt the whole of production; and the total number of production lines has increased.

The end result, much to the satisfaction of the team at Kani, is effective optimisation of both machine and human resources, as well as the production process and space – a true productivity gain. Mitsubishi Electric’s e-F@ctory concept shows how manufacturers can achieve their own smart factory concepts. www.mitsubishielectric.com.au

INDUSTRY 4.0

Why mid-sized manufacturers need to embrace IIoT According to CB Insights, world-class manufacturing sites are working at 85% of their theoretical capacity, yet the average factory is only around 60%.

But how can mid-sized manufacturers use the Industrial Internet of Things (IIoT) to digitise and streamline their processes by connecting their assets to the internet? By Rob Stummer, CEO of SYSPRO Australasia.

Just as the world-class manufacturers have done, mid-sized Australasian manufacturers want to increase production efficiency, improve quality and traceability, while improving the customer experience by being continuously updated. IIoT technology is a key part of Industry 4.0 and large multinational corporations have already adopted it as an essential part of doing business. It’s not good enough to adopt elements of IIoT for the sake of it though; there must be a clear perspective to identify the revenue and profit values at stake, the expected time frame to implement it, the technical enablers required, the optimal level of investment in technologies and services, and the capabilities needed to ensure success.

According to the report IIoT platforms: The technology stack as value driver in industrial equipment and machinery by McKinsey & Company, “Equipment and machinery companies considering a transformation to embrace the IIoT need to develop a clear perspective to drive impact at scale.”

Fabricated metal companies rely on a high level of customer service to ensure repeat business. If they cannot streamline the order-entry process, maintain strict ISO standards and deliver products on or before the promised date, their customers will find someone who can. By introducing machine learning for analysing their IIoT data, they can make operational predictions 20 times earlier and with far greater accuracy.

A mid-market sector that is really booming in this region is our food & beverage manufacturing sector, which requires strict quality control: products must be stored at just the right temperature and humidity to guarantee freshness. Sensors can be used in storage facilities and even retail stores to monitor and measure these levels. Algorithms are used to turn that data into visual information on a real-time management dashboard. The system then alerts the production manager of any deviations that could affect their products.

Not only is it possible for food & beverage manufacturers to use IIoT to improve quality and optimise production levels, there is also the potential to monitor workplace environments, including air quality, heat

and vibrations, and provide immediate notifications if changing conditions change might destroy products, cause downtime, or even harm employees or the public.

If, for example, a machine is constantly overheating, maintenance may be needed sooner than originally expected. Food & beverage manufacturers using IIoT to monitor their machines can reduce downtime while avoiding more serious and consequently more expensive repairs.

3D Printing Functional

Metal Parts

Almost unlimited potential While most mid-sized manufacturers have either already started or are considering IIoT technologies, there’s still some mystery around the potential benefits. Prior to implementation, manufacturers should reflect upon areas where IIoT can have most impact. From improving decision-making to increasing efficiency, pinpointing IIoT’s value proposition can clear up confusion and open doors to a future of connectivity.

For mid-sized manufacturers, IIoT is a strategic move that can provide cost savings and improve profitability, as well as the ability to become more competitive. Not only does IIoT help in optimising operations, but from an infrastructure standpoint, these tools can also help to optimise a production facility’s energy consumption.

The advantages of IIoT don’t stop there: many mid-market manufacturers will find it can also help them to develop new customer-oriented, revenue-boosting business models. No matter if the focus is on growing the revenue from new business models, or achieving improvements in production efficiency – or both – digital advances in manufacturing absolutely need full IIoT transformation at scale.

In the highly competitive world of manufacturing, it’s a case of adapt or die. It’s not enough to invest in IIoT as an add-on to a mid-market manufacturing business. Like many large multinational manufacturers, true adoption of IIoT solutions can mean organisational and cultural changes, and new personnel and processes, but the improvements to production efficiencies can make them significantly more competitive.

IIoT really does have almost unlimited potential. www.syspro.com

Markforged combines Metal Injection Molding (MIM) technology with a unique 3D printing platform

Call us now at

1 800 632 953

to discuss how you can transform your metal manufacturing processes emona.com.au/markforged

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The digital way to make internal turning more efficient and minimise waste Some manufacturers of large and expensive components, such as those used in the aerospace or oil & gas sectors, have at one time or another had to slow down their internal turning processes in order to protect the parts that are being worked on. The reason is, of course, that a mistake can be extremely costly. However, one way of preventing errors while speeding up machining times would be to carry out regular checks on what is taking place within a closed machine tool. Knowing what is happening inside a component when carrying out internal turning can generate significant efficiencies and keep waste to a minimum, especially when machining slender components.

Working closely with customers across the globe, Sandvik Coromant has developed a connected solution that enables manufacturers to speed up the machining of high-value components, confident that anything untoward (that is, anything that moves beyond strictly set parameters) can be identified. While Silent Tools technology from Sandvik Coromant is around 50 years old, the quantum leap comes from a new development that involves embedding sensors into the turning adaptors, making it much easier to fathom what is going on deep into a component being worked on behind a machine tool’s closed doors. This major advance in technology now makes it possible to extract accurate information from the machining process and – in real-time while cutting is taking place – share precisely what is happening with an operator via easily understandable and intuitive graphical displays.

Increased machining efficiency The new development – Silent Tools Plus – features a damped adapter with embedded connectivity, delivering information such as vibration levels or the temperature in the damping system. By arming operators with this data, Silent Tools Plus offers a significant range of benefits to the manufacturer, most notably optimising process security and machining efficiency while avoiding damage to the machine tool and component, including surface damage. In turn, this means less downtime through tool breakages and the ability to machine extremely costly materials and complex components at faster speeds, confident that the process is running satisfactorily.

machining process as it is progressing. With the aim of improving decision making at the machine face, other data provided by Silent Tools Plus includes a history of what takes place during a cut, which is crucial when working on projects for manufacturers operating in such demanding industries as oil & gas or aerospace. If there is any incident taking place outside set parameters – such as excess shaking or increased harmonics – the operator will be alerted to this instantly on the graphical display and will be able to take action accordingly to stop or adjust the machining process and avoid damage to the component.

Increased process security and better utilisation of equipment The goal, then, is to make the machining process significantly more secure and to reduce the scrap rate to a bare minimum – or zero if possible. As mentioned, this aim is particularly important when the parts being worked on – such as aircraft landing gear or sub-sea components – can be extremely costly in terms of the materials alone. Being able to prevent such high-value components from being scrapped or reworked means that the investment in this type of technology has the capability of paying for itself over a very short timeframe.

Improved decision making

Better utilisation of equipment can be achieved by reducing the amount of time that a machine is running without the tool in cut.

Optimised machine utilisation is also available through the quick change interface between adapter and cutting head which makes for easy handling and accurate changing.

By displaying data such as vibration levels on an easy-to-understand dashboard, the system enables the operator to obtain an instant picture of what is happening and to get a tangible sense of the

In addition, because the centre height setting functionality provided

by Silent Tools Plus displays the level of the cutting edge, operators can quickly and easily set the height of the insert to the correct level

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ARE YOU OPTIMISING YOUR R&D CLAIM POTENTIAL?

before machining begins. The result of this is significantly better machining performance and longer insert tool life. Because data provided also covers such essential issues as surface finish quality, the operator is able to adjust the settings with the aim of optimising the process parameters.

Examples of indicators, then, that are included in the standard offering of Silent Tools Plus relate to vibration, surface roughness, in-cut, temperature and the centre height setting. The engineered solution that is also available offers additional features that cover load and deflection.

The standard offering from Sandvik Coromant is now suitable for adaptor diameters of 60mm, 80mm or 100mm with overhang up to 10 x diameter, while the engineered solution enables manufacturers to work up to almost 18 x diameter overhang and diameters above 100mm. Just three years ago, it was only possible to work on a maximum overhang of 14 x diameter but these limits have been extended through the acquisition of cutting tool knowledge over many decades, which has led to this latest development in boundarybreaking technology.

Conclusion Essentially, this new functionality represents the eyes and ears within a component when internal turning is being carried out and the tool is simply not visible. Now that the operator is able to ascertain exactly what is going on in the cutting operation inside the component – in particular whether there are any disturbances in the process compared against agreed parameters – the key value that results from this is being able to make informed decisions based on actual and accurate data from the cutting process in order to increase machining security and productivity.

Being able to run operations faster while maintaining process security are major advantages for manufacturers who are looking to minimise waste for reasons of costs, delays and increased customer satisfaction.

William Buck are the accountants and advisers to Australian Manufacturing Technology Institute Limited (AMTIL) and preferred supplier to members. William Buck has a dedicated R&D Incentives team with over 15 years experience consulting in the R&D space. We offer a complimentary consultation to assess your businesses opportunity to make R&D Tax Incentive claims.

In a complimentary consultation we will undergo the following; — Preliminary evaluation of R&D claim eligibility — Review of past R&D claims — Explore opportunities to maximise R&D claims (past and future) — Uncover Accelerating Commercialisation (AC) grant opportunities.

A personal touch backed by relevant experience We work with a wide range of manufacturing clients offering a complete range of R&D, business, tax and advisory services from a network of local offices. This gives our team key insights to the industry and the ability to offer a complete business solution.

To book your William Buck Hour contact Dr Rita Choueiri Dr Rita Choueiri Principal, R&D Incentives Ph: 03 8823 6840 rita.choueiri@williambuck.com

In addition, with the move towards digital machining, Silent Tools Plus is one of several products that belong to the CoroPlus offer from Sandvik Coromant which contains connected solutions made ready for Industry 4.0. By delivering such powerful connectivity, the aim is to provide maximum support to manufacturers throughout their digital journey. www.sandvik.coromant.com

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Tools for large part manufacturing In principle, machining large parts involves the same cutting action and chip formation process as small or midsize parts. However, large dimensions demand a specific approach to machining, and manufacturers need to plan technological processes and choose more effective cutting tools to produce heavy parts that take up a lot of space.

Transporting a part inside a shop-floor, mounting and clamping it in a machine tool, and machine set-up are major challenges. Workholding massive and large parts is no easy task, and often requires nonstandard solutions. Machining large parts involves removing a lot of material that may cause significant deformations due to unrelieved stresses. Another factor, which leads to dimensional problems, is thermal expansion caused by heat generation during cutting: the large sizes make it much more sensitive compared with more standard-sized workpieces. The necessity to remove a significant material stock requires appropriate chip evacuation to prevent the chip re-cutting, which negatively affects the applied cutting tools.

The key for overcoming the difficulties lies in technology, based on effective process planning and utilising the most suitable machine tools, optimal workholding, and minimal part relocation. Single setup machining represents an absolute ideal for machining a large part, and producers from fields such as power generation, aerospace , railway, die-and-mould making, and heavy industry make every effort to achieve this ideal. Cutting tools play a meaningful role in reaching the target.

A distinct feature of these industries is their substantial consumption of large heavy-duty tools, mostly indexable, intended for productive removal of large quantities of material, especially in rough and semirough machining operations.

Large-part manufacturers expect the same from cutting tools as any other producer using metal cutting technologies: excellent performance, good tool life, and high reliability. The latter two are especially essential because the large sizes lead to increased machining time, but replacing a worn tool in the middle of a pass and unpredictable breakage of the tool during cutting are totally unacceptable. To meet the requirements of large-part manufacturers, cutting tool producers provide various solutions, based on both standard and special designs. As a leading company in the cutting tool industry, Iscar’s years of accumulated knowhow and experience have proved advantageous in developing efficient solutions to these challenges.

Heavy-duty facing It is hard to machine a large part without face milling operations.

Rough and fine machining of free and bounded planes and preparing datum surfaces require various indexable face mills. Iscar’s standard face mills possess nominal diameters up to 315mm, while special tailor-made tools might feature higher values. The inserts are mounted in face-mills and vary in cutting geometry as they are intended for machining different groups of material. Significant removal of machining stock by milling is primarily an issue for the production of large parts from steel and cast iron, and slightly less from titanium and aluminium.

Iscar’s line of standard face mills includes many tool families for large-part manufacturing. HeliTang T465 features cutters with a 65° cutting edge angle and carrying tangentially clamped inserts. The robust design enables productive machining with a depth of cut up to 19mm. The HeliDo 890 family features 89° face mills with lay-down square double-sided inserts. These efficient mills are indispensable in milling a plane near the shoulder, and offer an important economic advantage: the square inserts provide eight indexable cutting edges for depth of cut up to 9mm.

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Extended flute, extended effect Indexable extended flute ‘long-edge’ cutters are considered winning tools for productive rough milling. In manufacturing large parts, they excel in machining deep shoulders and cavities. Extended flute cutters are also utilised in ‘edging’ – milling wide straight edges, a common operation for various processes, from machining slabs and ingots, to primary contouring.

Iscar’s line of indexable extended-flute cutters varies in design configuration, integrating a shank- and arbor-type mounting method, and a radial or tangential insert clamping principle. These tools work in hard cutting conditions amid significant mechanical and thermal loading. Intensive material removal requires the appropriate volume of a tool chip gullet to ensure effective chip evacuation. The situation can be dramatically improved by applying Iscar’s extended flute cutters carrying inserts with chip splitting geometry to divide a wide chip into small segments. As a result, cutting forces are reduced, vibrations are stabilised, and thermal problems are eased.

Although 90° tools are the most commonly used cutters, machining large parts also requires rough milling of inclined and 3D surfaces, for which Iscar provides a family of tapered extended flute cutters with 22.5°-75°cutting edge angles. In some cases, particularly die-andmould making, combined rough and shoulder milling is needed. The DropMill 3 extended-flute ball-nose mills were designed specifically for such applications.

Producing large-size aerospace components from hard-to-machine titanium alloys is an extremely metal-intensive process with a significant buy-to-fly ratio. The eventual weight of a part may be only 10%, or even less, of the original weight of a workpiece. The XQuad extended flute cutter family, one of Iscar’s newest products, is intended for high-efficiency milling of deep cavities and wide edges in titanium parts. These tools are suitable for machining with highpressure coolant supply, which significantly increases productivity and improves tool life. The tools have already proved themselves: for example, component producers have achieved a metal removal rate (MRR) of 700-1000 cubic centimetres per minute by using an 80mm diameter XQuad cutter.

CUTTING TOOLS

In railway engineering, combine mills are used to ensure simultaneous machining on several areas of the part. These mills incorporate an extended cutting edge, formed by a set of successively mounted indexable inserts.

Productive fast runner High-efficiency machining by indexable extended flute cutters and large-diameter face mills can be likened to the work of a heavy excavator digging sand with a big bucket. The full sand bucket, operated by a powerful engine, slowly moves a large volume of waste material. At the same time, there is an alternative method for efficient excavating. Imagine a more compact track trencher with a rapidly moving digging chain. Each link of the chain removes a small volume of sand but does it fast. In metal cutting, this trencher is a high-feed mill, which machines at shallow depths of cut but with a feed per tooth that is far higher than the usual rates – millimetres as opposed to tenths of millimetres.

Fast-feed mills are applied mainly to rough machining of plane faces, cavities and 3D surfaces. These tools are more typical in manufacturing large parts from steel and cast iron, though high-feed milling (HFM) titanium and high-temperature alloys is not uncommon today.

Iscar has a wide choice of fast-feed mill families, intended for cutting various materials in different applications. Iscar’s HFM cutters encompass tool families in diameter ranges of up to 160mm that can meet the most demanding customer’s requirements.

High-feed milling requires machine tools with high-speed feed drive.

Large-part manufacturers often have heavy, powerful but slow machines that are not suitable for high-feed face milling. For these customers, Iscar developed moderate-feed (MF) cutters. Compared with fast-feed mills, MF cutters feature a higher cutting-edge angle; they move slower but machine at higher depths and need more power to make them suitable for applying to heavy machines.

Large parts are often made from difficult-to-cut materials such as hard and high wear-resistant steel or cast iron. The welded part structure and the process of repairing worn parts by spraying fillers or soldering, add materials that are not easy-to-machine either.

High-speed milling (HSM) resolves these issues. Originally applied in die-and-mould making, HSM was developed as a productive method of milling hard steel that led to decreasing a part relocation, lessening set-up, minimising manual finish and polish, and, as a result, reducing cycle time. HSM features a small-in-diameter tool that rotates at high speed and mills material at shallow, light cuts.

The most suitable HSM tool is a solid carbide endmill and Iscar’s MultiMaster family of assembled endmills, which carry cemented carbide exchangeable heads, also represents a viable option. Iscar’s line of solid carbide endmills offers various multi-flute tools in diameters of up to 20mm, intended for HSM of materials with hardness up to HRC 70. Decreasing machining allowances due to the production

of more accurate workpieces for large parts, for example by using precise casting or moulding, opens new opportunities for HSM.

Exchangeable heads change the dynamics In many cases, manufacturing large parts is small-volume and even individual. In this context, minimising machine tool downtime has critical importance. Intelligent process planning to reduce set-up time can help solve this issue. Each time a worn cutter is replaced, additional measuring and CNC program corrections are required, which increases downtime.

Iscar’s families of rotating assembled tools with exchangeable heads – Multi-Master mills and SumoCham drills – enable substantial decreases in downtime. Face contact between a head and a tool body ensures that the head overhang is within strict tolerance limits, resulting in high dimensional repeatability of the assembly. Replacing a worn head does not require additional set-up operations or removal of the tool from a machine.

U-turn with turn milling Turn milling, the method of cutting a rotating workpiece by a face milling cutter, is a good option for machining heavy rotary parts. In turning, cutting speed is a function of rotating velocity. If limitations of its working characteristics mean the main drive of a machine tool does not allow rotation of large masses with the required velocity, then the cutting speed is far from the optimal range and turning performance will be low. Turn milling offers an effective solution to the above difficulties. When turning large eccentric parts like crankshafts, off-centre masses of the parts cause unbalanced forces that adversely affect performance. Turn milling features low rotary velocity of a part, which prevents this negative effect.

The majority of Iscar’s indexable face milling cutters are suitable for turn milling. The success of their application depends on cutter positioning with respect to the machined part, choosing optimal geometry of inserts, and cutting data calculation. Iscar’s specialists in the field studied turn-milling kinematics and developed an appropriate methodology for defining these parameters.

Reliable performance Machining large parts is a time-consuming process, during which the tools cut material for a long period, and this means tool reliability, stability, and predictable wear are high-priority issues. A sudden tool failure may seriously damage the part and even cause its rejection.

A cutting tool manufacturer has a limited choice of instruments for improving reliability, including advanced tool design, progressive cutting material, and technological development. Effective utilisation of these instruments is the key to successful large-part machining, and Iscar’s recently introduced range of new tools and carbide grades provides that key. www.iscar.com.au

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Mapal meets the needs of automotive electrification The impending onset of electrified motor vehicles is setting new challenges for the automotive supply chain â&#x20AC;&#x201C; and in particular, cutting tool manufacturers.

Mapal already offers a wide range of innovative machining solutions for manufacturing individual parts and components in electric vehicles. However, the challenge is an ongoing one that Mapal is continuing to meet.

High precision for large diameters using ultralight tools One of the core challenges in electrified automotive powertrains is the high-precision machining of the main bore in the stator housing. Presenting a challenge for the tool and machine, all other steps in the production of the stator housing can be carried out on machines with a HSK A63 spindle configuration. However, in most instances the main stator bore requires machining with HSK A100 spindle. This is down to two factors: firstly, the high cutting torque requirements of up to 500Nm; and secondly, the maximum permissible tool weight and tilting moment.

Cost-effective manufacturing with short cycle-times calls for a solution whereby complete machining can be carried out on a single machine with small spindle connections. This is because these machines are characterised by their high spindle speeds, lower investment and operating costs, as well as lower energy consumption. In order to meet these demands, Mapal has developed a fine boring tool with an ultra-light design. The low weight of around 10kg meets the precondition for use on machines with smaller spindles. In addition to the weight reduction, Mapal has also optimised the cooling channels, introducing a special backflushing system that ensures a far more effective removal of the chips. This prevents chips from scratching the machined surface.

Spiral forms with tolerances in the micron range Aside from the drive and the energy storage systems being affected by the electrification of the modern vehicle, many auxiliary units and peripheral parts are also impacted by this relentless vehicle development. One example is the electric refrigerant compressor.

At the heart of an electric refrigerant compressor are two nested aluminium spirals, the scroll stator and scroll rotor. The efficiency of the electric refrigerant compressor depends essentially on how precisely these parts are manufactured.

The demands on form and positional tolerances lie in the range of a few microns. A particular challenge here is the machining of the â&#x20AC;&#x153;screwâ&#x20AC;?. A defined rectangularity of less than 0.04mm and a surface roughness (Rz) in the single-digit micron range are essential. Despite these demands, the thin walls and the depth of the part, finishing has to be carried out in a single pass. Mapal has developed an SPM milling cutter with a finishing geometry and highly positive rake angle for this application. It ensures lowvibration cutting and has an additional chamfer on the diameter.

It can perform the machining of base, wall and chamfer in a single step. As a result, the close tolerances for rectangularity and surface finish can be reliably achieved. www.mapal.com

Chatter-free machining of complex, thin-walled battery housings Mapal offers the necessary tools with the optimum strategy for the different variants of the battery housing. It is here that polycrystalline diamond (PCD) is applied as a cutting material and minimum quantity lubrication (MQL) technology is introduced for maximum cost-effectiveness. Different milling technologies are employed to reduce the cutting forces and this depends upon the required stock removal, machining application and component.

The SPM milling cutter from Mapal is ideally suited to this application. Thanks to its high positive cutting-edge geometry and its optimised chip flutes, the cutting force is reduced by up to 15% compared with conventional milling cutters. If deep pockets are to be machined, Mapal employs special PCD milling cutters whose cutting edges are arranged with both positive and negative axis angle. In combination with the trochoidal milling strategy, the cutting force is kept very low during the machining operation.

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1426AMTLOVITTTECH

Keeping me up to date with our industry As a member of AMTIL since its inception, Lovitt Technologies has appreciated the information we obtain from AMT Magazine, from the editor to CEO reports through to manufacturing trends and processes.

Also comments from various government personnel regarding our industry and general advertising of new machinery and tooling is of great interest to our organisation.

Marcus Ramsay, Manufacturing Director LOVITT TECHNOLOGIES AUSTRALIA

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READERS AMT the No. 1 trusted industry publication.

For information or advertising rates visit www.amtil.com.au or contact Anne Samuelsson, Sales Manager on 03 9800 3666 or email asamuelsson@amtil.com.au AMT proudly owned and published by Australian Manufacturing Technology Institute Limited (AMTIL)

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CUTTING TOOLS

Face milling with ceramic cutting tool materials for nickel-based alloys With high tensile strength and extreme heat resistance up to around 750°C, nickel-chromium alloys are used wherever very high temperatures are present, such as in gas turbines, rocket engines, spaceship components, nuclear power reactors and pumps. But even outside the aviation and aerospace industry, markets are shifting to favour heatresistant parts: Machines used for power generation need to become more efficient in all sectors and make do with the least amount of cooling possible.

The high temperature resistance of nickel-based alloys often presents process managers with challenges during machining, not least because there is still relatively little experience to draw on compared to other materials. If heatresistant super alloys are milled with carbide indexable inserts, the cutting speed is only around 45 metres/min. Milling cutters with ceramic cutting tool materials achieve cutting values that are approximately 20 times higher during roughing: with cutting speeds of up to 1,000 metres/min, they achieve a much higher metal removal rate.

The higher feed rate easily compensates for the depth of cut, which is generally lower for ceramic cutting edges than for carbide edges: In specific applications, the metal removal rate of Inconel 718 with ceramic cutting edges is more than 10 times higher during roughing. Machining times that are around 90% lower are an important factor in production planning, especially in sectors like the aviation industry, where order books are full and machine capacity is limited.

Milling with ceramic cutting edges imposes demanding requirements on the machine, cutting tool material and machining

process. The biggest difference between ceramic and carbide cutting edges is the extremely high temperature in the cutting zone: spindle speeds of over 10,000rpm generate the high frictional heat required, which melts the material and carries it out of the cutting zone. At temperatures of around 1,200°C, the energy between the tool and the component is so high that bright orange sparks can be seen – not unlike those created during grinding.

Application: Roughing engine parts Walter has optimised existing face milling cutters with ceramic indexable inserts, as well as the corresponding milling processes themselves, for roughing operations on a new component made from Inconel 718 for an engine component manufacturer.

Roughing the facets was identified as a critical machining stage on the conical turned part, which has a diameter of over 1m. The total machining depth on 12 areas was around 25mm. Using traditional tools, this stage would take around 50 minutes.

“Engine manufacturers face high workloads and the high hourly rates of modern machinery,” says Marlon Ries, Application Development Engineer at Walter. “Creating

additional machine capacities was therefore the most important factor for the customer.

Lower machining times also reduce the total machining costs significantly. We adapted an existing tool body with five indexable inserts and eight cutting edges per insert for this application and optimised the entire machining process over the course of several test series.”

Heat and speed – risk factors for process reliability Milling with ceramic cutting edges requires high-speed milling machines that can accelerate the spindle to more than 10,000rpm when required. These speeds represent a great challenge for the tools used. Over the course of the process, the insert seat and geometry of the milling cutter were optimised to create a higher level of operational smoothness.

Another challenge was that the heat created in the machining zone causes metallic fumes, which condense on the tool and clog its moving parts. To counter this, Walter covered the wedge clamp assembly parts with PVD coating, which has a higher melting point than the base material. This reduces deposits on the clamping system to a minimum.

Ceramic cutting tool materials generate a temperature of around 1200°C in the cutting zone.

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Engine housings are designed for maximum stability. They are therefore manufactured using materials such as Inconel, titanium alloys or Waspaloy.

A face milling cutter with five indexable inserts and eight cutting edges per insert.

There is one thing that makes Inconel special: when milling components, the material can rebound during machining operations or expand subsequently. Tests have shown that a smaller camber angle positively influences the tool life. The inserts are rotated at a certain angle in two levels to create a soft cut. This improved tool geometry results in less noise and vibrations.

Keeping thermal loads on the tool and workpiece low The frictional heat requires special adaptations to the milling process, in that the ideal run-in path, speed, feed and depth of cut need to be selected.

“Ceramic cutting tool materials originated in turning, where thermal loads are relatively stable,” explains Ries. “During milling, by contrast, the temperature on the cutting edge varies because the cutting process is interrupted. The abrupt change between frictional heat and cooling puts a strain on the cutting edge. We planned the tool paths to ensure the cutting process is as uninterrupted as possible.”

To prevent thermal shock caused by the tool cooling down, cooling lubricants are not used when milling with ceramic cutting edges. The process temperature is preferably discharged with the chips, rather than introducing high temperatures into the component. Walter drilled three holes in the milling body’s wedge, through which pressurised air is introduced into the machining area when machining cavities.

This makes for reliable chip evacuation.

“The customer was initially concerned that the very high temperature of nearly 1,200°C could cause warping on the component or increase surface hardness, as can be the case during grinding,” says Ries. “To prevent this, the outside of the turbine

Marlon Ries, Application Development Engineer at Walter.

housing is not milled in one step. After each section, the component is rotated to the opposite side before machining continues.

The tolerances of a tenth of a millimetre were met without problems. We ran many tests and even we were surprised to find that the parts were only lukewarm directly after milling.”

Lower costs per component despite higher tool costs Most of the heat created during the machining operation is absorbed by the cutting edge and the chips. These extreme heat and speed loads quickly leave their mark on the comparatively hard ceramic cutting edges.

“Signs of wear caused by temperaturerelated chemical wear or adhesion appear relatively quickly,” says Ries. “Customers are often surprised that even tools that look quite worn still achieve very good results.

The wear mark width during roughing was 2mm. When milling with ceramic cutting edges, the indexable inserts might be on the machine for as little as 10 minutes before becoming worn. But if work is carried out 20 times faster, the higher tool costs quickly pay off.”

Using ceramic indexable inserts and the Walter milling body optimised for this application, machining times are drastically reduced in this case. Compared with a face milling cutter with seven cutting edges (diameter 80mm), tool life fell from 29 minutes to seven minutes per assembly, while the machining time decreased by 92%. The costs per part for these roughing operations are now only 7% of the previous figure.

Suitable for different applications While Walter created the face milling cutter with ceramic inserts for a very specific process, the company’s machining experts are already thinking ahead. After all, components made from nickel-based alloys are becoming increasingly common.

“The pilot process with the engine component manufacturer was highly successful,” adds Ries. “There are already plans to adopt the milling body for other production processes as well.” www.walter-tools.com

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QUALITY & INSPECTION

What does ISO 9001 mean for customers?

It’s a small term that means so much in manufacturing: ISO 9001 certification. A globally recognised standard in quality management, ISO 9001 is synonymous with integrity, excellence and, ultimately, customer satisfaction.

If you’re hearing the term ISO 9001 for the first time, the short explanation is it’s a set of procedures dictating all of the processes in an accredited manufacturing business – everything from the design and prototyping to the manufacturing itself, right through to the delivery of goods and invoicing.

Image by Gerd Altmann from Pixabay.

As Paul Hughes, Managing Director of Integra Systems, explains, “It’s a set of procedures that pretty much govern the way you do business.

“I’ll build a quote in our system. If the job gets converted to a sales order then it gets converted to a work order. Once a work order is raised, all your materials can be purchased from it. In effect, it creates a ‘traveller’ that goes around the factory, through the process, tracks your materials then, finally, it gets invoiced out. So that’s ISO 9001’s underlying framework to the business.”

Having the official accreditation has not always been an essential component to doing business at Integra. However, the company’s growth and ever-expanding customer demands caused management to rethink its position. Changes made to the assessment criteria in 2015 also encouraged Integra to consider adding ISO 9001 to their list of achievements.

Ultimately, the move to attaining ISO 9001 certification has not only driven a comprehensive overhaul of Integra’s design and manufacturing processes for the better, but it has also been the catalyst for positive cultural change.

“For a long while, we had our own internal quality system that we ran by,” admits Paul. “We were a little bit reluctant to embrace the ISO way of doing things because a lot of our customers didn’t really require it. But with changes to the accreditation process, it’s become far more holistic and in line with our way of thinking.

“It’s not just about the quality of your parts now. It’s all to do with the touchpoints of your business, and how you conduct your business.

Before that, getting ISO 9001 seemed like a lot of cost to a business for no real benefit.”

A holistic approach Krystal Davis, Continuous Improvement Designer at Integra Systems, says the ISO 9001 was traditionally very ‘documentation heavy’: “You were documenting every single meeting, documenting the minutes of meetings, every person that had been on the factory floor, in the office, even your courier. It was really a mundane and lengthy process, so a lot of companies were, I guess, intimidated by it.

“Looking at the old version of ISO 9001 versus the new version, you just wouldn’t want to touch it, especially for a small company like us that doesn’t have a big team dedicated to it.”

Like Paul, Krystal isn’t short of praise for the way the rewritten accreditation challenges businesses to approach the process from a more holistic perspective: “It works side-by-side with your

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processes. It sharpens up processes to make sure your outputs are of a high quality, and your function within the business is also high quality.”

Pursuing ISO 9001 accreditation forced Integra to address a number of inefficiencies, which was both a welcome and unanticipated byproduct unearthed by the process.

“We were forced to learn what exactly our company needed,” explains Krystal. “The amount of times we changed a process or had to rewrite a procedure or something we didn’t think was going to happen that much. We just thought, ‘Okay, the way we do things now – or the way we did things back then – we put it on paper and it’s a quality system.’ But we found there were bottlenecks we didn’t realise we had in the company.

“So we would write something, and the guys from Vative [an external consulting organisation that helped Integra through the process] would say ‘Keep doing what you’re doing.’ Then we might give the guys in production a drawing and say ‘Follow your process, because it’s working, we’re getting products out to customers.’ But we then had to really break down into that process, and that’s when we uncovered all those bottlenecks – where parts were stopping and where we didn’t actually have a good flow of work building up.

“We didn’t realise you can’t just have one or two over-arching procedures,” continues Krystal. “You have to really go down, look at the nuts & bolts of your flow in your whole company and go through systems like that.”

Catalysing change As the law of unintended consequences dictates, the journey towards ISO 9001 certification was the catalyst for important change at Integra. While there were some initial suspicions about introducing external consultants and increased monitoring of processes where agility and flexibility could potentially be lost, Paul and Krystal agree that explaining ISO 9001’s role in the organisation’s bigger picture, and encouraging their employees to buy into the challenge, sparked a fundamental cultural overhaul.

“Originally, we would get around together and say we’re getting ISO 9001 – it’s a quality management system, and we’re going to implement it,” says Krystal. “And I think for a little bit, [the staff]

QUALITY & INSPECTION

weren’t really getting why we were doing it. They were a bit like ‘Oh, this is just the office doing something new, and trying to change what we’re doing down here.’ But we didn’t actually have a full understanding of what we needed to really do at the point either.

“When we saw that we really had to break down our flow into bits and pieces, we realised we could get everyone back together and say ‘We’re slightly changing what you’re doing now because of these reasons. And these reasons will have these flow-on effects.’

As soon as everyone saw why we were doing what we were doing, and the result of those actions and those changes, the cultural change was massive. This change management was critical to successful implementation.”

Staying on track Obtaining the accreditation was one thing but, as Paul and Krystal explain, there is ongoing heavy lifting involved in making sure Integra keeps its certification. Continual improvement is at the heart of ISO 9001, and that’s something that hasn’t been lost on Integra.

“There’s a checklist that we do on a regular basis,” says Paul.

“That just gives ourselves a healthcheck on how we’re adhering to the standards. And then, on a quarterly basis, Krystal and Sanjay [Production Engineer at Integra] will conduct a full internal audit, just as an external auditor would do.”

“And you’ve got to make sure that you keep talking with everyone,” adds Krystal. “We know there will be some changes that we’ll have to make at different stages and that’s perfectly fine. Every company has to do that anyway. So, on the back of one of our busiest periods of the year, we’ll see where the quality system has maybe failed, or it needs to be tweaked, and where our quality system has really succeeded. That’s how we keep the quality system going.

“I know, just off the top of my head, there are a few procedures I want to tweak just from observing the guys and having a chat with them,” Krystal continues. “It’s a lot of observing, talking with people and doing little tweaks here and there to really keep your points system running. It’s not just set-and-forget.”

At the heart of ISO 9001 is what it means for the customer. And, for Integra’s customers, the improved accountability is something Paul and Krystal hope will loom large, especially in the eyes of some of their major customers.

“As a minimum, defence companies actually require you to have the ISO 9001 qualification,” says Paul. “We’ve been involved in a number of projects with Mercedes Benz but, as soon as we got the ISO accreditation, it lifted us to a new level in their mind. It earned us an approved supplier status with Mercedes Benz.”

Krystal remarks: “On a really base level of delivery and providing products to customers, we’ve set up a system to be fluid and relatively predictable in how it’s going to turn a product out. We can say ‘Okay, we’ve got an order from someone. We’ve designed it, and this is when you’ll be able to get your part.’ We know it will be of a higher quality because we have quality checks throughout the whole process.

“Having ISO9001 certification makes it easier for us to do what we say we’re going to do. In the real world, stuff does go wrong but having ISO 9001 makes us a lot more accountable and gets us a lot closer to doing what we say we’re going to do for a customer.”

“I think it lifts you to a higher status in the market,” concludes Paul.

“It gives your business some definite credibility.” www.integrasystems.com.au

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Navigating automotive evolution with Mitutoyo Specialising in the production of prototype components and complex small batch runs for the automotive sector, UK-based Advanced Engineering has always maintained its ethos of investment in technology to deliver quality components, with lead times beyond the capabilities of its competitors. This philosophy has resulted in the company placing its trust in metrology equipment from Mitutoyo.

As a manufacturer that works primarily with automotive OEMs, as well as F1 engine manufacturers, aerospace, defence, rail and nuclear business sectors, Advanced Engineering prides itself on its quality management systems. As well as ISO 9001 accreditation, the Birmingham-based company can comply with all requirements, from other industry-specific criteria such as the TS: 16949 Automotive standard and the AS: 9100 standard, to meeting varying customer needs and expectations.

The Mitutoyo CMM with a full station of probes.

The company has spent more than over £3m ($5.4m) on new equipment in the last five years; two of the most recent arrivals have been a VARIAXIS i-700 five-axis machining centre and a Quick Turn 250 turning centre, both from Mazak. This now gives the company a total of 19 Mazak machines, which undertake everything from complex prototype work through to automotive production projects.

Such activities entail all levels of production part approval process (PPAP), advanced product quality planning (APQP), failure mode and effects analysis (FMEA), statistical process controls (SPCs) and full supply chain management. Mitutoyo is central to these strategies.

Producing everything from CAM covers, cylinder blocks, control arms and pump housings, to decorative door linings and prototype wheels for automotive OEMs, turnaround times are a critical factor for Advanced Engineering. This is why the combination of Mazak five-axis machine tools, hyperMILL CAM software and a complete suite of Mitutoyo inspection equipment is central to expediting highquality components through the business at breakneck speed.

Advanced Engineering’s relationship with Mitutoyo dates back over 20 years, acquiring its complete range of hand tools, and the first Mitutoyo co-ordinate measuring machine (CMM), a Crysta Apex 9106, arriving on site some 15 years ago. Still reliably running up to 12 hours a day, the Apex 9106 was followed by a smaller Crysta Apex 574 CMM around eight years ago. The second machine was acquired to relieve the bottleneck of work that was building on the company’s first CMM. As Andrew Stevens, Quality Manager at Advanced Engineering, says: “All our work is based around customer requirement. We deal with a single one-off prototype product, through to support, NPI products and new product model launch. We work closely with Tier 1 manufacturers and OEMs; and the diversification into electrification is being done by our customers. We almost ‘engineer to print’. So, where our customers are protecting themselves and looking at other products sectors such as light-weighting vehicles – this is having a dramatic effect on the work we are seeing here. We are being shielded by our customers, but also seeing a change in our products to suit the evolving marketplace.”

The smaller, more cost-effective Apex 574 CMM has not only relieved capacity, it was the perfect product for the changing market demands of the automotive sector.

“Our work initially evolved beyond cylinder head and engine blocks into turbos and other small complex powertrain parts,” says Stevens. “And the Apex 574 proved an excellent solution with its compact footprint. However, our workload has continued to evolve even further, with more body-in-white (BIW – the stage in automotive manufacturing where a car body’s sheet metal components have been welded together) work and in particular suspension parts being manufactured.

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“With the requirement for additional measurement capacity, we once again opted for a Mitutoyo solution, the Crysta Apex-S CMM. We bought the Apex-S as we wanted the new CMM to be capable of mirroring the Apex 9106 machine, something that would give our metrology team more flexibility, reduced set-ups and extra capacity as and when required.”

Stevens expands upon the continual changes in the automotive sector and how Advanced Engineering is addressing the issues from a measurement perspective: “We got to a point where our Apex-S and Apex 9106 have been working side by side, with the smaller Apex 574 being reserved for smaller parts, providing much needed capacity at busy periods. However, a lot of our OEM customers and their cylinder head work have taken on a new level of dimensional tolerances over the years.

“To facilitate this, we swapped out the TP20 touch probes that operate on a touch trigger mechanical mechanism to the new continuous contact SP25 Renishaw system. Mitutoyo fully retrofitted the system to both our Apex 9106 and Apex-S CMMs, and this gives us precision to two microns. Furthermore, by continuously scanning the complex features of parts, we are getting a full 3D scan of the components and this can be compared directly with the CAD model. All this is innovatively done with the Mitutoyo MCOSMOS operating software with full certification and traceability for our customers.”

QUALITY & INSPECTION

An automotive component being calibrated on the Mitutoyo CMM.

With 85% of work at Advanced Engineering passing through the metrology department, Mitutoyo was on hand when yet more demands filtered downstream.

“Surface finish has become more prominent in the automotive market with seal seat surfaces and waveforms on engine blocks and cylinder heads taking on more stringent controls,” says Stevens. “To measure surfaces, we approached Mitutoyo and they recommended the SurfTest SJ-410 Series portable surface roughness tester. OEMs are now placing more 100% inspection demands on critical features like cylinder head bores, and to once again relieve capacity and reduce set-ups on our CMMs, the SurfTest SJ-410 was the perfect addition.”

Stevens describes the relationship with Mitutoyo: “Our tie-up with Mitutoyo goes back for many years. We have always used Mitutoyo through the reliability and quality of the products that they supply and that goes right the way through from hand tools to CMMs. We have an amazing service contract with Mitutoyo and they carry out all our calibration work. We wouldn’t trust anyone else to calibrate our equipment. It’s a longstanding relationship that has been based on trust, good service and the level of product innovation.

“We chase microns on the shopfloor and we need to be able to repeatably be able to measure to microns and be confident that each measurement is accurate. With the type of products we are producing here, we are pushing the bounds of our CMMs through varying, changing customer requirements. So, when we see new customer requirements and we need the CMMs to do something slightly different to meet those requirements, Mitutoyo have engineers on the end of the phone, so we can get their technical support to resolve challenges very quickly.” www.ae-uk.net www.mitutoyo.com.sg www.mtiqualos.com.au

The Crysta Apex CMM at Advanced Engineering.

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Creaform launches HandySCAN BLACK Creaform has launched the HandySCAN BLACK, a re-engineered and refined update to its HandySCAN 3D handheld scanner with improved optics, multiple blue laser technology and powerful algorithms for faster, more accurate instant measurements.

This is the third-generation version of Creaform’s patented metrology-grade scanner. Its launch marks more than 15 years of innovation in technology to meet the evolving needs of the manufacturing and engineering industries. The HandySCAN BLACK has been designed for professionals who need an effective and reliable tool to capture accurate dimensional measurements of physical objects.

HandySCAN BLACK combines high-performance 3D scanning with a sleek, ergonomic design. Its distinctive simplicity and portability advantages are a staple of Creaform’s product line. As the company’s flagship portable metrology-grade 3D scanner, the HandySCAN BLACK sets the standard for measurement, regardless of size, material or complexity, within seconds anywhere.

Features include: • 4X resolution: Fine details and large volumes are captured thanks to the unique and versatile combination of improved high-performance optics and multiple blue laser technology.

• 3X faster measurement speed and instant mesh: The larger scanning area features 11 blue laser crosses that take up to 1,300,000 measurements per second, ultimately cutting down the time between acquisition and workable files.

• More accurate and traceable measurements: Volumetric accuracy of 0.020mm + 0.040 mm/metre, based on VDI/VDE 2634 part 3 as well as ISO 17025, ensures reliability and full traceability to international standards.

• Available in BLACK and BLACK|Elite: Customers can choose from two models based on their needs in terms of part complexity, measurement speed, accuracy, and so on.

“Over the past decade, Creaform technologies have become the standard in highly accurate metrology tools, trusted to take reliable measurements that help make informed decisions at all stages of the product lifecycle management (PLM),” said Simon Côté, Product Manager at Creaform. “HandySCAN BLACK packs the benefits of its predecessors and further takes on quality assurance inspections in the shop, at the machine, in process—where the customers need it.”

Meeting Boeing’s requirements In May, Creaform announced that the HandySCAN 3D scanner can now be used for recording physical attributes of aircraft dents and blends on all models of Boeing commercial airplanes. Boeing has released a service letter with guidance on the use of 3D scanners for measuring dents and blends on airplanes. The SmartDENT 3D solution and the flagship HandySCAN 3D scanner were used in the process of guiding Boeing’s quality requirements for the service letter.

SmartDENT 3D benefits include: • Speed: Up to 80 times faster than the pit gauge technique, it is the fastest and most reliable aircraft surface damage inspection tool available on the market.

• Metrology-grade measurements for aircraft maintenance: The scanner is accurate to 0.025mm and has a resolution of up to 0.100mm with high repeatability and traceable certificate.

• Intuitive pass/fail assessments: With its intuitive design and real-time software visualisation, Creaform’s NDT solutions ensure short learning curves and minimal operator experience influence on the accuracy of results.

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• Live visualisation and portability: Weighing less than a kilogram, the handheld scanner is the perfect tool for work in hangars or directly outdoors.

Users can easily perform 3D surface inspection of any part of an aircraft on which they would use manual techniques—including on and under wings.

In addition to complying with Boeing’s service letter, Creaform HandySCAN 3D scanners are listed in the Airbus Technical Equipment Manual, which is referenced in its Structure Repair Manual.

“Creaform is proud to see leaders such as Boeing, turn to 3D scanning solutions for surface defect inspection,” said Jérôme Beaumont, Global NDT Business Manager at Creaform. “With SmartDENT 3D, our goal is to provide the most accurate damage assessment to our customers, so they can make informed and safe decisions, while getting their aircraft back flying with minimal downtime.” www.hitechmetrology.com.au

WASTE & RECYCLING

CSIRO creation scales up to tackle waste

We’ve shredded the price, not the ASPIRE (Advisory System for Processing, Innovation & Resource Exchange) has transitioned out of CSIRO’s quality.

THIS YAWEI LASER IS Data61, the data and digital specialist arm of Australia’s HIS YAWEI IS national science agency,LASER and is scaling its operations Now that’s DESIGNED nationally to better manage the TO 67m tons ofCUT waste generated in AustraliaTO each year. CUT ESIGNED Applied Thinking.

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Developed in 2015 by researchers from CSIRO, ASPIRE is an online marketplace that intelligently matches businesses with potential remanufacturers, purchasers or recyclers to find new purposes for waste materials working towards the circular economy for Australia.

Dr Melanie Ayre, research scientist at CSIRO’s Data61, said that since its launch, ASPIRE has diverted hundreds of different waste streams from landfill, including batteries, e-waste, metals, organics, polystyrene, ferric chloride and timber pallets.

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BOVE THE REST. NOW THAT’S APPLIED OW THAT’S APPLIED THINKING. HINKING. “Almost 80% of Australia’s waste is generated through commercial, industrial, construction or demolition activities,” Dr Ayre said.

“We developed ASPIRE in response to rising costs of waste management, and to redirect waste to more productive uses.”

Cameron McKenzie, ASPIRE’s newly appointed CEO, said the online marketplace has seen an impressive uptake amongst businesses, state governments and local councils in Victoria, but that a national network was pivotal in tackling the widespread waste crisis.

“Around 300 businesses are using ASPIRE, which has collectively saved $207,000 in waste disposal and material costs,” said McKenzie. “This has also resulted in the reduction of CO2 emissions and water through reuse and diversion from landfill. While we’ve had strong traction in Victoria, we’re scaling ASPIRE nationally to address the increasing need for a way to manage Australia’s growing waste and recycling issues.”

According to the 2018 National Waste Policy, a hypothetical 5% improvement in efficient use of materials across the Australian economy could benefit Australia’s GDP by as much as $24bn.

The ASPIRE marketplace combines CSIRO’s domain expertise in

With its extreme accuracy, speed and consistency of cut, combined with very low operating manufacturing with the deep technology capabilities of Data61. costs, accuracy, the new Yawei HLF laser is the perfect way to take your low business to the next level. extreme andfiber consistency with very operating ASPIRE speed was recently named as oneofofcut, five combined start-ups awarded a Heavy he new Yawei HLFin fiber laser is the perfectPrecinct’s way to take your business to the next level.duty, reliable, cost effective the Swinburne Program, Dollar for place dollar, the new HLF Innovation is in a league of itsAccelerator own, opening up possibilities for companies recycling solutions an intensive programsector; supporting start-ups to through gain earlytotraction all across the laser cutting from start-ups full production, 3-shift or dollar, the innew is in aItleague of named its own,a opening upinpossibilities theirHLF markets. was also semi-finalist the 2019 for companies Australia’s favourite solution for all kinds of environments. ss the laser cutting sector; from start-ups through to full production, Australian Technologies Competition and has received support3-shift waste/materials reduction applications ments. from CSIRO’s ON Accelerator program.

With a quality German built Precitec auto-focus cutting head, IPG laser source, Siemens www.aspiresme.com Extensive 840DSL controller and a fabricated, fully laser annealed frame it really is a cutrange aboveavailable: uality German built Precitec auto-focusstress-relieved cutting head, IPG source, Siemens the rest.and a fabricated, stress-relieved fully annealed frame it really is a cut• above Vision Series Shredders controller Image by PublicDomainPictures from Pixabay.

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Deakin scientists create processes for recycling rare earths, plant waste Scientists at Deakin University have unveiled new breakthroughs in the recycling of rare earth materials and the transformation of plant waste into biodegradable plastics.

Working with Spain’s Tecnalia Research & Innovation hub, scientists at Deakin have improved the process for recovering rare earth metals (REMs), which are essential in mobile phones and technologies such as hybrid-electric cars. Deakin Institute for Frontier Materials (IFM) researcher Dr Cristina Pozo-Gonzalo, who leads the electromaterials project, said there is an urgent need to develop a cleaner, simpler process for recovering REMs, as current extraction methods generate huge amounts of toxic and radioactive waste.

“Consumption of REMs has been gradually increasing since the 1960s due to their use in electronics, optics, and magnetics, making them ubiquitous in everyday applications such as television screens and computer systems,” said Pozo-Gonzalo. “They’re also a key component of many modern technologies, including hard disk drives, clean technologies such as wind power turbines, and batteries for hybrid-electric vehicles.”

Pozo-Gonzalo added that increased demand for REMs – which include elements such as cerium, praseodymium, neodymium, and lanthanum – was creating pressure on global supply chains.

“Almost 85% of the world’s REM primary resources are in China, where their government has restricted exports for periods of time in the recent past, endangering availability and price stability,” Pozo-Gonzalo said. “There’s growing concern that future access to these materials won’t be reliable, leading to them being targeted for reclamation and recycling. The primary extraction and processing methods for REMs are also energy-intensive processes that lead to the excessive generation of toxic and radioactive waste. We need a real alternative.

“After separating the metals from their end-of-life product, our team uses advanced electrolytes known as ionic liquids (liquid salt-based systems) to recover the rare earth metals from the resulting solution using a process of electrodeposition – when you use a low electric current to cause metals to reform and deposit on a desired surface.

“This new method for recovering REMs has great potential and minimises the generation of toxic and harmful waste. We are also aiming for a method that can easily be implemented widely across the world.”

Pozo-Gonzalo said REMs were among the top critical raw materials identified by the European Commission, Geoscience Australia, and US Department of Energy: “The efficient recovery of REMs from

recycled materials is becoming increasingly important, given that only about 3% to 7% of REMs are currently recovered from endproducts because of technological difficulties. Our work addresses a key knowledge gap in the REM recycling process, and is an important early step towards establishing a clean and sustainable processing route for REMs and alleviating the current pressures on these critical elements.”

Turning plant waste into biodegradable plastic Deakin textile and fibre scientists have discovered how to turn plant waste into a biodegradable material that could replace environmentally damaging plastics such as those used for packaging and other throwaway items. The team from Deakin’s Institute for Frontier Materials (IFM), led by Dr Maryam Naebe, developed the bioplastic by repurposing cotton gin trash – the seeds, stems, short fibres and other waste by-products left behind from the ginning process used to separate cotton fibres.

“About 29m tons of cotton lint is produced each year but up to a third of that ends up as cotton gin trash, where it’s then sent to landfill or burned, representing a major environmental impact and lost material value,” said Naebe. “Adding value to this waste product will give cotton growers and farmers an additional income stream, while also offering a sustainable alternative to harmful synthetic plastics.”

Naebe said the results were part of a project from PhD candidate Abu Naser Md Ahsanul Haque, along with Associate Research Fellow Dr Rechana Remadevi. The team has been working on transforming gin trash for more than 18 months.

The researchers dissolve the cotton leftovers using environmentally friendly chemicals and then recast the recovered biopolymer into a useable bioplastic film. The resulting material has a range of applications, such as a bale wrap, fertiliser and cotton seed packaging.

“Cotton gin trash is a promising source of renewable biomass, because when it’s broken down, the resulting organic polymer can potentially be converted into a versatile biodegradable material,” Naebe said. “Compared to synthetic plastics, our bioplastic is made without the need for toxic chemicals – which makes it safer and cheaper to produce at a mass scale – and it has the added bonus of contributing to the circular economy.

“The bioplastic can biodegrade and turn into soil, which will then in turn be used to grow cotton, resulting in cotton gin trash during the ginning process, which can then be repurposed again into bioplastic.”

Deakin Institute for Frontier Materials (IFM) researcher Dr Cristina PozoGonzalo supervising a PhD researcher.

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The team is now applying their process to other organic waste and fibrous plant materials such as lemongrass, hemp, almond shells, wheat straw, wood saw dust and wood shavings. www.deakin.edu.au

WASTE & RECYCLING

Pure and simple: Applied Machinery, FIMIC provide improved recycling solutions With China’s National Sword policy putting pressure on plastic recyclers, equipment supplier Applied Machinery recently entered into a partnership with Italian company FIMIC to help recyclers hit contamination targets.

It has been more than a year since China’s Government implemented the National Sword policy which would go on to have significant impacts across the global recycling sector.

The policy set restrictions on the contamination levels of plastic waste, unsorted paper and textile materials, meaning China would only accept materials with a contamination level of 0.5% or less.

From the 1990s up until 2013, global wealth manager Credit Suisse says it was cheaper to transport recycled materials by ship to China than it was to domestically transport by truck or rail in its 2018 report, The age of plastics at a tipping point. One particularly difficult waste identified in the report was modern food packaging, which use layers of different polymers as well as other materials like aluminium and ink layers that need to be separated before sorting if they are to be reprocessed.

“Food packaging is also often contaminated by its contents, requiring screening and washing,” the report notes. “Councils also have different requirements for sorting and acceptance of products depending on the materials recovery facility in the area.”

To achieve a circular plastics economy, Credit Suisse highlights the importance of technology and innovation to improve the current methods of plastics recycling, processing and manufacturing.

David MacDonald, Director of Applied Machinery, says this need to find a technological solution led the company to begin investigating possible products for Australian recyclers needing to improve the quality of their recycled pellets. Applied Machinery currently represents two major companies in the recycling market: Genox and Polystar.

Genox is a supplier of plastics recycling machinery, such as shredders, granulators and washing and drying equipment. In Australia, its machines are used to reduce contamination from plastics and separate metals with individual machines or turnkey plants. Polystar’s Australian machinery are mostly pelletisers, which turns the washed plastics into pellets or granules to be sold.

of higher contamination levels, the blade holder can be operated in continuous mode.

According to MacDonald, the FIMIC system means operators are not required to constantly change the filter screens due to the often high levels of contamination in certain waste streams.

“For companies handling packaging waste, which often contains a relatively high amount of other materials, the FIMIC system can ensure the end product remains as pure as possible.” says MacDonald.

“Plastic waste from the agricultural and aquaculture industries can also benefit from the technology, as often there is a significant amount of dirt and soil that is difficult to wash off, especially when it comes to soft plastics.”

International contamination restrictions have led to a significant drop in the price of plastics and has led to increased stockpiling, creating a competitive domestic market environment. MacDonald says companies improving their contamination levels are able to stand out in the now volatile market and potentially reach the required contamination thresholds to resume exporting materials to China and other nations as Australia’s recycling infrastructure develops.

Applied Machinery plans to offer the technology as an ongoing option for Polystar processing plants. It sent one potential customer from Sydney to the US to see the system first-hand.

According to MacDonald, after inspecting it and seeing it in action, the customer was set on installing one in their plant.

“The technology will enable companies to process plastics that historically would have been considered too difficult and would have been sent to landfill,” he adds. “Not only that, but it may provide recyclers and exporters the edge they need to reach the strict contamination targets for international export and allow companies to take advantage of the less crowded market.” www.appliedmachinery.com.au

However, there are limits to washing technology. Even if a material is washed, it can still remain contaminated. For example, paper labels on plastic bottles can count towards the contamination level and reduce the overall value of the product. By removing these contaminants, recyclers are able to achieve a cleaner product and extract the most profit possible from recycled materials, which is why Applied Machinery has partnered with Italian screen changer manufacturer FIMIC. Generally, filters run material through a very fine screen mesh, which can become clogged or blocked with cleared debris. FIMIC’s technology uses a continually wiping screen with internal blades to ensure it remains clear. A pressure threshold can be programmed into the screen to begin turning the blade holder and collecting debris to be discharged when appropriate. Alternatively, in cases

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MATERIAL REMOVAL

Tornos introduces new models The last few months have seen Swiss machine-tool manufacturer Tornos launching a number of new products, such as the new Swiss DT13 and Swiss DT26 turning machines. These new innovations constitute a full product line-up that Tornos believes will inspire users with their performance.

The entry-level segment of Tornos’ machine tool range comprises two product lines, namely the CT20 (the second version of the machine recently introduced), and the Swiss DT machine. Both model variants are subject to constant evolution to remain at the forefront of technology with a costeffective and competitive platform. Against this backdrop, the Swiss DT13 and Swiss DT26 models have undergone significant modifications that are aimed at improving their rigidity and their axis feed rates.

Moreover, the TISIS programming software has been enhanced to enable maximum performance and productivity.

CT20: For a rapid return on investment The CT20 is a small and sturdy machine that is easy to use with its five linear axes and two C-axes. In its basic configuration, the CT20 machine comes equipped with drive motors for driven tools for main and back machining operations. Next to the counterspindle, the machine can accommodate two driven tools for work in main operations and can be equipped with 11 driven tools, with a total of 27 tools across the two machining areas. Such flexibility is simply unique for this machine class. All the more, the machine can be optionally fitted with a thread-whirling cutter, a polygon cutter, a triple drilling/milling unit as well as a slotting device for back machining.

“Our CT 20 is the most affordable machine of the entire Tornos product line-up and has proved to be highly successful in

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the market,” explains Philippe Charles, Product Manager at Tornos. “Thanks to its appealing price, it can easily replace aged machines in a workshop. It is a machine that allows a rapid return on investment. Its modular tooling system and its stable and rigid cast-iron frame make the machine an excellent partner for all situations.”

improves machining accuracy and surface finish of the workpieces. Moreover, it can spare valuable seconds when machining long parts. The machine can be converted for guide bush-less operation and adapted to the specific workpiece requirements.

It therefore boasts a flexibility that Tornos believes is unique in this machine class.

The CT20’s power is more limited compared to the Swiss DT13 and Swiss DT26 variants, the latter also being an entry-level machine that has been designed taking a minimum number of requirements into account. The machines of the Swiss DT range use the same optional equipment as the machines of the Swiss GT range, which ensures optimised investment with flexible tool holder systems.

With its extensive tooling, it is very easy for the Swiss DT13 to produce complex parts. The machine can be equipped with 21 tools including seven driven tools. Three driven tools are located in the main gang tool post. They can reach maximum speeds of 10,000rpm.

The Swiss DT13 can be optionally provided with a modular position, so a gear hobbing unit can also be mounted. For a long time now, this function has been used on the SwissNano and EvoDECO machines as well. It has proved its merits and has played its part in the recent success of the Tornos brand in the micro mechanics industry

Swiss DT13: Vast productivity possibilities The Swiss DT13 has been conceived for bar capacities of 13mm (10mm without bar preparation). In addition, it is provided with five linear axes and two C-axes and its kinematic system has been developed for high productivity applications. Thanks to its maximum feed rates that can reach 35mm/min and its L-type kinematics, the Swiss DT13 is extremely fast and its chipto-chip times are ultra-short. The spindles can be operated with a maximum speed of 15,000rpm – a speed that is normally reserved for higher-class machines. The machine is equipped with a motorised synchronous guide bush that can reach the maximum spindle speed. This guide bush

Swiss DT 26: power and modular concept The proven kinematics of the Swiss DT26 features five linear axes. Given the bar capacity and the performance of the machine, the Tornos engineers have prioritised good chip removal by arranging the gang tool post above the guide bush and the spindle. With its spindles having power of more than 10.5kW for both main and counter operations machining and a bar capacity of 25.4mm, the Swiss DT26 actually enables large cutting depths.

MATERIAL REMOVAL

Against this backdrop, excellent chip removal is required to be able to tap into the full potential of the machine. Just like the Swiss DT13 model, the machine is equipped with a motorised guide bush, and in less than 15 minutes, it can be converted to enable the operation with a collet.

The machine comes equipped with four radial drills for front machining operations.

This equipment grants the user high flexibility. To improve this flexibility, the machine can be provided with a threadwhirling cutter or a polygon cutter.

Consequently, it would be very easy for the Swiss DT26 to produce medical screws or to perform face milling tasks with these two attachments.

The thread-whirling cutter can be inclined by +/-15° and it can rotate with a maximum speed of 5,000rpm and machine diameters of up to 10mm. On the other hand, the polygon cutter can also reach a maximum speed of 5,000rpm while the diameter of the polygon cutting tool is 80mm. The back machining positions can be equipped with both stationary tools and driven tools.

These positions can also accommodate advanced tooling such as a high-frequency spindles specifically designed to machine Torx patterns or even a slotting device.

The CT20, Swiss DT13 and Swiss DT26 machine models are efficient solutions that are designed to permit a rapid return on investment. The Tornos machine line-up enables all users to find the appropriate

solution for their specific requirements. Like any Tornos machine, the Swiss DT and CT20 machines can be equipped with a lot of options such as long workpieces ejection up to 600mm, high-pressure coolant, and many others.

Standardised programming via TISIS Any Tornos machine can be programmed with the TISIS programming software â&#x20AC;&#x201C; and this equally applies to the Swiss DT and CT20 machines. Moreover, they can be equipped with the Connectivity Pack that enables remote monitoring of the status of the machines.

TISIS has a database that contains the data of all tool carriers, from simple tool holder plates to polygon cutters, milling units and thread whirling cutters. Each of these devices has its own features that are taken into account by TISIS. So, when a device is selected, only the positions that can be accommodated will be enabled.

Furthermore, TISIS manages any incompatibilities between various devices.

It provides intuitive user guidance through the operation of the machine. Each tool carrier has its own illustration and therefore can be identified with ease. It should also be noted that the standard geometries are automatically displayed as soon as a workpiece is selected. www.tornos.com www.swisstec.com.au

CT 20 Swiss DT 13 Swiss DT 26

Maximum diameter (mm)

20

13

25.4

Number of linear axes

5

5

5

Number of C-axes

2

2

2

Number of independent tool systems

2

2

2

Total number of tool positions

27

21

22

Positions for driven tools

11

7

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technotrans helps Kronprinz eliminate oil mist Steel wheels made by Kronprinz can be found on vehicles from nearly all the well-known trucks or car brands; they must, therefore, fulfil extremely strict quality requirements amid a price-sensitive market. One important step towards more efficient production was the company’s recent replacement of its spray lubrication system. technotrans technologies’ low-mist lubrication concept lowers the costs and ensures a healthy work environment for employees.

Accuride Corporation is one of the leading suppliers of wheels for the automotive industry. The company has a global annual turnover of US$1.2bn and a workforce of approximately 5,000 across 16 locations in North America, Europe and Asia. The product portfolio includes wheels for microcars (or motorised quadricycles), heavy vehicles, tractors, construction machines and agricultural machines.

As an important company within the Accuride group, Kronprinz alone provides approximately 1.6m truck wheels and more than 1.8m motor car wheels from its plant in Solingen, Germany.

The truck wheels with a particular high load-bearing capacity consist of a rim and a wheel disc. At Kronprinz, these components, which are made of rolled steel, are formed and then welded all around from the inside in modern gas metal arc welding lines. This sounds easy, but keeping an optimum balance between large quantities, high quality and a competitive price is quite a challenge.

Above: Steel wheels made by Kronprinz must fulfil extremely strict quality requirements on a price-sensitive market.

It is a challenge that Christian Simons, Project Manager for System Planning & Design at Kronprinz, must deal with: “We regularly invest in our machinery for numerous reasons. Costs are not always our main consideration.”

Left: Christian Simons, Project Manager for System Planning and Design at Kronprinz.

Reinhard Skricek, Key Account Manager at technotrans, was informed about the special challenges that the wheel manufacturer was facing on a daily basis. The machine for the lubrication of wheels made in Solingen is a bespoke system based on an in-house design and specifically adapted to the special requirements of the wheel production.

The environment also benefits from a sustainable, resource-saving production.

Moreover, Simons adds: “We want our employees to feel comfortable at the workplace.”

The company has optimised all three areas with a single investment: its spray lubrication system has been equipped with valves made by technotrans.

Spray lubrication without compressed air

excess oil as far as up to the neighbouring machinery was labour-intensive and blocked the personnel from completing other tasks.

To fulfil the company’s own exacting quality standards, and to ensure a sustainable, yet efficient, production, lubrication is a must during the forming step. It enables troublefree forming without damage during the subsequent production steps.

“The poor air quality because of the oil mist and the compressed air consumption were arguments against our old solution,” says Simons. “In addition, the maintenance and service of the system were rather challenging. The costs continued to rise due to increasingly frequent downtimes.”

However, the previous solutions could not fulfill the increasingly stringent requirements at Kronprinz any longer. It used expensive compressed air, which is not only a cost driver but also causes the oil to spread out in and around the entire system. As a result, the light barriers had to be blown free to prevent problems. The elimination of the

Then, several Kronprinz employees visited the technotrans stand at the EuroBLECH trade fair in Hanover. Kronprinz’s interest was piqued by a spray lubrication system without compressed air, which is already well-established in the metalworking industry and produced by a global company close to their own location.

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A conveyor belt feeds the rim band into the machine where it is lifted. The spraying system is installed above the holding point and enables the simultaneous lubrication of the band from both sides thanks to a smaller, inner ring with outward-facing nozzles and a larger ring with an inwardfacing spray lubrication system. The nozzles need to cover a precisely defined area with oil of always the same layer thickness. This takes place while the component moves upwards so that the entire process, including the lowering and exit of the lubricated band, takes fewer than 10 seconds. Simons and his colleagues finally became convinced that they had found a solution that was indeed suitable for this type of system when they visited the technotrans headquarters in Sassenberg.

PUMPS & VALVES

Right: technotrans’s low-mist, compressed air-free lubrication concept lowers costs and ensures a healthy work environment for employees.

Below: The spraying system at Kronprinz enables simultaneous lubrication of the rim band on both sides.

“To be honest, we were still slightly sceptical when we visited technotrans for the first time,” Simons recalls. “Being able to stand next to the system while wearing a white shirt sounded a bit too good to be true. However, the spray lubrication trials in the laboratory were really impressive.”

When he returned to Solingen, he was fully convinced of being in good hands.

Further research showed Simons that a comparable technology could not be found on the market: “We finally did not take anything else into consideration in view of our requirements.” After the order had been placed, technotrans supplied the entire spraying system, adapted the system to the installation situation and machine interfaces and trained the operating personnel. Since the start-up of the system in December

2017, it has been running 24/7 without any problems. “The cost savings are substantial,” explains Simons. “This is due to the elimination of compressed air, the reduced oil consumption in a high twofigure range and nearly zero downtime.”

Proven technology with numerous details The system is called technotrans spray. xact and it can be used for the spray lubrication of coils, blanks or formed parts.

The spray jet is produced with a highfrequency pulsating valve with a singleproduct nozzle. As a result, the expensive use of compressed air for the nozzles, which leads to the formation of spray mist in conventional systems, is no longer required. Consequently, an exhaust system is not necessary either. Thanks to precise

dosing and alignment, Kronprinz is able to adapt the spray cone to the round shape of the wheel band. Therefore, technotrans is further improving the efficiency of the company by lowering the material and energy consumption. In addition, Kronprinz is optimally prepared for any requirements or legal obligations in terms of a low level of aerosol formation (oil mist) at the workplace, which will surely become even more strict in the coming years in order to reduce the environmental impact and health burden.

After just a few months, Kronprin is absolutely convinced that it was a worthwhile investment, and not only in terms of the employees and the environment. The management is also completely on board in view of the substantial cost savings. www.technotrans.com

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ADVANCED MATERIALS & COMPOSITES

Bringing graphene and new materials to market Remember the computer triode? Unless you’re an early-tech enthusiast, it’s unlikely. Used as switches in the first electronic computers, these vacuum tubes were unreliable and consumed a great deal of power. With the invention of silicon chips, they were quickly replaced, showing how new materials can shift entire industries. Kari Hjelt explains how graphene is set to do the same.

Graphene, a material that is just a one atom thick, has exceptional physical properties.

The European Commission launched the Graphene Flagship in 2013 to facilitate the transition of graphene and related materials from academic laboratories to applications.

With a budget of €1bn for an initial period of 10 years, the Graphene Flagship is one of Europe’s biggest research initiatives, aiming not only to continue developing graphene in academic laboratories, but spearheading efforts for the commercialisation of graphene, preparing for its widespread adoption in industry.

Halfway through the 10-year project, the Graphene Flagship has successfully developed more than 25 commercial products, using the impressive conductivity, strength and flexibility of graphene to improve on the properties of previously used materials. However, bringing a new material to market is not without its challenges.

Historically, it takes an average of 30 years to take a material from its invention into the commercial realm. Low-cost aluminium, for instance, was first isolated in 1824, and for a while during the 19th century it was considered as a very luxurious metal, more expensive than gold. Aluminium wasn’t widely used until an affordable manufacturing structure was set up in 1886, and it didn’t become popular until the early 1900s. Materials that experienced similar time lags in their adoption include titanium, Teflon, Velcro and polycarbonate, a plastic material used in the manufacture of bulletproof glass. Careful planning is essential in the phase when research and commercialisation start to overlap – particularly due to the sharp contrast between the languages used in academia and industry. To ensure this process runs smooth and successfully, a key driver is the establishment of efficient networks between both worlds. The Graphene Flagship has done this through a core consortium of over 150 academic and industrial groups.

Around 40% of the current members are companies aiming to incorporate graphene into their products.

More recently, the Graphene Flagship established a new kind of working group among its consortium – the spearhead projects. These projects, led by key industrial partners, will boost the technology readiness level (TRL) of major technologies in sectors such as aviation, automation and energy generation and storage.

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Thanks to this multidisciplinary network, the Graphene Flagship envisioned the Graphene Technology and Innovation Roadmap — an expected timeline for the adoption of graphene technologies.

The roadmap focuses on fundamental industry areas, such as electronic devices, photonics, sensors, energy conversion, energy storage and biomedical devices.

The Graphene Flagship’s principal mission is to take technologies based on graphene from the laboratory to commercial application. During our first phase, we continued to witness the potential of graphene-based technologies to create market disruptions and transformational innovations. In our next phases we will continue to move from materials research towards component development and system-level integration. Our focus is in combining technology push and market pull by working with industry stakeholders to increase technology readiness levels.

The Graphene Technology and Innovation Roadmap predicts that graphene for use in flexible perovskite solar cells, high frequency electronics and supercapacitors for warehouse logistics is likely to occur in the next five years. Later technologies, including bioelectric medicine and 6G wireless networks may take a while longer, with estimated adoption in 2030 and beyond.

On top of that, the Graphene Flagship has established two new services for the validation and standardisation of graphene

and related materials, which will be of outstanding utility for industries looking into incorporating graphene into their products. So far, the absence of accurate measurement protocols and the lack of standards have become a serious obstacle to the commercialisation of graphene and related materials. The Graphene Flagship enabled professional validation and standardisation processes – provided by national measurement institutes renowned for their excellence, integrity and impartiality– that will accelerate the technology development and transfer.

Soon, the Graphene Flagship will also release an open access publication that gathers all the know-how in the manufacture of graphene and related materials acquired during years of basic research.

Encompassing over 1,500 references and the knowledge of over 70 co-authors from the Graphene Flagship consortium, this publication will provide a single source of knowledge on graphene and other layered materials.

There were 124 years between the discovery of silicon in 1824, and the creation of the silicon chip in 1958. Now, arguably the most influential invention in computing so far, this chip technology is used in almost all modern products. Bringing a new material to market cannot be rushed, but when managed properly, it can yield incredible results.

Kari Hjelt is the Head of Innovation at the Graphene Flagship www.graphene-flagship.eu

ADVANCED MATERIALS & COMPOSITES

Origami-inspired materials could toughen-up trains Swinburne researchers are turning origami-shaped two dimensional (2D) materials into useful three dimensional (3D) ‘metamaterials’ that could replace aluminium foam used in train manufacture.

Metamaterials are materials that combine composition and shape to produce properties different to the material alone. A prime example are foams, which become lighter than the base material, but have a relatively robust honeycomb structure.

Aluminium foam is commonly found at the core of the panels on trains, which are known as sandwich panels because they are essentially two tough thin sheets of material bordering a foam core.

These are essential to the lightweight strength needed to make trains cost-effective to run. But if a train were to hit something, the material properties of these panels make them quite brittle.

Professor Guoxing Lu from Swinburne’s Department of Mechanical Engineering and Product Design Engineering is working on a project with the Rail Manufacturing Cooperative Research Centre to find a better metamaterial to strengthen the core of sandwich panels.

Lu’s unique inspiration are the Miura-origami shapes used in very light and strong space ‘deployables’, such as satellite solar panels that must fold up during transport and unfold in space. The folds are named after inventor, Japanese astrophysicist Koryo Miura, who worked on designs for folding a single flat surface, such as a sheet of paper, into a smaller robust shape.

This work is being done in collaboration with Professor Zhong You from Oxford University, Professor Dora Karagiozova from the Bulgaria Academy of Science, and Professor Yan Chen from Tianjin University, China.

Photo by Max McKinnon on Unsplash.

Lu is working with aluminium, one of the materials of choice in the transport industry for its low cost and light weight. His latest analytical and numerical simulations of Miura-origami aluminium 2D folded structures, welded into 3D shaped materials, has shown better energy absorption than conventional honeycomb structures at low to moderate load intensities. Such origami metamaterials, said Lu, could be fabricated by stamping, lasering or 3D printing thin metal sheets (as pictured) or carbon-based composite materials, which could then be weld together to form 3D materials. www.swinburne.edu.au

Green light for a new generation of dynamic materials Developing synthetic materials that are as dynamic as those found in nature, with reversibly changing properties and which could be used in manufacturing, recycling and other applications, is a strong focus for scientists.

In a world-first, researchers from Queensland University of Technology (QUT), in collaboration with Belgium’s Ghent University (UGent) and Germany’s Karlsruhe Institute of Technology (KIT), have pioneered a novel, dynamic, reprogrammable material – by using green LED light and, remarkably, darkness as the switches to change the material’s polymer structure, and using only two inexpensive chemical compounds.

The new dynamic material could be used as a 3D printing ink to print temporary, easy-to-remove support scaffolds. This would overcome one of the current limitations of the 3D process to print free-hanging structures. Another potential application is as a cell biology study tool, with biologists using it as a cell surface support they could alter by light modulation without damaging the cells.

The research is part of a collaboration between QUT macromolecular chemist and Australian Research Council Laureate Fellow Professor Christopher Barner-Kowollik; Dr Hannes Houck, who recently completed his PhD across QUT, UGent and KIT; UGent Professor Filip Du Prez, and KIT’s Dr Eva Blasco.

The new material was formed with naphthalenes (used in moth repellent) and the coupling molecules triazolinediones (TADs). The material remained stable and strong as long as green LED light shone on it. Once the light was off and the material was kept in darkness, the chemical bonds of the network structure broke up and the material became soft and liquefied. The hard-to-soft process could be repeated with the flick of the switch, and the light could be dimmed to modulate the mechanical properties of the material. What makes the discovery unique is that light is used as the trigger to stabilise, rather than destroy, chemical bonds.

The researchers have coined a new term: light-stabilised dynamic materials (LSDMs). Further research is looking at other chemical combinations that can achieve the same result. According to the researchers, what they have achieved is the opposite of what is usually done in chemistry: “Typically, you use different wavelengths of light or additional heat or harsh chemicals to break up the polymer molecule chains that form a network structure. However, we used green LED light to stabilise the network. The trigger to break up the network, make it collapse and flow away is actually the mildest: darkness. Switch the light back on and the material rehardens and retains its strength and stability.

“This is what you call an out-of-equilibrium chemical system. The constant energy of the green light keeps the chemical system in this bonded form, pushing it out of its equilibrium. Take away the light, and the system goes back to its relaxed, lowest energy state.”

Professor Barner-Kowollik said the researchers had already been contacted by 3D printing technology companies interested in application of the research. Printing complex designs with overhangs or bridges is difficult or impossible because the process involves printing layer upon layer, and there is no direct support for layers in sharply angled structures.

“What you need to 3D print something like a bridge is a support scaffold, a second ink that provides that scaffold during printing of the design, but which you can later remove when it is no longer needed,” said Barner-Kowollik. “With a light-stabilised dynamic ink used as a scaffold you could 3D print under light, then switch the light off to let the scaffold ink flow away.” www.qut.edu.au

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Can we bend it? The challenge of making flexible technology Imagine the day when you’ll unroll or unfold your smartphone to answer it. If things go to plan, this day may be sooner than you think. And we’re not just talking flip-phones here, but smartphones where the actual screens are flexible, not just the handset. By Drew Evans.

Okay, so Samsung’s plans to launch its Galaxy Fold phone might be on hold after a few early reviews reported cracks in the screen, but in 2019 many of the major mobile phone manufacturers are aiming to release their new foldable phones. The promise of technology as intelligent as our smartphones that can simply be folded up like a piece of paper sounds amazing. So what are the challenges in making flexible technology? To answer this we need to understand what is meant by flexible. Do we need something that can be deformed without breaking (so it’s okay if you sit on your phone, as it will only bend and not break)? Maybe we want to roll it up into a cylinder with the ease of rolling a piece of paper? Or even to fold it like the Galaxy Fold?

These are very different scenarios, with each putting a greater performance requirement on the device and the materials within.

Are the materials brittle? Or are they inherently flexible? And when they are bent, rolled, flexed or folded, do they continue to work the way they did when flat? These are the questions many scientists and engineers are asking. Enter the world of materials science, mixed with a dose of advanced manufacturing.

The glass Consumer electronics traditionally use materials designed for use on rigid glass substrates, or surfaces. The beauty of glass is its rigidity and thermal stability, and that it can be made on commercial scales.

That means it will rarely bend or flex, and can be heated to high temperatures. These are important factors when manufacturing an electronic device – especially those with a flat panel display.

To make an electronic device, complex patterns of materials need to be made to create an electronic circuit. In some cases the patterns will have features smaller than the width of your hair, even down to the size of viruses (less than 100 nanometres). Producing such patterned coatings of high-performance electronic materials can be done easily on glass at temperatures greater than 500°C. However, when flexibility is required, the substrate needs to change.

The obvious choices are polymers and plastics. Thin sheets of these materials can be manipulated into a range of different shapes without breaking. But not many of these plastics can withstand temperatures greater than 500°C during processing. New developments from companies such as Corning Incorporated in the US have made special types of thin glass that are bendable. Bendable glass may be one of many steps towards flexible electronics. But, as we’ll see later, maybe even bendable glass is not that useful for some applications.

The electronics Beyond the substrate, there are still challenges for the electronic materials themselves. Modern electronics are built on metals and ceramics that require very high temperatures to be fabricated into electrical circuits, which are not ideal for bending.

Polymers such as Nylon, Teflon and polyester are inherently flexible and can be bent, folded or rolled. But polymers are usually insulators (they don’t conduct electricity) and they really do not like being

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heated too high. That is why efforts are being made to engineer polymers that are conductive (conducting polymers). Being conductive means the polymers can transport electrical charge with ease – like your charging cable carries electricity from the power outlet to your portable device’s battery.

In parallel, engineers are changing the way the existing and new materials are manufactured.

Manufacturing is moving away from high temperatures in large coating machines, into things similar to inkjet and roll-to-roll printing (printed electronics). Soon your new mobile phone may be printed at high speed in a similar way to a daily newspaper.

But should we bend tech?

Tackling these technical challenges of materials and manufacturing seems within reach. But why do we want flexible technology?

Sure there are some of us who dream of a flat panel TV that can be rolled and unrolled, mounting anywhere we like. Think about it as an electronic poster being hung on your bedroom wall and flexible TVs are almost here – in 2018 LG showcased a 65 inch rollable TV. Beyond this there are some neat advantages to flexible technology.

There is a big drive towards integrating electronics with biology in the ultimate wearable computer. As we know, our skin (and everything contained within it) is to some degree soft, flexible and elastic.

Having flexible technology would allow our wearable computers to seamlessly integrate with us. This will be done so well that we won’t realise we are wearing it.

Glass as a substrate, even if flexible, won’t fulfil the desire to interface with biology. This is because it lacks the softness and deformability to react to the body’s movement. On the other side of it, the contact lens is made of materials that many people routinely wear on a daily basis (with hopefully little annoyance).

So what about electronics on these soft gel-like substrates? An example of efforts to achieve this is work done by Madhu Bhaskaran and team at RMIT. They are developing electronics that can be worn like a temporary tattoo, giving wearers real-time data about UV exposure. Some companies are even developing electronics directly on a contact lens.

Like the Galaxy Fold, the electronic contact lens project has been paused, the early results from testing are not up to scratch at the moment. But sometime in the (near) future I believe we will have flexible technologies in our daily lives. This will represent major breakthroughs in the materials and manufacturing used to create them. Most exciting is by achieving this, opportunities will open to interface the physical and cyber worlds to a level we can today only imagine.

Drew Evans is an Associate Professor of Energy & Advanced Manufacturing and Australian Research Council Future Fellow at the University of South Australia. This article was originally published by The Conversation. www.unisa.edu.au

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by AMTIL

Look further from a higher vantage point.

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You need a specific component made, but don’t have the capabilities in house.

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Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

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Your business is diversifying into an area where the expertise available within the company is not sufficient.

HotSpots is a service designed to connect AMTIL members with opportunities to help their businesses grow. That piece of work that you need done might be just the sort of opportunity they’re looking for. And by featuring that opportunity as a HotSpot, you gain access to a wealth of Australian manufacturing capability and expertise.

Our regular AMTIL HotSpots email goes out to over 1,000 people every month, making HotSpots an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector.

Provided your opportunity meets our criteria for listing, inclusion in AMTIL HotSpots is free. If you have something you feel will meet our criteria, please forward it to AMTIL for assessment by emailing info@amtil.com.au with the subject line HOTSPOT. www.amtil.com.au/Membership/Hotspots

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FORUM FINANCE

How the Hayne Royal Commission findings could impact your manufacturing business.

In the opinion of company auditor - Jeffrey Luckins - a lack of integrity is the primary reason for business failures – a fact highlighted by the findings of the Hayne Royal Commission into the Financial Services Sector.

The great privilege of being a company auditor is being able to view under the bonnet of businesses, see how they really operate, get to know their people, systems and culture and understand the key drivers of their success and see potential areas of risk and concern.

It’s fair to say that we witness everything from high quality innovative respectful successful businesses to those struggling.

The key issues we identify, whether they be good or bad, are to be found at a macro level in the leadership and culture of the businesses and organisations we audit. It is at the Board level (and/ or with owners) of the business that culture and purpose emanate from and set the tone for the ethics and culture, quality of systems, people and ultimately the sustainability and successful performance of the business.

To support these assertions, consider the following quote from Warren Buffett, the American business magnate, investor, and philanthropist who serves as the Chairman and CEO of Berkshire Hathaway: “Look for three qualities in a person to hire: Intelligence, Energy & Integrity. And if you don’t have the last one, don’t even bother with the first two.”

A lack of integrity has been a key driver in business failures in Australia and around the world and you don’t have to look much further than HIH Insurance in Australia and the Volkswagen emissions scandal to understand how badly a lack of integrity or indeed not generating the right “tone at the top” can cause.

Greg Medcraft in his then role as ASIC Chairman and effectively the top corporate regulator in Australia in 2016 stated that ‘you cannot regulate culture, but you know bad culture when you see it’ and subsequently he noted that culture can provide a signal of behaviours, incentive frameworks and practices that do not support good governance or ethical conduct.

The impact of governance and culture on Australian business has come to the fore in the past few years following the APRA Prudential Inquiry into the Commonwealth Bank and the Hayne Royal Commission into the Financial Services Sector.

You may wonder how an investigation into the financial services sector is at all relevant to the manufacturing sector and indeed you may well question whether governance and culture really does have an effect at the SME level for manufacturing businesses?

So take a moment to reflect upon the key recommendations of the Hayne Royal Commission and consider how they could be applied to your business: 1. Increased focus on high quality oversight and governance by the board.

2. Culture: embedding the “Should we?” question into all key decision-making processes.

3. Greater implementation of risk management practices and its role in the organisation to be elevated.

4. Cultural change to support enhanced risk identification and remediation.

5. Accountability should be clarified and linked to (variable) remuneration.

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In the manufacturing context, it seems that all these recommendations would have relevance, especially if your starting point was safety. The manufacturing industry has a relatively high number of work-related fatalities, injuries and illnesses compared to our industry sectors.

From 2003 to 2015, manufacturing had the fourth highest proportion of fatalities according to industry type, representing 9% (275) of all worker fatalities.

Particularly concerning is that young workers (15–24 year olds) in the manufacturing industry recorded an injury rate 44% higher than young workers in the Australian workforce as a whole.

Safe Work Australia notes that manufacturing is the second most hazardous industry in Australia, with an overall incidence rate of 20.9 serious workers compensation claims per 1000 employees.

Work-related injury and disease cost the Australian economy over $60bn annually, representing 4% of GDP. For individual businesses the cost of workplace safety incidences is particularly high. Firstly, it can have a negative impact on people and clearly the culture and vibe of an organisation. The flow-on effect is that it can adversely affect productivity, timing of deliverables and client satisfaction. To properly address safety issues which arise, will require downtime from production and unfavourable labour cost variances will invariably occur.

The cost of insurance premiums will certainly rise with claims leading to shorter term loss of profits. Ultimately with reputational issues, difficulty recruiting the ideal workforce and potential loss of customer support, there is a considerable cost to workplace incidence resulting in injuries or fatalities.

Having a risk management awareness starts with culture and practically can be implemented by for instance, starting every meeting with a discussion about safety which empowers all Directors, management and employees to take responsibility for their own actions to be accountable to each other and to minimise the potential for harm.

This fundamental culture of care for each other, for your business, your customers and your community is exactly the point of the Hayne Royal Commission; we are all connected and the results of our actions, and inactions, can have far-reaching effects beyond the business and your workplace.

So the core messages contained in the Hayne Royal Commission in respect of risk identification and management, accountability, culture and vigorous Board oversight of management and operations is completely relevant to the manufacturing sector.

In this article I have highlighted how safety is the point of call for manufacturing businesses, but the flow-on effects to profitability and sustainability of business operations is clear and a fairly good incentive for you to address how you can improve your business based upon the findings of this Royal Commission.

Jeffrey Luckins is a Director of Audit & Assurance at mid-tier accounting firm William Buck in Melbourne. Ph: 03 8823 6835 www.williambuck.com

FORUM

HEADING

LOGISTICS

Australian manufacturers and the importance of understanding global supply chains.

Many Australian companies are still not properly versed on the huge variety of global supply chains – and how this impacts their business. By analysing not only your own supply chain, but also those of both your suppliers and your customers, real opportunities to increase supply chain effectiveness may be identified. Lawrence Christoffelsz explains.

We all know that Australian manufacturing has had, and will continue to face, a number of challenges due to a range of diverse factors.

Australia is an island nation, and we are located very far away from most of the world’s largest economies, which in essence means we have even greater pressure on managing our sales orders, production lead times, inventory holdings, logistics and distribution efficiently.

If any of these critical factors are not aligned, then it can have significant impacts on true cost-to-serve and customer service capabilities.

For example; if you are an Australian manufacturer who relies on import components and/or raw materials, then how well you work and communicate with your overseas suppliers, logistics providers and domestic delivery partners has an immediate and direct impact on your local business functions.

Similarly, if you’re an existing or aspiring exporter of products, then understanding your role in your buyer’s/customer’s global supply chain is critically important. Especially when it comes to managing the ability to have pro-active engagement with all of your stakeholders. By doing this, you may have the unique ability to offer not just great products, but a true competitive advantage via supply chain capabilities – which many global companies are happy to pay a premium for, or at very least, reward their supplier for with increased sales orders.

How would this work, you may ask? Well, let’s discuss some simple case studies…

An overseas order is made for raw materials or a number of widgets.

Sellers and buyers need to know how many, how much, and when do you need them, however too many companies are only able to consider this ‘single’ transaction, but not looking further down their supply chains in order to identify possible advantages or increased efficiencies. Imagine being able to work with your buyer/customer to deliver your products in smaller lots, directly to ‘their’ end customers… this would save them money on inventory, additional freight handling and expensive storage charges. Maybe even the ability to offer them varying payment options and incoterms.

Or how about the ability to leverage free trade agreements, tax free zones for value-added services (labelling, kitting, etc.), or even preparing ‘store-ready’ point-of-sale displays at the origin source?

How much time and money can be saved by taking a different view (and possibly a different approach) to your basic inbound and outbound flow of products?

There are so many ways that Australian manufacturers can improve the way they buy and sell globally, however many are still only considering the old-fashioned, “place an order for minimum quantities, ship it out and then shove it into a warehouse before I do the next steps at destination”.

By investing the time to properly analyse, not just your ‘own’

supply chain, but the supply chains of both your suppliers AND your customers, then you’ll be able to identify real opportunities to increase their effectiveness.

In short, if you’re prepared to take the time and have the correct expertise, then you’ll be able to truly create a ‘win/win/win’ scenario…. A win for your suppliers, a win for your customers and of course, a win for your own business as well.

Australian companies are increasingly competing against companies from other markets for the same sales opportunities – whether here in Australia, or abroad.

Sure, Australia has a fantastic reputation for product innovation, research and development across numerous growth sectors, but unfortunately, when it comes to supply chain innovations, we lag behind markets such as Europe, Asia and the USA. We have one of the most challenging supply chain environments to contend with …. We have a huge land mass, with a relatively small population of consumers, however we have comparatively high costs for real estate and wages, so achieving optimal economies of scale or cost-to-serve distribution models is much harder than in markets which are smaller in size but with much larger populations.

With these types of challenges, we absolutely must aim to ‘wring the towel’ on every single aspect of our global and domestic supply chains.

To achieve this requires an initial appetite to think about things differently and to place supply chain functionality (your own, your suppliers and especially your customers) at the very core of your business planning for future growth.

With the added mix of rapidly advancing technologies, combined with end-consumers demanding faster deliveries with real time visibility (not just on arrival, but on how products are ethically and sustainably sourced, manufactured and shipped), Australian manufacturers need to stay up-to-speed and adjust their supply chain capabilities in order to stay competitive globally.

We are at one of the most exciting times in global trade and supply chain innovations – it can definitely be a challenge for businesses, however for those companies who are prepared to embrace the new, and to take-on the challenge, they can be identified as true industry leaders (and even disruptors!).

Lawrence Christoffelsz is a recognized industry leader in international trade and developing global supply chains.

He is currently the CEO of The Australian Trade & Logistics Corporation. A community of professionals across Australia to support the continued growth and capabilities of all Australian businesses globally. lawrence@australiantradelogisticscorporation.com.au www.australiantradlogisticscorporation.com.au Australia-wide phone: 1300 817 055

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What Is silica dust and silicosis?

When stone or concrete is cut, the particles floating through the air likely contain silica dust. This dust increases the risk of a variety of health issues, including silicosis, a potentially deadly lung disease. Brendan Torazzi offers advice and explains the hazards.

To remain safe, tradespeople and even DIY enthusiasts should know more about silica dust and how to reduce exposure.

So, what is silica? We have known about ‘stone dust disease’ since the Greek and Roman times. Silica is silicon dioxide. It is a naturally occurring mineral and a major component of rock and soil. Different types of silica exist, including non-crystalline and crystalline forms. Most types of rock and products containing rock contain varying amounts of silica. For example, the composite stone may contain up to 90% silica while granite typically contains 25%40% silica.

When workers crush, cut, drill, grind, saw, or polish stone or man-made products containing silica, they release silica dust into the air. The dust particles are incredibly fine. Some are so small that they remain invisible. Respirable crystalline silica (RCS) refers to the fraction of airborne silica dust that poses a health concern due to its microscopic size. The microscopic particles can penetrate deep into the lungs, increasing the risk of silicosis.

What Is Silicosis?

Silicosis is a potentially deadly health condition caused by exposure to silica dust. It is a lung disease that often occurs years after exposure due to the buildup of silica. When you breathe in the tiny particles, the dust settles in your breathing passages and lungs. The silica particles cause scarring. The scarring stiffens the lungs, making it difficult to breathe. Besides trouble breathing, people may notice the following symptoms: phlegm; coughing; fatigue; weight loss; fever; swollen legs; shortness of breath; blue lips.

Three types of silicosis exist -- acute, chronic, and accelerated. Acute silicosis may present symptoms in a few weeks or a couple of years after exposure to silica.

The symptoms develop rapidly after a short exposure. With chronic silicosis, symptoms may not show up for decades after exposure to low or moderate levels of silica.

This is the most commonly diagnosed type of silicosis. The symptoms may appear mild and then slowly progress.

All types of silicosis are serious and potentially fatal. People suffering from silicosis are at greater risk of developing TB and lung cancer. Exposure to silica can

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Gold Coast stonemason Anthony White, 36, was diagnosed with silicosis in 2017 and tragically, passed away in March 2019 while he was on a double-lung transplant waiting list. He is praised for bravely and publicly exposing the dangers of silica dust, amid what’s being described as a “nationwide epidemic”.

“My brother is not going to be the only one who passes from this disease … you’ll see there will be a lot more very shortly.” Shane Parata, Anthony’s brother who has also been diagnosed with silicosis.

Anthony is believed to be the first tradesman to die of the disease in Australia.

also lead to chronic airway obstruction and simple chronic bronchitis. Exposure to Silica dust can also lead to a condition similar to MS (nervous system damage) called Systemic Sclerosis, scleroderma myositis and related syndrome.

How Long Does Silica Dust Stay in the Air? Silica dust is incredibly light and can remain airborne for long enough to travel outside of the immediate area. In a confined space without proper ventilation, the particles can accumulate. PCBUs (person conducting a business or undertaking) have a responsibility to maintain a reasonably safe work environment, which includes limiting exposure to health hazards such as silica dust. OHS regulations specify that workplace exposure should not exceed 0.1mg/m3 during an eight-hour work day.

To keep track of the levels of silica dust in the air, work sites with a significant presence of silica dust should have air monitoring equipment.

The use of ventilation systems can help reduce the amount of dust in the air. In fact, studies show that local exhaust ventilation can remove up to 99% of the dust in the atmosphere.

What Is the Best Respirator/PPE for Avoiding Silica Dust?

The use of personal protective equipment (PPE) is one of the recommended solutions for reducing exposure to silica dust. This typically involves the use of a respirator to help filter particles from the air.

Respirator masks receive ratings based on the assumed protection factor (APF) and the occupational exposure limit (OEL).

The standard ratings include P1, P2, and P3. SafeWork Australia recommends that workers be clean shaven and wear a minimum of a P2 efficiency respirator mask. Workers should also wear clothing that does not promote the collection of dust particles.

Besides respirator masks and appropriate clothing, the use of ventilation systems, water suppression, and tools with dust collection equipment help reduce exposure.

In some cases, PCBUs or supervisors need to implement shift rotations / modify cutting sequences / have extraction at source equipment to help limit the presence of dust particles in the air.

Silica dust is a major concern when working with materials containing crystalline silica.

To limit exposure and the health risks related to silica, ensure that your workplace complies with WHS / OSH legislation, including the use of the hierarchy of controls.

Brendan Torazzi is the CEO of AlertForce - a registered training organisation specialising in short Health and Safety courses to meet compliance. Brendan also runs the Australian Health and Safety Business Podcast and is the owner of OHS.com.au, an online marketplace for safety courses.

Ph: 1800 900 222 www.alertorce.com.au www.OHS.com.au

FORUM

HEADING

LAW

Do you agree to these terms & conditions?

Online agreements in Australia Emma Simpson and Julia Cameron explore different types of online agreements, their acceptance by Australian law and the importance of their legal enforceability.

• Online agreements allow businesses to transact with customers without having to negotiate or interact with each user individually.

• Australian courts recognise agreements that have been created online, provided that the basic elements of a contract can be established.

• Clickthrough agreements are generally legally binding in Australia, but browsewrap agreements (online agreement created without consent or positive step by the customer) are more difficult to enforce.

Have you recently bought a product online, downloaded an app or other software on your device, or purchased an online subscription? It is likely are that each of these transactions would have involved entering into an online agreement.

Online agreements are now commonplace in everyday transactions.

Properly implemented, an online agreement can permit businesses to create an enforceable contract with customers without having to negotiate or interact with each user individually.

For an online supplier of goods or services, it is critical that your online agreement is legally enforceable. Australian courts will recognise agreements that have been created online provided that the basic elements of a contract can be established. Generally this includes acceptance of contractual terms by both parties, a meeting of the minds, and an intention to create legal relations.

There are two types of online agreements, clickthrough (or clickwrap) agreements and browsewrap agreements.

Browsewrap agreements A browsewrap agreement is an online agreement that is created (typically between a seller of goods or services and their customer) without any consent or positive step by the customer. They do not require any consent or agreement to terms or conditions from a user before taking an active step to proceed with download of content or completion of a transaction (for example, ticking a box to confirm agreement to a set of terms and conditions).

These agreements are high risk as the user could claim they were not made aware of

the terms and conditions and did not have a reasonable opportunity to consider them.

Australian courts are less likely to consider browsewrap agreements as binding contractual relationships between the parties because it is difficult to demonstrate acceptance of the terms by the user.

Clickthrough agreements Clickthrough agreements are created when a user ‘clicks’ or ‘checks‘ a box (or otherwise takes a positive step) to indicate acceptance of terms and conditions displayed online. The positive step substitutes a real signature and is often used to enforce software licenses or authorise online transactions.

After the user has given their consent, they can continue to download the relevant content or complete the relevant transaction.

If the user rejects, or choose not to agree to the terms, the online agreement and their interaction terminates.

Australian courts are more likely to recognise a clickthrough agreement as legally binding if the following conditions are satisfied: 1. Reasonable Notice: The user must have had enough notice and opportunity to read the terms of the agreement before accepting the terms.

Ideally, users will be required to read the terms by scrolling through the text before proceeding, but a clickthrough agreement may also be enforced when there is a clearly and prominently displayed hyperlink indicating the existence of the terms and conditions.

2. Positive Step: The user must take a positive step (such as clicking ‘agree’ or ‘accept’) to confirm that they have read and consent to the terms of the agreement. The box should not be preticked. The wording of the acceptance and agreement is important, as is how the terms and the ‘accept/agree’ button are arranged on the page.

3. Unusual Terms: Any unusual or onerous terms should be displayed in bold or highlighted in some manner.

This point is particularly important when the user is a consumer or small business, as they are typically considered to have less bargaining power. There is also the benefit of

consumer protections contained in the Australian Consumer Law (ACL) which prohibit ‘unfair’ terms in consumer contracts. Whether a condition is ‘unusual’ depends on the circumstances. Relevant factors include the nature of the contract and the parties as well as the industry context. For example, if a term or obligation is typical in a particular industry, it will not be considered unusual in a commercial contract used in that industry and there would be no special onus to bring it to the user’s attention.

What does this mean for me?

For online suppliers of goods or services, it is critical that your online agreement is legally enforceable. If the basic elements of a contract cannot be established, you may not be able to enforce its terms for example, if a customer defaults in payment or breaches a term of a licence agreement or you would like to terminate the agreement.

Even the most carefully prepared terms and conditions will not be able to be enforced if they are not properly implemented.

If you sell or licence goods or services online, you should review your terms to ensure that they are drafted appropriately for an online context, and that they are properly communicated to your customers.

Our expert contracts team would be delighted to assist you.

Rigby Cooke’s expert commercial and PPSR teams can assist your business with these negotiations and to consider the best risk mitigation strategy for your business for each of your customers.

Emma Simpson is a Senior Associate in our Corporate & Commercial group with over five years of legal experience across a range of commercial matters.

Ph: 03 93217805; E: ESimpson@rigbcooke.com.au Julia Cameron is a Partner in our Commercial and Intellectual Property Groups and Manufacturing Industry Group Lead. Julia has extensive experience in advising brand owners, manufacturers and distributers in their distribution and IP protection.

Ph::03 9321 7807; E:JCameron@rigbycooke.com.au www.righbycooke.com.au

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AMTIL INSIDE

Supporting SMEs and developing export markets I recently attended a forum in Canberra focused on organisations that are set up to help SMEs in the development of export markets. AMTIL has recently signed an agreement with the Commonwealth to deliver an Export Hub in the Rail & Haulage Supply Chain and the forum was designed to offer third-party assistance through these various organisations.

Did you know that 75% of all businesses registered in Australia have fewer than five employees, and 99% of businesses are classified as SMEs, having fewer than 100 employees. It’s a staggering statistic that highlights the need for government programs to have a focus on supporting small-to-medium enterprises.

Given that statistic, it is also staggering to recognise that SMEs only account for 14% of Australia’s goods export (by value). SMEs in the G7 countries are responsible for an average of around 25% of goods exports and the EU average is 35%. Now we don’t expect to match that figure but if we could match the G7 average and lift SME exports to 25% of Australia’s exports, we would increase our GDP by $36bn.

Only 9% of Australian SMEs are currently engaged in any export activity.

So we have great scope to grow international markets if we can address some of the barriers at play.

Our Export Hub strategy over the next three years will be to break down some roadblocks and generate opportunities. Barriers such as the lack of resources to research international sales opportunities, the lack of capacity to build global networks, the lack of capability to promote and market products overseas, the lack of documented export plans and strategies and the lack of a critical mass to conduct trade mission activity will all be issues we focus effort on.

One of the assistance schemes showcased at the forum that was unknown to me was the Australian Trusted Trader Program (ATT), which is administered by the Australian Border Force. Businesses accredited under ATT are globally recognised for their compliant trade practices and secure supply chain, aiding their international competitiveness. It is voluntary, free to join and no ongoing fees. So if you are exporting and do run into issues from time to time, it’s a worthwhile exercise to look into. There are a large range of benefits available to businesses accredited under the ATT. For more information on the Rail and Haulage Supply Chain Export Hub being managed by AMTIL please contact Greg Chalker at gchalker@amtil.com.au

Shane Infanti, CEO AMTIL

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AMTIL HEADING INSIDE

Rail & Haulage – Breaking into international supply chains The Federal Government has engaged AMTIL to provide the Rail & Haulage Supply Chain Export Hub, an initiative to help small and medium-sized enterprises (SMEs) access international markets in the rail and haulage sectors.

AMTIL has been working on putting plans in place for the development of the Export Hub, and these are now starting to build momentum.

Phase One – Get ready The first stage of the Export Hub has involved setting up its governance structure, with an advisory committee and financial management system put in place, and the appointment of an Export Hub Manager and Export Hub Coordinator.

Industry engagement will be done through four mechanisms: • Primes and OEMs will be approached to identify their critical key supply chains and encourage them to work with the Export Hub on aspects as networking, business improvement programs and trade mission activity.

• Key partner organisations such as the Entrepreneurs’ Programme, the Industry Capability Network, the Australian Rail Authority, and Cooperative Research Centres (CRCs) will be invited to suggest relevant companies.

• AMTIL Members in these supply chains or who wish to access them will be encouraged to be involved.

• Other companies who find out about the project will be allowed to enter the eligibility process.

Any company that wishes to become a participant in the Export Hub must be approved by the Advisory Committee.

Export Hub participants will be required to undertake an audit to assess their Export Capability level and identify the productivity improvements required for them to become High-Performance Companies. Each Participant will be provided with a personalised assessment, and a tailored approach to building capacity and capability through training, facilitation, and engagement with other group members. The training will be carried out by High Performance Consortia (HPC), a specialist organisation which delivers education, and tailored support services with target market opportunities for SMEs engaged in rail and haulage supply chain commercial enterprise. These services will help participants to develop the knowledge, capability and capacity to successfully export their products and services.

Phase Two – Get fit Market research and intelligence across the rail, bus and truck industries will be sought through Austrade and AMTIL’s international network of associations. This market intelligence will form the basis of AMTIL’s Export Strategy and Trade Mission activity. Factors for

consideration include country overviews, macro-economic factors, political environment, legal environment, tariff and non tariff barriers, free-trade agreements, logistics and transportation issues, industrial trends, compliance issues, infrastructure issues, language barriers and ease of doing business.

Each Participant will engage in a process to deliver a Participant Export Plan. The Export Plan would cover the following factors: SWOT analysis; core business values and purpose; value proposition, audacious goals; resources; market niche; opportunities; budget allocations; demand validation; competitor analysis; sales channels; and customer service modelling. The Export Plan would take into consideration the overall Export Hub Plan to ensure all opportunities are addressed.

Each Participant will be invited to participate in Export Hub activities including facilitated member meetings, networking and social engagement activities, planned workshops, one-on-one mentoring sessions, plant visits, business breakfasts and progress reviews.

Phase Three – Export An overall Strategic Export Plan will be developed that covers Participants’ capabilities, target markets, resources and budgets.

This will be developed in consultation with the Consortia and Advisory Committee.

The Exporting stage does not tie into an actual timeframe as such; it is dependent on Participants’ capability, capacity and preparedness to undertake trade mission activity. Local exhibitions that are relevant will also be considered for Participant involvement, including Ausrail (December 2019), Megatrans (May 2020) and Austech (May 2021).

Each participant would have access to AMTIL’s marketing, communications and design team and develop material that will assist in the promotion and marketing of the participant in export activities. “Team Approach” material will also be developed to showcase the capabilities of the consortia as an entity.

Trade mission activity is dependent on the outcomes of export research and specific opportunities identified in their individual participants’ Export Plans. However, initial plans are to conduct a trade mission to Innotrans in September 2020. InnoTrans is the leading international trade fair for traffic technology, which takes place every two years in Berlin and covers five core areas: Railway Technology, Railway Infrastructure, Public Transport, Interiors, and Tunnel Construction. www.amtil.com.au 1382AMTIL

AMTIL is proud to acknowledge the support of its Corporate Partners.

AMTIL’s corporate partners offer a selection of products and services that will benefit our members in their business.

For any enquiries about our Corporate Partnerships, and how they can benefit you, contact Anne Samuelsson on 03 9800 3666 or email asamuelsson@amtil.com.au

Our Partners. Our Members. Your Benefits.

www.amtil.com.au

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Upcoming AMTIL events AMTIL has confirmed details for two of the biggest dates in its events calendar, our Annual General Meeting (AGM), and our Corporate Golf Day. AMTIL’s AGM will be held on Thursday 31 October at Riversdale Golf Club in Mount Waverley, Victoria. The AGM will be preceded by a Breakfast Seminar, featuring a special presentation by keynote speaker Simon Kuestenmacher, Director of Research at The Demographics Group.

Kuestenmacher is a rising star in data animation and interpretation, making astounding predictions for Australia’s future. A columnist for The Australian newspaper, he is frequently sought out

by SkyNews, The Project, newspapers and radio stations across Australia as a commentator on demographic and data matters. Reaching more than 30 million people every month through his Twitter account, Kuestenmacher speaks on demographic trends, consumer insights and cultural change in Australia.

Proceedings will begin at 8.00am with a networking breakfast, before the presentations get underway at 8.30am. The AGM will take place after the presentations.

WHAT’S NEXT?

Tee up for Golf Day The AMTIL 2020 Corporate Golf Day will also be held at Riversdale Golf Club on Friday 14 February. As always the event will include a light breakfast, lunch and drinks, plus trophies, prizes and giveaways. Golf commences at 7.30am.

Visit AMTIL’s events page for more details about our upcoming events and to register to attend. For more information, please call 03 9800 3666, or email Events Manager Kim Banks on kbanks@amtil.com.au. www.amtil.com.au/Events

Networking nationwide AMTIL members right across the country were out making new contacts and catching up with old friends, at a series of social events held by AMTIL in June.

Networking events were held in Brisbane (13 June), Perth (18 June), Adelaide (20 June) and Sydney (27 June). Several AMTIL staff and board members were also in attendance to represent the Association. the events were well attended and feedback from those who came along suggested a good time was had all round.

Brisbane

www.amtil.com.au/events

Adelaide

Perth

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The 2019 season is continuing to pull off a number of surprises. On field, the Brisbane Lions are sitting second after 18 rounds, the Pies after a good start are beginning to look very shaky and both the Bombers and Tigers are making a charge to cement their place post season – although fair to say so far the Tigers are yet to beat any top four team this year. Off field, three clubs have moved on their senior coaches with one of those sacked looking for a new home while the other two may not be as lucky. There’s quite a log-jam of teams vying for the last few places in the top eight and to be honest, any team on any given day can belt out the team song post game. 2019 won’t be remembered as a season where there was a tear-away leader. The tipping ladder has also seen some significant movement as well. Our last issue had SKN sitting comfortably on top and now hanging on for dear life in 10th, Mottdiggitydog is well out in front by three and with continued successful tipping should come away with the chocolates. Till next time, Sanchez ROUND 18 1 Mottdiggitydog 104 (440) 2 Tungaloy Australia 101 (389) 3 Mab eng 101 (479) 4 Matty 99 (499) 5 Magpiemad Rules! 98 (376) 6 Odds On 98 (464) 7 Shaftesbury Avenue 98 (502) 8 Brendan 98 (541) 9 Mal 97 (449) 10 SKN 97 (495)

Real Business Real People Real Members John Hart is proud to be a founding member of AMTIL. Our continued and active participation is fostered by the enthusiastic and engaging staff at AMTIL. Their staff have an intimate understanding of our industry from all perspectives and provide a valuable resource of skill, knowledge, and experience. There are many benefits that come from AMTIL membership, the most valuable of which is its people.

Mark Dobrich, John Hart

Since 1999, AMTIL has been connecting business, informing of opportunities and growing the manufacturing community.

To be become an AMTIL member contact our Corporate Servcies Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

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INDUSTRY CALENDAR

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event More events can be found on AMTILâ&#x20AC;&#x2122;s website

INTERNATIONAL VIETNAM MANUFACTURING EXPO Vietnam, Hanoi 14-16 August 2019 www.vietnammanufacturingexpo.com

IMEX India, Mumbai 20-22 September 2019 www.imexonline.com

LASER TAIWAN Taiwan, Taipei 16-18 October 2019 www.chanchao.com.tw/laserexpo/en

TAIMOLD Taiwan, Taipei 21-24 August 2019 www.odm-dmi.com/en

INDUSTRIAL AUTOMATION FIESTA Malaysia, Johor Bahru 23-24 September 2019 www.industrialroadshow.com/index.html

SIANE France, Toulouse 22-24 October 2019 www.salonsiane.com

CAMBODIA INTL MACHINERY INDUSTRY FAIR Cambodia, Phnom Penh 22-25 August 2019 www.camboexpo.com/cimif

INTERNATIONAL TECHNICAL FAIR Bulgaria, Plovdiv 23-28 September 2019 www.fair.bg

TOOL TECH Korea, Goyang 22-25 October 2019 www.tooltechkorea.com/english

EAM - EXPERIENCE ADDITIVE MANUFACTURING Germany, Augsburg 24-26 September 2019 www.experience-am.com

SMATOF South Korea, Changwon 29 October 1 November 2019 Smart manufacturing tech fair & conference. www.smatof.com

WESTEC USA, California 24-26 September 2019 www.westeconline.com

BLECHEXPO Germany, Stuttgart 5-8 November 2019 www.blechexpo-messe.de/en

METALEXPO Argentina, Cordoba 5-7 September 2019 www.metalexpo.com.ar/cordoba2019

MEDTEC CHINA China, Shanghai 25-27 September 2019 Medical device design/manufacture www.medtecchina.com/en-us

MITEX Russia, Moscow 5-8 November 2019 www.mitexpo.ru/en

SWISS MEDTECH Lucerne, Switzerland 10-11 September 2019 For medical device design/manufacture www.medtech-expo.ch/en

CANADIAN MANUFACTURING TECHNOLOGY SHOW Canada, Toronto 30 September-3 October 2019 www.cmts.ca

SCHWEISSEN Austria, Linz 10-12 September 2019 www.schweissen.at

TOOLEX Poland, Sosnowiec 1-3 October 2019 www.exposilesia.pl/toolex/uk

ALUMINUM USA USA, Nashville, 12-13 September 2019 www.aluminum-us.com

METAVAK Netherlands, Gorinchem 8-10 October 2019 https://booking.evenementenhal.nl/nl/ metavak-2019/gorinchem

PDMEX Philippines, Manila 28-31 August 2019 www.pdmex.weebly.com CIEME China, Shenyang 1-5 September 2019 China Intl Equipment Manufacturing Expo www.cnzbh.com

EMO HANNOVER Germany, Hannover 16-21 September 2019 www.emo-hannover.de FASTENER EXPO Las Vegas, USA 17-19 September 2019 www.fastenershows.com MWCS China, Shanghai 17-21 September 2019 www.chinaexpo-fair.com/mwcsmetalworking-and-cnc-machine-toolshow-2019 TECHINNOPROM Belarus, Minsk 17-20 September 2019 www.expoforum.by/en/exhibitions WORLD OF METAL India, Mumbai 20-22 September 2019 www.wom-expo.com/en-GB

AMT AUG/SEP 2019

VIMF -VIETNAM INDUSTRIAL AND MANUFACTURING FAIR Vietnam, Bac Ninh 6-8 November 2019 www.vietnamindustrialfiesta.com/vimf2019 IMT TAIWAN -INTERNATIONAL METAL TECHNOLOGY TAIWAN Taiwan ,Taichung 7-10 November 2019 https://en.imttaiwan.com FABTECH Chicago, USA 11-14 November 2019 www.fabtechexpo.com

MTA MYANMAR Myanmar, Yangon 9-11 October 2019 www.mtamyanmar.com

METAL-EXPO Russia, Moscow 12-15 November 2019 www.metal-expo.ru/en

MAKTEK Turkey, Izmir 9-12 October 2019 www.izmirmaktekfuari.com/en

RUSSIAN INDUSTRIALIST Russia, St. Petersburg 13-15 November 2019 https://promexpo.expoforum.ru/en

METALEX Vietnam, Ho Chi Minh City 10-12 October 2019 www.metalexvietnam.com

MACTECH Egypt, Cairo 14-17 November 2019 www.mactech.com.eg

MTA HANOI Vietnam, Hanoi 16-18 October 2019 www.mtahanoi.com/en-us

FORMNEXT Germany, Frankfurt 19-22 November 2019 https://formnext.mesago.com

METALCON USA, PITTSBURGH 16-18 October 2019 www.metalcon.com

INTERNATIONAL INDUSTRIAL FORUM Ukraine, Kiev 19-22 November 2019 www.iec-expo.com.ua/en/if-2019.html

INDUSTRY CALENDAR HEADING LOCAL AIMEX SYDNEY SHOWGROUND; 27-29 AUGUST 2019 Asia-Pacific’s intl. mining exhibition. Includes the latest technological advances and innovations in the mining industry. www.aimex.com.au SAFETY IN ACTION MELBOURNE CONVENTION & EXHIBITION CENTRE 10-11 SEPTEMBER 2019 Australia’s leading workplace health and safety event. www.safetyinaction.net.au WA MINING PERTH CONVENTION & EXHIBITION CENTRE 15-16 OCTOBER 2019 “Accelerating WA’s Mining Future to 2030” From operational strategy to execution, addressing the strategic and technical approaches to improve productivity, lower costs and optimise the end to end process. www.waminingexpo.com.au/en-gb.html ALL-ENERGY MELBOURNE CONVENTION & EXHIBITION CENTRE; 23-24 OCTOBER 2019 Australasia’s largest and most comprehensive clean and renewable energy event. Held in partnership with the Clean Energy Council www.all-energy.com.au INTERNATIONAL MINING & RESOURCES EXPO MELBOURNE CONVENTION & EXHIBITION CENTRE 28-31 OCTOBER 2019 Covers all aspects of mining, from exploration to investment, production to optimisation through to new technologies. www.imarcmelbourne.com

Advertiser Index

CEBIT SYDNEY INTL. CONVENTION CENTRE 29-31 OCTOBER 2019 Information technology, telecommunications, software & services. www.cebit.com.au WASTE & RECYCLING EXHIBITION EXPO SYDNEY INTL. CONVENTION CENTRE 30-31 OCTOBER 2019 Showcases the efficient, profitable and sustainable waste and recycling solutions.

Includes seminars & workshops. www.awre.com.au AUSBIOTECH MELBOURNE CONVENTION & EXHIBITION CENTRE EXPO 30 OCTOBER – 1 NOVEMBER 2019 Dedicated to growth and prosperity of the Australian biotechnology industry. www.ausbiotechnc.org AUSRAIL PLUS SYDNEY INTL. CONVENTION CENTRE 3-5 DECEMBER 2019 Largest rail event in Australasia – ‘Delivering Growth; Creating Opportunity; Embracing Technology”. The event provides a platform for knowledge sharing & networking with world’s leading industry figures, rail manufacturers & operators. www.ausrail.com

2020 AUSTRALASIAN OIL & GAS EXPO PERTH CONVENTION & EXHIBITION CENTRE 11-13 MARCH 2020 Showcasing the latest in instrumentation control and automation, asset integrity, subsea, health, safety & environment and drilling & completion. www.aogexpo.com.au

AGL 51 Alfex CNC

21

Amiga Engineering

25

Applied Machinery

15

Applied Machinery

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Bolts & Industrial Supplies

FLAP

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HISTORY

Big wheels & little wheels – the story of UK-born Australian Sir Laurence John Hartnett (1898 – 1986) Australia’s “Father of the Holden” and much more

PART 32

“TOTAL WAR” ON THE INDUSTRIAL FRONT

WW2 broke out in September 1939. Six months later Laurence was appointed Director of Ordnance Production, with Essington Lewis at the helm of the hastily-assembled Dept. of Munitions. Many of the machine tools necessary to make the munitions didn’t exist in Australia in 1940. The job called for someone with organisation, technical skills, and an understanding of machine tools. A job made-to-order for Laurence and GM-H!

E

ssington Lewis, who was appointed Director General of the Department of Munitions in May 1940, had been given the incredible responsibility of directing the switch-over of Australian industry from peacetime manufacture to war production. Towards the end of that first-day chat with Lewis, J. K. Jensen, (later) the secretary of the Munitions Department, came to see me in the Munitions Office’s bare room. Jensen, a tall, spare man, balding, with craggy, dark eyebrows and a quiet, brisk manner, told me: “This is a brand-new department, Mr. Hartnett. It’s starting from today, and so far we’re about the whole strength.” I could sense from his manner that he had no doubts the “strength” would grow quickly as the organization got into gear. “We’ve also got a principal supply officer, Colonel Rowe, upstairs,” Jensen said.

“He’s been foraging around for a long time finding out who could make what if war broke out. There’s an office next to his that might suit you.” He took me upstairs to an office directly above Lewis’. It was just an empty room: no furniture of any kind, no cabinets - nothing.

“We’ll put some stuff in here for you,” Jensen said. From somewhere a desk and a couple of chairs were found, and I moved in on the following Monday.

The structure of that new Department, and the function of the various Directorates, had been drawn up by Jensen in March 1939, but since there was “no requirement” for it at that stage, it was shelved. Jensen resurrected his plan and showed it to Lewis who adopted it there and then.

It was adhered to throughout the war. It called for the appointment of leading civilian experts as heads of the major branches of munitions production.

On my first day, I asked, “What do I do for a secretary?” I suggested Leila Williamson, my secretary at GM-H. Leila came in a few hours later and we were ready to start work. On what? That was the next question.

A document was delivered to me. “War Cabinet Approval for Munitions Requirements” was the heading. There were about forty items on it: two-pounder anti-tank gun, twenty-five-pounder, mines, searchlights, and a lot of other equipment. “Do you know where I start and where I end?” I asked Lewis. He said, “I’m not sure. We must get this sorted out, so let’s start now. There is a lot of ammunition on the list. Would you like to take on that?” “No, I said, that doesn’t appeal greatly. What about ordnance-guns?” ”All right, you take on the guns,” he said. “Oh, perhaps you could go a bit further. These searchlights are pretty urgent, too. And there are a number of other items you could probably take under your wing.” In that completely informal, almost casual, way I had dished on to my plate the responsibility for producing a well-nigh frightening list of weapons. Without them, Australia’s fighting forces couldn’t fight. And every item on the list was needed not only immediately - but yesterday. And everything on that list had to be made in Australia: in Australian factories that had not been planned or equipped to tackle any one of the jobs, by men and women mostly unskilled in fine-tolerance machine-tool operation. And, incredibly, there were very few drawings, or blueprints, designs or specifications available for some of these vital

Photo courtesy State Library of SA (Holden Collection, GM-H Defence Projects, 1939-43).

Pictured is a GM-Holden-supplied image of a welding operation for C.A.C. (Commonwealth Aircraft Corp.) associated with interceptor aircraft construction, circa 1942

weapons. The twentyfive-pounder-gun-howitzer was desperately needed: our army’s field artillery had only 1914-18-vintage eighteenpounders. Before the war, the Government munitions factories had done a very good job with limited finance and had mastered much of the art of gun-manufacture, but they did not have the capacity to cope with the sudden rush of orders. Only private industry, skilfully co-ordinated, could meet those demands. And it was our job to implement this.

With the outbreak of World War 2, manufacturing production in Australia was hastily swung towards wartime production. Australia was ill-prepared - lacking armaments, modern fighter aircraft and a shortage of desperately-needed machine tools. To overcome this, special machines were designed and built or old ones resurrected or modified.

GM-H (General Motors Holden) was the first appointed co-ordinating contractor for the war effort. In Australia at that time no company would take on a job to produce items of war equipment - they had no experience, nor were they equipped. GM-H had peacetime experience planning and organising for quantity production. Hence GM-H placed all plants, personnel and facilities at the disposal of the Australian Government in order to produce aircraft, military vehicles, ammunition, weaponry, tents, canvas goods, boats and associated materials. Car production was accordingly, delayed.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

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To be continued…

MACHINERY FORUM (NSW) Pty Ltd 33 Brodie Street, Rydalmere NSW 2116 Ref. Mr. Heino Windhorst T. +61 (02) 96389600 E. heino@mafosyd.com.au

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Article circa: 1989

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