AMT OCT/NOV 2020

OCT NOV 2020

Need finance to accelerate your export growth?

See how Export Finance Australia could help.

1800 093 724 exportfinance.gov.au

FAST-TRACKING HEADING… RECOVERY

RAIL, SHIPPING & LOGISTICS

Special Feature: Business Management State Spotlight: Queensland

We’re helping manufacturing businesses grow through COVID-19.

If you need a cashflow boost, or need finance to grow, we could help.

Export Finance Australia provides a range of loans and guarantees for exporters or supply chain businesses.

Without Export Finance Australia our business growth would have been substantially hindered. Their assistance has directly resulted in us meeting most of the global demand across our product portfolio, particularly in our key sales markets of North America, Europe and the United Kingdom.

Barry Calnon Chief Financial Officer & Finance Director, BirdDog

To see how we could support your business, contact us on: 1800 093 724 exportfinance.gov.au/covid19

OCT NOV 2020

FAST-TRACKING RECOVERY

RAIL, SHIPPING & LOGISTICS

Special Feature: Business Management State Spotlight: Queensland

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ex GST (M640D)

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MODEL Code

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mm

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10-1000

Power Feed - Vertical (Z)

5 - 500

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mm / min kg

1800

Spindle Speeds (Universal Head)

steps / rpm

27 (30 - 2050)

Motor Power (Universal Head)

kW / hp / V

7.5 / 10 / 415

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All prices exclude GST and are valid until 31-10-20

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Safety Enclosure The fully enclosed guarding system is designed so that machine stays compact, yet full access is available to all areas of the machine through lockable and safety interlocked doors

Laser Cutting Head The METALMASTER laser is supplied as standard with a RAYTOOLS Auto focus head

Servo System The METALMASTER servo system utilises YASKAWA AC servo motors and drives from Japan, this enables speeds up to 40m/min with acceleration of 0.5G (5m/s2) whilst maintaining superior and repeatable positioning accuracy

Available in several machine sizes we can customise the size to suit your needs

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MM-1313

MM-3015

CUTTING CAPACITY

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1300 x 1300

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METALMASTER Fiber Lasers are built with the highest quality components sourced from reputable suppliers around the world such as IPG Laser, Precitec Laser, Raytools autofocus cutting heads and Yaskawa CNC drive systems.

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1/2 Windsor Rd, Northmead

3000 x 1500

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mm

5

6

10

12

mm

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6

8

10

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Type

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CYPCUT

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Type

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Auto Focus

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Type Yaskawa Servo Yaskawa Servo Yaskawa Servo Yaskawa Servo

QLD

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625 Boundary Rd, Coopers Plains

VIC

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4 Abbotts Rd, Dandenong

WA

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11 Valentine Street, Kewdale

05_AMTIL_011020

1300 x 900

006

CONTENTS

Volume 20 Number 05 OCT/NOV 2020 ISSN 1832-6080

FEATURES RAIL SHIPPING & LOGISTICS Rail – A route to recovery?

Innovative ship cladding creates jobs/cuts emissions High-speed rail: A fast track to recovery?

Austal ferries highlight Australian capability Angel Trains rolls out 3D-printed parts on UK trains

42 46 48 50 52

ROBOTICS & AUTOMATION The key to successful automation projects Mitsubishi Electric – Manufacturing in the new normal One size does not fit all

54 56 58

CUTTING TOOLS Iscar: Grade upgrade Carmaker sees 1,150% increased tool life MRO tools weather turbulent industrial economy Walter – New dimensions in drilling

64 67 68 70

FORMING & FABRICATION Bertazzo Engineered – Engineering passion Government urged to modernise outdated welder training

72 74

COMPANY FOCUS Elexon Electronics – Bringing work onshore and in-house

76

42 RAIL – A route to recovery?

Gladys Berejiklian’s assertion that Australia “can’t make trains" has been met with offended outcries.

Australia has a substantial rail manufacturing industry and a reputation for quality. Could this sector offer one possible route to a post-COVID recovery?

60

STATE SPOTLIGHT: QUEENSLAND Evolve Group: The value of Oz design/manufacturing 78 Technofast – Innovating and succeeding in challenging times 82 A centralised manufacturing network – Laser Central 83 ADDITIVE MANUFACTURING AM capability sees Romar Engineering soar Sentient Bionics gets a helping hand from the AM Hub FELIXprinters: Vegan-friendly 3D-printed salmon

84 86 90

MATERIAL REMOVAL Floor space and efficiency as a key concept

91

BUSINESS MANAGEMENT AMGC: Ten ways for Australian manufacturers to succeed Resilient leadership in the time of COVID-19 Performance management in a COVID-19 world BOOK REVIEW: Drain The Defence Swamp PhoenxPLM: Digitally transforming businesses Part 2

92 94 96 97 98

COMPRESSORS & AIR TECHNOLOGY Kaeser celebrates 30 years in Australia

Professor Bronwyn Fox is the Deputy Vice-Chancellor (Research and Enterprise), Swinburne University of Technology. She spoke to AMT.

76

100

WASTE & RECYCLING Micro-recycling science delivers new ‘material microsurgery’ 104 Boeing Australia awarded for carbon fibre recycling program 105

REGULARS From the Editor From the CEO From the Ministry From the Industry

8 10 12 14

INDUSTRY NEWS Current news from the industry

16

VOICEBOX Opinions from across the manufacturing industry

28

PRODUCT NEWS Our selection of new and interesting products

34

ONE ON ONE Professor Bronwyn Fox

60

COMPANY FOCUS Elexon Electronics – Bringing work onshore and in-house

76

AMTIL FORUMS

106

AMTIL INSIDE The latest news from AMTIL

110

MANUFACTURING HISTORY – A look back in time

118

AMT OCT/NOV 2020

One-on-One

Bringing work onshore and in-house Electronics manufacturers have long been inclined to look offshore for outsourcing work.

One company bucking that trend is Queensland-based Elexon Electronics.

86 Sentient Bionics gets a helping hand from the AM Hub When Sentient Bionics required rapid production of prototype parts for its new robotic hand project, it turned to AMTIL’s AM Hub for assistance.

HEADING

OKUMA MULTI-TASKING The MULTUS U3000 is in Okuma’s Premium Multitasking Machine range with Sub Spindle for even higher Productivity.

• New Compact head with up to 25kW of Milling power • Machining Navi L-g and M-gii – Okuma’s own chatter suppression technology • New Cycle time reduction feature for Workpiece transfer between 2 Spindles

Okuma. Welcome to OPEN POSSIBILITIES.

08

FROM THE EDITOR WILLIAM POOLE

Manufacturing faces a fight for its fair share There’s no doubt the COVID-19 pandemic has made 2020 a year we’d all rather forget. But if there has been a silver lining, for our industry at least, it has been the way COVID-19 has put Australian manufacturing back on the national agenda.

From empty supermarket shelves to shortages in vital medical equipment, the pandemic highlighted how vulnerable the lack of a strong manufacturing base leaves us. Disruptions in supply chains both local and international have exposed the risk of us not being able to access essential products when we need them.

At the same time, we saw the dynamism and ingenuity that the sector has to offer, as Australian manufacturers joined the battle against the virus, rapidly adapting their operations to produce everything from face masks and hand sanitiser, to ventilators.

Nonetheless, a report from the Centre for Future Work has shown that manufacturing still has some way to go if it is to stake a claim in Australia’s recovery from the crisis.

The report, A Fair Share for Australian Manufacturing: Manufacturing Renewal for the Post-COVID Economy, found that Australia ranks last among all OECD countries for manufacturing self-sufficiency. Australians use $565bn worth of manufactured goods each year, but we produce a mere $380bn. In other words, we produce just over twothirds of what we use: less than any other advanced economy.

While these findings reflect the decline seen in Australian manufacturing over recent years, the pandemic has highlighted the need for domestic manufacturing capacity. The report stresses that manufacturing is not just ‘another’ sector of the economy. It carries strategic importance to national prosperity and security, for a number of reasons: • Australians are purchasing more and more manufactured goods, and manufacturing output is growing around the world. Consequently, allowing domestic manufacturing to decline, while our use of manufactured products grows, undermines national economic performance.

• Manufacturing is the most innovation-intensive sector of the economy; no country can be an innovation leader without a strong manufacturing base.

• Manufactured goods account for over two-thirds of world merchandise trade. A country that cannot successfully export manufactured goods will be shut out of most trade.

• Manufacturing anchors hundreds of thousands of other jobs across the economy, thanks to its long, complex supply chain. Billions of dollars’ worth of supplies and inputs are purchased by manufacturing facilities, supporting many other economic sectors.

• Manufacturing offers high-quality jobs, full-time hours and above-average incomes.

Moreover, strong productivity growth and the capacity to apply modern technology mean that manufacturing offers the prospect of rising incomes in the future.

The report shows Australia faces an enormous task in rebuilding our domestic manufacturing capacity. However, its author, Dr Jim Stanford, stresses there are enormous potential economic benefits in getting manufacturing back to a proportional size: including $180bn in new sales, $50bn in new GDP, and more than 400,000 new direct jobs. With politicians, business leaders and the general public realising the importance of manufacturing in rebuilding the national economy after COVID-19, this is surely a challenge worth taking on.

Editor William Poole wpoole@amtil.com.au Contributors Brent Balinski Head of Partnerships & Sales Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Editorial Assistant Sarah Cayless 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 PEFC™ Programme for the Endorsement of Forestry Certification Chain of Custody certified from sustainable forests 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 $175 (ex GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

1525AMTOCT/NOV2020

AMT OCT/NOV 2020

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010

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Now is the time to invest in our future Advanced manufacturing is currently defined by the Australian Government as “any manufacturing process that takes advantage of high-technology or knowledge-intensive inputs as an integral part of its manufacturing process”.

I couldn’t agree more, but it seems we are more focused on developing cheaper gas than we are on developing strategies that will increase the potential of our advanced manufacturers as described above.

A starting point would be to recognise that manufacturers across the developed world succeed not because they make certain products, but because they have invested in manufacturing technology, adopted sophisticated manufacturing methodologies and process techniques. They typically use a combination of three factors to remain competitive: advanced knowledge, advanced processes and advanced business models.

But this is not new news. According the World Economic Forum’s Readiness for the Future of Production report, Australia is a “high potential” country for this type of future production. Key opportunities and advantages are arising for Australian manufacturing from increasing amounts of investment in digital technologies, but also from the integration of these new technologies into an increasing range of the manufacturing processes and supply chains.

Manufacturing workplaces increasingly rely on technologies, methodologies and techniques (what we refer to as TMTs) to deliver highly complex products and solutions.

The Advanced Manufacturing Growth Centre (AMGC) was established in 2015 as a key plank of the Australian Government’s Industry Growth Centres Initiative. Funded by the Commonwealth, its goal is to drive innovation, productivity and competitiveness across Australia’s manufacturing industry. Its most recent Sector Competitiveness Plan stated: “Manufacturing is transforming, so we need a new definition to accurately measure who we are and where we need to go. Our research presents a real opportunity for Australian manufacturers. It shows that we have huge growth potential if we can emulate and adopt the advanced manufacturing characteristics of advanced knowledge, advanced processes and advanced business models”. Another tick for TMTs. The latest CSIRO report on Advanced Manufacturing - A Roadmap for unlocking future growth opportunities for Australia – identified a number of growth opportunities and enablers. It highlighted the fact that: “Sustained growth in the sector will require proactive investment and translation of enabling science and technology.

Combinations of sensors and data analytics; advanced materials; smart robotics and automation; 3D printing; and augmented, mixed and virtual reality are emerging as key enablers of future growth.”

Tick for TMTs and the need for early adoption.

The Prime Minister announced the establishment of the National COVID-19 Coordination Commission (NCCC) on 25 March 2020, and its renaming to the National COVID-19 Commission Advisory Board on 27 July 2020. This name change reflects its strategic advisory role in providing a business perspective to Government on Australia’s economic recovery. In its new role as an Advisory Board, the Commission will be concentrating its efforts on supporting the Government’s plans for Australia’s economic recovery and getting as many people back into jobs as quickly as possible.

It should be noted that the NCCC submission and recommendations to the Commonwealth were presented as a draft in June, and have not been publicly responded to by the Government as yet.

Many industry leaders have publicly commented on the lack of transparency around the NCCC submission and process, and have had to rely on leaked documents to have an appreciation for what the Commission is trying to achieve.

AMT OCT/NOV 2020

“Manufacturers across the developed world succeed not because they make certain products, but because they have invested in manufacturing technology, adopted sophisticated manufacturing methodologies and process techniques.”

AMTIL made a submission to the NCCC in May this year that included a total of 21 recommendations, noting that Technology Dissemination (TD) programmes are an effective way for Government to provide the intensive knowledge transfer and support that private sector industry needs to expand into new technologies, methodologies and techniques. One of our recommendations was to commit $15m over five years to a National Technology Dissemination Programme. We will continue to engage with the Commission to seek a response to our submission.

AMTIL has recently undertaken a number of surveys, workshops and video conferences with our members regarding an industry-led technology diffusion project, and we have a strong commitment for a three-to-five-year, persistent, consistent approach to encouraging the early adoption of manufacturing technologies and the uptake of management methodologies and process techniques. We strongly believe we have the support to undertake a project of this scale, and are currently in discussions with Ministerial and Government Departments to match the industry commitment. We encourage the Commonwealth to support this initiative, which is in line with a number of reports that have been generated in recent times.

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012

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

Building resilience for our post-pandemic future As politicians, we’re not known for understating things. But it’s a massive understatement to say 2020 has been a tough year for Australia.

From a summer of devastating bushfires to an unprecedented global pandemic, families, communities and businesses have been challenged like never before. The unseen enemy of COVID-19 has tested us not only as a health crisis, but as a barrier to being able to do business as usual.

But we are enduring.

Regions devastated by fire are rebuilding and those businesses who had to change how they operate because of COVID-19 have gone online, pivoted their operations and are using amazing Aussie ingenuity to continue to open their doors.

As a Government we knew we had to take immediate, short-term steps to keep Australians in jobs, support businesses and position the economy to recover. As the pandemic rolls on we are continuing to provide unprecedented levels of support to households and businesses.

We are extending JobKeeper by six months to March next year.This extension will provide further support to significantly impacted businesses so more Australians can retain their jobs and continue to earn an income. We are also providing cash flow support for small and medium-sized businesses, wage subsidy support for businesses with apprentices and trainees, as well as tax support.

But throughout this pandemic we haven’t lost sight of the future, because we know that resilience is key to ensuring our businesses can seize opportunities when conditions improve.

Our manufacturers are a great example of what can be achieved by addressing the here and now, while also thinking about the future. Our manufacturers were called on to step up during the COVID-19 crisis and with the support of government managed to deliver a range of incredible outcomes – from ramping up production of face masks, to making highly technical invasive ventilators.

Our need to respond to the COVID-19 crisis has helped develop resilience that will hold us in good stead for the future. Not only will we be able to support ourselves in a crisis going forward, we have established new market opportunities in a post-pandemic world. Our Government has also been focussed on supporting our manufacturers to become more competitive. We’re helping around 200 manufacturers to invest in new technologies and upskill their workers

AMT OCT/NOV 2020

“Throughout this pandemic we haven’t lost sight of the future, because we know that resilience is key to ensuring our businesses can seize opportunities when conditions improve.

Our manufacturers are a great example of what can be achieved by addressing the here and now, while also thinking about the future.” through the Manufacturing Modernisation Fund. Our $48.3m has unlocked $215m in projects that will create around 2,600 new jobs.

But it’s not just our manufacturers who’ve been embracing digital tools to become more resilient and competitive. Small and medium-sized businesses of all kinds have turned to technology to help them get through the crisis. In doing so they’ve made themselves stronger and more likely to succeed when things open back up.

Increasing digitisation of businesses is essential to the growth of our economy and to creating jobs. But with opportunity comes risk and we need to make sure our businesses have the cyber skills they need to protect themselves in the digital world.

Upgrading cyber security and online skills are particularly important for the resilience of small and medium-sized businesses which

comprise 98% of all Australian businesses.

Our Government’s Cyber Security Strategy 2020 includes a $26.5m Skills Partnership Innovation Fund that will help build cyber career pathways and get Australians into jobs.

Another initiative of the strategy is the $8.3m Cyber Security Connect and Protect Program, which will boost existing industry efforts to help small and medium-sized businesses increase their cybersecurity capability.

We want to emerge from the COVID-19 crisis with competitive and resilient businesses that can compete both at home and on the global stage.

Shocks and stresses like COVID-19 will continue to happen, but by addressing the now with a view to the future, Australia will be prepared to weather them.

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014

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Australia’s 2020 Cyber Security Strategy underscores risks to businesses Cyber security threats continue to be a growing and evolving risk management issue for many businesses, with news about data breaches and ransomware attacks becoming more mainstream. What used to be considered a ‘niche’ issue is now well and truly an issue for boardrooms and senior management.

Experts recognise that cyber attacks are not a matter of “if” but “when”. The intensity and volume of attacks makes us all vulnerable.

chain members, companies need to look beyond production capability and credit risk and ask detailed questions about cyber security preparedness.

The Government has stated that cyber security incidents cost Australian businesses up to $29bn each year, with almost one in three Australian adults impacted by cybercrime. Just last month, in releasing its inaugural Annual Cyber Threat Report (July 2029-June 2020), the Government revealed the Australian Cyber Security Centre (ACSC) is receiving almost 60,000 reports a year – or one every 8.8 minutes.

It is very timely, therefore, that in August the Government released its 2020 Cyber Security Strategy, highlighting that it is now more critical than ever for closer collaboration between governments, businesses, other organisations and the community to address our mutual concerns and interests.

And with more people working from home in light of the COVID-19 pandemic, there are new risks. Australians are becoming increasingly reliant on the online environment, making it even more essential that we are all adequately protected against cyber crimes and related threats (check out the ACSC’s tips for when working from home at: tinyurl.com/y2wthl4v).

Ai Group’s membership represents a diverse range of businesses, of many sizes and from many sectors, and COVID-19 has highlighted to us how many of these businesses are essential to our economy.

Digital technologies have been a key enabler for such businesses to remain open and sustainable. These businesses contribute to our sovereign industrial capability, our various supply chains, and critical infrastructure and services.

Now, amid a pandemic-driven recession, businesses are facing challenges greater than any in living memory. The pandemic has also highlighted broader economic vulnerabilities, raising questions about the scope of our domestic capabilities and resilience of global supply chains.

This unstable environment presents an opportunity for industry to emerge more globally competitive by taking fuller advantage of Industry 4.0 and digitalisation. Various Government announcements, including building our sovereign industrial capability, should contribute to our economic growth and resilience.

But to ensure that businesses can make the most of these opportunities, we need to ensure that businesses are equally cyber secure and resilient.

As AustCyber – the Australian Cyber Security Growth Network – has stated, cyber security is a function of insurance for a resilient economy, and cyber security is a shared responsibility for everyone.

In June the Government made an announcement about malicious cyber activity against Australian organisations during this pandemic.

It was a sobering reminder that businesses and the community need to be vigilant at this time of increased geopolitical tensions and with our changed work practices. In light of growing public awareness and government scrutiny of data privacy and rights, which may arise from cyber security incidents, it is also important that businesses ensure that they are adequately meeting consumer and government expectations and levels of trust.

All Australian organisations should be alert to cyber security threats and take appropriate steps to build resilience into their systems, networks, supply chain and partners. When assessing supply

AMT OCT/NOV 2020

The Strategy includes a $1.67bn commitment over the next ten years to invest in initiatives to help strengthen Australia’s security. There are several positive funding commitments directly targeted at supporting and working with industry. These are aimed at: • Enhancing incident response procedures.

• Improving information threat sharing.

• Strengthening cyber security partnerships.

• Improving critical infrastructure security.

• Uplifting cyber security of small and medium-sized enterprises (SMEs).

• Growing a skilled workforce.

• Supporting R&D industry partnerships.

• Enhancing access to guidance and assistance on cyber security.

There are also actions for governments, businesses and the community to address various aspects of cyber security, which will need to be properly worked through with stakeholders. This includes reforms such as the critical infrastructure security reforms.

Other activities that have flowed from this Strategy include the Department of Home Affairs’ recent release of its Voluntary Code of Practice: Securing the Internet of Things (IoT) for Consumers (https://tinyurl.com/y3qwdkuc), as well as the ACSC’s tips for securing IoT devices (https://tinyurl.com/yxpymf27) and guidance for manufacturers (https://tinyurl.com/yxjamkhg).

Just as no company is immune from cyberattacks, managing risk is not beyond the scope of most companies. The ‘Essential Eight’ outlined by the Australian Signals Directorate (https://tinyurl.com/ y3ujzcvn) is a set of strategies to mitigate cyber security incidents that will protect companies from 80% of risks. This includes: • Mitigating known application control bypass techniques.

• Raising the bar for less mature implementations of application control.

• Expanding the scope of application control for servers.

• Correctly identifying less mature approaches to testing restoration of backups.

• Increasing the frequency of testing restoration of backups.

We encourage businesses to pay close attention to these recommendations, and to the important range of Government initiatives designed to strengthen our resilience. It is crucial to seek the best advice possible, particularly given our current vulnerability.

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016

INDUSTRY NEWS

Ronson Gears shoots for the stars with Lockheed Martin Satellites produced by Lockheed Martin will carry Australian-made precision gear components into space, manufactured by Melbourne-based Ronson Gears.

In the last year, Lockheed Martin has signed five contracts with Ronson Gears under its Global Supply Chain (GSC) Program agreement with the Commonwealth. This makes the gear manufacturer, headquartered in Highett, Victoria, the first-ever Australian company to supply precision gear components that will be carried into space.

Ronson is providing prototype gears for the Common Solar Array Drive Assembly (CSADA), which will be utilised on several Lockheed Martin satellite platforms. The CSADA performs key functions, including the deployment and rotation of the solar cell arrays that power the spacecraft. This helps ensure they remain optimally positioned towards the Sun. Additionally, Ronson has been awarded a contract for the delivery of anti-backlash output gears.

Designed to perform with tight tolerances, these components will be integrated into a subassembly that will be used on several satellite programs.

“The agreements with Ronson Gears reinforce Lockheed Martin’s commitment to developing Australia’s space sector,” said Joe North, Lockheed Martin Australia Chief Executive. “Our collaboration with local research and industry partners, like Ronson, demonstrates that Australia has the capabilities here and now to participate in Space.”

Lockheed Martin follows a rigorous qualification process to ensure gold-standard manufacturing practices. It’s critical that the components it uses are designed to withstand the extreme environment of space. Ronson Gears met these standards and demonstrated its ability to maintain precision over the lifetime of the spacecraft.

“Coming from the automotive industry, it was important that we prioritise innovation and invest in digital technologies that could enhance precision across our production processes – especially for a Space environment,” commented Gavin New, General Manager, Ronson Gears. “From our first introduction, Lockheed Martin has been collaborative and supported our vision. We’re proud to be the first Australian company to supply precision gear components that will be carried into space.”

New is the most recent graduate of Lockheed Martin’s Program Management Institute (PMI), with Australia being the only non-US market approved for non-Lockheed Martin employees to attend.

Because of the pioneering work that companies like Ronson Gears have accomplished, Lockheed Martin Space procurement teams are continually scanning Australia to identify potential technology partners for its global supply chains. This includes everything from machined parts to software and even propulsion technologies.

“The Global Supply Chain (GSC) Program is uniquely Australian and provides the local market with access to Lockheed Martin’s global programs,” added Christopher Hess, Head of Industrial Development, Lockheed Martin Australia. “We’re continuously identifying new opportunities for Ronson Gears to contribute to our missions, and applaud their dedication to supporting innovative initiatives such as IoT technologies.”

These agreements also represent downstream supply chain opportunities for Ronson Gears’ partners, including Heat Treatment Australia and Electromold Australia. Their hardening processes and magnetic particle inspection, respectively, are evidence of the world-class capabilities available in Australia to the space industry. www.ronsongears.com.au

Nine in ten Australians believe Australia should produce more locally New consumer research from Roy Morgan has found that nine in ten (89%) Australians believe Australia should be producing more products locally following the COVID-19 pandemic.

The research found that Australians’ key motivations to manufacture locally were to reduce Australia’s reliance on other countries (38%), create jobs (26%), support Australian business and industry (26%), a safeguard for vulnerable international supply chains (20%), and to strengthen Australia’s economy (16%).

“Australia’s over-reliance on imported products has been highlighted during the COVID-19 pandemic,” said Australian Made Chief Executive, Ben Lazzaro. “This research indicates that Australians are placing priority on manufacturing self-sufficiency and job creation, along with a renewed appetite to address the imbalance between locally made and imported products, to ensure Australia’s long-term prosperity.”

The preference for Australian-made products was already high before the COVID-19 pandemic, with Roy Morgan research in January finding 88% of Australians were more likely to buy products

AMT OCT/NOV 2020

made in Australia. Since the pandemic, more than half of Australians (52%) say they now have an even higher preference for Australianmade products.

Roy Morgan CEO, Michele Levine, said “The impact of COVID-19 on Australians is unprecedented in so many ways, not least of which is our shopping behaviour. More Australians are now organising delivery of products; doing online research prior to making a purchase; shopping online, both in stores they would usually visit and different stores. And critically since COVID-19, Australians have an ever greater preference for Australian Made products.”

The research found that since the start of the pandemic, 37% of Australians are conducting more research online prior to purchasing products. Data from Australian Made’s website supports this finding, with traffic more than doubling in April to June compared to the same period prior.

INDUSTRY NEWS

UTS boost for Australian advanced manufacturing University of Technology Sydney (UTS)’s new Centre for Advanced Manufacturing (CAM) aims to support Australian manufacturing by helping it harness rapid technological change, develop competitive products and generate valuable jobs by meeting the challenges of Industry 4.0.

CAM will work closely with industry to understand how communication technologies, the Internet of Things (IoT) and data science can make manufacturing businesses more efficient and sustainable. A key driver of CAM is to give Australian manufacturers the skills to maintain and expand manufacturing activities in Australia, including supporting growth in the number of jobs.

Centre Director Professor Jochen Deuse, from UTS’ School of Mechanical and Mechatronic Engineering, said CAM will be a bridge to the manufacturing industry, actively engaging with the profession and using consultation with leading industry experts to inform its strategic direction: “We want to be the first choice for industry collaboration and to supply graduates to work in a dynamic and agile industry.”

CAM aims to become Australia’s leading research centre in advanced manufacturing, with access to advanced manufacturing facilities including UTS’ Tech Lab, ProtoSpace, and Industry 4.0 testbeds. UTS’ ambition is for it to be the number one choice as university collaborator for Australian manufacturers, with a reputation for fundamental and applied industry-relevant research with measurable impact. This will lead to a revolution in advanced manufacturing education, with graduates ready for the global workplace and future leadership in Australian manufacturing.

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CAM is intended to act as a catalyst for strong, lasting industry partnerships, promoting increased self-sufficiency and onshoring of Australian manufacturing. The Centre is already working with partners such as Balluff Australia, Marley Flow Control, Siemens and RapidMiner, and on jointly-funded projects with Alrick Healthcare, Innovation Connections, Defence Innovation Network and Australian Wool Innovation. Balluff manufactures and distributes components for Industry 4.0 applications, and is also a major training provider.

“We believe Balluff has a responsibility to the industrial automation industry to share the opportunities possible with current and emerging technologies,” said Balluff’s Managing Director Jason Bouyer. “Our challenge is how we inform the industry of these possibilities before they’re ready to accept them? Education will help overcome this and drive acceptance of innovative technologies that will propel Australian businesses to be relevant on a world scale.”

Industry training will be at the core of CAM activities, developing novel and innovative approaches to manufacturing education with short courses that are dynamic and flexible, responsive to the quickly changing needs of industry. CAM will also lead UTS activities regarding the recently announced ARC Industrial Transformation Training Centre in Collaborative Robotics and the governmentfunded Pilot Associate Degree in Advanced Manufacturing.

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INDUSTRY NEWS

Businesses invest in tech to offset COVID-19 impacts Epicor’s 2020 Global Growth Index has revealed that companies are embracing technologies to offset the impacts of global volatility and supply chain disruptions amid the COVID-19 pandemic.

Epicor’s Global Growth Index explores the growth trajectory of companies around the world and provides insight into how business leaders are using technology to drive growth. The index looks at the constantly changing state of growth in the manufacturing, distribution, retail and e-commerce industries along with what trends impact the bottom line.

When surveying Australian respondents, the report’s findings included: • Increasing competitiveness: Most companies surveyed are using excellent customer service (42%) and big data analytics (47%) to increase competitiveness. Data analytics had already been in use for between one and five years for two-thirds of Australian respondents, and 92% said big data is driving growth.

• Impacts on business growth in the coming year: The ChinaUS trade dispute/tariffs (30%), environmental challenges (32%) and COVID-19 (66%) are most likely to negatively impact business growth over the coming year for Australian respondents.

• Positive influences on business growth: Planning and strategy (40%), technology and IT infrastructure (34%) and brand reputation (29%) were said to have the biggest impact on their industries over the last 12 months.

• Technologies set to have the biggest impact: 5G (37%), cloud technology (36%) and digital transformation (31%) were predicted to have the biggest positive, direct impact on

future growth in the respondents’ industries over the next 12 to 18 months.

Andy Coussins, Senior Vice-President and Head of International at Epicor, said: “2020 has been a year characterised by significant disruption. These disruptions have accelerated the move towards digital transformation for many organisations; businesses will look to technology and IT infrastructure to drive company growth in the next 12 months. This continued investment will be important for organisations to maintain business resilience, adapt to global volatility, and stay flexible as the market changes.”

Further results from the report reveal that: • Growth is strong: For 54% of Australian companies, growth in the past six months was a slight improvement over the previous six months. For 22%, recent growth was a significant improvement. Growth had slightly or significantly worsened for just 10% of Australian respondents.

• Key success factors include digital: 26% of Australian companies said a strong digital and online presence was a key indicator of a successful growing business in their industry.

• Overcoming challenges requires technology: 46% of Australian respondents said working more efficiently would help them overcome business growth challenges in the next 12 months. 41% said it would come down to better planning and 40% said better technology was a key factor.

Poll reveals public favours manufacturing transition over gas-fired plan A new national poll has revealed that just 14% of Australian voters support the Federal Government prioritising the gas industry over other sectors in its plans to rebuild the economy, with strong approval for greater measures to support energy transition in the manufacturing sector.

The poll – conducted from 14-16 September – showed close to two-thirds (65%) of those surveyed supported taxpayer funds being used to transition the Australian manufacturing industry towards using clean renewable energy, while only 19% supported continuing to rely on fossil fuels such as gas. Just under one-third (31%) of Coalition voters support Australian manufacturing continuing to rely on fossil fuels like gas.

“The Prime Minister’s move to put gas, a fossil fuel, at the centre of our recovery from COVID-19 is deeply concerning and clearly at odds with the wishes of the Australian people,” said Morgain.

“Australians do not want their money to be spent on an industry that is uneconomic, provides few jobs and causes further damage to our climate. The market has made clear the lack of viability of fossil fuels through their reluctance to fund gas projects.”

The survey was conducted by YouGov on behalf of Oxfam Australia with a nationally representative sample of Australian voters. Releasing the survey results, Oxfam Australia Chief Executive Lyn Morgain said the poll found support for prioritising funding for the health sector was highest at 74%, while 47% supported prioritising public investment in the tourism industry, 46% in schools and universities, and 41% in renewable energy – almost three times as much as would prioritise gas. A majority (56%) opposed taxpayer money being spent on subsidising multinational gas companies and new gas infrastructure, with only 26% supporting subsidising of gas companies.

A briefing paper released by Oxfam in July, Australia’s energy future & the recovery from COVID-19, stated that gas was an “unstable foundation on which to rebuild an economy and build a better future”. Morgain said the Government risked imposing a crippling burden on future generations in the form of climate damage, stranded assets, fewer jobs and big debts.

Morgain said the Government should listen to taxpayers before investing their money at such a critical moment for the nation.

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“We have an opportunity to take serious action to tackle climate change by investing in renewable energies, while stabilising and strengthening the Australian economy,” Morgain said. “Backing fossil fuels is a missed opportunity. Oxfam is calling on the Government to use the October 6 Federal Budget to scrap their plans for a fossil fuelled recovery, and instead invest in economic stimulus measures that accelerate the transformation of our energy system and economy.”

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INDUSTRY NEWS

ICN Victoria announces new CEO Industry Capability Network (ICN) Victoria has announced the appointment of Dianne Smith as its new CEO. On behalf of the ICN Victoria Board, Chairman Tim Piper confirmed the appointment on 10 September. He acknowledged the significant contribution by outgoing Executive Director, Grant Anderson, and thanked him for his stewardship of ICN over the past two years.

Chamber of Commerce for the past four years, and also as a member of the Victorian State Government’s Advanced Manufacturing Advisory Council. Prior to that, she led the state’s peak body for tourism and events, the Victoria Tourism Industry Council.

“As Victoria emerges from the substantial impacts of COVID-19, the role of ICN and growing local jobs and content could not be of greater importance,” said Piper. “Grant has been a knowledgeable and excellent leader for ICN, and Dianne will build on this, bringing a fresh perspective for our future challenges.”

“With the current situation, and in line with our Local Jobs First policy, it is certainly the time to continue our State’s investment in Victoria’s future capability,” said Smith. “I’m looking forward to working with the Board and team, and playing an instrumental role in Victoria’s recovery from the pandemic.”

Smith brings impressive industry and government connections to ICN having served as Chief Executive of the Melbourne

Smith will commence work at ICN Victoria in early November, with Anderson retiring from the role on 29 October.

Victorian manufacturers create lifesaving new ventilator industry Ballarat manufacturer Gekko Medical has received permission to fast-track production of the ‘GeVentor’, an Australian-designed ventilator that could save the lives of COVID-19 patients around the world.

Gekko Medical is a new medical start-up launched by the award-winning mining innovation company, Gekko Systems in response to shortages of ventilators in Australian hospitals at the beginning of the COVID-19 pandemic. It aims to use its manufacturing expertise to continue to produce medical equipment and create a medical technology hub in Ballarat.

The Victorian State Government on 1 September announced an order for 170 of the units, after Gekko’s machine was provided with a production exemption from the Therapeutic Goods Administration (TGA). Gekko will now harness its local suppliers and 100-strong workforce to build the GeVentor ventilators, which will be among the first to go into production. They are expected to be available within five weeks and will be used in health services across the state.

The GeVentor is an affordable alternative to the latest model ventilators, designed to be simple, robust and reliable. It features low gas and power consumption and can be operated using batteries and an oxygen bottle, making it ideal for more remote and regional health centres. A prototype for the GeVentor was developed in April by Gekko’s innovation team lead by technical director Sandy Gray, in consultation with Ballarat anaesthetist Doug Paxton. The initiative was in response to fears of shortages of ventilators in Australian hospitals. The development of the prototype was assisted by a Victorian government grant and support from the Ballarat community.

“We are pleased to have developed a ventilator that can help save the lives of COVID-19 patients around the world, particularly in developing countries that don’t have the medical resources they need to cope with the pandemic,” said Gray. “It is a big success story for Ballarat and regional

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Victoria, resulting from a collaboration between local medical and manufacturing experts, with the support of the community.

We understand the GeVentor is the first Australian-designed ventilator to be eligible for supply in Australia specifically for the COVID-19 pandemic.”

With Australia now in a strong position in the fight against COVID-19 due to low infection rates and the availability of ventilators, the GeVentor will be available to global hotspots, including Indonesia, India, and Latin America. The unit has attracted interest from humanitarian organisations that aim to supply ventilators to developing countries, with the affordability and rugged construction of the GeVentor of particular benefit in these settings.

Health Purchasing Victoria has also placed orders for 200 ventilators that are being produced by Grey Innovation. The company established a consortium of local companies to build its transportable Notus Vivere Emergency Ventilator, with components coming from manufacturers ANCA, Marand, Hosico, Bosch Australia and Hydrix. Grey Innovation is also producing machines under licence to fill an order from the Commonwealth Government.

Two other Victorian companies – Planet Innovation and Compumedics – are in the final stages of the TGA process for their ventilators.

Minister for Industry Support and Recovery Martin Pakula commented: “Creating a local ventilator industry in a matter of just months is testament to the excellence and agility of Victorian manufacturers. We have seen an amazing response to the challenges posed by the pandemic and that has helped to shore up jobs and place the state in the best position possible to recover once the health crisis is behind us.”

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RUAG Australia lands MRO contracts with US Navy for F/A-18 RUAG Australia has received the first contracts awarded by the US Navy under the AUSMIN Defence Acquisition Committee (ADAC) – a collaboration between the US and Australian Departments of Defence.

RUAG is the first Australian company to receive an award under the ADAC initiative covering the maintenance, repair and overhaul (MRO) of selected components for the F/A-18 Hornet fleet. RUAG is now a designated and approved source of repair for Navy Supply (NAVSUP) within the APAC Region under this program.

“RUAG Australia appreciates the trust that the US Navy has placed in their ability to support their regional activities,” says Terry Miles, General Manager RUAG Australia. “RUAG’s MRO capabilities and track record of success with the Royal Australian Airforce (RAAF), will form the basis of a partnership with the US Navy to support the fleet readiness of the F/A-18 fleet in APAC and other Foreign Military Sales (FMS) customers moving forward.”

ADAC is a senior bilateral forum for co-operation between the US and Australian Military, aiming to facilitate closer defence and industry collaboration related to the acquisition, logistics and followon support of defence equipment.

“We are pleased and proud to be recognised as an essential contributor to defence industry capability,” said Stephan Jezler, Senior Vice President Aviation International, RUAG MRO International. “We are looking forward to applying our technical expertise to other fleets in the APAC region and globally. It confirms our good reputation and our vast experience and know-how on the life-cycle support of F/A18 fleets.”

RUAG Australia has been supporting the RAAF F/A-18 fleet and other platforms since the early 1980s. RUAG’s focus on engineering and technical expertise has built a comprehensive knowledge base achieving high quality standards and short lead-times enabling RAAF and other end users to benefit from sustainable aircraft availability.

World-first University of Queensland rocket headed to space The University of Queensland could next year become the first university to fly a student-built rocket and scientific payload into space.

UQ Space is designing and building ‘Project Asteria’, a rocket that will zoom past the Kármán Line, 100km above sea level, reaching speeds greater than Mach-5. With support from UQ aerospace engineering experts and industry partners including Queenslandbased Black Sky Aerospace, the 90-strong student team hopes to set a new world record.

UQ Space Managing Director Myrthe Snoeks, an engineering and arts student, said the team had been working towards this ambitious goal despite delays caused by the global COVID-19 pandemic.

“We started developing the rocket in 2019, and we are now planning and undertaking static testing and sub-orbital launch preparations before our official launch next year,” said Snoeks. “The UQ Space team has achieved so much already, having taken out the top position in Australia for competitive university rocket launches in 2019, only one year after establishing the team.

“While 2020 has presented some additional challenges to our progress, we haven’t given up – we absolutely intend on achieving this goal with the help of our supporters.”

UQ Space will be using the Beyond the Blue Aerospace launch and test facility near Goondiwindi in western Queensland, known as ‘Funny Farm Space’. This will be one of the first industry collaborations to take advantage of the $3m commitment from Black Sky Aerospace and Beyond the Blue Aerospace to encourage space ventures from Queensland. The launch facility is Australia’s only sub-orbital facility permitted to fly through and above controlled

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airspace and was home to Australia’s first commercial payload rocket launch by Black Sky Aerospace in 2018.

Black Sky Aerospace Director Blake Nikolic said there were real benefits to working on Project Asteria.

“Together we are advancing Australia’s space capabilities and showing the world that we’re here and we’re ready,” Nikolic said.

“Working with these bright and committed students also helps us as we develop our internship program in this new industry, and provides our future employees with practical knowledge-based learning.”

The team plans to travel to Goondiwindi in the coming months for their first static test fire of Project Asteria.

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DESIGNE ABOVE T New two-year term for Women in STEM Ambassador NOW TH THINKIN INDUSTRY NEWS

Professor Lisa Harvey-Smith has been reappointed as the Federal Government’s Women in STEM Ambassador for an additional two years.

Professor Harvey-Smith has played a central role in the Government’s efforts to encourage girls and women to study and work in science, technology, engineering and mathematics (STEM) since her appointment as the inaugural Ambassador in 2018. The Office of the Women in STEM Ambassador is a Government initiative to address gender equity in STEM. It promotes awareness of STEM careers to young people, parents and carers, and works with educators to challenge gender stereotypes and promote inclusive and engaging STEM education for all.

With her reappointment, Harvey-Smith and her team will continue working across industry, government, research and education to address gender equity in STEM. Announcing the reappointment, Minister for Industry, Science and Technology Karen Andrews praised HarveySmith for the work she had already done and the challenge ahead: “Professor Harvey-Smith shares my passion for advancing women and girls in STEM and is an outstanding role model.

“As Ambassador, Professor Harvey-Smith has driven social and cultural change and established herself as a public authority on STEM equity issues. She will continue to play an integral role in our efforts to remove barriers and open up opportunities for women and girls in STEM, which will benefit the entire nation.”

Professor Harvey-Smith said she was immensely proud of the work her team had done over the past two years to increase the participation of women and girls in STEM. “We are now determined to accelerate this progress as we bring together industry, organisations and educational providers to deliver the recommendations of the Women in STEM Decadal Plan and the Government’s Advancing Women in STEM strategy,” Professor Harvey-Smith said.

The Ambassador and her team will continue to be based at the University of New South Wales. The Government is providing $3m over 2018-19 to 2021-22 for the Women in STEM Ambassador initiative. www.womeninstem.org.au

Hawkei ready to enter full rate production The Australian Army’s new Australian-designed and built Hawkei protected vehicle is ready to enter full-rate production at Thales’ Protected Vehicles facility in Bendigo, Victoria.

The vehicle’s production will support more than 200 local jobs in Bendigo as well as more across the national defence industry.

Defence Minister Linda Reynolds CSC said the vehicle had performed exceptionally well throughout comprehensive ballistic and blast testing, meeting Defence’s stringent requirements for protection.

“This is a highly effective capability being delivered in partnership between Defence and industry that builds on Thales’ iconic Bushmaster, which has been highly successful in operations overseas and exported around the world,” said Reynolds. “The Hawkei is a significant enhancement to existing land capability that will provide superior mobility, survivability and communications, while protecting the lives of our soldiers when operating in increasingly lethal and complex environments. This is yet another example of Defence and defence industry managing business practices in a COVID-19 safe manner to continue delivering ADF capability.”

Under project LAND 121 Phase 4, 1,100 Hawkei vehicles and 1,058 associated trailers will be delivered, with the full rate production vehicles expected to commence delivery from mid-2021.

Melissa Price, Minister for Defence Industry, said: “The manufacture and ongoing support of the Hawkei vehicle creates significant longterm opportunities for Australian industry, including potential export opportunities, as we have seen with the Bushmaster vehicles.

This Government is investing in the skills and knowledge base of Australia’s defence industry and delivering an internationally competitive and sustainable sovereign Defence industry.”

Eighteen of Thales’ key 25 suppliers are based in Victoria, including: • Albins Performance Transmissions, based in Ballarat, for the vehicle cross drive, steering rack, castings and shafts.

• Flexible Drive Agencies, based in Oakleigh, for the wiper and gear selector assembly.

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GOVERNMENT NEWS

South-west WA gears up for potential new advanced manufacturing hub The Western Australian Government is allocating $485,000 towards a study that will examine the feasibility of establishing an advanced manufacturing hub in the state’s South-West region.

Regional Development Minister Alannah MacTiernan announced on 3 September that the State Government will take the next steps in exploring the viability of the proposed hub. It is envisioned a facility in Bunbury Geographe would give manufacturers an edge when competing for work by providing local access to infrastructure, technology, training, education and research.

The State Government has identified technology and advanced manufacturing as a priority economic sector that will help to grow and diversify the economy, create jobs, and secure WA’s future.

By boosting business capability and capacity to develop new supply chains that would capitalise on global markets, the hub would support hundreds of future jobs, including apprenticeships.

the industry has the potential to grow, build capability and become more competitive.”

There has been a groundswell of local support for the South West Development Commission-coordinated project. Industry and local government organisations will also be contributing funding towards the study, as well as participating on a steering committee. The announcement of the study follows on from industry roundtables held in Bunbury.

“I am a big believer in the capabilities of our local businesses including in advanced manufacturing Western Australia Regional and I believe there is room to expand this sector,” Development Minister added Don Punch, Member of the Legislative Alannah MacTiernan.

Assembly for Bunbury. “The South-West region with its access to port, rail and road supply chain “We have the capability to be manufacturing much more than we infrastructure, available industrial land, highly trained workers, and currently do in WA,” said MacTiernan. “We know that the skills local supplies of key minerals and other resources is ideally placed and services developed by our mining expertise can drive local to host a manufacturing hub. It is fantastic to see State Government, manufacturing. We are inspired by success stories of numerous local government and the private sector coming together for the South West advanced manufacturers. This study will show where good of the local economy and creating the jobs of the future.”

Major skills funding boost for defence industry The Federal Government has bolstered its investment in growing the skills of Australia’s defence industry by significantly increasing funding to its Skilling Australia’s Defence Industry (SADI) grants program.

Companies will be able to apply for skills grants from a funding pool that has been expanded from $4m per year to $17m per year, to the end of 2021-22. The increased funding is intended to support a skilled workforce in the defence industry sector as part of the Federal Government’s response to the COVID-19 pandemic.

Minister for Defence Industry, Melissa Price said the additional investment would help Australian defence industry retain and expand relevant workforce skills to support Defence’s most critical capabilities.

“This will provide more funding for skilling and training opportunities, supporting small to medium sized enterprises across a range of trade, technical or professional skillsets,” Minister Price said. “The boost to SADI funding will give smaller businesses the confidence

to continue developing the skills of their employees during these uncertain times. “The funding will also help industry associations facilitate skills training for smaller defence industry businesses. Our support for skills training is part of our plan to develop the workforce needed to deliver on our ambitious $270bn investment in Defence capability.”

Minister Price said she was pleased to support local businesses to help them boost skills needed for new jobs in the sector.

“Our Defence investments will deliver a generation of jobs in an exciting new world of advanced manufacturing and innovation,” Minister Price said. “Australia’s defence industry had world-leading capabilities and we want to help them to broaden and deepen their skills base to meet Defence’s needs.”

Victoria announces TAFE upgrades The Victorian Government has announced upgrades to TAFEs across the state in a bid to create jobs and drive economic recovery from the coronavirus pandemic.

Minister for Training and Skills and Higher Education, Gayle Tierney, announced on 13 September that every TAFE in Victoria will share in $55m to carry out essential upgrades to learning facilities and amenities, as well as to refit and modernise existing learning spaces to adapt them to deliver more courses. All Victoria’s 12 TAFEs will share in the funding through the TAFE Asset Maintenance Fund, with 30 projects to be delivered through the package. An extra 18,000 Victorians will be able to train at TAFEs and Learn Locals under a $163m package of new measures,

AMT OCT/NOV 2020

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Saving Australian business COVID-19 is killing our small manufacturing businesses and ruining the economy. Flavio Romero Macau and Andrei Alexander Lux discuss what business owners and governments can do about it.

Small and medium-sized businesses (SMEs) are at the heart of our economies, employing around 70% of labour markets and keeping profits within local communities. They are also suffering the most with COVID-19. Small manufacturers have been left behind by successive governments in favour of big businesses in the resources sector, and this may well be the final straw.

Our research shows that successful companies are the product of resourceful entrepreneurs and favourable business conditions – their success depends on the local business environment. We’ve come up with three things that business owners can do, and twice as many that governments can do to boost firm performance and support recovery.

What you can do: Knowledge, Network, Mindset A lot depends on what you know, who you know, and who you are.

The more you know, the more places your business will go. Playing it by ear and blundering your way through means making costly mistakes that are easily avoided. Business schools, polytechnics, and start-up hubs all offer targeted, practical training to help you run a business. Go to a webinar, enrol in a course, share your experiences and learn from other entrepreneurs.

But competence alone won’t get you there. Who you know can make all the difference, and we’re not talking about friends and family. Improving the quality and breadth of your business network will give you privileged access to emerging opportunities and valuable resources. Pursue every chance you get to meet key people in your field and work at making a strong impression. Join the conversation in engineering, supply chain management, and manufacturing excellence. Time invested in a council or association opens opportunities for small business.

One last thing all business owners know but often don’t give much credit: running a company is a psychologically challenging endeavour. To succeed, they must be hopeful and optimistic, to believe in their own potential and persevere when things go wrong.

Now more than ever, they need to cultivate the kind of mental fortitude that will help see them and their business out the other end of the pandemic. As manufacturing is technical, business owners often downplay the importance of the psychological. This isn’t a call for motivational self-help, but recognition that a “can do” mindset will prevail.

Policy can level the field by commanding the same requirements from offshore that local businesses are subject to with regards to social responsibility, employee safety, and green manufacturing.

• Access to mentors. Learn from other people’s mistakes.

Mentors have the practical knowledge about what works and how to get it. Governments must encourage start-up hubs and chambers of commerce that help new business owners make important connections.

• Access to innovation. Universities are at the cutting edge of development, and Australian universities continue to rise in international rankings. Collaborating with businesses to convert this knowledge into products is not an easy task. Government must bridge these two worlds, bringing research expertise to industry problems that stimulate innovative solutions. Workshops, awards, grants, professional conferences, networking events … they all count and governments are in a better position to co-ordinate and organise such events.

• Access to talent. You need qualified employees, adapted to the pace of work at small businesses. Now is the time to upskill, and governments must incentivise programs to help attract and maintain a highly-skilled talent pool. Retraining and reskilling workers in the age of automation is fundamental to a strong manufacturing sector in a time where Industry 4.0, the Internet of Things, and blockchain are opening opportunities in Lean manufacturing, mass customisation, and supply chain management.

• Access to professional services. Tax, legal, real estate, insurance, accounting … you can’t do it all on your own.

Business owners must be confident to outsource these tasks to trusted local service providers on favourable terms.

Intellectual property is a fundamental piece where business owners often suffer in silence while their proprietary knowledge is ripped off by foreign companies. Having specialised support with ample knowledge on how things work can save time, money, and produces better results.

What governments can do

• Local attitudes. How people see small businesses actually affects their performance. Does your community support local manufacturers, or stick to the big brands? Governments must work to cultivate positive cultural attitudes towards local businesses.

Even the most resourceful business owners can only just stay afloat when the business environment stifles their efforts. So what makes a favourable manufacturing business environment?

These factors will determine whether or not business owners can leverage their own resources to drive firm performance and ride out the recession.

• Access to capital. It takes money to make money.

Guarantee schemes, support to the flow of credit, relief packages, innovation grants, rebates, manufacturing stimulus packages are examples of initiatives that governments must offer small businesses on a regular basis.

The pandemic has reignited discussions about the risks of offshore supply chains and the opportunities to boost onshore manufacturing. Governments can turn around the recession by deploying strategic resources to address local challenges and support manufacturing SMEs.

• Policy relief. Policymakers can support or hinder manufacturing in Australia over importing from overseas: taxes, regulations, permits, licenses, incentives … you name it. Regulatory hurdles hurt small businesses more than large organisations and often put manufacturers at a disadvantage.

Flavio Romero Macau is a Senior Lecturer in Supply Chain Management and Global Logistics at Edith Cowan University.

Andrei Alexander Lux is a Lecturer in Leadership and Organisational Behaviour at Edith Cowan University. www.ecu.edu.au

But this is not enough. Here’s where governments come in.

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

The waves of evolution in engineering Engineering has contributed a great deal to our everyday lives. Scott Philbrook looks at the evolution of the engineering industry and what innovations we can expect to see next.

Imagine where we’d be without the engineering feats we’re all too familiar with today. Hard to imagine, I know. At the end of a long day at work, we come home to comfortable and efficient living spaces, decked out with appliances that are both time and cost-effective.

The pandemic would have been twice as difficult to endure if we didn’t have telephones, radios, and television to keep in touch with loved ones, receive the latest updates from authorities, or pass the time spent in isolation. Through imaging technologies, engineering has changed the way we view ourselves and the world around us.

There’s no limit to where innovation in engineering might propel us to in the coming years.

Engineering was first conceptualised with human ability in mind. The very first tools were invented to accommodate human sustenance.

Before buildings towered over our heads, humans have been innovating tools or devices to solve problems or improve their state of living. The Egyptians, for instance, used wooden trunks to drag material across deserts efficiently, as opposed to carrying these by hand. The birth of the mechanical spinning wheel in 1775 changed industrial engineering for good.

By the centenary of British settlement, a thriving manufacturing industry had matured in Australia, producing a range of goods sufficient to supply most domestic needs. From the earliest times, manufacturing’s contribution to Australia’s economic development has been immense. Australia in the 1950s enjoyed a rich and diverse manufacturing sector, with a third of the population employed in it.

In the early 1990s, tariffs were cut drastically, adversely affecting the manufacturing sector, and sending Australia down the path of deindustrialisation.

On a global level, the mid-19th century saw new processing methods, most notably for steel and petroleum. It reshaped transportation, construction, and manufacturing. In the 20th century, engineering electrified the world. It took us to the skies and gave us the power to explore space. It continues to help cure our thirst, cleaning and making our waters safe for drinking. It has even revolutionised the way we produce food, and has helped simplify our everyday lives.

Racing to embrace digital technologies Manufacturing and engineering have come a long way since the rapid innovation of the Industrial Revolution. Operations have shifted from machine production to computerised manufacturing and design.

Since then, data has been the name of the game. Manufacturers easily sift through datasets without sacrificing workflow. This wide exposure to data has helped detect anomalies and has played a huge role in making predictions, ultimately improving efficiency and streamlining processes in a more uniformed approach.

Now Industry 4.0 is upon us, and plenty of people are welcoming manufacturing automation and information exchange across operations with open arms. Many are also going beyond computer automation and are shifting to cyber-physical machines. This includes game changers like the Internet of Things, machine learning, and smart manufacturing robots.

Artificial intelligence (AI) is also being widely embraced in manufacturing, and is a key piece in the larger trend of fully automated production or “smart factories”. AI systems have the potential to transform the way companies run their production lines, enabling greater efficiency by enhancing human capabilities, and providing real-time insights, facilitating design and product innovation.

The impact of innovation in engineering extends beyond financial value. As the digital age continues at full speed, many industries grapple with a state of constant change and instability. Innovations such as the first generation of the Industrial Internet of Things (IIoT) have helped ease and simplify the way these industries work. Smart sensors and intelligent devices within products are easier to get a hold of today.

Manufacturers today are in a race to embrace digital technologies.

To remain a strong backbone of the global economy, manufacturers are adopting technologies such as Industry 4.0. Gone are the days of laborious mass production models in manufacturing. Today, integrated and seamless automated factories reign supreme.

Meeting evolving needs Engineering processes began at the birth of humanity and provided solutions to the different challenges facing people. It seems safe to say innovation will continue driving engineering and manufacturing in the coming years. What we’re seeing today may very well be the early days of the next Industrial Revolution – Industry 5.0. From its early innovations, Industry 5.0 has the potential to transform the modern manufacturing processes, enabling humans and machines to work together in unison. This will pair the unique, cognitive skills of people with the precise, technical skills of robots, fostering an innovative culture in the workforce.

Engineers have been and will continue to be critical in advancing technologies that will allow individuals to work, learn, and play in new and interesting ways. Engineers of the future will have to confront a society accustomed to constant change. Changes to market developments and consumer preferences will push companies to develop more innovative solutions to meet evolving production needs.

Scott Philbrook is Interim Managing Director – Australia & New Zealand at RS Components. www.rs-online.com

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Do you make and sell consumer goods?

No? Think again…

The Federal Government has recently passed a legislative change to the Australian Consumer Law, which will broaden the definition of a ‘consumer’. Paul Kirton and Greta Walters examine the potential implications for your business.

The recent change to the Australian Consumer Law (ACL) directly impacts manufacturers and sellers of goods that are not generally used for domestic or household purposes. A buyer of an $80,000 industrial motor may now be a “consumer”.

Currently, a person or business is considered a “consumer” for the purposes of the ACL if they purchase goods or services for their own use that: • Are of a kind ordinarily acquired for domestic, household or personal use or consumption; OR • Cost up to $40,000, irrespective of their kind or purpose.

A person who on-sells goods or uses them up in the course of manufacturing other goods is not a consumer. But their customer may be a consumer for those on-sold goods or new goods.

This definition has been amended by the Treasury Laws Amendment (Acquisition as Consumer – Financial Thresholds) Regulations 2020. From July 2021, the monetary threshold will increase from $40,000 to $100,000. This will, undoubtedly, shake up the traditional ‘business to business’ (B2B) liability landscape for highvalue industrial and commercial goods.

For example, the buyer of an industrial laser or robot, for use in their factory, will be a consumer. The buyer will gain all the usual consumer law rights and consumer guarantees, if that laser or robot costs less than $100,000 and is defective or does not perform as promised or required.

The role of consumer guarantees Under the ACL, businesses making or supplying goods or services to consumers are bound by consumer guarantees that are imposed by the ACL. These are a set of automatic guarantees that apply to goods and services purchased by consumers, regardless of any voluntary or extended warranty offered. The guarantees require goods to be of acceptable quality (safe, durable, without faults), fit for disclosed purpose, match any description or samples provided, meet promises of performance or quality and have spare parts available. The rights under the ACL cannot be waived or contracted out by limitation of liability clauses in terms and conditions of sale.

Failure to comply with the ACL’s consumer guarantee provisions may result in a maximum infringement notice of $13,320 (or $133,200 for listed companies), or prosecution at court with penalties ranging from $10m.

Impact on businesses who make or sell goods Businesses that manufacture or supply (by selling, leasing or hiring) goods or services that cost up to $100,000 will become subject to the strict provisions of the ACL relating to refunds, warranties and liability for damages.

Depending on whether the problem with the goods is major or minor, the seller must repair, replace or refund a good or service if it fails to meet a consumer guarantee. The seller is also liable for any reasonably foreseeable loss or damage suffered by the consumer arising from the defect.

The manufacturer of goods with a major or minor defect can be liable directly to the consumer (for compensation), or must indemnify the seller if the seller is required to provide a remedy or payment to the consumer.

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Impact on businesses who buy goods If your business is a buyer of commercial or industrial-type equipment in the $40,000 to $100,000 range, you will now benefit from their newfound protection under the consumer guarantees.

While you may not have realised you already had these rights for industrial goods below $40,000.

This is a significant win for businesses who are ‘purchasers’ of such goods or services. Any claims against suppliers or manufacturers of these goods are easier to prosecute, and claims for damages flowing from the defect (eg. production line shutdown) may well exist.

As the ACL provides a solid foundation of non-excludable consumer protection rights, this also simplifies the always contentious negotiation of guarantee and warranty provisions.

Voluntary warranty requirements Manufacturers or sellers who offer their own warranties against defects are required to comply with the strict provisions of the ACL. For example, warranty documents must be presented in a certain way and include mandated statements and specific information that is easily understood by consumers.

Businesses who will be newly subject to the ACL’s obligations should update their warranty statements as soon as possible.

Those which are found to have a non-complying warranty face a fine of up to $50,000.

Get on top of your obligations Businesses that haven’t traditionally made or supplied ‘consumers’ should review their product ranges, business practices and trading documents to ensure they are meeting their ACL obligations. Come 1 July 2021, the ACL will invalidate any businesses’ contractual terms which are inconsistent with their consumer protections requirements.

Given the enhanced liability that comes with making or selling these higher value goods, businesses should also review their product insurance policies, to ensure they cover “consumer” type claims.

Businesses who will be regarded as consumers should not forget that they can take advantage of this legislative change if the equipment they buy after 21 July 2021 is defective or does not perform as expected.

Paul Kirton is a principal at the commercial law firm Macpherson Kelley. Greta Walters is a lawyer at Macpherson Kelley. www.mk.com.au

WE’RE HERE TO DRIVE AUSTRALIA FORWARD A proud Australian company driving Australian industry forward.

Find out more at www.ronsongears.com.au

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TECH NEWS

Australia: Zero-emission blocks for coal-fired power stations

at a high pH. It was combined with another non-toxic molecule polyethylene glycol. This molecular combination remained stable at a high pH and inhibited ice crystal growth.

A new type of thermal storage material, housed in blocks, could see coal-fired power stations converted to run entirely fossil-fuel free. Named Miscibility Gaps Alloy (MGA), the blocks receive energy generated by renewables, store it cheaply and safely as thermal energy, then use it to run steam turbines at power stations. They can be retrofitted to retired power plants or introduced to existing ones.

The blocks are far cheaper, safer, lasted much longer and were more scalable than a battery and are 10% of the cost of the same size, yet produce the same amount of energy. The blocks are made from non-toxic, recyclable material with high thermal conductivity. They are made of two components: one component melts when heated to store huge amounts of energy, and the other acts as a matrix, keeping the block in solid form and embedding the melting particles.

This process of heating, storing energy, cooling and recovering energy can be repeated thousands of times.

University of Colorado at Boulder

University of Newcastle

Australia: First Australian-made spacecraft to host foreign payload University of Melbourne researchers have been awarded $3.95m to build and launch a small (9kg) innovative satellite called SpIRIT (Space Industry – Responsive – Intelligent – Thermal Nanosatellite) to be launched by 2022 in collaboration with multiple Australian space industry companies and the Italian Space Agency. Though small, it will be powerful: carrying X-ray sensors, on-board computers and radios, and a miniaturised electric propulsion engine. This will demonstrate that Australian-made spacecraft are internationally competitive, opening new market opportunities. Building an innovative space-ready nanosatellite comes with unique challenges and it is expected that this project will help to break new ground in nanosatellite design and manufacturing, acting as a guide for Australian aerospace research in the future.

University of Melbourne

Australia/Sth Korea: High purity titanium with environmental benefits Metals and rare earth processor Australian Strategic Materials (ASM) and JV partner South Korea’s ZironTech has produced high purity (99.83%) titanium metal powder through its new electrorefining process at the commercial pilot plant in South Korea. This was the final stage of the patented metal process and it confirms 50% less energy is used than traditional methods. “This will position ASM as the only integrated mine-to-metal producer outside China, providing critical materials directly to Australian and international manufacturers” says ASM MD David Woodall.

Mining Weekly

USA: Nature's antifreeze' provides formula for more durable concrete Researchers have discovered that a synthetic molecule based on natural antifreeze proteins minimises freeze-thaw damage and increases the strength and durability of concrete while decreasing carbon emissions. Adding a biomimetic molecule - one that mimics antifreeze compounds found in Arctic & Antarctic organisms - to concrete, effectively prevents ice crystal growth. This new method challenges more than 70 years of conventional approaches, where, since the 1930s, small air bubbles have been put into concrete to protect it from water and ice crystal damage. But this process can decrease strength and increase permeability. Concrete made with this molecule instead of air bubbles was shown to have equivalent performance, higher strength, lower permeability and a longer lifespan. A synthetic molecule - PVA - was used, that behaves exactly like the natural antifreeze proteins but is much more stable

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Germany: Additive manufacturing of multi-functional parts A Multi Material Jetting system has been developed that allows different materials to be combined into a single additively manufactured part, making it possible to create products with combined properties or functions. The new system can be used with particularly high-performance materials such as ceramics and metal and can be used to make highly complex parts such as the ignition system in a satellite propulsion engine made of ceramics.

The process relies on custom micro-dosing of the metal or ceramic slurries. Thanks to its high precision and flexibility, it is suitable for more than just manufacturing multi-functional components, but could for example be used to make blanks for carbide parts.

Fraunhofer

USA: Record speed with advanced spectroscopy technique For the first time, researchers have used an advanced analytical technique known as dual-comb spectroscopy to rapidly acquire extremely detailed hyperspectral images, with the potential to greatly advance a wide range of scientific and industrial applications. It uses two optical sources (optical frequency combs), that emit a spectrum of frequencies that are perfectly spaced. Spectral interrogation of a 2D object in just one second was demonstrated, more than three orders of magnitude faster than previous demonstrations. This fast acquisition time enables dual-comb hyperspectral imaging of fast or dynamic processes for the first time. The technique was used to acquire hyperspectral images of ammonia gas escaping from a bottle. An optical resolution of 1 GHz (0.0033 cm-1) at video

TECH HEADING NEWS rates of 25 frames per second was achieved, with each frame containing 327,680 individual spectral measurements. This allows easy distinction between different gases and 100 times better than current commercial equipment.

The Optical Society

France: Hydrogen powered train enters service in Austria Following successful trials in Germany, the Coradia iLint – a hydrogen fuel cell powered train developed by French rail giant Alstom – has begun carrying passengers on Austria’s train network.

The cell generates electrical energy for propulsion, generates zero emissions and is capable of a top speed of 140 km/h. According to Alstom, as well as being completely emissions-free, the Coradia iLint boasts a number of innovations including clean energy conversion, flexible energy storage in batteries and intelligent management of motive power and available energy. Alstom has already sold 41 of the hydrogen-powered trains in Germany.

The Engineer

Tesla: Installation of world’s biggest casting machine Tesla has taken delivery of the world’s biggest casting machine. The aluminium caster, reportedly built by Italian die casting company IDRA, is about the size of a small house. With the Model Y electric SUV, Tesla has introduced some important underbody engineering and manufacturing improvements - turning what was originally 70 parts in the Model 3’s rear underbody into just two - facilitating body assembly and creating fewer failure points. Molten aluminium will be injected into the “Gigapress”, moulded, and removed by robots - effectively bypassing riveting and gluing. Traditional stamping results in a large amount of scrap residual while with the Gigapress, 100% of the raw material is used. There are plans to make the entire underbody in just one part by the end of the year. In Tesla’s factory in Germany, there are plans to replace hundreds of robots with the casting machines.

Reuters/Tesmanian/Electrek

Australia: Funding for technology to detect wildfires in minutes Fireball International - based in Queensland - has been granted $500,000 to roll-out its detection system across Australia and overseas. The system allows for fires to be reported to emergency services in as quickly as three minutes and it has already been successfully identifying blazes and alerting authorities in the US. Using the ALERT Wildfire sensor network, Fireball applies powerful machine learning combined with satellite imaging to detect and evaluate wildland fires early. The satellite used by Fireball detected the Kincade fire in California 66 seconds after a falling power line ignited it last October. The tower sensors confirmed the alarm within 3 minutes, even though it was night and the fire was in a canyon, and thus not directly visible to the sensor. Authorities were immediately

alerted and a town 10 km away was evacuated 20 minutes after ignition. In San Diego County alone, Fireball reported 494 fires in October and November last year.

Industry.gov.au/Fireball.International

Singapore: Fruit peel – Turning old batteries into new Scientists have developed a novel method of using fruit peel waste to extract and reuse precious metals from spent lithium-ion batteries in order to create new batteries. Traditional methods of recycling battery waste generates harmful pollutants. The team found that the combination of oven-dried orange peel ground into powder and citric acid can achieve the same goal. In lab experiments, the team found that their approach successfully extracted around 90% of cobalt, lithium, nickel, and manganese from spent lithium-ion batteries – a comparable efficacy to that of using hydrogen peroxide.

The key lies in the cellulose found in orange peel, which is converted into sugars. These enhance the recovery of metals from battery waste. Solid residues were non-toxic. New lithium-ion batteries were assembled from this process, which showed a similar charge capacity to commercial ones.

Nanyang Technological University

USA: Real-time 3D printing quality assessment Researchers have developed AI software (named Peregrine) for powder bed 3D printers that assesses the quality of parts in real time, without the need for expensive characterization equipment. The software uses a custom algorithm that processes pixel values of images, taking into account the composition of edges, lines, corners and Peregrine detects an anomaly textures. If Peregrine detects in a component being additively manufactured on a an anomaly that may affect the powder bed printer. quality of the part, it automatically alerts operators so adjustments can be made. During the printing process, problems such as uneven distribution of the powder or binding agent, spatters, insufficient heat, and some porosities can result in defects at the surface of each layer. Some of those issues may happen in such a very short timeframe that they may go undetected by conventional techniques.

It can be installed on any powder bed system.

Oak Ridge National Laboratory

“We could well say that we will be building a tiny robotic spaceship” - Associate Prof. Michele Trenti of Melbourne University’s School of Physics and the lead investigator of the SpIRIT satellite program which obtained a grant. The program will generate wider benefit for Australian businesses and the next generation of the space workforce and the grant reflects the excellence of the researchers.

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PRODUCT NEWS

Hydrafeed and Dimac – A winning combination In recent years it has become common knowledge that a barfeeder significantly increases any CNC turning centre’s productivity. But like any piece of equipment, not all barfeeders are created equal.

The Hydrafeed barfeeder offers a number of unique features. One of those is that it is a full servo-driven barfeed eliminating the need for compressed air.

It can also accommodate different bar diameters and lengths including random bar lengths, and is suitable for both bar or shaft feed.

One of the most important time-saving features of the Hydrafeed is that once you’ve set a bar size and saved the set-up, you never have to open the cover again. Simply call up the program from the touch screen and the Hydrafeed will set itself on the centreline automatically thanks to the servo drive bar lifter mechanism. “This feature alone puts the Hyrdafeed Barfeeder on a different level and really does take barfeeder productivity to a new level,” said Paul Fowler, Managing Director of Dimac Tooling, suppliers of the Hydrafeed barfeeder. “It’s also quick and easy to set up which helps businesses to remain flexible as they can run small batch jobs without excessive set-up times.”

Other standard features include complete servo control on all axes plus a fully automated set-up through a user-friendly HMI screen.

The product is CE-certified and comes with a comprehensive 12-month warranty.

The quality and features of the Hydrafeed is what has attracted numerous customers to the brand. Greg Humphries from Tasmanianbased Maltec Engineering chose the Hydrafeed as it offered a number of features over and above their existing barfeeders.

“The ability to quickly set up the servo-driven backstop when processing multiples of non-barfed material is a real time saver compared to having to manually set-up and fit one,” said Humphries.

“Having the barfeeder mounted on linier rails allows us to move it out of the way and accurately return it to its previous position when machining longer parts or servicing the machine.”

It is not just the quality of the Hydrafeed that has seen many customers choose the brand – it is the quality of Dimac’s service and support that has been a key reason for purchase.

“After the Hyrdafeed was installed we received a follow-up to ensure that the machine was functioning correctly and met our expectations,” Humphries added.

“We have always received terrific service from the team at Dimac – reliable and timely service is very important to us,” he went on to say. It was the same experience for Jorge Campagno of Campagno Engineering in Melbourne.

“Price of course was important in our purchase decision, but it’s the support and service from the supplier which I believe is crucial, as wasted time becomes very expensive,” said Campagno. “I’ve been dealing with Dimac for 30 years and it’s their knowledge, quality products and after-sales support that was another key reason for opting for the Hydrafeed.”

To further enhance productivity, Dimac offers the Royal Rota-Rack; a patented, cost-effective device that safely collects finished parts as they come off of a CNC lathe, providing a competitive advantage to manufacturers by enabling their machine tools to run unattended for extended periods of time.

“We can now offer CNC owners a unique retrofit automation solution to improve both productivity and efficiency whilst protecting the finished product,” said Fowler. “By using a Hydrafeed Barfeeder and a Royal Rota-Rack working in conjunction, you can add a massive dose of productivity, keep your machines running long after your last employee has left for the night or weekend and improve your competitiveness in the market. They can be retrofitted to any entry level CNC machine as well as multi-tasking turning centres. It’s really the ultimate in ‘lights-out’ production.” www.dimac.com.au

Mapal: Getting chips under control To ensure reliable chip breaking and the optimal machining performance, Mapal has now developed a new chip guiding stage for the machining of steel.

When undertaking the fine machining of steel, long chips can prove detrimental to machining performance and surface finishes, especially when machining with tools that incorporate guide pads. To prevent long chips from wrapping around the tool and creating a negative impact on surface quality, dimensional accuracy and automated process flow, Mapal has introduced the new line of inserts with chip guides.

The new chip guiding stage combats these very problems; a credit to the new geometry design. With a special geometry that has been designed and optimised with extensive finite element method (FEM) analysis and practical testing, Mapal now

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ensures that chips are broken reliably. This prevents automated workflows and production environments from being disrupted.

The chip guiding stage is compatible with all indexable inserts with AS leads. Furthermore, the new chip-guiding inserts are available with a wide variety of coatings to support the machining of a vast selection of material types. That means the new chip guiding inserts can be integrated with the relevant inserts irrespective of the application in question. www.mapal.com

PRODUCT NEWS

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Bridgman brings in cost-effective laser cutting with Bystronic When Queensland manufacturer Bridgeman Stainless Solutions decided to invest in a laser cutter, it found the solution it needed with Bystronic Australia.

Based in Brendale, north of Brisbane, Bridgeman has been in operation for over 20 years. During this time the company has evolved into a specialist in stainless steel fabrication, with the ability to undertake fully customised designs, engineering and installation.

Bridgeman’s work can be found in restaurants, shopping centres, domestic and commercial kitchens, and bespoke bars , as well as for leading food manufacturers in Queensland and across Australia.

A key to Bridgeman’s success has been its ability to work within tight deadlines while producing complex solutions. To enhance this capability, the company recently moved into brand new purposebuilt facilities with greater floor space. The nature of Bridgeman’s activities necessitated working around the clock and on weekends to meet tight deadlines. Third-party supply for profile parts also created delays. This prompted Bridgeman to investigate the purchase of a laser cutter for internal use. When Bridgeman began narrowing down the list of potential suppliers, Bystronic was identified as a leading manufacturer. To support the case for investment, several companies were asked to provide time and cost studies. The Bystronic BySmart Fibre 4kW laser provided ample evidence to Bridgeman that this was the way forward. Purchase price and operational efficiencies were important to Bridgeman. A chance meeting with one of Bystronic’s service technicians during an equipment demonstration at a reference customer offered real insight into the support that Bystronic offered. That meeting also provided the reassurance that Bystronic had technicians based in Brisbane, rather than flying in.

The operational efficiencies have been greater than anticipated.

The speed and efficiency of the laser, coupled with the accuracy and repeatability that can now be achieved, have further enhanced Bridgeman’s profitability. The company has found that it is turning jobs around in days that would have taken weeks, and there has been a substantial reduction in the amount of scrap metal due to reworks. Paul Walmsley, Finance Manager at Bridgman, notes that cutting operations are particularly simple due to the ease of use of the Byvision software installed with the machine. The original plan had been to have dedicated operators at the laser, but the intuitive interface has allowed for a number of confident people to be trained quickly in the machine’s use.

In dealing with Bystronic, the team at Bridgeman has been reassured by the strong support it received during the sales and installation phase, and its ongoing access to Bystronic’s dedicated hotline. With further investment in equipment planned in the future, Bridgeman expects to look to Bystronic again. www.bridgeman.com.au www.bystronic.com

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PRODUCT NEWS

Konecranes – New C-Series lasts more than a million lifting cycles Konecranes is introducing to Asia-Pacific its toughest and most reliable electric chain hoist for lifts up to five tonnes, with extended service life for more than one million lifting cycles.

The new Konecranes C-Series – now launched in Australia, Singapore, China, and Malaysia, with the rest of the APAC region to be included progressively in the months ahead – is designed to be the most durable electric chain hoist available, to provide a hard-working industrial hoist for industries such as manufacturing, materials handling, infrastructure, power generation, steel, automotive and waste-to-energy.

“The new Konecranes C-Series is designed for operators seeking minimal downtime and long hoist service life,” says James Dowe, Managing Director, Konecranes Australia & New Zealand. “It has an entirely new workhorse motor, improved chain sprockets, proven braking technology, enhanced operator comfort and simple serviceability.” The Konecranes C-Series features a new motor engineered for optimum efficiency with enhanced built-in cooling to reduce heat build-up and extend power to the hoist. The enhanced cooling, coupled with its extended cycle duty factor, allows for longer continuous operation up to 60% ED compared with the standard 40%. (“% ED” refers to Intermittent Duty Rating, which shows how much time a motor can be operating within a given period of time – maximum 10 minutes.)

“Rigorous in-house testing has resulted in Konecranes’s most reliable and long-lasting motor to-date,” adds Dowe. “The longevity of the motor also reduces the need to service the hoist as often, further reducing downtime.”

To keep busy operations moving, Konecranes has designed improvements into the core components of the new hoists to boost their service life, enhance safety and improve performance. New features include: • Purpose-built long-lasting gearbox. The new lifetimelubricated gearbox is capable of greater speeds, low noise levels, and enhanced performance and safety – with a new safety clutch design.

• Redesigned sprocket. The new sprocket fits seamlessly with the hoist chain drive. The pairing decreases hoist downtime and provides smooth, consistent performance.

• Proven braking technology. Konecranes’ brakes are designed to last more than one million operations, and the Konecranes C-Series includes improved self-adjusting brakes with a longer coil life. Safety is enhanced with a brake that always engages, even in cases of power loss.

The new Konecranes C-Series has been designed for efficient use of available working space. A new top bracket design allows easy installation, positioning the hoist in an optimal position to have less wear between chain and chain guide.

“In addition to user comfort features, the hoists are fast to install and simple to maintain, to maximise uptime,” says Dowe. “There is easy access to all wearing components, so the hoist can be up and running in minutes.”

The new Konecranes C-Series hoists, along with the complementary Konecranes S-Series hoists, have been recognised by Design Forum Finland, winning the 2020 Fennia IPR Excellence prize for the protection of intellectual property rights and with the S-series earning honourable mention for the top design award. The Fennia Prize competition awards companies and organisations that use design strategically in their business operations. www.konecranes.com

Coherent – Major leap in fibre laser welding technology The new Coherent HighLight FL4000CSM-ARM fibre laser builds on the success of Coherent HighLight ARM fibre laser series that is already qualified for automotive applications.

The new laser enables more advanced welding capabilities for high thermal conductivity metals, and aligns to welding requirements for e-mobility, energy storage, and general electrical interconnects consisting of dissimilar materials, such as copper and aluminium, and foil stacks that require precise control. The new technology represents a significant improvement in simplicity, and overcomes the limitations of other joining technologies. The latter include unstable welds due to welding head wear and the large heat-affected zone caused by ultrasonic or standard fibre laser welding. The ability to move beyond the limitations of traditional fibre laser for welding thin conductive materials is possible because of a unique dual beam output (the centre beam surrounded by a ring beam). The centre beam has extremely high brightness (the nominal beam parameter product (BPP) is 0.6) allowing a smaller spot size compared with its multi-mode

AMT OCT/NOV 2020

counterpart. The small spot size results in very high laser intensity that minimises heating of the material, and, together with the preheating effect achieved by the ring beam, significantly improves stability of the melt pool and therefore weld consistency – a challenge when welding thin conductive materials.

The Coherent HighLight FL4000CSM-ARM is available with an output power of 4kW (a 1.5kW centre beam and a 2.5kW ring beam). As with other Coherent Adjustable Ring Mode lasers, power in the centre and ring beams can be independently varied and modulated. The CSM-ARM is supplied with a 15m length process fibre, making it easy to integrate in virtually any production environment, and is compatible with the standard process heads from Coherent and other manufacturers. www.coherent.com

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PRODUCT NEWS

Kennametal introduces KCS10B for Superalloy Applications Kennametal has introduced KCS10B, its newest and most advanced turning grade for nickel, cobalt and iron-based superalloys used in aerospace and other high-temperature applications.

KCS10B, which features a revolutionary coating applied to an ultra-fine grain carbide substrate for superior layer adhesion, delivers up to 50% greater tool life, more predictable processes, and improved productivity when working with difficult-to-machine superalloys.

KCS10B overcomes the most common challenges encountered in turning superalloys – cratering and depth-of-cut notching – two wear modes that often lead to unexpected and even catastrophic tool failure.

Robert Keilmann, Senior Global Product Manager – Turning at Kennametal, explains that the secret behind the success of KCS10B is the company’s proprietary High-Power Impulse Magnetron Sputtering (High-PIMS) technology. Rather than the light rain of droplets that fall on cutting tools during traditional physical vapour deposition (PVD) coating processes, High-PIMS generates a fine mist of AlTiN, building a series of “extremely thin, smooth, and wear-resistant layers”.

Metals such as Inconel 718 and Stellite 31 are notorious for causing rapid wear and unpredictable tool life. KCS10B is proven to reduce

depth-of-cut (DOC) notching and extend tool life from three minutes to upwards of five minutes in roughing operations.

Tool life in finishing operations fares even better, with visible cratering and subsequent tool failure often delayed by a factor of two or three compared to competitive brands.

Positive and negative rake inserts are available, as well as various chip formers, edge preparations, and geometries, making KCS10B the ideal solution when turning iron-based (S1), cobalt-based (S2), or nickel-based (S3) alloys.

“Aside from a smoother surface, the new coating process also allows us to create a much sharper edge,” Keilmann adds. “Our advanced honing and edge-preparation process reduces the friction that leads to heat, which further improves tool life. It also means less built-up edge, another common failure mode in super alloy materials.

“When coupled with the excellent dimensional accuracy that Kennametal turning inserts are known for, shops can now expect the increased performance, stability, and predictability needed to be successful with these challenging alloys.” www.kennametal.com

OnRobot – Soft gripper for challenging pick-and-place applications The flexible OnRobot Soft Gripper uses three interchangeable silicon-molded cups in star and four-finger configurations to pick up almost any small object under 2.2kg with a delicate, precise touch.

The electric Soft Gripper is food-grade certified (complies with FDA 21 CFR for non-fatty items and EC 1935/2004) and unlike traditional vacuum grippers, it requires no external air supply, so it can reduce both cost and complexity.

“Our new Soft Gripper is challenging existing solutions for picking hard-to-grasp, delicate and odd-sized items,” says Enrico Krog Iversen, CEO of OnRobot. “Unlike proprietary solutions, the Soft Gripper offers seamless integration with most collaborative robots and light industrial robots through our One System Solution.”

OnRobot’s award-winning One System Solution is a platform that provides a unified mechanical and electrical interface between leading robot arms and any OnRobot end-of-arm tooling (EoAT).

The One System Solution has been newly expanded to include integration with robots from ABB Robotics and Hanwha Precision Machinery. Now, users of those robots can take advantage of the unified mechanical and electrical interface of any OnRobot product, for easier integration and faster return on investment (RoI).

While the Soft Gripper is ideal for food & beverage applications, it also provides flexible, delicate gripping for manufacturing and packaging. Features include: • Payloads up to 2.2kg based on shape, softness and friction of items to be handled.

• Grip dimensions ranging from 10mm-118mm depending on cup used.

• FDA certification.

• Flexible, interchangeable silicon cups.

AMT OCT/NOV 2020

• Ideal handling for delicate objects and irregular shapes.

• No need for supplied air.

• Fast, flexible deployment with seamless integration on all major robot brands.

IDC has forecast that global spending on robotics systems and drones will reach $128.7bn for 2020, with spending expected to reach $241.4bn by 2023. AlphaBeta estimates that automation can boost Australia’s productivity and national income by $2.2 trillion by 2030, while leading to the development of new products, services and business models. www.onrobot.com

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PRODUCT NEWS

McIntosh Farm Machinery selects SYSPRO McIntosh Farm Machinery has selected enterprise resource planning (ERP) specialist SYSPRO to help the company expand its highly customisable range of agricultural machines that it supplies in New Zealand and Australia.

McIntosh specialises in supplying quality forage and feed-out wagons, tip trailers, manure spreaders and bale feeders to farms and vineyards and wanted to replace its existing ERP system to significantly improve its production and scheduling capabilities. The company has been designing and manufacturing reliable farm and agricultural machinery for more than 60 years from its Palmerston North production facility on New Zealand's North Island, after being established by the McIntosh brothers as a farm equipment maintenance business. The company provides its farming equipment through over 200 trusted dealers across New Zealand, Australia and Chile. The firm had concerns over its ability to plan for future customer orders, ensuring it had the right stock on hand to meet production needs. The management team also felt that as a family-run business with a loyal longstanding workforce, much of the knowledge and expertise is in people’s heads. Many processes are paper-based, and the company has over 6,000 production drawings featuring around 20,000 parts.

“We found our former system to be incredibly inflexible and the technology was too complex for our current workforce to grasp,” said Managing Director Brett McIntosh. “What we really needed was a more flexible ERP system that was built around simplifying the manufacturing process and would improve our ability to plan ahead. We selected SYSPRO ERP for its ease of use and strong scheduling and planning capabilities.” McIntosh has fully embraced automation at its high-tech manufacturing plant, with a Yaskawa robot welder and Hypotherm plasma cutter being some of its smart factory investments to date. The next part of the company’s Industry 4.0 strategy was to replace its existing ERP system. Implementing SYSPRO will enable the equipment manufacturer to manage its endto-end supply chain, from inventory management, production and bill of materials (BOM), part traceability, quality control and financials, which is being implemented first and will go live in November.

Additionally, the company requires the new ERP system to integrate with CADTalk and other software such as payroll.

“We are excited to be working with SYSPRO and its channel partner, MNM Business Solutions, to implement our new ERP system,” Brett McIntosh continued. “The SYSPRO platform will help us to continue developing innovative new products and will enable us to maintain our reputation as a quality provider of robust farm machinery that is delivered on schedule.” The rolling implementation will be completed during 2021 and its workforce will receive practical training as each major phase goes live.

“Implementing SYSPRO will enable McIntosh Farm Machinery to improve its production scheduling, streamline and simplify its manufacturing operations and automate its new equipment design processes, whilst providing end to end supply chain management and part traceability,” said Rob Stummer, CEO at SYSPRO Asia Pacific. “Together with our partner MNM Business Solutions, we are excited to be working with this highly innovative and trusted farm equipment developer that is positively impacting the production of food and wine across New Zealand and Australia to ensure it remains competitive in the future.” www.mcintoshfarmmachinery.co.nz www.syspro.com

ABB integrates drive safety functionality to simplify machine automation ABB’s PROFIsafe plug-in module with integrated safety functions for variable speed drives provides cost-effective safety functionality to simplify installation and commissioning.

ABB is providing integrated safety functionality for its all-compatible variable speed drives (VSDs) to simplify the engineering design process in machine manufacturing and automation. The new plugin PROFIsafe module (FSPS-21) removes the need for external safety components and reduces the need for configuration.

The new functionality enables safe machine control and seamless safety communications between the drive and the programmable logic controller (PLC) in a wide range of machines from conveyors to grinders. This is enabled through the PROFIsafe over the PROFINET IO communication protocol.

Machine builders must ensure applications can be controlled safely and stopped quickly if anything goes wrong. To meet demanding safety requirements, engineers have traditionally designed and installed safety functions using external (hardwired) devices. This usually requires additional installation space as well as being costly and time-consuming. These challenges can now be overcome by using drivebased safety solutions.

The FSPS-21 module is TÜV Nord-certified and is compatible with ABB ACS380 machinery drives, ACS580 general purpose drives and ACS880 industrial drives. The module offers Safe Torque Off (STO) and Safe Stop 1-time controlled (SS1-t) safety functions. It achieves the highest safety levels in machinery safety: SIL 3 / PL e and is, therefore, suitable for even the most demanding applications and simplifies the design and verification of the safety solution. www.abb.com/au

AMT OCT/NOV 2020

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042

RAIL, SHIPPING & LOGISTICS

RAIL… A route to recovery?

With the COVID19 crisis continuing to wreak havoc around the world, there is a growing debate about how to stimulate Australia’s struggling economy. Could the rail industry and its supply chains offer one possible route to recovery?

On 2 September, data from the Australian Bureau of Statistics (ABS) confirmed what many people had been expecting for most of 2020: Australia was officially in recession. Gross domestic product (GDP) shrank by 7% in the June quarter, the largest contraction since records began in 1959. With the COVID-19 pandemic continuing to have a devastating impact, both here and worldwide, the economic outlook is the bleakest it has ever been since the Great Depression of the 1930s.

Confirmation of the recession also intensified a debate that had already been building since the COVID-19 crisis began: about ways to stimulate the economy as we emerge from the pandemic. While the Government’s stimulus measures so far have concentrated on emergency assistance for individuals and businesses affected by the downturn, there is a growing sense that more far-reaching measures will be needed, including funding for large-scale projects in infrastructure such as energy and transport networks. One notable voice backing investment in the rail sector and its supply chain is opposition leader Anthony Albanese. In a speech in May, Albanese cited rail as an area with the potential to play a key role in rebuilding Australia’s economy.

“We must invest in nation-building infrastructure including iconic projects like high-speed rail and we should be building trains

AMT OCT/NOV 2020

here,” said Albanese. “Government procurement policy in rail manufacturing has produced superior outcomes to imports, and created regional jobs in Queensland, Victoria and Western Australia.”

High-speed rail remains something of a pipe dream for Australia.

Although proposals for a network linking the country’s eastern cities have surfaced intermittently for decades, significant questions remain about its feasibility (see page 48) in a country like Australia.

However, we do have a substantial rail manufacturing industry that offers a strong foundation to build on.

According to the Australasian Railway Association (ARA), rolling stock manufacturing generated about $3bn of revenue in 2016 and contributes about 4,000 jobs to the Australian economy. The sector is led by companies including Alstom, Bombardier, Downer and UGL, with more than 900 companies involved in manufacturing and supply across the industry. Rolling stock manufacturing and assembly capability currently exists in Cardiff and Broadmeadows in New South Wales; Dandenong, Ballarat and Newport in Victoria; Maryborough in Queensland; and East Perth in Western Australia.

Moreover, rail manufacturing is an important industry for our regional centres, with 46% of rolling stock manufacturing and repair services jobs located outside of the eight state capitals.

043 Work on the Forrestfield-Airport Link, part of the METRONET program.

Nonetheless, not everyone seems to share Albanese’s conviction that we should be building trains in Australia. In August, New South Wales Premier Gladys Berejiklian reportedly asserted that “Australia and NSW are not good at building trains, that’s why we have to purchase them.” Berejiklian was speaking a week before the arrival in the state of a fleet of Chinese-built Waratah 2 trains. Unveiling the new trains, NSW Transport Minister Andrew Constance went further, saying “there’s a reason” why they were imported: because locally manufactured trains would – he claimed – be likely to cost 25% more than imports because of our higher labour, energy and material costs.

The comments drew widespread criticism. Albanese said: “Australians are great at building trains. The Tangara trains built in Newcastle have been the backbone of the Sydney rail network for decades. With demand for new rolling stock about to skyrocket, we need a national rail plan. We need to use the power of government purchasing to help revive and grow manufacturing in this nation.”

Geoff Crittenden, CEO of Weld Australia, echoed Albanese’s remarks, urging state governments to adopt procurement policies that would create jobs, a solid local supply chain, and an industry equipped to export trains all over the world: “Australia already has

a substantial rail repair and maintenance industry. But it is not being supported by the state governments. Only weak-minded nations and leaders export strategically critical infrastructure projects.

It is precisely this attitude – that sees state governments send what could be local jobs offshore – that will prevent Australia from recovering from the COVID-19 pandemic” Manufacturers also took issue with the NSW Government’s claims.

Based in Bayswater, Victoria, Catten Industries has been involved in rail manufacturing for nearly two decades, producing parts for trains and trams in service across Australia as well as overseas. Catten’s managing director Ian Cubitt described Constance’s comments as “ill-informed”.

“I can categorically tell you we have the people, the knowledge and the facilities to manufacture trains and trams locally,” said Cubitt.

“We just need the informed support of the decision makers to back the locally produced product. Germany can certainly do it, with high wages, so that is not an excuse. Keep the work local and allow our generation and future generations to improve and sustain a local supply chain, rather than supporting the growth of economies that are not conducive to building a better Australia.”

Continiued next page

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RAIL, SHIPPING & LOGISTICS

As well as advocating for the industry, the Australasian Railway Association runs the AusRAIL Conference and Exhibition

Continued from previous page

Advocating for rail The Australasian Railway Association (ARA) also criticised Berejiklian and Constance’s remarks. CEO Caroline Wilkie said state government failures to adopt a nationally consistent procurement process – one that considers the whole-of-life costs of critical public transport assets – were behind moves to source overseas content.

Caroline Wilkie, CEO of the Australasian Railway Association (ARA).

“Passenger trains are being manufactured right here in Australia to the highest international standards,” said Wilkie. “There are facilities across the country that can design, manufacture, maintain and repair rolling stock to individual operator specifications, if government purchasers make the choice to do so.

“Australia builds trains very well and has a rich history of doing exactly that. When governments make choices to prioritise local content, they secure an outstanding quality of product while supporting local jobs creation and strengthening our supply chains.”

As the peak body for the rail sector in Australia and New Zealand, the ARA represents more than 150 member organisations including listed and private rail-related companies, government agencies and franchisees. Members include passenger and freight operators, track owners and managers, suppliers, contractors and consultants, as well as a significant cohort of manufacturing businesses.

“Manufacturers are a key part of the rail industry and many are ARA members,” says Wilkie, who has been CEO at the Association since February. “We work with members ranging from large manufacturing firms with a global footprint, through to local suppliers delivering rail products and services at the state level. Our Rail Industry Group supports the development of the ARA’s policy and advocacy agenda on issues relevant to rail manufacturers and suppliers.”

The ARA recently released its tendering framework, aimed at providing a best-practice guide for rollingstock and signalling tendering in the Australian rail industry. Since its launch, the ARA has been advocating for a nationally consistent approach to rail procurement in Australia. Further research to provide a deeper understanding of the rail supply chain is also underway.

The rail industry has continued to provide essential services to the public during the COVID-19 crisis, and the ARA has been working closely with its members during this time to ensure a whole-of-industry response to the pandemic. It also engaged with government regularly on the unique issues facing the rail industry during COVID-19.

In addition to its advocacy work, the ARA runs the AusRAIL Conference and Exhibition, the leading industry event for the rail sector in Australia and New Zealand. This year the organisers have bowed to the constraints imposed by COVID-19 and will

AMT OCT/NOV 2020

be holding the event online; AusRAIL Live & On Demand will take place on 1-3 December, bringing together speakers from across the industry worldwide, and a dedicated online exhibition featuring live demos. The ARA also runs an extensive calendar of industry events throughout the year.

“We are currently hosting a series of Meet the Buyer webinars to give manufacturers and suppliers the chance to hear direct from transport departments, operators, major projects and Tier 1 suppliers about major projects, upcoming tenders and new works packages,” Wilkie adds.

Projects picking up pace While there is little sign as yet of Anthony Albanese’s call for highspeed rail being met, governments across Australia are still pressing ahead with a variety of infrastructure projects that will create opportunities throughout the rail industry supply chain. In Victoria, the State and Commonwealth Governments in July announced the commitment of more than $300m in additional funding for the Regional Rail Revival program, bringing the total investment to more than $2bn. The Regional Rail Revival program is upgrading every regional passenger rail line in Victoria and creating 1,000 jobs.

More recently, the Victoria and Commonwealth Governments announced a $28m investment in direct rail freight between the Port of Melbourne and Dandenong South, with a new track connecting the main rail line with Dandenong South-based Salta Properties freight hub. The upgrade will connect to the Port of Melbourne’s $125m on-dock rail project, allowing shuttles to run from Dandenong South directly into the port. Deputy Prime Minister and Minister for Infrastructure, Transport and Regional Development Michael McCormack said the new freight rail link will support hundreds of jobs.

RAIL, SHIPPING & LOGISTICS In Western Australia the METRONET program will add approximately 72km of new passenger rail and up to 18 new stations

“We are backing this vital freight rail connection to support Melbournians through the pandemic and unlock private sector investment and economic growth into the long-term,” McCormack said. “The new spur line will connect the intermodal freight terminal at Dandenong South to the Cranbourne Line. As part of the Port Rail Shuttle Network it will help cut the number of trucks on inner Melbourne roads by up to 100,000 each year and support hundreds of jobs during construction and as part of the terminal’s ongoing operations.” In NSW, the State Government has announced the investment of $28m in a project to upgrade the Tamworth Intermodal Rail Line to support regional NSW’s freight sector, creating hundreds of regional jobs. Deputy Premier John Barilaro said the investment will fund works to reinstate a section of nonoperational railway line, support the development of an intermodal rail facility in Westdale and link Tamworth to the state’s major port.

“This significant investment is key to the development of the new intermodal rail hub that will better connect Northern NSW’s producers and businesses to the world,” Barilaro said. “This funding will restore and raise five kilometres of track on the West Tamworth to Barraba line and install new level crossings to activate rail freight access to Tamworth’s new Regional Freight Terminal. When complete, a functioning intermodal rail hub and freight terminal in Tamworth will create a direct rail route to vessels docked at Port Botany, saving businesses significant freight costs.”

Perhaps most ambitiously, in Western Australia, the State Government has embarked on Building for Tomorrow, the biggest transport infrastructure program the state has ever seen, and intended as a key driver of its COVID-19 economic recovery. More than $6.5bn has been committed to major infrastructure projects over the next two years, with $2bn to be spent on regional projects.

“As part of our WA Recovery Plan we’re making immediate investments in job-creating initiatives to help us rebound stronger than ever,” said Premier Mark McGowan. “And we’re also pushing ahead with the biggest ever investment in transport infrastructure.”

A major component of the Building for Tomorrow program is the METRONET construction program, which will add approximately 72km of new passenger rail and up to 18 new stations. In addition a new assembly facility is being built at Bellevue, where Alstom Transport Australia will built 246 new railcars to replace trains currently in service in WA. Bassendean-based manufacturing company Hofmann Engineering has been appointed by Alstom to manufacture bogie frames for the trains.

Grasping the opportunity In April the ARA surveyed 58 Australian and New Zealand rail suppliers, contractors and freight operators about the impact of COVID-19 on their business. The survey found that constraints on the international shipment of goods and a decline in customer spending had been the biggest impacts of the pandemic on the rail industry, and that the most important thing governments could

do to support the recovery was maintain their project pipeline. The survey also revealed a significant opportunity for local manufacturing and production. Responses from rail manufacturers, suppliers and contractors indicated that many businesses are looking to increase their use of local suppliers in the wake of COVID-19, with 75% of participants considering changes to their supply chain planning to seek more suppliers within Australia or their home state.

Caroline Wilkie sees this as a unique opportunity to strengthen the local supply chain and create new jobs in the industry as part of Australia’s economic recovery.

“There is $155bn in rail investment planned in the next 15 years, so there is a huge opportunity to realise more Australian jobs and economic benefits if the local manufacturing industry plays an increasing role in rail industry development,” says Wilkie, adding that there is also notable export potential. “There is a significant global rail manufacturing industry, and Australia’s reputation for quality delivery is well known.”

Nonetheless, there are still a number of major challenges facing manufacturers in the rail sector in Australia. Wilkie believes that many of these issues are compounded by flaws in government procurement policies.

“Procurement processes for rail manufacturing are fragmented, with state and territory governments taking different approaches to meet their local needs,” she explains. “This means specifications can differ from state to state due to historic procurement practices, often requiring bespoke approaches for each jurisdiction. Greater economies of scale could be achieved with a nationally consistent procurement process that takes away the need to tailor product and service offerings by state or territory.”

The ARA’s survey found that the industry is optimistic that the recovery would be fast once the full impact of COVID-19 was over. When asked how quickly they’d get back to normal once the impact of the pandemic had passed, most respondents forecast a relatively fast resumption of the activity levels reached prior to the crisis. However, there was also heightened demand for further government action to support a powerful rebound, including additional stimulus measures, together with strong local content policies and smarter procurement processes.

“A nationally consistent approach to rail procurement would improve productivity in the Australian manufacturing sector and provide new opportunities for jobs creation,” says Wilkie. “Local content policies that take a national focus, rather than state or territory focus, would also allow manufacturers to invest in larger, more efficient manufacturing hubs to service the Australian industry.

“The experience of national cabinet this year has shown that a national approach is achievable, and we would like to see greater co-ordination to support the industry’s post COVID-19 recovery.” www.ara.net.au www.ausrail.com

AMT OCT/NOV 2020

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RAIL, SHIPPING & LOGISTICS

Innovative new ship cladding creates jobs and reduces emissions A new lightweight, fire-resistant cladding that can withstand temperatures of more than 1,000 degrees Celsius is set to change the face of ships around the world, creating advanced manufacturing jobs in Tasmania and reducing carbon emissions.

The material, developed by Australia’s national science agency CSIRO in collaboration with Tasmanian small business CBG Systems, has already been installed on two new ships and used to replace cladding on another. The prototype paneling, called Rapid Access Composite (RAC) Plus, is the first of its kind in the world and uses a thermal protective coating that can withstand temperatures of over 1,000 degrees Celsius and remain structurally stronger than conventional fire protection coatings. The innovative panels are also reversible and can repel water, potentially doubling their service life.

The current design is specific for high-speed aluminium ships, but the composite has the potential to be modified for construction products. Weighing about half as much as traditional metal cladding, the resulting reduction in fuel consumption will lower carbon emissions, leading to greener ships across the globe as well as enhancing overall operational efficiencies.

The new technology was supported through several Federal Government programs and has created new jobs and increased international trade to Hobart. CSIRO Chief Executive Dr Larry Marshall said the partnership showed the power of science to solve real world challenges.

“By working side by side with industry, innovative science and technology creates new value and growth for Australian businesses to grow our way back from the current crisis,” Dr Marshall said.

“This home-grown Aussie innovation has enabled CBG Systems to become an advanced manufacturer of globally-competitive marine insulation products and services, which is now bringing in valuable export dollars from around the world.”

CSIRO Senior Experimental Scientist Mel Dell’Olio spent four months at CBG in Hobart, training and upskilling employees in advanced manufacturing techniques and assisting with the commercialisation process. During that time the team manufactured 2,500 insulation panels, which are now being built into new ships to supply international customers, all meeting the relevant fire standard tests for the marine industry and offering at least 60 minutes of fire protection.

Dell’Olio said CBG Systems’ long history of research and development in marine fire protection had been demonstrated again through the innovative RAC Plus.

“To be filling production orders within two years of the first project meeting, demonstrates how Australian SME manufacturers can benefit from positive research partnerships,” Dell’Olio said.

CBG Systems has been a manufacturer of passive fire protection systems for the past 30 years, and its panelling is currently found on 90% of the world’s high-speed ferries.

AMT OCT/NOV 2020

Senior experimental scientist Mel Dell’Olio holds up a sample of the new and improved RAC Plus fire-resistant panels.

Javier Herbon, Managing Director of CBG, said that CSIRO had decades of experience and expertise in developing advanced new materials with special properties for industry, such as fire-resistance, durability and protection.

“Being able to access the wealth of scientific knowledge and innovation within CSIRO has been an incredibly enriching experience for everyone at CBG Systems,” said Herbon. “With three ships already ordered, and two ships complete, CBG systems has hired six new roles, with partners and suppliers also increasing their staff as a result. This project shows how innovations from CSIRO can help Australian businesses create manufacturing jobs.”

CBG Systems has lodged its own patent on RAC Plus, and recent fire tests indicate the new and improved panels, with greater durability and fire-resistance, can be used on steel ships and aluminium highspeed crafts. There are also potential applications in aerospace, such as for battery enclosures, and the civil construction industry, enabling CBG to expand into new markets. www.csiro.au www.cbgsystems.com

The RAC Plus panels are fully non-combustible and remain structurally strong after exposure to extreme heat. © Floodlight Media

The innovative panels use a thermal nonintumescent based protective coating that applies CSIRO’s patented Hybrid Inorganic Polymer Systems (HIPS) technology. © Floodlight Media

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High-speed rail: a fast track to recovery?

Proposals to build a high-speed rail network linking Australian cities have been surfacing intermittently for decades, most recently raised as a way to boost our post-pandemic economic revival. However, there are also widespread concerns about the feasibility of such a plan. Here Greg Moran of the Grattan Institute voices his doubts, while Marcus Luigi Spiller of the University of Melbourne looks at the positives.

High-speed rail on Australia’s east coast would increase emissions for up to 36 years Bullet trains are back on the political agenda. As the major parties look for ways to stimulate the economy after the COVID-19 crisis, Labor is again spruiking its vision of linking Melbourne, Sydney, Canberra and Brisbane with high-speed trains similar to the Eurostar, France’s TGV or Japan’s Shinkansen.

In 2013 when Labor was last in government, it released a detailed feasibility study of its plan. But a Grattan Institute report released in May shows bullet trains are not a good idea for Australia. Among other shortcomings, we found an east coast bullet train would not be the climate-saver many think it would be.

The logic seems simple enough Building a bullet train to put a dent in our greenhouse gas emissions has been long touted. The logic seems simple – we can take a lot of planes and their carbon pollution out of the sky if we give people another way to get between our largest cities in just a few hours or less. And this is all quite true. We estimate a bullet train’s emissions per passenger-kilometre on a trip from Melbourne to Sydney would be about one-third of those of a plane. We calculated this using average fuel consumption estimates from 2018 for various types of transport, as well as the average emissions intensity of electricity generated in Australia in 2018. If we use the projected emissions intensity of electricity in 2035 – the first-year trains were expected to run under Labor’s original plan – the fraction drops to less than one-fifth of a plane’s emissions in 2018.

It should be remembered that while coaches might be the most climate-friendly way to travel long distances, they can’t compete with bullet trains or planes for speed.

There’s a catch So, where’s the problem? It lies in construction. A bullet train along Australia’s east coast would take about 15 years of planning, then would be built in sections over about 30 years. This construction would generate huge emissions.

In particular, vast emissions would be released in the production of steel and concrete required to build a train line from Melbourne to Brisbane. These so-called ‘Scope 3’ emissions can account for 50%-80% of total construction emissions.

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Scope 3 emissions are sometimes not counted when assessing the emissions impact of a project, but they should be. There’s no guarantee the quantities of concrete and steel in question would have been produced and used elsewhere if not for the bullet train.

And the long construction time means it would be many years before the train actually starts to take planes out of the sky. This, combined with construction emissions, means a bullet train would be very slow to reduce emissions. In fact, we found it would first increase emissions for many years.

Slow emissions benefit We estimate building the bullet train could lead to emissions being higher than they otherwise would’ve been for between 24 and 36 years.

This period would start at year 15 of the project, when planning ends and construction starts. At the earliest, it would end at year 39. This is the point at which some sections of the project would be complete, and at which enough trips have been taken (and enough plane or car trips foregone) that avoided emissions overtake emissions created.

This means the train might not actually create a net reduction in emissions until almost 40 years after the Government commits to building it – and even this is under a generously low estimate of Scope 3 emissions. If Scope 3 emissions are on the high side, emission reductions may not start until just after the 50-year mark – 36 years after construction began.

The bullet train would create a net reduction in emissions from the 40 or 50-year mark onwards. But the initial timelines matter.

The world needs to achieve net zero emissions by about 2050 if we’re to avoid the worst impacts of climate change. All Australian states and territories have made this their goal. Unfortunately, a bullet train will not help us achieve it.

Hitting the 2050 net-zero emissions target implicit in the Paris Agreement remains a daunting but achievable task. Decarbonising transport will play a big part, including the particularly tricky question of reducing aviation emissions. But during the most crucial time for action on emissions reduction, a bullet train will not help. Our efforts and focus ought to be directed elsewhere.

Greg Moran is a Senior Associate at the Grattan Institute. Milan Marcus assisted in the preparation of this piece. This article was originally published by The Conversation. www.grattan.edu.au www.theconversation.com

RAIL, SHIPPING & LOGISTICS

Don’t abandon plans for high-speed rail in Australia – just look at all the benefits The Grattan Institute’s call to ‘abandon’ plans for any high-speed rail network in Australia fails to look at the wider benefits such a project can bring by way of more productive economies and more sustainable towns and cities.

The study authors argue the development of any bullet train network linking Brisbane to Melbourne via Sydney and Canberra is ‘unsuitable for Australia’. But what their argument neglects is that a project like high-speed rail has a unique capacity to reshape cities and population settlement patterns in positive ways.

A question of cost The Institute’s study says the idea of high-speed rail is an unwanted distraction in policy-making for the nation’s transport future. Its case relies on a review of the high-speed rail experience in Europe, Japan and China. All of these nations, it says, have vastly different distributions of towns and major cities to that in Australia, which has extremely long distances between a few large cities.

The study also critiques a 2013 Commonwealth analysis that found a $130bn high-speed rail project linking Brisbane, Sydney and Melbourne would generate a benefit-cost ratio of 2.3 to 1. So, every dollar invested in a high-speed rail network would generate $2.30 in benefits such as travel time savings, avoided vehicle operating costs and reduced road congestion.

But the Grattan study authors say that figure is based on a ‘cherry-picked’ discount rate of 4%. This is economics jargon for the minimum return that the community would expect from the investment of its collective resources in any project.

The Grattan study also says the 2013 cost-benefit analysis did not allow for cost over-runs. Nor did it consider the greenhouse gas emissions associated with the enormous quantities of concrete and steel needed to build the infrastructure.

So why are some people, including the federal Labor Party, still so enamoured with the idea of high-speed rail when others would have it binned?

Some projects reshape cities Not all transport infrastructure projects are equal when it comes to cost-benefit analysis. Some investments have a transformative effect on population settlement patterns – they shape cities and regions.

The Sydney Harbour Bridge and the Melbourne Underground Rail Loop are classic examples of city-shaping projects. Each altered travel times between different parts of the metropolis, which then shifted the location preferences of households and businesses.

This led to a substantially different city structure compared to what might otherwise have developed.

the city-shaping investments. These “follower” projects include the local arterial roads and tramways that circulate people and goods within cities. The Commonwealth’s official guidelines for major project evaluation recognises this distinction.

New ways of living, learning, working and playing become possible with city-shaping projects. By comparison, the procession of follower projects simply perpetuates settlement patterns and economic structures. This is the claim and appeal of high-speed rail. Advocates argue such an investment would divert a significant proportion of urban growth from the far-flung suburbs of metropolitan areas to new regional locations. That’s because these regions will then have similar travel times into core city labour markets.

In these regional locations, households would enjoy greater housing choice and affordability, more walkability, and better access to open space. They could even have better access to a range of community facilities than their metro suburban counterparts.

Advocates also argue that businesses in the big cities and intervening regional areas will be able to connect with each other at lower cost and source the skills they need more efficiently. This would boost productivity.

Consider all the benefits The 2013 analysis took into account issues such as congestion, emissions (from travel) and transport accidents. But it did not attempt to quantify and monetise the effects of high-speed rail shaping cities and regions. Arguably, the most important set of benefits from this investment were left out of the economic evaluation, simply because they are difficult to measure.

Modelling how the supply chains of businesses might change under the influence of city-shaping projects, or how the housing preferences of people might shift, is undoubtedly challenging. But being difficult to measure makes these impacts no less real.

Despite this limitation on the scope of benefits, the 2013 study said the high-speed rail project would return a benefit-cost ratio of 1.1 at a 7% discount rate, which the Grattan study says is the usual test applied to transport projects. Grattan says the project barely scrapes in at this higher discount rate, and implies many other projects would offer ratios greater than 1:1 and should be preferred.

These would typically be smaller follower projects that address local congestion problems. But a project achieving a 1:1 benefitcost ratio means Australia would still be better off undertaking the project compared to a business-as-usual case.

If the transformative effects of high-speed rail include more compact and walkable cities with less car dependency and greater productivity, then such a network has good reason to keep its grip on the Australian imagination.

Marcus Luigi Spiller is an Associate Professor of Urban Planning (honorary) at the University of Melbourne.

This article was originally published in The Conversation. www.unimelb.edu.au www.theconversation.com

Other projects, the vast majority of government transport outlays, merely follow or service the pattern of settlement established by

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Austal high-speed trimaran ferries highlight Australian shipbuilding capability Austal Australia celebrated the company’s success and Australia’s shipbuilding capability on 17 July, following a successful side-by-side ‘sprint’ by the 118-metre ‘Bajamar Express’ and the 83-metre ‘Queen Beetle’ high-speed trimaran ferries off the coast of Perth, Western Australia.

As Bajamar Express (Austal Hull 394) was departing Australia on her delivery voyage to the Canary Islands, she was joined by Queen Beetle (Austal Hull 396), undergoing sea trials, in an historic moment capturing two Austal trimaran ferries. The two vessels, designed and constructed by Austal Australia, are the latest designs of a proven hull form first developed for Spanish ferry service Fred.

Olsen Express’ 127-metre Benchijigua Express in 2005.

Austal Chief Executive Officer David Singleton said it was a very proud moment for everyone at Austal Australia and supply chain partners to see two trimarans out on the water together.

Austal Australia farewelled Bajamar Express with a stunning water salute (Image: Austal).

“Our shipyards, supply chain partners and of course our customers are thrilled to see the results of all our hard work, showcased in these two impressive trimarans,” said Singleton. “Seeing Bajamar Express sideby-side with Queen Beetle really does highlight Austal’s success in developing the trimaran hull as an effective high-speed commercial maritime transport solution.

“Following the delivery of Bajamar Express to Fred. Olsen Express, we have a further nine trimarans under construction or scheduled at the company’s shipyards around the world; and Austal remains the only shipbuilder designing, constructing and sustaining large high speed trimaran ferries, globally.”

Austal’s trimaran hull form offers ferry operators greater flexibility in vessel design configuration for vehicle and passenger capacity, while delivering a more comfortable and enjoyable journey for passengers. The enhanced seakeeping of the trimaran hull, coupled with Austal’s MOTION CONTROL SYSTEM and MARINELINK-Smart program, ensure a smoother, more stable ride for passengers and crew in the most challenging of sea states.

The delivery of the two ferries comes at an exciting time for Austal. Headquartered in Henderson, Western Australia, with shipyards in the US, Vietnam and the Philippines, the company announced in August that it had delivered record earnings for FY2020, with revenue exceeding $2bn for the first time, up from $1.851bn for FY2019. “I’m delighted that Austal has generated a record full-year result amidst significant global economic volatility, exceeding the record revenue and profit milestones that we set in FY2019,” said Singleton. “I am particularly proud of the fact that we kept all of our sites open during the pandemic, kept all of our people employed, and have been in a position to pay full time employees a bonus to reflect their exemplary performance in this difficult time.

In service in the Canary Islands, Bajamar Express will transport up to 1,100 passengers and 276 cars at cruising speeds of 38 knots; while the distinctively red-painted Queen Beetle will be able to transport 502 passengers across two passenger decks at speeds of up to 37 knots on JR Kyushu Jet Ferry’s route between Fukuoka in Japan and Busan in South Korea.

“The strong performance shows good operational momentum across all of our USA and Australasia operations as we constructed and delivered naval vessels and large ferries, and provided ongoing support services to the US Navy, Royal Australian Navy and the Australian Border Force.”

Austal’s Australasia operation reported revenue of $496.8m (up from $393.2m), accounting for 24% of total revenue. An

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expansion of the company’s Philippines and Vietnam shipyards, has allowed the Henderson shipyard to focus on Defence projects, primarily for the Commonwealth of Australia. The Henderson yard continues to deliver the Guardian Class Patrol Boat program and was recently awarded a $324m contract to design and construct six Cape Class Patrol Boats (CCPB) for the Royal Australian Navy – Austral’s largest ever contract for a vessel construction program in Australia.

After five years overseeing the impressive growth of Austal’s business, Singleton will be stepping aside as CEO in the new year.

His successor Patrick Gregg is currently Austal’s Chief Operating Officer and will take over in the CEO’s role as of 1 January 2021. Singleton will have completed nine years as a Director including five years as CEO when he completes his term with Austal “Austal is an incredible company producing excellent defence and commercial vessels and support services, delivering strong returns for shareholders,” he said. “After an extended period with the company the time is now right to hand over to Paddy and explore new challenges.” www.austal.com

RAIL, SHIPPING & LOGISTICS

University of Wollongong wins $4m rail infrastructure research boost A University of Wollongong (UoW) research project to increase safety and use of heavy-haul and high-speed rail infrastructure has been awarded $1.5m through the Federal Government’s Cooperative Research Centres Projects (CRC-P) grants scheme.

The project, High Output, Low Cost Automated Embedded Rail Track (ERT), will focus on developing automated solutions to reduce the installation time and cost of ERT. Including cash and in-kind contributions from partner organisations, the project is valued at more than $4m. UoW will use part of the CRC-P funding to support two researchers for two years as well as a PhD scholarship. The project is led by Downer, and UoW is the lead research organisation.

Other project partners are Embedded Rail Technology (Charles Penny, inventor of the ERT system), the University of Technology Sydney, and Antoun Civil.

ERT is a relatively new slab-track technology, which consists of a continuously laid bed of concrete with the rails embedded in the concrete in a unique way. Where ballast track has nearly 100 individual parts per metre – requiring regular inspection and maintenance – ERT uses only four components per metre, reducing

maintenance costs and maintenancerelated track closures. While it offers a number of safety and usage improvements, the installation time and cost of current ERT are significantly higher than those for ballast track – issues that this research will address.

Project leader Dr Philip Commins said ERT had many safety benefits, such as reduced track buckling and fewer derailments, but also increased track use by up to 30%.

“An ERT system provides greater safety, performance and availability, with lower maintenance and reduced whole life costs,” Dr Commins said. “As Australia’s plans are well advanced for many major rail infrastructure projects, the need for improved safety in heavy haul and high speed rail is a high priority. This project is a key part of the chain to provide an economic alternative to traditional rail systems.”

Downer Infrastructure Projects Executive General Manager Mark Mackay welcomed

the funding announcement and said Downer was looking forward to working on the project with UoW and other partners. “The University of Wollongong has always had a close affiliation with industry,” said Mackay.

“When Downer was seeking a technology partner, the university’s automation technology and rail engineering prowess made it a natural choice.”

Dr Commins and his team from the Facility for Intelligent Fabrication (FIF) in UoW’s Faculty of Engineering and Information Sciences will focus their research on new construction techniques and will explore automation technologies to dramatically reduce the cost and improve the speed of installation to make ERT competitive with traditional ballasted track.

“UoW will focus on the automated solutions using Industry 4.0 technology, such as industrial robots coupled with smart sensors and end-effectors,” Dr Commins said. www.uow.edu.au

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Angel Trains rolls out 3D-printed parts on UK trains Faced with the challenge of producing replacement parts for a diverse fleet of trains, UK firm Angel Trains found a powerful cost-effective solution in 3D printing.

Founded in 1994, Angel Trains is a leading rolling stock provider for the UK rail industry, financing and delivering high-quality trains to UK passenger service operators. Each year, it makes significant investment in innovative solutions to modernise train fleets. One of its biggest challenges is finding an alternative to the traditional supply chain for replacement parts, which struggles to cope with growing demands.

Unlike the automotive industry, where vehicles are mass produced in millions each year, rail industry fleets are comparatively small, and in some cases more than 30 years old. This combination presents several challenges for train operators, especially regarding vehicle maintenance and part replacement.

3D printed grab handles installed on a Chiltern Railways train.

“In recent times, we’ve seen growing concern among operators that sourcing replacement parts for older train fleets at a reasonable cost and in a short timeframe is proving increasingly difficult,” explained James Brown, Data & Performance Engineer at Angel Trains. “The problem is that traditional manufacturing methods only make it cost-effective to produce high volumes of spare parts, even though an operator may only need a few obsolete train parts replaced. Lead times can also take months, exacerbating the issue even further.”

As a result, Angel Trains teamed up with Stratasys and engineering consultancy DB ESG to show train operators how they can overcome these hurdles by 3D printing lower quantities of parts in a fraction of the time and cost of traditional methods. This crossindustry collaboration soon resulted in the first 3D-printed parts ever deployed within an in-service passenger train in the UK. They included four passenger armrests and seven grab handles, installed on Chiltern Railways trains.

Cutting production costs and lead times Stratasys’ Rail Industry Solution comprises rail-qualified materials and production-grade fused deposition modelling (FDM) 3D printing.

This lets Angel Trains achieve major time and cost efficiencies in part replacement.

Using conventional manufacturing, the lead time for the armrest would be approximately four months. However, according to Brown, the final part can be produced within one week with Stratasys, representing a lead-time decrease of almost 94%, with cost savings of up to 50% per part.

Similarly, in the case of the on-seat grab handle, the replacement part was obsolete, and the original supplier was no longer in operation. To make new grab handles, a new manufacturing tool would have been required, costing up to £15,000 ($27,500) with an expected lead time of two-and-a-half months. With the Rail Industry Solution, the grab handles were produced in just three weeks at a significantly lower cost per part.

“With Stratasys’ Rail Industry Solution, train operators can be much more responsive to replacing passenger-facing parts that get damaged or vandalised,” said Brown. “An obsolete replacement part can be 3D printed on demand and installed immediately, enabling operators to get vehicles back into service quicker and better maintain their trains – improving the quality of service for passengers.”

To overcome the challenge of certifying 3D printed parts for use in passenger trains, DB ESG conducted comprehensive testing on a range of industrial-grade 3D printing materials. The final parts were printed in ULTEM 9085 resin using a Stratasys Fortus 450mc 3D printer. The highly accurate production printer features a large heated build chamber, so parts meet the strict tolerances

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A 3D-printed armrest, produced 94% faster compared with traditional manufacturing methods.

and repeatability requirements of industry, as well as allowing large single parts or multiple smaller parts to be printed in one run. Last year, ULTEM 9085 resin was certified to the rail industry’s fire, smoke and toxicity standard, EN45545-2, a first for the rail industry.

Martin Stevens, Mechanical Engineering Manager at DB ESG, commented: “Gaining this certification removes a major barrier that has prevented more widespread implementation of 3D printing across UK trains.”

Improving passenger experience With low-volume production now achievable, Angel Trains is already exploring how it can leverage Stratasys’ Rail Industry Solution to customise interiors better suited to the passenger commute.

“We’ve tested 3D-printed seat-back tables with braille, informing the passenger that the toilet is ten rows back from that particular seat,” said Brown. “This level of customisation is unprecedented and can only be enabled by 3D printing, offering the potential to significantly improve passenger experience in the future.”

Following the success of the Chiltern Railways trial, the group has established a repeatable process for future projects that produces parts compliant with rail industry standards and suitable for use in passenger vehicles. With positive responses from train operators, the deployment of 3D printed parts will now be extended onto trains with another UK passenger train operator. www.angeltrains.co.uk www.objective3d.com.au

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The key to successful automation projects In any automation deployment, “The Three Ps” – Product, Process and People – are of vital importance, writes Barry Hendy of Andrew Donald Design Engineering.

I have been involved in the robotics and industrial automation industry (on and off) for more than 30 years. Over the years I have seen a lot of projects make the transition from wild concept to productive and effective reality, and I have learnt a lot about what is behind both the successful and the difficult projects. That experience boils down to what I call “The Three Ps”: Product, Process and People. You must manage all three for success.

It is easy to do simple automation that ‘should’ work most of the time, but life rarely travels down the middle of the road. Great and successful automation projects must take full account and manage all the things that can go wrong so they can keep going when the road gets a little rough at the edges. Achieving 99% is not good enough – that might mean a stop every five minutes.

To get rock-solid automation you must take account of all the exceptions – all the things that might go wrong – because if it can go wrong … it will.

Product The first step when thinking about automation is to fully know your product.

Intimately. Totally. All its nuances, variations and faults. While some customer operations are single-product, most manufacturers have a range of products they make in different batch sizes and rates. Knowing and documenting the full scope of products is the most important section in the requirements document. It is probably the fastest and the biggest that will determine the design solution, but you should also weigh that up with the percentage of your production that is spent on each product.

If there is one very big or heavy product but you only run it occasionally, is it worth including in the must-have list?

Just as important as the range, and for single-product operations, you must also have a deep understanding of the variation in each product. It might be seasonal, it might be temperature, it might just be tolerancing – but every product will have its variances. One project Andrew Donald Design Engineering (ADDE) did was packing croissants, but if they were left in the proofing room too long, they fluffed even more and didn’t even fit in the box! Variation in the amount a bread loaf rises is perhaps obvious, but the variance in a bottle, carton or casting might be more subtle. Cardboard packaging dimensions typically vary by about 3%, so how well a product fits in the package can change from batch of packing supplies to batch.

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We had one project where the parts were injection-moulded and supplied to us pressed together. It is a high-rate system (about 30 parts per million) so they were both made in a multi-cavity die. While we were promised all the parts were the same, there was one combination of cavities where the parts didn’t fit together quite as snugly, so occasionally – certainly often enough to be debilitating – the parts would come apart in the descrambler.

And then there is all the ways that the product can fail – or be a bit less than perfect. What are the checks that your operators might make, possibly even subconsciously, on every part? Do they know the sound or feel of how a part clips on and realise when they occasionally aren’t right? All these things can be managed, but only if they are known.

If you miss them or don’t understand them, you run the risk of shipping bad product or having to add additional quality checks to a finished machine.

Even documenting or quantifying what is good and bad can be a challenge. I have watched on more than one occasion while a group of the client’s team debate if a sample part is acceptable or a reject.

You must know your product – completely.

Process Just as you must know your product intimately, you also have to know your processes just as well. What are all the steps you need to execute your production?

And I mean ALL the steps. Yes, most will be obvious, but it is the subtle or occasional tasks that are probably just as important as quality and reliability.

What can go wrong? What doesn’t always work perfectly? What are the checks you need, the alternatives and the subtleties of all the products? Especially dig deeper for the subtleties because they are the things you might not notice, or perhaps don’t always need to be done, but can have a big impact on the finished product.

I frequently see operators on a line, perhaps packing product, flip some or all the products over and quickly glance at something. When you ask the manager what they are doing they often have to ask the operator and learn that the printer might not be super-reliable, or there might sometimes be a flash from the injection moulding.

Some level of Failure Mode and Effect Analysis (FMEA) is probably a good idea, but at least have a discussion with your operators on all the small things they see and do to make sure you fully understand what is needed to ensure everything goes well. Part of this will be consideration of if it is acceptable to just control the process, or if you need to check the result – somehow.

Also consider that often automating a process will make it inherently more reliable since you have removed the variations natural in human tasks and brought consistency to the process, and that alone may address an issue.

As your automation system is being designed, a deep understanding of your processes will be critical to ensure all the checks, fault capture and failure management is in place. Make sure you fully understand all your processes, the failure modes and the checks required.

ROBOTICS & AUTOMATION

Barry Hendy is the Managing Director of Andrew Donald Design Engineering (ADDE).

People Regardless of what equipment you purchase, what machines you have bought or what robot you install, if your production team is not committed and on-side to make the project work – it won’t work. That is not a statement about your team – it is just human nature. When the thing stops, is the operator going to say: “I told you it wouldn’t work”? Or will the question be asked: “How can I stop that from happening?”

Get your team involved right from the start.

Get the people who are going to make the system run, buy-in from the beginning, especially since they are probably the ones with the most insight into the subtleties of the product and the process. Trust me, there is nothing worse than having an operator explain to you, while you are training them on-site how to run a machine, that there is a problem because the boss doesn’t realise all the issues they have with this part or that process!

I have seen perfectly good and capable automation projects struggle because the shop-floor team does not want it to work.

They might see it as a threat, or just feel sidelined. Whatever their motivation, I can guarantee that if the production crew don’t want a piece of equipment to work, it will never work, no matter how good a job your system integrator has done.

We recently installed a major upgrade to a palletising system that runs 24/7. Almost every night, the system was getting locked up at about 3am and the crew could not recover the system so an emergency crew had to be called in to hand-palletise. We did more training of all the crews, updated alarms and messages, but the problem continued. One day we told the crew we were getting the CCTV camera moved so we could understand what was happening and we could fix it – but funnily enough, the problem never happened again.

Conversely, I have seen some ‘less than perfect’ systems run very effectively because one of the crew has taken the machine under their wing and wanted to make it work. Any automation system is going to stop at times – it is how the crew react that will determine if that will be a big problem, or if they will learn the idiosyncrasies of the whole system and work to manage and minimise them, and probably eliminate them.

Engage your team early and get them onside. Find a champion who will ‘own’ the system and be proud when it works.

The most challenging automation projects that ring alarm bells when the first enquiry is made are for products that are still in development. There will be prototypes and perhaps pre-production equipment, but there will not be the deep experience with both the product and the process. It is not that these projects cannot be automated from the get-go, but it is certainly challenging. In our 24 years at ADDE, we have only had two clearly ‘unsuccessful’ projects, and both were cases where the

automation was being developed before the product was proven and production experience established. By the time the automation line was developed, the product and assembly process had evolved and changed and the challenges started.

The 3 Ps The most successful automation projects are those where the whole team is involved and committed to success, and where everyone’s input is used to ensure a thorough definition of what is needed.

When you have covered: • Products – all the variations, all the rates, and all the faults.

• Processes – all the operations, all the failure modes, and all the checks.

• People – the team who will be responsible for making it work, and will take that responsibility early in the project. … then you will have the Three Ps covered and will be set for a successful automation www.adde.com.au deployment.

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Mitsubishi Electric – Manufacturing in the new normal Social distancing, protecting your employees, restarting operations and machines, catching up on supply chain gaps – just like society as a whole, manufacturers are experiencing a lot of additional challenges they didn’t expect, and to top it all, many are facing reduced budgets. So how do you navigate the new manufacturing normal?

“Manufacturers are now trying to adapt to the changes in conditions, especially in two major aspects,” said Hajime Sugiyama, VicePresident Factory Automation at Mitsubishi Electric. “For example how do you implement social distancing in a factory?”

It’s a very interesting question, which has more permutations than most people initially consider. Starting with the individual, we can all imagine the use of face guards and masks. And indeed many industries have traditionally used such personal protection equipment (PPE), though this was driven from a hygiene or clean environment standpoint for industries producing such things as food, drugs or even sensitive electronics and semiconductors.

Such PPE is not necessarily desirable in all industries. For example, in hot or humid environments the act of wearing a mask may actually increase risks of heat exhaustion, so care must be exercised in truly understanding the worker’s environment.

Some plant managers are considering using screens between workers, but this is also not a panacea as there potentially can be space and restricted movement issues, as well as possible problems around access to emergency devices (E-STOPs) or reporting/controlling devices, or simply visibility challenges.

Stepping back from the individual challenges, Sugiyama goes on to say: “Many manufacturers are focusing on social distancing through shift management. For shift management, you need to balance work shifts so that fewer people are working together at the same time to prevent a pandemic situation inside the factory.

But this presents a whole new set of challenges.”

Balancing shift patterns provides factory managers with a level of operational redundancy – i.e. if one shift needs to be suspended due to infection, the second and/or third shifts can continue business as usual after the plant has had a thorough cleaning. However, it is a natural consequence that fewer people working will naturally lower the productivity. So how do you counter that?

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Let your co-bot take the strain “Building extensive automation solutions takes a great deal of time, budget and planning,” says Sugiyama. “And in these times when manufacturers want to get up and running quickly and flexibly, all three resources are likely to be in short supply.”

So what’s the alternative? One possible solution is the increased use of industrial collaborative robots such as Mitsubishi Electric’s Assista. Typically these ‘light’ devices can be quickly deployed, are human-friendly and so flexible that they can be quickly trained to do a variety of tasks – i.e. you do not need to have extensive robotics expertise. And probably a key deciding factor is that on the whole they are very cost-effective. Enhancing the co-bot solution further with AI-driven environmental management software as seen with solutions such as e-F@ctory Alliance partner Realtime Robotics reduce programing burdens even further and offer live travel path adaption so that the robot can dynamically navigate around obstacles such as humans, other robots and alike. “It’s clear one solution will not fit all, so flexibility to adopt the right social, ‘mechanical’ and collaborative solutions will be the norm,” says Sugiyama. “An additional area of consideration is remote access.”

Remote is not just for homeworkers Returning to full operations, restarting processes and lines often reveals underlying problems that were not previously visible and creates a maintenance nightmare of unquestionable proportions.

Remote access is a key benefit, but if the device you are accessing is not intelligent, the value is drastically reduced as the amount of information is restricted. However, if you are lucky enough to be using intelligent automation devices, which have degrees of selfdetermination and extensive diagnostics, resolving maintenance issues can be accelerated.

But aren’t all automation devices intelligent?

ROBOTICS & AUTOMATION

The name to remember ...for all your linear motion needs

Some plant managers are considering using screens between workers, but this has operational limitations (top). One possible solution is the increased use of industrial collaborative robots (bottom).

“While the essential product performance/function may be similar, you would be mistaken if you thought that all products are equal,” states Sugiyama. “For example, it is not really true to say ‘a drive is a drive, is a drive’.”

As an example, many traditional users of Mitsubishi Electric’s inverters will be familiar with simple features such as a three-wire fan, the significance of which only becomes apparent in times like now. The benefit is the ability to diagnose the health of the cooling fan – which in turn helps extend the life of the inverter. In more recent products there are unique environmental sensors on the circuit boards to detect effects of corrosive or polluted atmospheres, which is complemented by the merging of communications, intelligence and AI through the inverter hardware and partner software, to provide advanced maintenance diagnostics.

Sugiyama explains: “Advances in product technology are not limited to the ‘external function’ of the device, but also in how its operational life is managed, and that means maintenance and performance KPIs. But such knowhow cannot remain locked up inside the product and really excels when it can be remotely accessed by the maintenance teams.”

Developments such as the Industrial Internet of Things (IIoT) and Industry 4.0 have already been talked about for years, but at their core is the process of communication, extraction of data and subsequent analytics. However, often when plant managers consider remote access solutions they quake in their shoes as they contemplate a large, extensive SCADA system and all its associated paraphernalia. It is true these comprehensive systems are excellent for capturing vast amounts of data, providing alarming and analytics and reviewing historical data, but earlier they do take time to correctly plan and install. Other quicker solutions can – remotely, but directly – be connecting to an HMI device on the shopfloor to mimic the local screen, or accessing data over a wireless interface.

So what is the new normal? Sugiyama sums it up: “A practical approach is critical. Sometimes the answer is simply a partition screen, other times it is an investment in a co-bot, but the watchwords are flexibility, scalability and results-focused. So maybe the new normal is actually reminding us to identify what is important.” www.mitsubishielectric.com.au

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www.lineartechnik.com.au AMT OCT/NOV 2020

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ROBOTICS & AUTOMATION

One size does not fit all: Environmental and ergonomic considerations in choosing the right robot When making a robot selection, criteria such as payload, dimensions, weight or force are often given priority, but environmental and ergonomic considerations are equally as important.

The modern industrial robot has come a long way since 1961 when Unimate #001, the first industrial robot arm, appeared on the General Motors assembly line in Trenton, New Jersey. When entreprenuer Joseph Engelberger, the father of modern robotics, appeared on the Tonight Show with Johnny Carson in 1966 to demonstrate the Unimate, many began to envision a future where it might be possible for artificial intelligence to completely take over industrial production processes.

Six decades later, we have not seen the Hollywood narrative of the 1956 sci-fi movie Forbidden Planet play out, where robots perform every task requested of them by their masters. And we are still some time away from full automation with a science fiction icon like ‘Robby the Robot’ taking control of manufacturing systems.

We have, however, seen industrial robotics improve rapidly and adapt into its most commonly recognisable form: the SCARA (Selective Compliance Assembly Robot Arm, or Selective Compliance Articulated Robot Arm) format. For business owners and engineers, selecting the right SCARA robot for the task is critical for maximising return on investment.

There are a myriad different robot manufactures globally, with an exhaustive number of robot models to choose from. But what makes a robot the best fit for your business? Most engineers would primarily be concerned with objective and quantitative criteria (payload, dimensions, weight, force) when making a robot selection, however the environmental and ergonomic considerations are equally as important when choosing the right robot for the application.

One of the most obvious environmental consideration factors in the ability to isolate human-robot interactions safely, with advances in collaborative robot development in response to a growing requirement for flexible alternatives to completely caging a robot.

Robot manufacturers have long identified the need for robots to endure harsh operational environments, freeing up workers from potentially hazardous conditions. Painting robots are a good example of this, exemplifying just one sector of a very wide area of specialist robot designs based on environmental requirements. Just as paint series robots are able to operate in the hazardous environment of a spray booth due to their specific design, there are other specially designed robots for working in the fabrication, food and semiconductor industries and other harsh environments.

Robots designed for industrial food applications must be able to withstand regular cleaning with sanitising chemicals, and robot construction materials must conform to regulatory standards to avoid the introduction of toxins into the food processing stream. This is a good example of how the environment dictates the robot permissible for selection. Ergonomic design features would include the elimination of deep crevasses in the robot body to ensure effective cleaning and the removal of sharp edges to prevent snagging fibres during the cleaning process.

Another example where environmental and ergonomic considerations have driven the design of a robot is modern MIG or GMAW (Gas Metal Arc Welding) robots. These are is the result of many years of research & development in the laboratories of robot manufacturers together with operating feedback from real life scenarios.

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Whilst essentially identical up to the Axis Joint #3, there are some significant differences between a MIG welding robot and a standard manual handling robot (apart from the obvious end-of-arm tooling).

Consider the M20iA and the M120iA FANUC robots: this comparison highlights how two similar robots built on the platform can be customised based on their end use.

Effectively what we see between these two robots is an ergonomic variation in the wrist assembly configuration (Axes #4, #5 and #6) to allow a rear entry to the end of arm tooling, specifically for the MIG torch. Both robots offer the same payload capacity and degrees of accuracy; however the MIG customisation for the Arc Mate M120iA model includes specific internal cabling for the wire feeder and welder power systems. Additionally the Arc Mate M120iA is fitted standard with severe dust and liquid protection cabling for its operational environment, whereas for the M20iA these are optional additions if the manual handling application is required to operate in an environment that requires such protection.

Remember, taking a one-size-fits-all approach generally ends up costing more in the long run. Beware of buying more robot than you need or buying into a lack of reliability. It is important to formulate a checklist when selecting a robot that includes not just the payload, reach and size requirements, but the environmental conditions and ergonomic criteria to select the robot for the best fit for your application. Intelligent design variations allow for robot selection to be specifically tailored to your individual needs, providing a degree of certainty about selecting the right robot for your business. www.automatedsolutions.com.au

ROBOTICS & AUTOMATION

Agile Robotic Systems – Flexible, affordable productivity Having supplied Australian manufacturers with innovative advanced manufacturing technologies since 1946, John Hart’s depth of experience and technical knowledge has formed the foundation for the development of its Agile Robotic Systems range of robotic machine tending solutions.

Joining a small group of Australian companies that build and export manufacturing technology, John Hart designs and manufactures the systems in its Melbourne facility for local and international markets. With a facility in Cincinnati, Ohio, Agile Robotic Systems offers on-site demonstrations, technical support and sales for the entire North American region.

Three levels of machine tending products provide the basis of this innovative success story. The Agile Flex range is an out-of-thebox machine tending solution that is solid in construction, rapid to deploy, easy to use and very affordable. The Agile Modular range offers a flexible machine tending solution created by bringing together pre-engineered modular system components to meet project requirements. Finally the Agile Engineered range offers a fully bespoke solution designed specifically to meet the unique requirements of each project.

Known for their advanced design, simplicity of use, build quality and reliability, Agile Robotic Systems come in a range of sizes and configurations to meet the individual needs of manufacturers.

Unique to Agile Robotic Systems is the Agile Flex Cell Controller software. Developed in-house to offer unparalleled ease of use, this revolutionary control system allows users to efficiently change to new parts in a matter of minutes.

At the heart of this system is a revolutionary wizard-based process, which prompts users in a question and answer format to input simple process information for the next part. Ideally suited to small and large batch sizes alike, Agile Robotic Systems allow customers with no robotic knowledge to be fully self-sufficient in setting up any number of new parts over a normal week. System flexibility together with simple and fast part changeovers helps customers to remain flexible, productive, and profitable in a tough global market.

Having successfully installed many systems into a large variety of industries locally and in the USA, John Hart is a local success story highlighting what can be achieved through the hard work and ingenuity of the very capable people in Australia’s manufacturing industry. Agile Robotic Systems set a new benchmark in rapidly deployable, compact, and affordable machine tending systems. www.johnhart.com.au

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B Com (Hons) Otago University

Founding Director, Empower Software sean@manufacturingandengineering.co.nz +64 27 2284211

AMT Magazine 20/08/2020

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ONE-ON-ONE

Professor Bronwyn Fox is the Deputy Vice-Chancellor (Research and Enterprise) at Swinburne University of Technology.

She spoke to William Poole.

AMT: Swinburne has always been very active in the manufacturing space. What can you tell us about any projects and initiatives you’ve got on at the moment in that area?

Bronwyn Fox: Well, Swinburne has a really deep history in manufacturing, and that comes from our founder, George Swinburne himself. He did a world tour in about 1897, where he travelled the world, looking at energy technologies. He went to the UK and the US and looked at gas and electricity, which were emerging as competitive technologies, and he realised that actually the solution would be to integrate the two systems. I think that that holistic approach of George Swinburne, to integrate different, seemingly competitive systems together to create a better outcome, is a part of our history and part of our DNA at Swinburne. So it’s really exciting to be here, it’s a very creative environment.

Most recently, we’ve been really focused on our Industry 4.0 strategy. My former role was heading up Swinburne’s Manufacturing Futures Research Institute, and when we launched that in 2016, it was the first institute in Australia to focus on Industry 4.0. It raised a few eyebrows at the time – some people thought ‘Oh you know, this will never catch on’ – but it has turned out to be really ahead of its time. We could see what was happening in Europe. We could see this emerging trend of the digitisation of manufacturing and thought that it was such an opportunity for Australia and other developed economies. It brings us back into competition because it’s independent of labour costs, and yet it enables you to scale, which also creates more jobs at the same time. So a great opportunity for Australia.

And since then we’ve worked with industry extensively: everything from the automotive sector to the aerospace sector, to the food and beverage industries. We’ve worked on new materials and photovoltaics, and looked at how digitalisation can transform these industries. It’s been a really fun and exciting adventure, and we’ve got a great team of researchers who are really industry-engaged and down to earth, and able to talk with industry and listen to them, hear their challenges and help solve problems for them.

There’s also some really inspiring work being done around sustainability and the circular economy. One of our staff members, Dr Stacy Konash, works in our Factory of the Future facility, and she has actually been awarded a Fulbright fellowship to look at the circular economy in particular. I’ve been working with her on a project with a company called Mallinda in the US, who have an incredible technology for completely recycling carbon fibre composites. They have a resin system that can be completely recovered, as well as the fibre, which can be recovered in strips and continuous fibres, rather than having to be chopped up, where you lose the properties. To actually recover the fibre and the matrix is really hard, and that’s what this start-up Mallinda is able to do.

AMT: Obviously the COVID-19 pandemic has been a challenging time. How has it affected Swinburne?

BF: Every university is experiencing challenges, particularly with respect to our budgets, which have all dropped due to our inability to enrol international students, who have really brought so much to the diversity of our community and are such an important part of the

AMT OCT/NOV 2020

fabric of our university and the way that we do research. So that’s been particularly challenging.

What’s really inspired me is the resilience of our researchers and where they’ve been able to look at finding creative solutions. We’ve had researchers working on everything from developing a carbon fibre stretcher for carrying patients, to 3D printing copper door plates, because copper has been shown to be more resistant to viruses than other materials.

One of my favourite projects involved an epidemiologist who got together with an astrophysicist at a coffee machine. Our leading epidemiologist Richard Osborne had come up with a very well thought-through questionnaire for tracing the transmission of influenza. He’d had that translated into more than 50 languages.

And he bumped into Matthew Bailes, who being an astrophysicist is naturally au fait with data analytics and data visualisation, and he said: “Why don’t you create an app out of it?” Within 40 days they had held a hackathon and had a workable version of that. And I think it really will come into its own as we start to open up society more.

It’s a symptom tracker where rather than just tracking the contacts of someone who’s been tested positive, you’re actually looking at the symptoms that are leading to that positive test. It’s a canary in the coalmine for COVID19 effectively.

During the pandemic I’ve been hearing it from the manufacturing sector as well: so many different manufacturing companies who wouldn’t ordinarily work together getting together to find solutions and develop new technologies. And that’s really inspiring. I think the reason that it happens is it gives us a sense of agency, that there’s something that we can do to help rather than just sitting back passively.

AMT: What are some of the most exciting developments that you’re currently seeing emerging in advanced manufacturing?

BF: There’s some really incredible things. The first thing I need to talk about is the National Industry 4.0 Testlab in Composite Additive Manufacturing, our new joint facility with CSIRO. That will be on CSIRO’s Clayton campus, and the building is now almost completed.

It will house a world-first process for additive manufacturing with carbon fibre composites. To me, that’s really super-exciting, and it’s at industrial scale. We can make parts that are 1.6 x 1.6m.

To do that in partnership with the national science agency in Australia is so important. It gives us access to their depth and their national reach. The facility will not just allow us to rapidly prototype new materials, it will also allow us to push the boundaries of virtual commissioning, of the digitalisation of manufacturing, and of remote access to the facility. We’ll have CSIRO’s Data 61 team to look at the data analytics, the production data. How do we turn that into information? How do we create self-correcting processes? And how can we demonstrate the benefits of digitalisation to the broader manufacturing sector in Australia?

One of the centrepieces is a process developed by a company called Fill, which is based in Gurten in Austria. It’s really beautiful: ‘The Sound of Music’ country, and you turn a corner and there’s an enormous factory that employs 700 people. Fill is the world leader in digitalisation: the company started from a family business that made

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skis, then they realised a ski was a composite, and then they were the major supplier for the BMW i3 factory in Leipzig, in Germany.

Their new technology, which is a world-first multilayer process, enables you to put fibre down really quickly and minimise waste.

It reduces the waste from 60% to about 10%. You create a near net shape pre-form. I was in Austria late last year, where one of our Swinburne students had designed a car bonnet; he’d optimised it for pedestrian impact and reinforced areas of it with additional carbon fibre. He sent the code to Austria, and it was printed out while I was there, which was incredible.

There’s a lot of other exciting trends. One of them is the monetisation of manufacturing production data. This is an emerging trend in Europe, which uses integrated ledger to securely transfer data between companies. So for example, I might be making a gin. I’ve got a process for making a gin, I have botanicals that I use, I have temperatures that I can control. And you might see in a window shop that I have data for gin manufacturing. So you can make me an offer to share that data in a secure way. And that way I’m not only making money from making gin, I’m making money from sharing my data on making gin. You might be in another location around the world, but we can still securely share that data. That’s a trend that’s coming through Europe.

Another trend that I’m seeing is around secure cloud platforms.

There’s a program in Europe called GAIA-X, which is really interesting, which is looking at a secure cloud platform for Europeans who do

not necessarily want to be locked in to having all of their historical data accessed. It’s really to avoid the locking effects of some of the major cloud providers who, once your data is with them, they own it for eternity. So there’s gonna be a lot of changes in the way that we transact data.

And then enormous changes to the internet of things (IoT). The time is right to really re-explore IoT. It feels like we’re already familiar with it, it feels like we already know it. We’ve all got lightbulbs and heaters that are IOT-connected, but there’s so much more that’s possible.

As sensors are becoming cheaper and smaller, there’s so much more we can do with IoT in manufacturing, and we’re really just at the beginning of what we do with that, how we integrate those sensors, what we do with that information. And I think that’s going to be really important for the Australian economy in the future, that we look at that as a platform and invest and utilise it in manufacturing and learn from the mining sector and what they’ve done in particular.

AMT: What can Australian manufacturers do to capitalise on these developments?

BF: Well, I think that there’s an enormous appetite to do that right now. We are suddenly really valuing our own manufacturing sector for the first time in a long time. And that’s a wonderful change, that we really value our own ability to make things. It’s an incredibly important cultural shift.

Continued next page

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ONE-ON-ONE Contiuned from previous page

And with that will be enabled the development of new products, new processes, new technologies that are still globally connected, we’re still exporting them, but it’s using advanced manufacturing to connect into those global value chains with something that’s really unique. I see a lot more collaboration than has ever happened before, and I see a lot more cross-sectoral learning than we’ve previously seen.

All of those things will set us up for success if we stay focused, if we remain focused on developing and commercialising new technology, and if we can continue to build public private partnerships.

My first job was at CSIRO; I’ve collaborated with them for my whole life, since I was probably 22. They were a core partner in building the Carbon Nexus hub that became a key part of my former role at Deakin. I really saw there the advantage of having a publicprivate partnership with government-supported research between a university and the national science agency and industry. If we can continue to look at that as a model and work together, we will continue to develop new technologies. That’s what I’m really excited about with what we’re doing with Swinburne at Clayton. You create an innovation ecosystem, with industry, university, you get that talent through those graduates who have unencumbered thinking and you can do really incredible things.

The establishment of Carbon Nexus supported the creation of a whole precinct, a whole ecosystem. (Australian manufacturer) Quickstep made the decision to set up their presence there on Deakin’s Geelong campus, the day that Carbon Nexus opened in 2014. And then my former PhD students founded Carbon Revolution, which was supported by the growth of the whole area, and they’ve just employed 570 people. And that’s been so important to the economy of the Geelong region, because that all happened right at the time of the global financial crisis. That’s when we got the funding for Carbon Nexus and right at the time were Ford was shutting down and Alcoa was shutting down.

AMT: We often hear about the importance of collaboration between industry and universities or research bodies. What’s your advice to manufacturers about engaging with an organisation like Swinburne?

BF: It’s really about building trust, and having constant conversations.

Picking up the phone: “What do you think about this? I’ve heard this is happening.” You know, constantly having those mechanisms for knowledge transfer, which create trust networks. I think that’s most important side of it. And it’s based around individuals; you need to have the right people involved.

AMT: What do you think are the biggest challenges and opportunities right now for manufacturing in Australia?

BF: The challenge is re-establishing supply chains. We have relied on bringing in a lot of materials from overseas. If we’re cut off again, we may not be able to do that. So how do we develop robust supply chains? I thank that’s going to be a big question for the future. The opportunity is to still think globally when we can’t travel. A lot of countries will become inwardly focused and insular. We need to shore up our own capabilities, but at the same time think globally and think where we can export, and to continue to have those conversations digitally where we can’t meet physically.

There are a lot of opportunities. We had a fantastic visit from the head of materials and manufacturing at Mercedes at the beginning of this year. They are focused on sustainability; sustainable luxury is their new focus. They’re making leather out of apple skins. They’re doing incredible work around recycled plastics. And there’s an opportunity for Australian technology to be integrated into their supply chains because we’re really creative, we’re focused on sustainability, and we can develop some of the technology they’re really looking for.

One more challenge: companies like Mercedes are now not only making their business decisions based on cost. Now they are basing the business decisions on your CO2 footprint, and they have tools to evaluate what the CO2 footprint is of your manufacturing process

AMT OCT/NOV 2020

and your product. That will determine whether you’re integrated into their supply chain. That’s a challenge for the future for Australia: to be aware of that and to be able to demonstrate compliance.

AMT: Tell us about your professional background up to your current role.

BF: It’s kind of embarrassing. Both of my parents were scientists, so I tried not to be a scientist; I tried very hard, but I think it was in my genes. I guess I grew up in a family where we were building papier-mâché volcanoes and exploding things in the backyard.

We were always just making things and testing them and blowing things up. I did a chemistry degree because I didn’t quite get into optometry, which was my first choice, and I’m so glad I didn’t. I got into chemistry and then realised that what I was really interested in was engineering. I don’t think we articulate what engineering is very well. It’s really about working in teams and solving big problems and making a difference to society. I think that would really help us engage with more STEM students, if we were able to articulate some of the really exciting career paths you can have in engineering.

I finished my PhD and I was offered a job at Deakin by Peter Hodgson, who had come from industry, from BHP. And he was really inspiring in setting up Deakin to do something different other than the big universities. He was really supportive of new ideas and gave you the space to try things and fail. So I was lucky to be in that really great environment. We grew from a one-man band into a team of 30 people and part of a hundred-million dollar precinct around Carbon Nexus. And then I moved to Swinburne having been at Deakin for 15 years. I just needed something new to do, and I’ve loved the move.

Swinburne has that same really open creative environment where if you come up with a new idea, it’s “Let’s explore that and test it”, rather than “Oh, that’s never gonna work. We tried that in 1984 and this happened.” It’s a really wonderful environment and a lot of fun to be part of.

AMT: And you’ve been Deputy Vice Chancellor (Research and Enterprise) since April. What does the role entail?

BF: The role really entails supporting our research community, understanding where the strategic opportunities are, and leading the research at the university through what is a very challenging time.

I’m very fortunate to be working with not only some very clever, innovative academics, but very nice human beings as well. I’m incredibly grateful for that; they’re strategic and smart and they’re fun to work with. Through everything that’s happened, that’s really kept me inspired every day. If I can meet with a researcher or a research team every day, it just puts a spring in my step to hear about the incredible things they’re working on – everything from health technologies, to social innovation, to smart cities. It’s a really interesting role to think about research much more broadly than my own discipline.

AMT: What’s the most satisfying part of the job?

BF: Absolutely the people. The incredible leadership, but also the emerging talent, and looking at how you can nurture that and help it grow. www.swinburne.edu.au

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CUTTING TOOLS

Grade upgrade Building a house begins with laying the foundation. The strength and the reliability of the whole house depends on how strong the foundation is. In cutting tool engineering, this foundation is a cutting material.

There are various types of cutting materials: cemented carbide, polycrystalline diamond, high-speed steel, ceramics and so on, and each type contains different grades. At various stages in the history of metal cutting, the introduction of each new cutting material and its use have led to a significant change in the level of cutting speeds, and consequently of productivity. However, if the previous century, especially its second half, was marked by the rapid progress of tool materials, today we do not see any significant new solutions in this field. Does this mean that the development of new tool materials has already reached its peak and is experiencing stagnation?

Of course not. It is simply that the new developments are deep within the cutting material and are focused on its structure and can be observed only with the help of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBCD), and other sophisticated methods. They cover a tremendously complicated world of coatings that is extremely diverse despite its very small thickness, measured only by microns.

The most commonly available cutting material today is cemented carbide, primarily coated. In terms of performance, it represents a reasonable balance between efficiency, tool life and cost. Cemented carbide is known also as ‘hard metal’, ‘tungsten carbide’ or simply ‘carbide’. A combination of cemented carbide, coating, and postcoating treatment produces a carbide grade. Only one of these components – the cemented carbide – is an essential element in the grade. The others are optional.

Cemented carbide is a composite material comprising hard carbide particles that are cemented together by binding metal (mainly cobalt). Most cemented carbides used for producing cutting tools integrate wear-resistant coatings. There are also various treatment processes that are applied to already coated cemented carbide – for example, the rake surface of an indexable insert. New developments in cemented carbide, as a tool material, are concentrated in three directions: carbide production technologies, advanced coating

methods, and innovative post-coating techniques. Considerable success has been achieved in each of these directions; this is reflected in the wealth of new products introduced to the market by leading cutting tool manufacturers.

Cutting tool customers might analyse the grades using parameters such as productivity, tool life, and performance. Indeed, the question of how a new product was created to meet customer requirements fades into the background as applicability and efficiency form the main measure of progress from the customer’s point of view.

In upgrading carbide grades, Iscar is very sensitive to a challenge faced by the metalworking industries. In this context, Iscar’s tool material solutions, which are developed considering the trends of modern metalworking, can be quite indicative. Take, for example, difficult-to-cut materials such as titanium and heat-resistant steels and exotic superalloys. Recently, the share of their application in industry has increased significantly. Along with the aircraft industry, a traditional consumer of these materials, they may be increasingly found in power engineering, automotive and oil & gas branches.

The growing usage of the materials demands technological solutions, including machinery and cutting tools. The new tools require an appropriate foundation, made of advanced cutting tool materials, to achieve the desired cutting geometry. And for the construction of this foundation, Iscar offers its new effective ‘bricks’ – upgraded carbide grades developed by company metallurgists in the last few years.

In milling, Iscar has developed PVD (physical vapour deposition)coated IC882 and CVD (chemical vapour deposition)-coated IC5820 grades– two chocolate-colour carbide grades for cutting titanium, high-temperature alloys, and stainless steel. An integral component of the grades is a post-coating treatment that facilitates longer tool life, due to increased resistance to chipping, notch wear, and build-up edge formation. The IC882 grade demonstrates impressive performance when machining conditions are hard, and Insert production starts with carbide powder.

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CUTTING TOOLS

the advantages of the IC5820 are most fully manifested when applied to milling with pinpointed high-pressure coolant supply.

For drilling applications, the company introduced IC5500, a new grade that features a multi-layer CVD coating and a post-coating treatment to prolong tool life. Following the grade’s success, IC5500 has been utilised in milling products as well: the new round inserts in cutters for machining 3D surfaces such as blades in turbomachinery, for example, are produced solely from this grade.

The PVD-coated carbide grade IC806 was designed especially for turning high-temperature superalloys. As a result of the high mark that the grade received from the manufacturers of aerospace components, Iscar expanded the application range of IC806 for laydown threading inserts.

In addition to cemented carbide, the metalworking industry consumes other hard cutting materials such as ceramics, diamond and cubic boron nitride (CBN). Their application to machining difficult-to-cut materials facilitates considerable increases in productivity. In recent years, Iscar has enriched its cutting material range by introducing several new non-carbide grades, including the SiAlON ceramic grades IS25 and IS35 for cutting high-temperature alloys, and the CBN grade IB20H for hard part turning.

At the same time, customer demands are not limited to the effective machining of exotic superalloys or titanium. Steel is still the main structural material, and cutting tool manufacturers are constantly searching for the most advanced appropriate solutions, including the development of advanced cutting material grades. An example may be Iscar’s latest innovation in parting and grooving: two new PVD-coated carbide grades, IC1010 and IC1030, which were utilised in inserts from the TangGrip and DoGrip families. The grades are intended for machining stainless steel and steel. While the hard submicron grade IC1010 is recommended for productive parting and grooving with high cutting speed, the tough IC1030 is more suitable for interrupted cut and unstable machining conditions.

Upgrading cutting material grades is an essential component for tool manufacturers’ success, and innovations in cutting tools should have a strong foundation. This why Iscar’s motto, “To be on the upgrade”, guides and inspires new tool material developments. www.iscar.com.au

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CUTTING TOOLS

Carmaker sees 1,150% increased tool life with CoroDrill 860-GM For automotive manufacturers, longer-lasting tooling solutions are integral to profitable production, but often manufacturers see little reason to change their existing set-up. James Thorpe, Global Product Manager at Sandvik Coromant, explains why the benefits of longer tool life shouldn’t be underestimated.

Unpredictable tool life is one of the biggest threats in automotive production, particularly as its operations are so highly automated and use some of the world’s most advanced robotics and automation systems. Downtime is time-consuming, disrupts production and is expensive, so it goes without saying that tool failures should be avoided at all costs.

In some instances, manufacturers set the tool change interval to less than the maximum tool life. This approach is normally preferred because material variations in automotive components are minimal.

It follows that the tool changes should be predictable, and safer than trying to extend the tool life to manufacture a few more components.

For Sandvik Coromant’s specialists, the key to longer tool life is not limited to the amount of time a tool spends in use, but also the drill design itself. This approach led to the development of the CoroDrill 860 with enhanced -GM geometry, a new-design solid carbide drill optimised for a wide range of materials, applications and industry sectors. For the CoroDrill 860-GM, Sandvik Coromant applied its machine tooling and metal cutting expertise to develop a new grade, a unique fine-grained carbide substrate known as X1BM. The fine-grained carbide is imbued with increased hardness while maintaining toughness.

Furthermore, the drill is tip-coated with a multi-layer physical vapour deposition (PVD) thin film coating. This is key to improving the drill’s productivity and delivering a consistent tool life across a variety of materials. The result is a tool with excellent stability, machining security and improved tool life when machining cast iron, steel, stainless steel, hardened steels and non-ferrous metals.

A better way to assess tool life is by measuring the amount of material removed. To aid productivity, the CoroDrill 860-GM has an innovative, polished flute design that improves evacuation of chips and yields greater hole quality. This also helps to reduce heat build-up in the tool; further benefits include high core strength and reduced cutting forces while drilling.

The 860-GM forms part of Sandvik Coromant’s CoroDrill range of solid carbide drills. They are designed not only for optimised performance but also versatility, which means they can be deployed in a variety of applications and materials across multiple industries.

This includes use with the following material groups: ISO-P, the largest material group in metal cutting, ranging from unalloyed to high-alloyed material; ISO-M, which includes difficult-to-cut stainless steels, austenitic steels and duplex steels; ISO-K grey, nodular and compacted graphite cast iron; ISO-H steels with a Rockwell hardness of between 45-65 HRc; and ISO-N, for softer, non-ferrous materials such as aluminium, copper and brass.

But what exactly does the CoroDrill 860-GM’s enhanced design entail? The drill itself includes an advanced optimised point and flute geometry, reinforced core and corner chamfers, edge preparation to remove cutting edge micro defects, and a double margin to enhance drilling stability. The drill’s point is also designed with refined clearance angles and improved surface quality.

Overall, these design features stabilise the drill, reduce entry and exit burr and improve the hole tolerance, finish and straightness.

The drill also gives stable wear progression and delivers excellent hole accuracy.

For automotive manufacturers, the CoroDrill 860-GM has proven useful for drilling engine blocks, casings, flanges and manifolds.

Beyond automotive and general engineering, the drill is also suitable for all applications where hole quality is critical — such as in aerospace, oil & gas, and nuclear or renewable power.

Among the most striking results achieved so far with the 860-GM was reported by an automotive manufacturer in South Korea. The customer’s operation was to drill through holes in a production batch of automotive transmission connectors. Overall, eight 8.2mm-diameter through holes were drilled into each component that measured a depth of 10mm.

The existing solution produced 200 components, drilling 1,600 holes in total, with a cutting speed (Vc) of 80 metres/min (3,102rpm) and cutting feed (Vf) of 381 mm/min. In comparison, the CoroDrill 860-GM produced 2,300 components (18,400 holes) with a Vc of 100 metres/min (3,878rpm) and Vf of 814 mm/min. The result was a significantly improved tool life, increased by 1,150%, and a productivity increase that helped significantly lower the costs-perpart.

Similar, impressive results have been reported by other Sandvik Coromant customers within the automotive segment around the world. The CoroDrill 860-GM’s abilities go beyond its machining security and improved tool life. Because the solution delivers one drill for all materials, stockholding can be reduced and greater machine flexibility is provided, which leads to reduced set-up times and cost reductions. These advantages show that automotive manufacturers should consider the positive impact of enhanced drills, like the 860-GM on their bottom line — particularly the longerterm benefits for when life is a marathon, rather than a sprint. www.sandvik.coromant.com

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MRO tools weather turbulent industrial economy The metalworking industry has experienced both positive and negative periods of economic development in recent years. This is often linked to the performance of several key industries, such as automotive, aerospace and oil & gas.

However, there is one segment which seems to weather the storm regardless of the economic climate: maintenance, repair and overhaul (MRO).

Regardless of whether times are good or bad, many industrial companies have continual requirements for maintenance and to support production operations. Their primary aim is to find alternative options to keep costs low by reusing existing equipment or materials, repairing items or simply choosing a cheaper option to get the job done. The latest report by business intelligence provider Visiongain, says that Europe’s MRO market alone reached spending of $170bn in 2019 and is expected to grow at an annual rate of 2%.

A key feature of MRO is hand-drilling operations, particularly standard high-speed steel (HSS) drills, which represent the lifeblood of the segment. Dormer Pramet is a leading manufacturer of HSS and HSS-E general purpose drills, with more than 100 years’ experience of providing cutting tools to meet companies’ MRO needs. The most popular items within its ranges include jobberlength and stub-length drills for use in hand-held power drills, pillar drills and other manually operated machinery. Its stub length drills, for example, feature shorter flutes to increase toughness and precision. This makes them ideal for tight spaces and handheld operations that require rigidity. In addition, the shorter length reduces deflection, breakage and runout.

However, when performing hand-held applications, the length of the drill is not the only important criteria to consider when choosing the right cutting tool. Consistent and predictable performance is critical, meaning the right geometry and torque capabilities are paramount.

Torque The drilling torque is predominantly determined by the workpiece material properties, diameter, drill geometry and machining parameters. From the machining parameters, the feed is the main factor to consider, because cutting speed has little influence on the development and size of the cutting forces.

With modern CNC machine-tools, the drilling torque is rarely a limiting factor, but with light-duty machines, pillar drills and hand-held power drills it is a primary consideration. When torque becomes a limiting factor, a reduction of the feed per revolution

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is needed or alternatively a change to a two-stage operation. This means pre-drilling with a smaller sized drill (≈ 0.2xD), followed by drilling with the desired diameter.

Point geometry In general CNC machining environments, maximising drilling speed, while maintaining required hole-quality, is often favoured as it can result in greater cost savings. However, for the MRO engineer, safety and reliability is paramount. It is therefore important to understand the connection between the features of the drill-point geometry and the allowable penetration rate.

The rake angle, for example, is measured at the peripheral corner and approximately equal to the lead of helix. However, it changes along the length of the major cutting edge, getting smaller to eventually become negative near the drill axis. This improves the sharpness of the drill, which in turn, reduces the amount of torque required.

Just like the rake angle, the clearance angle also changes in the radial direction. But where the rake angle decreases from the peripheral corner to the drill axis, the clearance angle increases.

This helps to create a smooth exit hole during hand-held operations.

Also, the chisel edge is the first point of contact, pushing into the material. However, it doesn’t cut the work-material, but instead displaces it while penetrating. As a result, the chisel edge creates most of the thrust forces exerted. The geometry of the chisel edge, together with the point angle, determines the centring characteristics which control hole positioning, size and straightness.

Versatile cutting tools One cutting tool that features these characteristics is the popular Dormer A100 HSS drill. Suitable for drilling a variety of materials, such as steels, aluminium and stainless steel, the versatile A100 is ideal for hand-held applications. Its strong 118-degree standard point is easy to regrind and a steam oxide finish prevents the workpiece material from sticking to the cutting edge.

CUTTING TOOLS Hand-held tools In addition to standard jobber drills, Dormer Pramet has a range of cutting tools for other hand-held applications. Spot weld drills are one of the most common used in MRO applications, especially when replacing sheet metal panels welded together. Removing a spot weld with a standard twist drill can be messy and dangerous because the drill can wander on the hardened, uneven surface.

Also, the Dormer A002 general-purpose jobber-length drill, developed more than 20 years ago, continues to be sold in significant quantities around the world. Providing a smooth cutting action and consistently high quality in a wide variety of materials, its self-centering split point offers excellent positional accuracy.

Its lesser-known cousin, the A108, features a split point and a quick-spiral helix specifically for machining stainless steel. A sharp geometry limits the onset of work-hardening and a steam tempered surface treatment helps retain cutting fluids and prevents material sticking to the cutting edge. Manufactured from M2 grade of HSS, which is one of the toughest available, make it ideal for hand-held operations.

The Dormer A777 and A117 high-speed cobalt jobber and stub drills provide other options for hand drilling. Their heavy-duty design makes them suitable for machining high-tensile, tougher materials, such as tool steels. A 135-degree split point design helps with selfcentering when used by hand and reduces the push force required.

A bronze oxide finish prevents workpiece material from sticking to the cutting edge during usage.

The A723 high-speed cobalt spot weld drill is available in several standard sizes to suit common applications in the automotive and trailer repair industry. A special lip and spur point provides accurate centering by preventing the drill from wandering. In addition, a sharp outer corner cuts the softer material around the spot weld at the same time. A strong web design gives strength for improved penetration in tough conditions and ensures a safe and reliable use.

Short flute options enhance rigidity for the hand-held drilling of thin panels and sheet steel, increasing stability even more.

Finally, HSS sheet metal drills are available in several standard sizes to suit common rivets, screws and bolts. Suitable for drilling thin sheet steel and panels, the A123 range features a 120-degree point geometry with a short flute to provide easy penetration and rigidity in portable applications. No body clearance further increases stability during drilling and breakthrough to give superior hole quality. Its thin web at the point provides excellent self-centering properties, while its steam tempered surface improves performance and reduces the chance of built-up edge. An economical double-ended version (A119) is also available, helping to reduce inventory costs.

Dormer Pramet’s range of economical hole-making tools is supported with additional options, such as threading taps and rotary carbide burrs. This demonstrates the company’s commitment to the MRO segment, helping to ensure it continues to develop, no matter what the market conditions are. www.dormerpramet.com

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Walter – New dimensions in drilling Walter Tools has unveiled a number of additions to its drilling tool range, aimed at reducing cutting costs, maximising efficiency and enabling safe handling.

With the X·treme Evo solid carbide drills from the DC160 Advance range of drills, Walter aims to forge a link to the ‘next generation of drilling’. By introducing lengths of 16 to 30 x D, the tool manufacturer its expanding its range to now include deep-hole drilling. Like its predecessor the Alpha 4XD drill, which has been established on the market for a long time now, the DC160 Advance makes deep-hole drilling possible in a single operation without pecking – and therefore boasts the advantages of XD Technology.

The coating and geometry have been optimised. Just like the existing versions of the DC160 Advance, the deep-hole drills also feature the innovative new thinner web with 140° point angle and the fourth land in an advanced position. The former ensures increased positioning accuracy and reduced cutting forces in the centre, while the latter optimises the guidance of the drill.

with internal coolant in dimensions of 5, 8 and 12 x Dc; and the DB131 Supreme pilot micro drill, with a geometry and diameter tolerance perfectly tailored to the DB133 Supreme, in the dimensions of 2 x Dc. Both drills cover the diameter range from 0.7mm to 1.984mm, while the pilot drill is also suitable for diameters from 0.5mm. The combination of these two drills is not the only factor behind the positive effects. Thanks to a new flute design, the chips break so that they are shorter and are reliably evacuated. A special cutting-edge preparation enables outstanding surface finish quality on the component and ensures a long tool life.

With these new products, Walter has further refined the adaptation of the L/D ratio to the required drilling depth. The result is a range of micro drills that ensures maximum stability when machining thanks to its broad scope and the optimised design. Walter offers both micro drills in the WJ30EL grade with micrograin carbide and full-length AlCrN coating, while the DB133 Supreme is also available in the WJ30ER grade with micrograin carbide and AlCrN point coating.

The grades of the drills (WJ30ET and WJ30EU) are another new addition. These comprise the K30F fine-grained substrate and a TiSiAlCrN/AlTiN multi-layer coating (as a point or complete coating).

The layer structure makes the drills both tough and wear-resistant, and plays a crucial part in the process reliability and performance of the DC160 Advance drills. Polished flutes from 8 x Dc also optimise chip evacuation. Typical application areas of the drills, which are available with or without (internal) cooling, include general mechanical engineering, mould and die making, and the energy and automotive industries. Walter offers intermediate sizes and special dimensions via its Xpress service with faster delivery times.

The drill and pilot drill can be used with emulsion or oil and are suitable for all ISO material groups.

In addition to the watchmaking industry and medical technology, the premium manufacturer cites general mechanical engineering, mould&-die making, and the energy and automotive industries as other specific areas of application.

All-round cost efficiency When machining components made of materials with difficult cutting properties, such as turbine blades, drive parts or engine parts for the energy or aircraft and aerospace industries, round insert milling cutters are often the first choice. Until now, single-sided indexable inserts have primarily been used for this purpose.

Drilling precision parts reliably Walter’s externally cooled DB133 Supreme micro drills have become established around the world for machining precision parts. Walter has now released two new developments in micro drilling: the DB133 Supreme solid carbide micro drill

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CUTTING TOOLS

Professional Measuring Instruments

With the indexable insert size RNMX1005M0 for small depths of cut, Walter is bringing an extension for the M2471 copy milling cutter to the market – the first to feature a double-sided round insert with eight useable cutting edges. The system for milling cutters with diameters of 25mm or more with ScrewFit, parallel shank or bore adaption is suitable for machining steel, stainless steels and materials with difficult cutting properties. Indexing using the flank face of the indexable insert ensures simple, safe handling.

The M2471 copy milling cutter brings all the benefits of single-sided round inserts to double-sided round inserts, particularly in terms of their positive cutting behaviour. To ensure that this does not negatively affect process reliability, the insert and body are designed so that their overall stability is guaranteed during use of all eight cutting edges. The technical features, as well as the eight useable cutting edges, reduce cutting material costs by up to 20%.

Walter offers the new indexable insert in geometries ‘G57 – The universal one’ and ‘K67 – The easy-cutting one’, respectively for medium and good application conditions. It is also available in Tiger·tec Silver PVD grades WSM35S and WSP45S.

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

On the safe side when drilling In 2018, Walter launched a flexible all-rounder onto the market in the form of the D4120 indexable insert solid drill. The tool manufacturer is now completing its D4120 product range. With dimensions of 2, 3, 4 and 5 x D, Walter offers a wide range spanning diameters from 13.5 to 59mm.

Specialist range of digital ultrasonic & laser measuring instruments and gauges.

Specially developed outer and centre inserts ensure precise balancing of the cutting forces. To this end, centre inserts slightly larger than the outer indexable inserts were selected and equipped with a corner protection chamfer. Besides greater process reliability, this plays a crucial part in increased precision and minimal drilling noise.

Walter also offers a version with wiper edge for high surface finish quality. The drilling body features two coolant-through channels and a measuring collar (Dc) for easy drill identification, even when assembled. Polished flutes and a hardened surface optimise chip evacuation and wear resistance.

The combination of D4120 and four-edged indexable inserts offers users cost-efficiency advantages and the greatest possible flexibility thanks to a coordinated system. This is of interest to users, both in the case of difficult machining operations, such as cross holes, chain drilling and inclined inlets and exits, and because these drills can be used in ISO materials P, K, M, N and S. Users in general mechanical engineering, mould-&-die making and the energy and automotive industries can benefit from outstanding precision in hole diameters, a high degree of process reliability and cost-efficiency. Alongside the standard dimensions, Walter also offers the D4120 in special dimensions via Walter Xpress with faster delivery times. www.walter-tools.com

Available now at:

www.accud.com.au AMT OCT/NOV 2020

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Bertazzo Engineered – Engineering passion Wodonga-based Bertazzo Engineered has acquired a strong reputation for quality component fabrication and installation services. Owner and Managing Director Raymond Bertazzo discusses how his company has evolved over the years, and its recent decision to upgrade its workshop with a range of equipment from Prima Power – supplied, installed and serviced by IMTS Machinery.

Since starting the business 23 years ago, in a home workshop with a Brobo saw, an MIG welder and a variety of hand tools, Bertazzo Engineered has continued to move with the latest trends and technologies as our industry has evolved over that time. I remember buying a copy of AutoCAD Release 9 on floppy discs, and a 186 computer with 4MB of RAM to run it!

Back then plasma cutting machines were the norm – they followed an outline profile, and it had to be the right black ink as well. Laser cutting machines were still around 2kW and could only cut thin material, at a cost of over $1,000 per hour. Press brakes were hightech if they had one axis back-stop. But regardless of that, I could always see that the future of metal fabrication was to run with this new technology.

Our first couple of jobs were architectural projects, with lots of small simple parts that were perfectly suited to laser cutting. They were all the same, with a nice finish and accurate to the original drawings.

The cut parts’ cost was much cheaper than doing them by hand, and there was no need for extra processes.

This pretty much set the path that Bertazzo Engineered would follow from then on. Industrial projects were all now being drawn in smarter versions of CAD, 3D models of the equipment that we were making were also being developed, DXF files were available on request. Fabrication was getting easier and smarter. I loved the fact that corners had radiuses and not just 45-degree cuts.

We needed to change what we are doing and the direction we were going in. I was fortunate enough to attend EuroBlech in Hannover, Germany, where I saw so much more new machinery and ideas.

We bought our first CNC press brake, which after a few challenges proved to be awesome. We soon learnt that customers who wanted repeatable parts folded also needed them to be laser cut as well.

So then we bought a very tired 3kW laser cutting machine, which got us in the game.

Not long after that we upgraded to a new 4kW laser cutter, always using the propriety programming software to suit the machine. We also bought another larger press brake, which came with more challenges, but we got the desired results in the end.

Following its latest investments in Prima Power machinery, Bertazzo Engineered’s workshop includes two Platino 4kW fibre lasers, a 200T eP2040 servo electric press brake, and a FBe6 servo-electric panel bender

Over the years we continued to attend EuroBlech regularly to keep an eye on the changing trends within manufacturing. We lost a large contract for panel work to a company that had newer more task-specific equipment – in particular a panel bender. We needed to invest in better equipment, so we went to the market, did our research and ended up purchasing a Prima Power FBe6 servoelectric panel bender through IMTS Machinery. Simon Stain and the team at IMTS, along with everyone from Prima Power in Italy, were fantastic, the project went ahead without any problems, and we ended up regaining the lost work.

Based on this experience with IMTS, we quickly replaced our aging press brake with a Prima Power eP1030 servo-electric press brake.

By then fibre laser technology was really starting to flex its muscles; it was no longer just for cutting thin material. Fibre laser was the future we needed to pursue, and there were only a few true fibre laser machines that we were interested in.

Following on from our experience with IMTS Machinery and Prima Power with the panel bender, we decided to shift the whole workshop to Prima Power machinery and programming systems.

Bertazzo Engineered’s premises in Wodonga.

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FORMING & FABRICATION

ASSESS YOUR ELIGIBILITY FOR REBATES ON PRODUCTION CHANGES Has the COVID-19 crisis disrupted your sales or changed your target market’s needs? Have you identified new market opportunities but lack the investment required to develop products or change your manufacturing facilities? If so, the R&D Tax Incentive program could help you finance your innovation or the re-purposing of your manufacturing operations.

After a lot of consultation work with Simon from IMTS, we went ahead and purchased two Prima Power Platino 4kW fibre lasers, including different levels of automation, along with a 200T eP2040 servo electric press brake.

Simon and the Prima Power project team visited us and we laid out the machines to the correct standards, along with our own tweaks.

We were able to fit two laser machines where we previously only had one. The lasers and chillers were installed in the roof space with the dust extraction outside. Through all the sleepless nights during the installation, Simon, Peter Tucker and the IMTS Machinery team continued to work through any issues with us and Prima. Not all stories of buying and installing machinery are roses, but after some teething problems, this one ended up with fantastic results for Bertazzo Engineered.

The lasers were named after two iconic Italian prima donnas – Sofia Loren and Gina Lollobrigida – rather than boring old Laser 1 and Laser 2. One of the amazing benefits of the Prima fibre laser machines is that combined they use 60% less power than our old 4kW CO2 machine on its own, and they have a fraction of the maintenance costs. All the press brakes and the panel bender are servo electric so there’s no more humming of hydraulic motors or using up hundreds of litres of oil.

All the equipment has been running relatively free of problems ever since they were installed. The feel of the area fits in with our company’s persona. We have always tried to show that modern engineering and fabrication here in Australia can be as good as anywhere else in the world. We have the newest and the best technologies here in this country, and it helps us compete.

Our passion is to share the knowledge and learnt skills with our customers; we love nothing more than inspiring them, and then to see an idea grow to a refined finished product. Simple changes result in not only a better finish, but in most cases reductions in production costs.

Whether you’re looking to improve old processes or develop entirely new products, the R&D Tax Incentive is designed to minimise the risk of these developments. It may provide you with a cash rebate of up to 43.5 cents for every dollar you spend on your eligible R&D activities.

You could be considered eligible for the R&D Tax Incentive if you are: - undertaking the development or improvement of processes and products with the intention of generating new knowledge - unable to determine the outcome of these developments in advance without undertaking a systematic progression of work - planning to spend more than $20,000 on these developments.

If you would like further advice on your eligibility or on claiming the R&D tax incentive, please contact our R&D Team on (03) 8823 6840.

Dr Rita Choueiri Director R&D Incentives Ph: 03 8823 6840 rita.choueiri@williambuck.com

www.imts.com.au www.bertazzoeng.com.au

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Government urged to modernise outdated welder training Weld Australia is calling on the Federal Government to undertake an in-depth review of the TAFE welding curriculum, describing the latest Manufacturing and Engineering (MEM 2.0) training package as inadequate for the needs of industry while imposing significant burdens on apprentices, employers and TAFEs. Weld Australia’s Chief Executive Officer Geoff Crittenden explains.

Welder training in Australia is outdated. The TAFE curriculum has remained relatively unchanged since 1998. TAFE has been required to teach courses such as fabrication, in which the welding modules are of varying degrees of complexity and are usually optional. This has not produced welders that are skilled or qualified to the levels needed by industry, especially within the defence sector.

Young welding apprentices enter the workforce without the requisite skills or knowledge. Generally speaking, TAFE graduates cannot read a welding procedure, set up a welding machine, or weld according to Australian standards.

Released in June 2019, the latest version of the Manufacturing and Engineering training package (MEM 2.0) differs very little from the previous versions (released in 1998 and 2005). In fact, many of the units and much of the content remains identical to the 1998 version.

Not surprisingly then, MEM 2.0 bears no relation to what is actually required by industry. It ignores the huge technological advancements and changes that will continue to occur in Australia’s engineering and manufacturing industries. The course still devotes time and energy to oxy-acetylene welding, which industry has not used for about 20 years.

The future of Australian industry in a post-COVID-19 world cannot rely on regurgitating a curriculum that is 20 years old.

The MEM 2.0 training package The only real differences in the MEM 2.0 training package are a significant increase in prerequisites, and the addition of more than 2,000 hours of mandated workplace practice. Both of these will impose significant restrictions and burdens on students, industry and TAFE. • Significant increase in prerequisites – The significant increase in prerequisites in MEM 2.0 will eradicate any modicum of flexibility for students, industry and TAFE. Course duration will be extended, increasing both the delivery costs for TAFE and the course costs for students. With extended courses, completion rates are likely to drop, with students expected to complete a greater number of theory-based, non-practical units before having the opportunity to learn the hands-on practical skills in which they are most interested. For TAFEs, delivering courses in a meaningful way will be hampered by the additional prerequisites, and there will be little opportunity to deliver short, sharp micro-credentials.

• Prescribed workplace practice – MEM 2.0 mandates a workplace practice component of more than 2,000 hours.

This will place considerable burden on employers who have to ensure that students are able to meet this requirement.

Over 90% of manufacturing firms in Australia are classified as Small to Medium Enterprises (SMEs), which are comprised of fewer than 19 employees. These businesses are unlikely to have the capacity to sufficiently monitor the workplace practice requirements and may deter businesses from employing apprentices. This situation will be difficult enough for apprentices but is likely to be even more challenging for transitional workers hoping to train up and enter manufacturing and engineering. In essence, welders will be required to be employed in industry before they can successfully gain their formal qualifications.

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The skills of the future The implementation of MEM 2.0 by Australian TAFEs is due for completion by the end of 2020. Before this happens, industry must voice its concerns.

The welding curriculum must concentrate on the skills that will be essential to the future of industry. These skills must be focused on advancements such as automation, robotics, artificial intelligence, big data, and advanced manufacturing processes. It is these skills that will see Australian industry continue its push into high-quality, complex, small-batch manufacturing.

The Federal Government must revise MEM so that the curriculum teaches skills such as programming, operating and maintaining robots, co-bots and welding machines integrated with artificial intelligence. It must include units that teach students how to analyse and leverage big data. It must delve into concepts such as Industry 4.0 and additive manufacturing.

The TAFE welding curriculum must be revised so that it meets industry demand both now and into the future. It cannot be bogged down by excessive prerequisites, mandated workplace practice that employers simply can’t deliver, and training in skills that just aren’t relevant to industry anymore.

While many of the state governments have backed this vision and invested in Advanced Welder Training Centres around the country, TAFEs still need real support from the Federal Government. TAFEs do not need more free apprenticeship programs. They need funding from the Federal Government so that they can invest in the necessary cutting-edge technology and equipment required to teach a forward-looking curriculum focused on the skills of the future.

Our young people need to acquire complex, high-order technical knowledge and skills. They need robust, deep and transferrable qualifications that provide a strong base for life-long learning and skill development. They need a TAFE system that is properly funded with curricula focused on the future.

If you support Weld Australia’s position that MEM 2.0 training package is inadequate for the needs of industry, apprentices and TAFEs, Weld Australia encourages you to write to the Hon Steve Irons MP, Assistant Minister for Vocational Education, Training & Apprenticeships, via am.irons@employment.gov.au or PO Box 1060, East Victoria Park, Western Australia, 6981. www.weldaustralia.com.au

FORMING & FABRICATION

TruFlow bolsters capability with Deratech press brake TruFlow Spray Booths Australia designs and manufactures industrial and commercial spray booth products. TruFlow’s Director Anton Pirie discussed their recent purchase of a Deratech press brake from CMTS Sheetmetal Machines.

From humble beginnings with only two staff members almost 20 years ago, TruFlow Spray Booths Australia has grown to an Australia-wide operation employing 40-plus workers. The company manufactures unique custom-made spray booths that have been installed in a variety of industries including aviation, automotive repair, commercial trucking, industrial painting and cabinet making.

doing it for years. The software is so simple that if you can draw the folds with your finger and insert the sizes required, then you are good to go. It’s just that easy to deal with. This is so important to us because the new operator is now running the machine like a pro and that helps production levels.

AMT: Why did you need the new machine?

AP: We had about six different companies who gave us quotes.

When Michael [Schneider, Director of Sales & Service at CMTS] came in, there was a difference about him. He was honest and to the point, he told me exactly how it is – that enabled me to trust him.

He even talked about competitor products in high regard, and I liked that. I liked the way he approached things. He didn’t talk down his competitors, and just told me the facts about the Deratech machine and everything I needed to know.

Anton Pirie: We had an old second-hand 3.2m press brake that we had purchased through CMTS about 10 years ago, and although it was still running well, it wasn’t keeping up with our production.

Neither was the additional 5m press brake machine, which is about 40 years old now, so we understood that we needed to update our press brake technology.

AMT: How important are the press brakes to your business?

AP: Very important! The press brake machines are a major piece of our production; they run all day every day. They are a major part of the manufacture of the roof and wall packs for our spray booths and burner boxes. Both machines are 95% of our business. This is why it is so important to get the right machine from the right company. If something goes wrong, it will have a drastic effect on our production.

AMT: How is the Deratech press brake machine?

AP: It’s brilliant; it’s so simple to work with. We purchased a Deratech Technica 250-ton, 6,100mm machine, with two CNC front sheet supports. We had just put on a new operator, and it normally takes a while for a new operator to get up to speed. The Deratech press brake machine is so easy to use it is like the operator has been

AMT: Why did you choose CMTS?

AMT: How was your experience with CMTS? AP: It was great. Michael kept us updated all the way through the process. When the machine was installed, they were fantastic - so helpful. He came in and gave my team all the training we needed. He even came back to deliver extra training when we asked. He knew that this installation was important to us and treated it with the respect it needed. I’ve had machines installed before and sometimes it can take months to get it operational, but with CMTS it only took a short time and we were up and running. They are such good people to deal with – if more people were like them the world would be a better place. www.truflowspraybooths.com.au www.cmts.net.au

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COMPANY FOCUS

Elexon Electronics – Bringing work onshore and in-house Electronics manufacturers have for a long time been inclined to look offshore when it came to outsourcing work.

One company bucking that trend is Queensland-based Elexon Electronics. By Brent Balinski.

The manufacturing capabilities that Australia has available within its borders have received a lot of attention this year, becoming the subject of much discussion in the media and elsewhere. Whether or not this interest will be sustained in the long term remains to be seen. Manufacturers are hoping that it will be; that the country can rebuild its industrial muscle, and that public and private procurers will look locally first.

livestock tracking tags or air conditioning control systems for buses.

For many years the tendency for electronics manufacturers and others has been to look offshore. Elexon Electronics, a successful electronics engineering and contract manufacturing business based in Brendale, admits there are challenges to resisting this trend.

However, the company is on a mission to change it.

The team

About two years ago, Elexon went through a significant growth phase due to demand for its unique mining products. At that time Elexon considered outsourcing due to capacity constraints. Instead, it decided to double its own production capacity, investing heavily in a new Industry 4.0 line, restructuring the company, and beginning to offer its services as a contract manufacturer.

“There are obviously a lot of advantages to producing in-house,” says Frank Faller, CEO at Elexon Electronics. “For example having engineers close to manufacturing has a huge benefit of fast communication and flexibility. We can be more responsive to customer needs.”

Today the Elexon Group has five divisions: Elexon Electronics, Elexon Mining, Ambler Systems (which focusses on mobile signage), wildlife monitoring developer Titley Systems, and TPS (a producer of instruments to analyse water quality.) The latter two are acquisitions.

Elexon Group currently has about 80 employees. Elexon Electronics is the manufacturer of choice for the sister companies and employs around 40 staff.

The most successful items manufactured in Brendale are the worldleading equipment used to monitor the ore movement in large underground mines. Most of the products are exported overseas.

“You can find Elexon mining instruments on every continent besides Antarctica,” says Faller with pride.

The Elexon Group’s electronics division also takes in a wide range of engineering work for third parties, including control systems and displays for supermarket ovens and bakeries, RFID readers,

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“We continue the business model of turning ideas into products,” explains Faller. “Traditionally, we did not engage in contract manufacturing, but the new production line that we commissioned last year, with this extra capacity and unique capabilities now enables us to reach out to high-value contract manufacturing, including the defence industry.”

Elexon Electronics began in 2006, and is owned by Peter Kuiper, a former chief engineer at Boeing, and creative engineer and innovator Leigh Bateman. Bateman began predecessor company IEDEC in 1992. Faller grew up in East Germany, trained as a manufacturing engineer, and began his career at Siemens telecommunications.

After moving to Australia he started working at Suba Electronics in 1995, followed by Bosch for many years, then Ampac and Crystalaid.

“Back then there were many more electronic manufacturing companies around, such as Startronics, and ERG Electronics in Perth, and some other big ones,” he recalls. “Unfortunately, I have seen a huge decline in manufacturing in Australia. We are certainly trying to end this trend.”

Faller remembers his decision to join Elexon being influenced by the company’s established quality management system, which remains a focus for the business.

“Even though it wasn’t customer demand, it was an internal protocol,” he recalls. “Every product was serial numbertracked in order to make sure that no faulty product slipped through to the next process step.”

The company’s advanced quality management system was another key factor for Faller: “The way Elexon had an advanced

Frank Faller, CEO of Elexon Electronics.

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the ability to backtrack the production process are becoming an essential capability for SMD manufacturers.

According to Faller, the new assembly line enables a tripling of output, provides capabilities for new technologies such as micro BGAs, flexboards, re-soldering, and many other benefits. In addition the pickand-place machine allows up to four boards to be set up in parallel and reduces idle time between jobs by up to 80%.

The jet printer is “classic Industry 4.0”, according to Faller, and eliminates any need for tooling. There is now no need for stencils for printed circuit boards (PCBs), solder paste squeegees, or lessthan-perfect joints.

system in place that captured and analysed the quality data… it was a proof of continuous improvement I was impressed with. This really helped to make the decision.”

Part of the company’s strategy to arrest the decline in the electronics sector is focused around training. It’s harder than it was years ago to find the right SMT (surface-mount technology) technicians or manufacturing engineers, so extra efforts are made when it comes to in-house development. All assembly workers on the floor are IPC-A-610 certified, or at least trained according to IPC. The company maintains a continuous hunt for “stars”, with a lot of cases of final-year engineering students being taken on part-time and then moved into full-time roles once their degrees are completed.

“A great example is our SMT team leader,” says Faller. “He has a background in the hospitality industry, and was a chef before he joined us. He has grabbed an opportunity and learned. Looking at him now, you would think he is a trained SMT operator or a technician with 10 years experience. It’s a dramatic shift, and we are proud of him. These are the people that make really Elexon strong.”

Becoming more agile Faller describes the company’s output as high-mix, low-to-mediumvolume. To be competitive in making its own products and in the new contract manufacturing phase, Elexon had to address changeover times between different production batches.

Previously, it could easily take six hours to set up an SMT line for a new job, which might run for only a few hours. Then you have to do the same process for the next project.

The company began investigating Industry 4.0 solutions in 2018. Faller led a successful grant application through the State Government’s Made In Queensland program, securing $890,325 in support to invest in a Mycronic 4.0 solution.

“With the new system we can start setting up for a new job while the previous one is still running,” says Faller. “It is very efficient.”

The new line features a MY700 jet printer, highly-automated conveyors, two MY300 pick-and-place machines, an X-ray inspection system, a vapour phase reflow oven, and an intelligent storage system. The storage system both saves space and provides intelligent inventory management, housing up to 980 reels. Component traceability and

“And no matter if it’s a small flexible board, or whether it’s a very large 20-layer board, the oven has so many sensors and can achieve the target soldering profile the first time, so we don’t need to do any trial and error program optimisation. The board comes out and it’s perfectly soldered. Especially for prototyping, that’s just huge.”

The list for upcoming investments includes 3D automated optical inspection, Faller adds. “We continue to be on the forefront of technology.”

Moving into defence The new investments are part of Elexon’s aim to win a steady supply of high-value contract manufacturing work. This has received a boost recently, with the company engaged for its first project with EM Solutions, who Faller says was impressed with Elexon’s quality management system and its new capabilities Other recent projects include Elexon’s involvement in the OzVader consortium. The Olitek-led group, with input from clinicians, universities and engineers, has created a ventilator that can be assembled cheaply and from local sources. Currently awaiting approval from the Therapeutic Goods Administration (TGA), it would be another tick for local manufacturing sovereignty.

Discussing his views on reshoring and whether the long-term trend to look overseas for electronics manufacturing needs can be overcome, Faller believes an “accountant’s view” of product costs is very common when companies decide whether to source work in Australia or overseas.

“People don’t take into consideration lead times, shipping costs, IP risks and so on,” he says. “There is still this mindset that sees people look to China for suppliers, because they automatically think it is cheaper.When we talk to customers or potential customers and show them our capabilities and service, they’re really surprised. We often hear them say that if they had known what available is around the corner, they wouldn’t get their boards assembled in China.

“Reshoring is certainly a trend that we see. We are passionate promoters of it too. Lately we have had customers approaching us.

Some of them are actively moving their production from China to Australia, because they’re really proud of being able to market their product as Australian-made.” www.elexonelectronics.com

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Evolve Group – Proving the value of Australian design and manufacturing Queensland-based Evolve Group is proving the extraordinary value to the Australian economy of innovative advanced design and local manufacturing, with exports from this multiple-award winning company destined for more than 130 countries.

Founded in 1978, Evolve Group’s status as a company at the very forefront of competitive Australian manufacturing has never been more apparent than in its response to the ongoing COVID-19 crisis.

In a vivid demonstration of the benefits of manufacturing in Australia, Evolve Group was able to provide an advanced design and a commitment to manufacture 100,000 P2/N95 respirators and medical face masks per day, with the construction of a clean room and production commencing within just two weeks.

Working closely with local Queensland hospital surgical teams, Evolve Group’s design of a new face shield is now being heralded as the most comfortable face shield in the healthcare industry. Studying how a face shield is used by medical professionals has delivered the outcome of a shield featuring a comfortable gel pad relieving pressure on the forehead of the wearer, a removable vent cap for ventilation, an easily replaced shield with anti-fog and scratch properties, and an ergonomic design for all-day comfort. With the further benefit of one size fitting all, this advanced design medical face shield is already attracting interest from the USA, South Africa and Europe.

“So many companies source product from overseas in the belief that it is cheaper,” says Mayer Jung, Evolve Group’s Design & Development Manager. “Yet as a company, we have been successfully reshoring manufacturing to Australia and expanding our exports with a competitive advantage and shorter lead times for our clients.”

required by Evolve Group engineers once the current pandemic restrictions are eased.

“In looking at CNC machining centres, Okuma was our first choice based on our experience,” explains Jung. “It is considered to be top of the range and the machine we needed was immediately available.

Evolve Group recently acquired an Okuma MB56VA S15 CNC vertical machining centre.

To meet the critical time frame and the precision tooling required, Evolve Group invested in the latest Okuma MB-56VA S15 CNC vertical machining centre, with an OSP-P300MA control. Featuring an extremely rigid double-column structure and a large bed size incorporating a highspeed 32 position automatic tool changer, the machining centre is providing greatly enhanced additional capacity, consistent precision output that does not require finishing, plus the ability for long multiple unaided production runs.

With the COVID-19 lockdown in place, the installation and commissioning were successfully and seamlessly completed remotely, with all training undertaken by Okuma’s National Technology Manager Karl Cory, via online meetings applications such as Zoom and TeamViewer. Further training will be undertaken by Okuma as

“For the operators of the Okuma machining centre there is the ability to produce more tooling in-house. The operating system is good to work with, there is a dramatic increase in utilisation of the machine and the quality of the finished product is exceptional.”

“Our company has had a long-term relationship with Okuma and still operates a 20-plus year machine that has served the company well. And back-up service and technical advice from Okuma Australia is amazingly supportive.”

Wide-ranging capabilities Headquartered in Crestmead, in Brisbane’s southern suburbs, Evolve Group has been innovating and expanding its wide-ranging capabilities for many years. Today the company employs a highly skilled team of more than 100 staff, and services a diverse range of markets including medical; automotive; electrical; heating, ventilation, air conditioning and refrigeration; building and DIY; plumbing and gas fitting; pool and spa; fishing; industrial; and general engineering.

Evolve Group’s design for a medical face shield has been heralded as the most comfortable face shield in the health care industry.

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cups and plastic bottles from waterways, currently operating across 52 countries. Seabin production has recently been relocated from France to Evolve Group’s facility in Crestmead – a decision taken both on a sound economic basis as well as the advantage of supporting local jobs.

Evolve Group’s extend design and manufacturing capabilities encompass injection moulding, over-moulding, material sourcing, tooling and fabrication, robotics and automation, supply chain and distribution. The company utilises the latest rapid tool and conformal tool verification technology, and every injection moulding machine on the floor is equipped with a servo-driven robot with a custom-made end of arm to retrieve specific parts in the most efficient way.

Design, development and sustainable marketing is at the heart of this innovative ISO 9001 accredited company, winning it awards such as the coveted 2016 Good Design Award of the Year, and also the prestigious Best Product Innovation Award for the design, manufacture and optimisation of the Flow Hive, an inventive beehive system.

The company has been named in the top 50 most innovative companies in the Australian Financial Review Awards, plus multiple Australian Good Design Awards.

“Our team not only designs new products but works closely with customers to refine and/or improve a design to maximise efficiency, reduce the cost of production

STATE SPOTLIGHT

The company is already looking at acquiring additional sites to provide for further expansion of its design, manufacturing and logistics facilities.

and improve return on investment for your clients,” says Jung. “Our ability is getting it right the first time, at the lowest possible cost, in the shortest time-frame with minimal risk, but we also look and advise customers on the marketing aspects for long-term sustainability of a product.”

A recent demonstration of the advantages of reshoring manufacturing production back into Australia has been Evolve Group’s involvement in the innovative Seabin Project. Created by two Sunshine Coast residents and a Byron Bay local, the Seabin collects tens of thousands of discarded plastic bags, disposable

“At Okuma we understand the importance of competitive manufacturing to Australia and the need to adapt service levels to meet customers’ essential service requirements in the current climate,” said Dean McCarroll, Managing Director for Okuma Australia.

“It is a pleasure to work with such an innovative company as the Evolve Group in commissioning latest Okuma CNC machining technology, and an example of what can be achieved to ensure Australian manufacturers remain highly competitive in the international market.” www.okumaaustralia.com.au www.evolvegrp.com

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QSP Engineering gears up for the future With a vision for future demand, QSP Engineering recently moved premises from Loganholme to Bethania in the outer suburbs of Brisbane, and introduced new technology into its metal spraying business.

With the aim of retaining QSP’s position as a key provider of metal spraying repairs for worn parts, Managing Director Neville Brokenshire looked to install the latest innovations in metal spraying technology, to ensure high-quality output and a more efficient, cost-effective process to integrate into its workshop services. Already utilising a fibre-coupled high-power diode laser by Laserline supplied by Raymax Applications for laser cladding with metal powder, Brokenshire sought advice from Dr Cédric Chaminade from Raymax in regard to improving output. A new coaxial nozzle was deemed the solution.

High processing speeds with specifically designed coaxial nozzles used with Laserline fibre-coupled diode lasers provide distinct advantages, including low exposure time, strong metallurgical bonds between the cladding layers and substrate, low warpage, and short, highly energy-efficient cladding times. By introducing a new laser cladding nozzle, QSP has effectively extended the current available advantages to its customer base.

A coaxial nozzle combines inert gas flows and metal powder with exceptional throughput capability. Additionally, protection glass monitoring extends the lifetime of consumables, while at the same time ensuring a reliable process. The new Coax11, developed by the Fraunhofer Institute for Material and Beam Technology, represents a flexible processing tool for cladding applications and guarantees

a stable and controllable process as well as the highest precision in material deposition. Highpower diode lasers from Laserline in Germany can provide cladding solutions with up to 20kW of laser power, and use wide track processing optics providing the highest powder deposition rates available.

Industries where components are constantly exposed to high stress become fatigued and worn, requiring replacement or repair. Today, highthroughput laser cladding, or metal deposition, is demonstrating not just the effectiveness of repair but the metallurgical connection between the additional layer and the basis material can actually extend the life of the original part. Repairs to large-sized drilling tools used in oil extraction, boring or mining, marine engine parts, or earthmoving equipment can all be effectively repaired using laser cladding.

In Australia, there is a growing market for laser coating of hydraulic cylinders from technical mining facilities such as coal extraction.

Its new laser cladding equipment is a timely acquisition for QSP, as the economic downturn and limitations imposed on importing new component parts are changing industry behaviour and fuelling demand for local repairs. With trained and experienced staff and over 25 years in the industry, QSP stands to gain an edge over its competitors, geared up and ready to meet this increased local demand. www.qspengineering.com.au www.raymax.com.au

Global Manufacturing Group continues to invest in Mazak.

Global Manufacturing Group (GMG) has recently made significant investments in productivity, adding three new Mazak CNC machines to its already-impressive machine shop.

Established in 1982, GMG is a metal manufacturing and engineering company offering customers exceptional quality and service utilising the latest advances in technology. Located in Maryborough with a second facility in Gladstone, GMG employs 60 highly skilled staff servicing industries including mining, defence, construction, transport, rail, medical, marine/shipping, and oil & gas. GMG offers a complete turnkey solution using world-class equipment and Lean manufacturing principles.

process,” Aylward adds. “Just a good deal and short lead time was what we needed, and John Hart delivered on all fronts. The training with each new purchase was a big benefit. Most of our operators are already well across Mazatrol, so our young apprentices were able to get some really high-level one-on-one training, which advanced them significantly.”

The new Mazak machines are a VTC-530/20 vertical travelling column machining centre, a VCN 530C vertical machining centre, and a HCN-5000 twin-pallet horizontal machining centre. GMG Managing Director Richard Aylward cites increasing client demand as the driver for the investments, together with productivity increases brought by newer technology. “The latest Mazatrol Smooth conversational controllers have delivered a significant reduction in programming and set up time for us,” he explains. “And together with the latest technology Mazak offers in their machines, this has given us significantly reduced in-process times.”

“The fact John Hart is committed to providing support for our much older Mazak machines means we would be reluctant to look elsewhere,” says Aylward. “I think the back-up service is 80% of your decision. John Hart responds very rapidly to our needs, and this reliability is a big part of why we like to continue with Mazak machines.” www.johnhart.com.au www.gmqld.com.au

The Mazak VTC-530/20 vertical machining centre features a fixed 2,300mm x 530mm table design and travelling column, providing exceptional versatility for mounting long workpieces as well as multiple parts along the table length. The VCN-530C vertical machining centre has a 1,300mm x 550mm table and performs heavy-duty machining of steel and high-speed machining of aluminium. The HCN-5000 horizontal machining centre, with 500mm x 500mm pallets and a BT50 spindle, is capable of heavy machining and highspeed operation. “We know Mazak machines very well so we didn’t need to look any further than John Hart for advice in the purchasing

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The Mazak machines continue to perform under high workloads, so GMG benefits from John Hart’s service and support.

Two of the new Mazaks at GMG: the HCN-5000 twin-pallet horizontal machining centre (left) and the VTC-530/20 vertical travelling column machining centre (right).

Real Business Real People Real Members AMTIL is an organisation that is ‘For the Manufacturer’ and that is why Hardman Bros. is a member. Manufacturing in Australia is facing some challenges and having AMTIL as our voice I believe is invaluable. The organisation of the Austech exhibition coupled with the Manufacturers Pavilion is a brilliant showcase and a great opportunity to meet with peers from the industry. AMTIL’s association with large suppliers has brought discounts to my company that pay for our membership tenfold each year, savings we need to stay competitive.

Mark Hardman, Hardman Brothers

Since 1999, AMTIL has been connecting business, informing of opportunities and growing the manufacturing community.

To be become an AMTIL member contact our Corporate Services Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

amtil.com.au 1311AMTIL/MH

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Technofast – Innovating and succeeding in challenging times While the economy officially entered recession in September, there are plenty of manufacturers who are holding up well. One example is Technofast Industries, a Crestmead-based manufacturer of specialised industrial fasteners.

“Technofast has been fortunate in that the company was positioned to be able to take advantage of opportunities generated by various government agencies in both domestic and export markets,” explains Matt Blundell, Technical Solutions/Sales Manager at Technofast. “The company’s base markets such as those of mining and quarrying have continued to operate at near-normal levels, which has been of huge benefit to the company’s aims of retaining its best assets in its staff throughout the challenges thrown up by the COVID-19 crisis.”

Recent wins for Technofast include work on the Kingsford Smith Airport control tower.

Levels of mining investment (up 1.3% in the quarter, versus a 6.9% decline among non-mining businesses) have been a positive for manufacturers working within the mining equipment, technology and services (METS) sector. Blundell cites sales of Technofast’s Outer Shell Nut for mining crushers, along with the company’s HP4 Head Nut and large EziTite nuts within the sugar mill industry. Other recent wins include work on the Kingsford Smith Airport control tower, and some successes in entering the crusher market in the US. Technofast currently employs 17 staff in Australia, with the addition of a new engineer in late August. It operates sites at Brisbane (covering sales, distribution, tech support, rental and manufacturing) and Rockingham, Western Australia (sales, tech support, and rentals.) As well as manufacturing, it provides training, equipment hire, contract engineering and laser marking.

Its product range is focussed on hydraulic fastening solutions, providing time-saving, productivity and safety advantages, and where it has contributed world-first innovations. Hydraulic tensioning is very accurate compared to mechanical tensioning, as the resultant tensile forces are simply calculated from the responsive hydraulic pressure area (HPA) of the hydraulic nut or bolt tensioner being used. Using digital technology, engineers can provide the highest standard of calculated bolt loading, thereby avoid many of the losses and dangers associated with other methods of tensioning fasteners.

Technofast has its origins in founder/owner John Bucknell’s work in engineering for agriculture. The son of a broadacre wheat farmer, Bucknell developed the original hydraulic nut, enabling tensioning, removal and repair of plough gangs in the field, operated using a handheld grease gun. This was a godsend for maintaining heavy agriculture equipment such as plough disks, which would often feel the brunt of below-ground tree stumps. The invention was followed by a screwed locking ring in the late-1980s, with engineering input from University of Queensland.

Along with mining, Technofast today serves markets including oil & gas, power generation, nuclear power, steelmaking and shipbuilding. It operates an ISO 9001 quality management system,

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and has the ability to manufacture under standards set by DNV, Lloyds, ASME, and the American NRA 10CFR50 Appendix B (for nuclear applications.)

Technofast describes its product offerings as grouped under Standard Products (“me too” items such as hydraulic bolt tensioners and hydraulic nuts where the company’s products compete directly with those from other manufacturers); Custom Products (variants produced to conform to certain application requirements where products of ‘standard dimensions’ would not be sufficient) and Innovative Products.

The latter incorporates novel features to permit use in unconventional or demanding applications.

“For example, the EziTite TR hydraulic nuts can be produced to operate in extremely hot environments in excess of 600°C,” says Blundell.

Manufacture and finishing of its product range is, Blundell adds “almost exclusively performed inhouse, with the exceptions being specialised processes such as heat treatment of alloys and machining of oversized pieces too large for the Crestmead facility”.

Since its official founding in 1992, Technofast has earned industry recognition including at the Endeavour Awards and Telstra Business Awards. It has described its success as based on finding its niches through innovation and development of intellectual property, arguably a winning approach for Australian manufacturing SME. Its research & development program involves “a number of prospects running at any given time”, with R&D expenditure accounting for roughly 5% of company revenues. This is guided by challenges to customers, which include a host of multinationals wanting to be both smarter and faster in their maintenance, reducing the downtime of critical equipment while removing potential hazard sources such as hot works for bolt removal.

There are countless other examples of manufacturers powering ahead despite the challenging economic conditions, and the sector is being targeted by policymakers to help drive the economic recovery in the wake of COVID-19.

For Technofast, long-term growth will continue to be driven by delivering engineering breakthroughs that answer client challenges around industrial fastening.

“Yes, the COVID-19 era has presented challenges, especially to our export sales, which are important to us and were growing handsomely before the outbreak” says Blundell. “But like any serious manufacturing business, we’re here for the long term, and we’re investing accordingly. For all the talk of the new normal, the old normal of innovating to help your customers work safer and smarter is here to stay.” www.technofast.com

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STATE SPOTLIGHT

A centralised manufacturing network – Key to Laser Central’s growth Laser Central recently completed its move into a purpose-built, much larger factory in Darra, south-west Brisbane, while enhancing its workshop with three new machines supplied by Headland Machinery.

Suzanne Shipp is one of the key people responsible for Laser Central’s aggressive growth strategy. Since being appointed as the company’s new CEO earlier this year, Shipp has been busy driving new ideas and initiatives at this 100% Australian, family-owned business.

“One of our core strategies has been around establishing a complete, centralised network of suppliers that can provide complimentary services and a full capability suite to our clients,” says Shipp. “The reasoning behind this, is that we can simplify our client’s supply chain. The client can come to us and while we might provide 80% of the work, we might also incorporate another supplier to provide the finishing, which means we can provide a full end-to-end service.

“This makes it easier for the customer as they only have to deal with one supplier, while they receive the end product that they need.

We’ve worked hard to establish a large and reliable network of partners that we can work with and fill any capability gaps.”

Laser Central recently relocated to a purpose-built and much larger factory in Darra.

Moving to the new facility has given Laser Central an increase in capacity of more than 30%. The increased space is not only better for the company’s employees, with increased safety and improved workflows, but also for its clients, with leads times drastically reduced.

“We have more options now in terms of storing more materials, enabling shorter lead times when required,” says Shipp. “More space in our new factory means that clients can preorder parts for faster turnaround times, ensuring that same day delivery is possible.

Consignment-type options are now available with the extra space.

“We also have variable transport options available with a dedicated local courier and preferred freighting companies that we can use to supply interstate. Clients can supply their own material as well. This can help the client reduce risk. We are more flexible with materials and transport options which is all part of our client focus initiatives.”

Laser Central is now looking to expand the number of clients it can serve, particularly in the industries where it is well known, such as mining, defence, agriculture and fabrication and construction.

The company is also seeing growing demand from the rail projects sector, and more recently camping and caravaning.

The new facility features a number of new technology acquisitions supplied by Headland Machinery. A new TRUMPF 6m flatbed fibre laser is ideal for oversized materials and for clients in rail and construction, as well as architectural screens and cladding. A TRUMPF 3m flatbed fibre laser was also recently acquired. The TRUMPF lasers have added capability and are up to 1.5 times faster, allowing Laser Central to respond quickly when required.

The company’s Mazak, TRUMPF and Adige tube machines provide service for up to 12m at 300mm in diameter for long product materials.

“Success to us is supplying our clients with what they need,” adds Shipp. “We’ve invested in new technology; now offering faster service and greater capability. “We have also increased the number of operators we employ – 12 new people have been added to team.”

As well as new machinery, Laser Central invested in training at TRUMPF’s headquarters in Germany earlier last year, and has also completed some software and operator training onsite.

“We’ve invested in this new technology and the new facilities provide our clients with what they need: fast turn around times,” Shipp

The company’s workshop has been upgraded with a number of new machines from TRUMPF.

explains. “We are good at understanding a client’s requirement and the desired outcome, and then providing an optimised solution that can improve the outcome or save them money and time. That’s when it gets exciting!

“For example in the construction industry we are able to provide 3D, optimised, precision-cut parts that the builders can then assemble like a Meccano set on-site. The end product is in the exact format they need. We’re receiving good testimonials, which is great.”

Shipp emphasises that local support from Headland has been key to Laser Central’s success “Headland local support has been great, and the response times are what we need. The knowledge of the local guys is impressive, and having a local service manager is good – having that single point of contact is fantastic. We can pick up the phone and contact Shellie Woodham at the Queensland office and she can put everything into place to ensure we are supported until the problem or improvement is resolved.”

For the future, Shipp and her team at Laser Central are strongly focused on growth.

“Our strategies all revolve around providing greater value to our clients,” she says. “We listen to what our clients need; it’s what they’ve told us that matters. In these times our sovereign capability is also helping drive growth, being 100% Australian-owned and using Australian steel in our processing. With our end-to-end partner network, increased service capabilities and faster turnaround times, we feel greater growth is just around the corner.” www.headland.com.au www.lasercentral.com.au

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Additive manufacturing capability sees Romar Engineering soar It doesn’t always take a giant to reach for the stars. Romar Engineering is a small Sydney-based manufacturer that has quietly built a robust reputation for quality and expertise over the last 50 years, and continues to enhance its capabilities – most recently diversifying into metal additive manufacturing.

Based in Sefton, New South Wales, Romar Engineering is well known across the industry for medical device manufacturing, yet it also has remarkably diverse proficiency across silicone, micro moulding, precision moulding, clean room manufacturing, elastomers and several other areas of industrial manufacturing, including precision inspection, five-axis machining, metal additive manufacturing and design for manufacture.

Romar’s success lies at the intersection of manufacturing expertise and cautious innovation. It has continually looked at ways to strengthen and expand its capability, while remaining committed to core objectives of high-quality, commercially viable, scalable manufacturing solutions.

In recent years Romar has invested in technology and additional expertise to build an entirely new arm, in the field of advanced additive manufacturing.

“Currently, around 65% of our business is with the manufacture of medical devices,” says Alan Lipman, CEO of Romar Engineering.

“In recent years we’ve built up deep knowledge and capability in advanced manufacturing for industrial sectors. This means we are firmly positioned to offer innovative manufacturing solutions for sectors including aerospace, mining and defence, and we are looking to expand in those sectors over the next few years.”

Facilitating growth in advanced manufacturing sectors At the heart of Romar’s advanced manufacturing capability is a state-of-the-art 3D printer with significant and singular capability – the DMG Mori Lasertec 65 3D 5-axis synchronous laser deposition, welding and milling machine. It’s the only machine of its kind in Australia – and indeed one of only three operating in commercial settings globally – so it brings something very special to the local market.

With the Lasertec 65, Romar can develop, prototype, test and manufacture superior-quality components and can repair, renew and replace existing components. The potential across the defence, rail and aerospace sectors is immense.

Romar has been working with Jet Engines Australia to manufacture engines for military and commercial autonomous operations.

Casting technology is one of the oldest manufacturing processes, and is used extensively in aerospace and defence. The cost of maintaining investment casting tools is a significant portion of total lifecycle budgets, and it can be avoided through intelligent process selection. The Lasertec 65 is enabling high value aerospace and defence customers to eliminate these costs by substituting a digital model with flexible manufacturing instead.

With the Lasertec 65, Romar’s additive manufacturing potential includes metal-on and metal-off hybrid manufacturing of highly complex components. It can engineer scalable new designs and develop one-off prototypes, quickly, cost-effectively and with precision accuracy. Additional features of the Lasertec 65 include the ability to combine different metals (including hard and soft metals), a large build size up to 600mm in diameter, quick-build capability (up to 10 faster than traditional powder bed-based systems), and the option to manufacture parts that require no modification or treatment, for immediate use. For Romar’s customers, it means increased flexibility and fast-response production solutions.

Collaborating with Jet Engines Australia Romar’s capability to produce fast-build, large-size, one-off and scalable production has potential across multiple advanced manufacturing sectors. “Our 3D printer affords us the capability to create monolithic, multi-material metal structures that can be finish-machined and inspected all in a single set-up,” says Steve Milanoski, Romar’s Head of Advanced Manufacturing, and a former additive manufacturing specialist with SpaceX. “This increase in machine accuracy correlates strongly to component performance, allowing clients to push designs harder for longer.”

One of the first Australian aerospace companies to collaborate with Romar is Jet Engines Australia, a local manufacturer currently developing high-tech jet engines for multiple applications. Romar is working with Jet Engines Australia to manufacture engines for military and commercial autonomous operations.

Steve Milanoski, Head of Advanced Manufacturing, and Alan Lipman, CEO of Romar Engineering.

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“We are working with Jet Engines Australia to create a turbojet engine around a metre long,” says Lipman. “This will be the first Australian designed and manufactured engine in some time, if not ever. Engine manufacture will fully leverage Romar’s additive and advanced manufacturing capabilities and focus on resilient supply chain sourcing models.”

ADDITIVE MANAUFACTURING

At the heart of Romar’s advanced manufacturing capability is a DMG Mori Lasertec 65 3D five-axis synchronous laser deposition, welding and milling machine.

Romar Engineering’s facility in Sefton, New South Wales.

Beating powderbed additive at its own game Conformal cooling, in the parlance of additive manufacturing, typically belongs solely to the powderbed additive methods … until now. Romar has recently been redesigning existing mould cores that utilise conformal cooling to achieve greater cooling efficiencies.

“Where directed-energy deposition (DED)-based additive manufacturing is disadvantaged through complex geometries, we make up through the combining of multiple materials to optimise performance,” says Milanoski.

Romar Engineering is using advanced mould-flow simulation to optimise the channel size and shape, while also adding highly conductive copper to the core for greater thermal efficiency.

Utilising hybrid manufacturing to modify existing parts allows for faster turnaround times – as opposed to powderbed processing cycles that can often last months – which is an Australian advanced manufacturing capability unique to Romar.

The work has the potential to reduce moulding cycle times further.

Decreasing cycle times results in higher energy efficiency, which results in not only a cost benefit but an environmental one as well.

While Romar is building credentials in the additive and advanced manufacturing arenas, it has not altered its scope for first-class medical manufacturing and the provision of medical-grade silicone.

It remains a leader in the manufacture of medical devices with facilities including a world-class clean room.

Romar’s cutting-edge facilities and technology are drawcards, but at the core of the company’s breadth of capability is an exceptional, multi-disciplined team of leading biomedical engineers, advanced manufacturing engineers and materials scientists.

“Nothing replaces engineering experience,” says Lipman. It’s why Romar has built a formidable reputation for manufacturing excellence and why its future projects are set to soar. www.romareng.com.au

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Sentient Bionics gets a helping hand from the AM Hub When Sentient Bionics required rapid production of prototype parts for its new robotic hand project, it turned to AMTIL’s Additive Manufacturing Hub (AM Hub) for assistance.

Based in Port Melbourne, Sentient Bionics has been developing anthropomorphic robotic grippers for more than half a decade. During that time the company has worked with prosthetic users, hospitals and industry partners to develop a range of grippers suitable to satisfy everyday human and robotic needs. Familiarity, versatility and affordability are at the core of Sentient Bionics’s ethos, and it has developed hands that allow people and robots to interact in a natural and effective way.

Additive manufacturing has already been a large part of Sentient’s business, giving it the ability to quickly prototype both adult and child-sized prosthetic mechanical hands.

Additive manufacturing’s fast development time has allowed Sentient Bionics to start clinical trials and quickly respond to feedback gained through them with helpful and progressive design changes.

While Sentient Bionics specialises in the design and assembly of technology and devices, it has outsourced the manufacturing of components. Although it has some basic desktop fused deposition modelling (FDM) printers in-house, which it uses for rapid prototyping operations, the company gets all the parts that it uses for testing and consumer-level products made professionally by additive manufacturing (AM) service providers.

several prototype parts to be manufactured quickly so they could be tested and altered according to results, and additive manufacturing was chosen as the primary method of manufacture.

The solution Sentient Bionics received manufacturing services from two Victorian companies – GoProto (ANZ) Pty Ltd and Objective 3D Pty Ltd – within the scope of its BiB voucher, which covered 50% of the service costs.

The challenge

AM Hub member GoProto was engaged for a range of additive manufacturing services including:

Sentient Bionics accessed the Build It Better (BiB) voucher programme via the Additive Manufacturing Hub (AM Hub) to assist it in initiating a new robotic hand project, as well enhancing the continuation of its prosthetic hand product line. Sentient Bionic’s dynamic design process required

• Manufacturing structural and functional parts designed by Sentient Bionics for the robotic and prosthetic hands, including the palm (front and back), internal mechanism and phalanges, using GoProto’s HP Multi-jet Fusion Printing capabilities.

• Manufacturing various other parts designed by Sentient Bionics required for internally used tools and rigs, as well as parts for several smaller side projects of Sentient Bionics as part of their professional design contract work.

The services received from GoProto reflected Sentient Bionics’s sustainable mindset, through the use of HP MJF PA11 and PA12. Both PA11 and PA12 are highreusability materials that minimise waste, and PA11 is a renewable raw material produced from vegetable castor oil, resulting in a reduced environmental impact.

Objective 3D, also an AM Hub member, was engaged for services including the manufacture of structural and functional parts of the prosthetic and robotic hands, which require alternative manufacturing methods not supplied by GoProto such as metal 3D printing and Polyjet 3D printing.

Sentient Bionics’s prosthetic hand product line

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ADDITIVE MANAUFACTURING Sentient Bionics now sees additive manufacturing playing a crucial role in its future – as its development continues (as it will for a number of years), so do its requirements for a manufacturing method that allows for iterative design changes and high-quality parts. The current designs for its new robotic product rely primarily on additive manufacturing, and the team at Sentient Bionics do not expect that to change anytime soon.

With the help of the AM Hub, Sentient Bionics went from a simple, harness-powered prosthetic product with no motor actuation (left), to a versatile robot gripper capable of integration with existing robotic systems (right).

The BiB voucher programme would be crucial in allowing Sentient Bionics the capacity to expand its product range, grow its intellectual property (IP), and delve into new industries.

The outcome With the help of the BiB voucher programme, Sentient Bionics went from a simple, harness-powered prosthetic product with no motor actuation, to a versatile robot gripper capable of integration with existing robotic systems.

Thanks to the financial assistance of the BiB voucher programme and the guidance

and expertise of the AM Hub, Sentient Bionics’s research project was able to cut down manufacturing costs significantly.

It made it feasible to undertake more development work across one year than Sentient Bionics had previously achieved ever since forming as a company. More engineers were hired, and the company relaunched its website with new content and new products. In addition the team attended more conferences, broke into new industries, and developed promising leads for future collaboration and sales pipelines as a result of networking within the AM Hub community.

With the help of the AM Hub, Sentient Bionics was able to expand into new industries and markets, and within these new markets demonstrate the benefits of additive manufacturing.

The AM Hub is an initiative delivered

by AMTIL in partnership with the Victorian State Government to provide an industry-driven collaborative network of technology users, suppliers and supporters that will promote the adoption of additive manfacturing technology. For more information, please contact John Croft, AM Hub Manager, on 03 9800 3666 or email amhub@amtil.com.au. www.amhub.net.au www.goproto.com.au www.objective3d.com.au www.sentientbionics.com

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3D printing during COVID-19 – A blueprint for future manufacturing While the COVID-19 pandemic has disrupted many industries and their supply chains, it has been incredible to see how the healthcare sector has responded – helped in many ways by the clever use of 3D printing. By Michael Boyle, Managing Director, HP Australia & New Zealand.

The sudden shortage of essential medical equipment brought on by the pandemic, including respiratory support and personal protective equipment (PPE), has offered a glimpse at how supply chain disruptions can be mitigated with 3D printing, as well as new business opportunities 3D printing can provide when adopted at a large scale.

One advantage of 3D printing is extreme flexibility and the ability to rapidly redeploy equipment from one task to another – in other words, to retool. Using a 3D printer, you can be creating building materials one moment and medical prosthetics the next by loading a digital design of the new part into the printer. This agility makes 3D printing useful for prototyping and for making lowrun parts that can be used to repair outdated equipment or create custom products to solve unique challenges.

Flexibility has allowed industries to repurpose their production and R&D capabilities towards manufacturing mass quantities of hand sanitizer, producing tens of thousands of masks and gowns, and retooling factories to assemble face shields. In New Zealand, notfor-profit group ShieldsUp has worked with HP New Zealand, Emirates Team New Zealand and Rodin Cars New Zealand, along with hundreds of 3D printing enthusiasts and volunteers across the country, to design and deliver almost 18,000 face shields in under two months. Triple Eight Race Engineering managed to successfully transfer its 3D printing capabilities from the racetrack to the ICU ward. When approached by the Queensland State Government, the team redirected their HP 3D printers that were typically reserved for producing car parts, towards designing and manufacturing critical ventilator components.

At HP, we have been mobilising our 3D Printing team and global Digital Manufacturing Partner Network to design, validate and produce essential parts for medical responders and hospitals. More

than 158,000 3D-printed parts have been delivered to frontline workers in Asia Pacific, with over 2.3 million parts printed globally. Beyond boosting the supply of PPE for healthcare workers during COVID-19, 3D printing is allowing companies to transform their supply chain strategies and introduce on-demand manufacturing for the long term. The real-time nature of 3D printing not only helps businesses retool to solve immediate supply shortages, it simplifies and shortens supply chains by allowing components to be produced closer to home and nearer to the customer. By extension, the headaches that often come with navigating international transportation, tariffs, and exposure to geopolitics, are reduced.

Moreover, cost-effective trial and error can encourage rapid prototyping that fosters greater innovation, personalisation of products, and improved time-to-market. The ability to print a customer’s order as required also has the potential to save businesses from holding large inventories of product and reduce costs associated with holding warehouse space.

The current crisis has reminded us how interconnected our supply chains are, with conduct in one country having a ripple effect across the globe. Yet thanks to 3D printing, the pandemic has also reminded us of the value of local manufacturing and the need to promote capability-based alliances across industries.

Replicating experiences seen in the healthcare sector, the benefits of on-demand printing to shortened supply chains and improved timeto-market apply to all industries and businesses. As businesses begin assessing their strategic priorities and changes to manage the impact of COVID-19 on operations, we should learn from past experiences and embrace cutting-edge technology, like 3D printing, to streamline operations and reduce exposure to global fluctuations. www8.hp.com

Amaero launches two new machines Amaero has expanded its machine offering with the launch of two additional metal 3D printers – the SP260 and the SP400 – as well as new powder-handling ancillary equipment.

The new machines build on Amaero’s existing product line-up, including the SP500 and SP100 metal 3D printers, and decanter, conveyor, autosieve and depowdering modules. Their launch means Amaero will have one of the safest, most cost/capital-efficient and diverse ranges of metal 3D printers on the market.

The new SP260 machine has a build chamber volume of 250mm x 250mm x 400mm. Rapid changeover capability makes it ideal for producing components for the aviation, defence and biomedical industries. The SP260 is simple to use, easy to maintain, ideal for research and small scale manufacturing, and with the safe powder handling ancillary equipment is one of the safest on the market.

Similarly suited to manufacturing for the aviation, defence and tooling industries, the SP400 machine has a larger build volume of 400mm x 400mm x 400mm, and with its advanced technology, is safer and more productive than alternative machines of a similar size. Both machines feature a tethered build chamber for rapid job changeover and a bi-directional re-coater for faster production

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cycles, and also provide optimised powder usage with variable build areas, further improving efficiency and cost-effectiveness. Amaero CEO Barrie Finnin commented: “Amaero welcomes the new SP260 and SP400 to its line-up, giving our customers access to a broader range of machine sizes to meet their needs. Previously, Amaero had commissioned the SP500 and SP100 machines, providing customers with access to products at both the larger and smaller end of the scale. After the addition of the new machines to the lineup, Amaero’s product list meets the market’s requirements for small to mid-sized machines, addressing a larger segment of the market.”

Amaero also plans to further expand its line-up with the launch of the SP800 (currently under development), which is anticipated for release in 2021. The SP800 will address the large build volume capacity segment of the market with a build chamber size larger than 800mm x 400mm x 500mm (which is currently the largest laser powderbed fusion build volume available). www.amaero.com.au

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

www.amhub.net.au 1407AMHUB

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FELIXprinters assists in commercialisation of vegan-friendly 3D-printed salmon FELIXprinters’s BIOprinter has been used to successfully manufacture vegan salmon with a taste, texture and appearance seemingly identical to real salmon.

Headquartered in IJsselstein, in the Netherlands, FELIXprinters was established in 2010 to provide top-end, robust, reliable, and competitively priced 3D printing solutions for industry users. FELIXprinters has established itself as a key player in the supply of mid-priced highly accurate industrial additive manufacturing machines.

The company’s reputation is built upon the Pro 3, Pro L, and Pro XL platforms, which are used throughout an array of industry sectors for challenging additive manufacturig (AM) production applications.

FELIXprinters recently introduced the BIOprinter, which was developed on the chassis of the established FELIXprinters product line, building on tried and tested technology that has already been serving manufacturers for years. The printer is characterised by several key features that are specifically designed for medical, scientific, and research applications, including syringe cooling, print bed cooling and heating, a dual head system, easy syringe positioning (ergonomic access to the machine supports researchers in their work), and automatic bed levelling.

In recent months a group of international students has developed a 3D printing technique that enables them to print complex binders and proteins into plantbased fish alternatives, and at the heart of this research is the FELIX BIOprinter.

The trio of students from The University of Gothenburg (in Sweden), Universidad Autonoma de Madrid (in Spain), and The Technical University of Denmark (DTU) started to work together on an EU-led project in 2017. During their work research as part of Training4CRM, a research project which uses 3D printing to develop treatments of neurodegenerative disorders, the team realised that similar techniques could be applied to 3D print plant-based proteins.

Identifying a gap in the market within the seafood sector for more structured vegan-friendly fish-based products, the team began developing its plant-based alternative. The process is now set to be launched commercially under the trading name Legendary Vish, with the aim of providing a healthier and tastier alternative to existing vegan-friendly fish substitutes.

The step forward in the technology is the ability to create seafood products with complex structures that would be

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impossible using traditional extrusion technologies, and this was achieved through the use of the FELIX BIOprinter.

The key driver behind the use of 3D printing for fish production centres around sustainability issues, addressing the fact that many of the world’s fisheries are at the moment pushed beyond their biological limits. In addition, 3D printing fish rather than relying on traditional fishing methods reduces greenhouse gas emissions and the destruction of the oceans, and negates the need to use antibiotics, a common necessity to “aquacure” salmon in fish farms.

In an attempt to tackle these environmental challenges, the student team built on the extrusion-based 3D printing technique they’d developed as part of project Training4CRM, to 3D print fish instead of medicinal products. Using the FELIX BIOprinter, the AM method works by extruding a range of plant-based bio-inks, the BIOprinter allowing the extrusion of different plant-based ingredients (basically “food-inks”) through different print heads.

This allows the production of the complex appearance of salmon fillets, showing the realistic distribution of orange/red meat tissue and white connective tissue.

Wilgo Feliksdal, co-founder of FELIXprinters, commented: “The BIOprinter consists of an adaptable and flexible ecosystem to ensure that it can meet a wide range of researchers’ needs without generating unnecessary costs, and we are delighted

that it has been at the core of the work undertaken at Legendary Vish.

“One major advantage is the source control system, which enables the user to use standard slicing software and make changes themselves if needed. Also, syringes are not restricted to expensive brand-specific or in-house produced products that essentially drive up operating costs. The machine instead has been designed to use a standard 5ml syringe, and standardised petri dishes and culture plates, so there are no limitations on auxiliary parts and materials.”

Beyond the optimisation of its industrial range of printers, FELIXprinters has extensive engineering and R&D capabilities, which it is able to utilise to provide specific services in the development of tailor made, customised 3D printing platforms — working in partnership to produce new and innovative solutions.

“The FELIX BIOprinter is appropriate for all types of bio-printing research, and is equipped with strong motors that can extrude a range of different viscosity of materials, which was invaluable when being used to simulate the look and feel of salmon,” Feliksdal added. “In addition, the BIOprinter has been designed to be easily upgradeable, which means that the lifecycle of the machine can be extended without compromising quality, reliability, and productivity.” www.felixprinters.com

MATERIAL REMOVAL

Floor space and efficiency as a key concept The SwissNano 7 sliding headstock lathe has proven its worth in the machining of parts for the medical, dental, electronics and the micromechanics industries. It can optimise workpiece production in workshops, but how does it do this?

First and foremost is the floor space. With a length of 3m and 1m width, the SwissNano 7 is extremely compact. This machine configuration even includes a high-pressure pump. Consequently, a workshop can accommodate 10 machines on a floor space of less than 80sqm.

Since the machines have spindles equipped with optimised motor drives, heat dissipation is low. The workshop benefits from this in terms of reduced power consumption and less technical effort required to dissipate heat. For workshops with air conditioning, the electricity bill will be much lower. To enhance the characteristics in terms of machine heating and dissipation, the spindles are equipped with an integrated cooling circuit. To optimise the thermal characteristics, both the spindles and the rotating guide bush are provided with ceramic bearings.

Thermal behaviour The SwissNano has short thermal circuits.

This is the basis of a machine concept that mainly consists of a symmetrical cast-iron core that allows perfect control over thermal variations of the machine, with quite simple results. Stabilisation of the SwissNano 7 sliding headstock lathe reportedly takes no more than five minutes, even under the most adverse conditions such as cold machine shops. Therefore the machine can provide maximum productivity from the very first workpiece produced.

In addition to favourable thermal behaviour, the machine offers heightened rigidity. The wear resistance of the tools is excellent and permits cost savings and tool life enhancements of more than 30%. The structure of the machine and its base is simply perfect; it provides quick stabilisation and ultra-rigidity.

Production efficiency During the production process, the SwissNano 7 machine retains high dimensional stability and impressive productivity levels. Thanks to its compact footprint, its tooling system and kinematic system enable the machine to achieve a higher productivity rate than more complex, more expensive machines. These differences have been reported by one of the first customers of the SwissNano 7,

CUSTOM MADE

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TO YOUR EXACT REQUIREMENTS

Thanks to its compact design, 10 SwissNano 7 machines can be arranged on a surface of less than 80sqm.

• Quick delivery non-standard taps • Special thread forms • Carbide Step Drills • Extra long Carbide Drills with IK • Made-to-order Endmills • Regrind & Recoating

who noted the SwissNano 7 produces 650 parts per shift with a daily throughput of 1,300 workpieces across shifts. The previous machine had two supplementary tool systems and a theoretically higher performance, but could only produce 350 parts per shift. In this example, the small SwissNano 7 is 85% faster. One could also say that the customer needs three competitor machines to achieve the annual production of one SwissNano 7 machine.

Furthermore, its thermal stability ensures the SwissNano’s scrap rate is much lower.

Workpiece quality and unloading Thanks to its pooled machining capabilities, the SwissNano 7 sliding headstock lathe allows a drastic scrap rate reduction. A well-designed machine core contributes to the overall quality of the machine. Often, it is very difficult to unload parts correctly without damaging them; the SwissNano 7 offers an excellent solution. It can be equipped with a vacuum system, a carousel that enables workpiece sorting, and convenient statistical monitoring.

The machine is suitable for all types of workpieces and the part outlet in the machining area can also be adapted to specific workpiece requirements. With its high performance, flexibility and efficiency, the SwissNano is a good choice for any machine shop manufacturing small precision-turned parts whether they already use sliding headstock lathes or not. www.tornos.com

Contact us for more information digital@sutton.com.au

www.suttontools.com

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AMGC: Ten ways for Australian manufacturers to succeed A new industry research report from the Federal Government’s Advanced Manufacturing Growth Centre (AMGC) has revealed that even before the COVID-19 pandemic, 65% of Australians regarded manufacturing as important or very important, yet key challenges are holding back the industry from growth opportunities.

Entitled Ten Ways to Succeed in Australian Manufacturing, the AMGC’s report identifies – as a result of expansive industry consultation – the manufacturing industry’s pain points and opportunities. These points were stress-tested against industry peers, the public and more than 1,000 students to gauge where Australian manufacturers can focus to better align their practices, to increase positive perception, and to grow their overall business impact.

COVID-19 then struck, thrusting Australian manufacturing into the national spotlight.

Manufacturers responded in record time to produce everything from hand sanitiser to invasive ventilators. However, for some, the impact of the pandemic served to reinforce pain points identified in the report and that businesses need to be worked ‘on’, rather than ‘in’. The response to the pandemic has proven that there is a high level of onshore manufacturing capability and significant public appreciation for the industry. By adopting 10 practical steps, manufacturers can become smarter operators: more advanced, resilient, competitive, and globally impactful. “Australia remains very much a manufacturing nation, reliant on global trade,” said Dr Jens Goennemann, Managing Director of the AMGC. “We must take decisive action to reduce our dependence on the export of primary raw materials and transition from being a lucky country to a smart country, by adding value and advancing our onshore capabilities.

“We must expand our understanding and look beyond the outdated view that manufacturing is just production.

Manufacturing is a capability, an enabler and a vital component of our economy, it is a key driver of prosperity – it deserves our attention and needs to be nurtured.”

“Ten ways to succeed in Australian manufacturing” offers the following insights:

1. Australia needs to recognise its manufacturing strength • 60% of Australians believe manufacturing is changing, becoming safer and more innovative.

2. Manufacturers should focus on good leadership

5. Work with Australian research institutions

• Local management skills rate average when compared with countries with similar GDP.

• 81.4% of small and 75.4% of mediumsized enterprise do not engage with research institutions.

• Good leadership is crucial to success and practical steps can be taken to address leadership issues.

• Manufacturers that invested in collaboration are more successful than those that do not.

• Business culture, self-confidence and leading by example are vital for innovation and growth.

• Collaboration is a two-way street: Researchers gain practical experience, industry gains expert insight.

3. Change has to be planned for

6. Adopt technology

• 88.2% of business do not have a strategic plan, while 42% do not monitor KPIs.

• Far from being a ‘job-killer’, technology is an enabler and equaliser – it can lead to productivity, quality and upskilling opportunities.

• The AMGC found business owners and operators worked ‘in’ rather than ‘on’ the business.

• Manufacturers are encouraged to make time to plan, seek advice and engage with industry or governmental support agencies to unlock potential.

4. Build a network and collaborate • The 12% of Australian manufacturers that collaborate are more successful.

• Young people see potential in manufacturing careers, rating job security and career progression highly.

• ‘Zero-sum’ thinking is a barrier to growth. Collaborating with peers and research institutions can unlock productivity, quality and product gains while delivering 8% in revenue gains.

• Industry and media have an active role to play in addressing common industry myths.

• Australian manufacturers’ competitors are not the businesses next door, but the businesses overseas.

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• Australian manufacturers lag behind other industries in adopting advanced technologies.

• Some manufacturers are ‘putoff’ by a lack of understanding or misconceptions about the cost of investment. These businesses should seek expert advice.

7. Accessing capital • One in five Australian businesses have stated difficulty accessing finance ,and 45% of SMEs do not use accountancy software.

• Access to capital was cited as an obstacle by 17.6% of respondents. A further 15.8% also cited cost inputs as a barrier, and 18.6% listed overdue accounts as a handbrake on capital.

BUSINESS MANAGEMENT

• Accessing capital should not be onerous. Having an up-to-date business plan, accessing grants and talking to your financial institution are good places to start.

8. Hire the right people • Manufacturing suffers from one of the highest skills shortages, as shown by an ABS finding that 17.2% of manufacturers found a lack of skilled people was a barrier to general business activities or performance.

• Just 3% of students considered a career in manufacturing, and many were advised to seek careers elsewhere.

• Two-thirds of the public recognise that manufacturing is evolving and will become more innovative.

• In-house upskilling, job shadowing and mentoring lead to better performing and more productive teams.

• Culture is not a nice to have, it is a must-have and can impact retention and innovation.

10. Extend your market reach • Just 5% of Australian manufacturers account for 99% of the industries’ total export value.

• Four out of five Australians recognise that trade and export of Australian goods benefit the economy.

• Companies that export demonstrate growth, productivity, profitability and wage benefits, and more should take active steps to increase their reach and customers.

Paul Cooper, Chairman at the AMGC, said the report arrives at a very important time for the manufacturing industry: “By embracing technology, attracting the right people, investing for growth and actively managing their business, Australian manufacturers 9. Build your workforce culture can realise substantial benefits for their • Building a healthy workplace culture business and in the process support greater can lead to a ready talent pool and an AMTIL-ADVERT-MAIN-2020-OUTLINED(FA).pdf 10:49 am local1jobs17/1/20 and capabilities.” engaged workforce.

• Talent can be sourced by engaging with local schools, providing internships, and using technology to recruit.

A complete copy of the report ‘Ten Ways to Succeed in Australian Manufacturing’ can be downloaded at the AMGC website. www.amgc.org.au

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Resilient leadership in the time of COVID-19 As a manufacturer operating in an economic environment like Australia, Integra Systems is no stranger to successfully navigating crises. The world hasn’t seen anything like the COVID-19 pandemic since the early 20th Century but the team at Integra is applying what they’ve learned in overcoming previous challenges to position themselves for survival, and indeed for growth, in a post-COVID world.

Professional services and global consulting firm Deloitte recently published a study – The heart of resilient leadership: Responding to COVID-19 – into what effective leadership looks like in a crisis.

Integra’s leadership team – Managing Director and CEO Paul Hughes and Commercial Director Erika Hughes – discussed how their organisation is meeting Deloitte’s benchmarks for resilient leadership in the context of COVID-19.

Stabilise today, spark innovation tomorrow The Integra team is using the COVID-19 crisis as an opportunity to emerge stronger on a number of fronts. One of the key strategies of Integra has been to use what otherwise would become a bit of downtime for an informal internal review; an opportunity to prepare, refine and then “plough ahead” – as Paul describes it – with the company’s development.

“There’s an underlying mission to really enhance our positioning, so that Integra’s in a really good position when we come out the other side,” says Paul.

Erika adds: “We’re talking with our people about how we move forward through this. What we’ve been talking to our team about is our mission as a company to provide cutting-edge and innovative design services. For us, it’s all about harnessing that – reshaping the way we’re delivering our services.”

The principles of Industry 4.0 have also played a significant role in Integra’s quest to turn the present crisis into an opportunity for the organisation. Prior to the outbreak of the pandemic, Integra had already been working on some Industry 4.0 initiatives within the factory, such as connecting machines together and leveraging realtime data through real-time monitoring.

“We realised that there are lots of parallels with what we’re doing in-house with Industry 4.0 connectivity, to what might be required in external applications as well,” says Paul. “We have effectively created an in-house touch screen kiosk system that links our drawings, our machines, our ERP systems – all our internal data – into a single user interface.”

Taking decisive action with courage Recognising that Integra’s output would take a hit from COVID-19, Paul and Erika immediately initiated a top-down review, which involved brainstorming ideas for where to focus energies in a rapidly changing landscape.

“We assembled team members from production and from design, and had a really good spread of viewpoints,” explains Paul. “We looked at different markets that we could apply our technology to, and targeted some growth areas. So, again, while the external production has taken a bit of a hit in the earlier stages of COVID, we’re really ploughing ahead with our own developments.”

As well as taking the temperature of every aspect of their organisation, Erika believes roundtable meetings and business development plans have demonstrated to staff that Integra is powering forth, despite external threats.

“Our team knows that we’ve been through some really tough times in the past,” says Erika. “They know we’ve got through those tough times, so they trust that the decisions we’re making now – the investments we’re making now – will pay off long-term, even though there’s nothing set in stone. We’re the ones taking the risk and we’re being brave and getting in there, boots and all, at a time when a lot of people are backing off.”

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Photo by James Pond on Unsplash.

“I think that investment in ourselves and our development, and also investment in new equipment, new processes… continuing to do that while things were starting to go pear-shaped around us is really inspiring for our people,” adds Paul.

Design from the heart Erika and Paul believe that keeping the team together, and not instantly looking to furlough staff, has been a concrete demonstration to their employees, their customers and the wider community that they have everyone’s best interests at heart. They believe that doing what they can to provide job security for their team employees has a number of important economic and social benefits.

As well as these priorities, they also place a premium on positive mental health. Erika makes a point of noting that a positive frame of mind facilitates the kind of inspirational and innovative design that’s become synonymous with Integra.

“We don’t want anybody to feel they are less valued,” Erika admits.

“We want them to come into an environment that’s supportive and stimulating. We want them to have good, strong mental health.”

From the customer perspective, constant communication has been the order of the day. As Paul explains: “We’re reinforcing the fact that we’re all in it together. We’re continually talking with our customers and suppliers to get their thoughts, and empathising with their situation, listening to their concerns about their health and their family’s health.” “It’s important that we keep things running for the business,” concludes Paul. “But it’s important that everyone’s health and their families are all good.”

Embrace the long view COVID-19 has seen the closure of global borders, leading to a scarcity of manufactured imports into Australia. It’s a position that Erika and Paul have been active in warning the industry about for a number of years – well before COVID-19 impacted the global economy – and, consequently, have been positioning Integra accordingly.

“We have long argued that Australia needed to be a lot more selfsufficient, build our sovereign capability, and reduce our exposure to overseas markets,” explains Paul. “That’s been our mantra for many years now, so we haven’t changed anything in what we’ve been about. [COVID-19 is] reinforcing that. For a long time, we have felt like we have been swimming against the stream. And now we feel like the stream’s starting to go in our direction.”

BUSINESS MANAGEMENT Erika continues: “All of a sudden, people are starting to see what we have been talking about all these years – about agility, speed to market, import replacement through relentless innovation, rapid change and maintaining competitive advantage. That way, we’re helping our customers have a competitive advantage.

“For once, we’re actually in that sweet spot. We’ve never been there before, because we’ve always been the ones trying to push the message that this is the way the country should operate – and now we’re here! So, we’re working with customers on new product development. We know they’re not in a position to move forward with a lot of the ideas they’ve got, but we also know, through collaborative relationships we have with these clients, if we invest in them now, they’ll be on the front foot when the time is right.”

Own your narrative Regular briefings with staff and talking about what’s happening in the global economy has been an important factor in combating misinformation and rumour at Integra.

“We’re talking to them about what’s happening on a global basis, and about a global recession and what that means for us,” says Erika. “Because we’ve focused on agility, we hope to be able to invest in the way we operate, invest in our people, and invest in market opportunities that are going to make the company stronger.

So that’s part of just trying to keep a lid on that boiling pot – the boiling pot of misinformation and rumour.”

External news has helped fill the void at Integra. As Paul explains: “We also shared good news stories from our customers and suppliers. I get on the phone most mornings on the way to work with customers to check in to see how they were going. They’d pass on really good news, and I’d pass that onto the team. Our Production Manager, Sanjay Babu Jeyachandran, has been doing a fantastic job of really focusing on the job at hand. He’s an example of ‘come to work, get stuck into it, enjoy it’.”

Integra Systems’s Managing Director and CEO Paul Hughes, and Commercial Director Erika Hughes.

Looking into the crystal ball …

Everyone is still contemplating what a future after COVID-19 might look like. Which businesses will be the survivors? Which businesses will be the thrivers? And which businesses will disappear in the aftermath of the pandemic?

The team at Integra knows they’re here to stay but, as mainstays of Australia’s rapidly changing manufacturing landscape, they also know the market will look quite different in the post-COVID-19 era.

Harnessing these changes, strengthening their business model, and engaging the energy and agility of their team will be critical, while still keeping their values front and centre. www.integrasystems.com.au

The Australian manufacturing and transport industry has never been so important Whether you need to maintain your existing workforce and supply chain, or pivot to new products or markets, we can help

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For more information contact Rob Jackson: RJackson@rigbycooke.com.au +61 466 774 478 | + 61 3 9321 7808

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Performance management in a COVID-19 world “Unprecedented” is the buzzword for 2020, a year that has seen monumental upheaval. Which makes it refreshing to be able to say that when it comes to performance management, the rules haven’t changed! Nonetheless, the reality of living with the COVID-19 crisis brings its own challenges. By Victoria Comino and Rob Jackson.

Before you take a business-as-usual approach to managing an underperforming member of your team, consider this: what expectations can you, as an employer, reasonably have of a worker who is working from home with children underfoot, or being checked for a permit en route to work, or simply struggling with the mental load that has been dished up by 2020?

When an employer manages a worker’s performance, it needs to be reasonable both in terms of the expectations that are being set, and the process that is followed.

This is because ultimately, the risk is that you have to dismiss an underperforming employee.

At that point, if the worker files an unfair dismissal claim, your entire process will be under scrutiny. A Fair Work Commissioner will assess whether you had set and communicated clear and reasonable expectations, whether the worker was warned about their performance, whether they had a reasonable opportunity to improve, and whether the dismissal process was fair.

After considering those factors (and anything else it considers relevant) the Commissioner will decide whether the dismissal was harsh, unjust or unreasonable. Make no mistake, a Commissioner can decide that the worker was underperforming and that you had a valid reason to dismiss the worker, but that in the extraordinary circumstances, the dismissal was too harsh, or was unreasonable.

Your worker might be awarded lost earnings or get their job back or a combination of both.

This means that when you are addressing underperformance you need to give active consideration to the causes of the underperformance. For example: • Are the extraordinary circumstances of 2020 contributing to the problem, or not?

• If the worker is working from home, are factors such as home schooling, poor internet connection and/or mental health contributing to the performance issue?

• Are there steps that you can take to help improve the situation? Reduced hours? A compressed working week?

Altered working times? Provision of a dongle?

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Ask the worker what is contributing to the problem, and if there is any support the employer can provide.

If you as an employer take these steps, it does not mean you are obliged to provide everything the worker asks for. What it does mean is that you, the employer, will be better placed to prove to the Commission that you did tried to look to the source of the performance issue, rather than proceed to a warning or dismissal. Your hands are not tied, and you do not have to tolerate poor performance. It is important to realise there is a balance and, in many cases, you can’t apply the same criteria as you would have done this time last year.

Employers must also give careful thought to the process followed. In these times of social distancing and working from home, many performance discussions are being held over the phone or video conferencing.

Performance management is tricky, even at the best of times. And, in 2020 it requires an employer to consider a few additional matters.

Victoria Comino is a Special Counsel – Workplace Relations at AMTIL corporate partner Rigby Cooke Lawyers.

Note: in most cases, a purely written process should be avoided. If you need to have a formal performance management discussion with a worker, and if it can’t be face to face, video conference is next best option. Give the worker notice that it will be a performance management meeting so that they can arrange to have a support person with them if they want to, or so that they can arrange to be in a quiet place instead of the kitchen table with their housemates listening in.

After the discussion has occurred, the usual process should still apply. Employers must confirm the warning in writing, including the agreed timeframes for improvement and review, and that failure to improve may result in termination of employment. The employer must ensure they provide any agreed support and reviews should occur as scheduled.

Rob Jackson is a Partner – Workplace Relations at Rigby Cooke Lawyers.

Rigby Cook Lawyers Workplace Relations team is well placed to advise on all aspects of Performance Management. www.rigbycooke.com.au

BUSINESS MANAGEMENT

BOOK REVIEW: Drain The Defence Swamp Bruce Griffiths OAM reviews ‘Drain The Defence Swamp – A Blueprint for Weapons Acquisition Reform’, by Gary D Stewart.

I found Drain The Defence Swamp to be a compelling read. It is a powerful, thoughtprovoking page-turner that, despite the negative tone of the title, in fact offers a very positive argument. It brutally and unflinchingly reviews Australia’s current and past performance failures at product development in terms of Defence Weapons programmes. Gary D Stewart’s brutal dismantling of every excuse used by the Department of Defence to justify their equipment acquisition failures is quite riveting to read. For some readers this book will be very controversial, as indeed it was for me. I am a strong believer that Australia needs to continue to develop a strong and efficient defence manufacturing industry.

It made me think twice about writing this review, but the book is absolutely inspiring and persuasive, and for those looking for solutions, it will not disappoint. The book includes facts and new information that I was not aware of, and includes many interesting anecdotes and stories. The writing style makes it easy to read – and hard to put down. This is clearly a book written by a passionate expert in this field.

Given my own background, with almost 50 years in the Australian manufacturing industry, I was particularly interested in any inputs that will lead to a resurgence of best-practice global manufacturing in this country. Without giving the story away, Stewart describes the problem as one of a form of organisational incompetence that has evolved over an extensive period.

Industry continues to scramble to resolve these problems but never resolves the issues. Mistakes are repeated time and time again.

Stewart walks us step-by-step through reallife examples of those failures, explaining as he goes why and how they happen. He also explains in simple terms precisely why the well-documented cost and time blowouts are unavoidable using current processes.

The enormous amounts of ‘taxpayer gold’ that is wasted is truly astounding and disturbing, a concern that Stewart tries to address with sound recommendations.

The reform chapters methodically lay out a persuasive blueprint for how to shift away from dysfunctional product developments to a new world’s-best-practice method that for some will be challenging but for most readers will just make total sense.

Complexity is made simple. Excellence is made simple. Stewart walks us step-bystep through the solutions in an accessible, conversational style.

There are many good lessons to be discovered in this book, for both Defence and general industry; I believe that everyone in business leadership and engineering should read it. For me there was a significant moment when the promise in the book came together. After forcefully describing the big problem (the Swamp), then persuasively describing a solution that will solve that big problem, Stewart shares his knowledge, understanding and experience, in an eloquent and quite masterful book that can enrich readers’ lives and careers in many ways.

The book concludes with: “Success is about creating and establishing Superior SYSTEMS for Weapons Acquisition programs. Those Superior (product development) SYSTEMS then deliver muchneeded, better cost and performance outcomes. Those Superior SYSTEMS enable the Weapons Acquisition Swamp to be drained.”

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Powerful words. Don’t pass this book by; it’s well worth your time.

‘Drain The Defence Swamp – A Blueprint for Weapons Acquisition Reform’ by Gary D Stewart will be released on 12 October. www.draintheswampbooks.com

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The chapters on affordability and cost reduction were particularly eye-opening.

I’ve never seen it explained so clearly and thoroughly. Initially it’s hard to believe the scope of cost reductions described as possible. But Stewart’s explanations and examples of 30%-50% cost reductions will change your mind.

I was troubled by one metaphor: “For far too long now Defence has been selling us ‘square wheels’ and telling us they will eventually make them round.”

The time to deal with these issues is now, given Australia will need to rebuild manufacturing as an outcome of the COVID-19 pandemic and its impact on our country’s productivity and opportunities globally. The time for disruption is now. And disruption Stewart delivers. In spades.

AMTIL PRODUCT E-BLASTS

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PhoenxPLM: Digitally transforming businesses in the manufacturing sector (Part 2) In the last edition of AMT, Reece Moore, Head of Digital Technologies at PhoenxPLM, discussed the importance of adapting to new technologies, streamlining processes and data management. Here he expands on why companies need a product lifecycle management (PLM) strategy, and the challenges of implementing one.

AMT: Does every company that manufactures need a product lifecycle management (PLM) strategy?

Reece Moore: I believe they do. A PLM system brings data together and provides a single source of truth. Every business needs that in today’s competitive manufacturing environment. I think companies – even if they don’t have a PLM system today, and they are paper managing their product information and product lifecycle – eventually they are going to need to move to deploying a PLM strategy.

Usually companies start to realise they need a formal PLM System when they notice they’re actually doing the basics of a PLM system through various different systems and spreadsheets already, and not getting any benefit from the data. Basically, they’re doing the work anyway. Deploying a PLM system brings all that data together to make the data more usable; in turn, it makes doing business that much easier.

Most modern manufacturers need four key enterprise systems.

An enterprise resource planning (ERP) system, a supply chain management system, a customer relationship management (CRM) system… and the fourth one being PLM. AMT: What levels of implementation are there, and just how scalable is PLM? RM: PLM is built to be scalable, both in terms of the number of users, but also in terms of functionality. I’ve worked with customers on PLM systems of various sizes and requirements. User-wise I have implemented PLM into companies with anywhere from one or two users, through to multinational companies with thousands of users, all using the same PLM system.

The great thing about PLM is you can start with a limited functionality, and only a few users and then as you move along your personal PLM roadmap, you can bring in more capability, more functionality and more users.

With Teamcenter, which we support, you can start with Teamcenter Rapid Start, which is a pre-configured system for small and medium businesses. It has the most common functionality that businesses need, a defined workflow, et cetera. We also offer cloud-based Teamcenter X, which is new from Siemens Digital Industries. It is a Software as a Service (SaaS) solution, again pre-configured,

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but jumps straight to functionality which could be preferred by manufacturers wanting more than just the basics. In terms of difference or deployment options, you can deploy it on premises, you can deploy to cloud, you can have subscription licensing.

AMT: Who benefits from PLM implementation?

RM: Any employee or partner who needs to access or use product information will benefit from a PLM system. The reason being that it’s a single source of truth. Having access to the right information at the right time of product design and or manufacture is essential for so many reasons. PLM solutions can reduce operational costs and take the guesswork out of how to work more efficiently and effectively. PLM allows you to standardise best practices across the business, identify issues early, leverage data that once you probably could not see or find before, help automate and centralise, support product growth, and so much more.

Basically, PLM implementation means product information can be linked together. It allows you to make much better decisions in a collaborative way within the team. The entire business is going to benefit from that. Just one example would be, it is much easier for you to assess the impacts. If you’re making a change to your particular area, you can easily see what else is going to be affected.

If a requirement is changing and you’re managing requirements, you can quickly look in the one system in PLM and see that that’s going to affect the engineering, it’s going to affect manufacturing, and identify the particular parts.

PLM will allow you to quickly see what the impact is, of any change.

AMT: What are the challenges of deployment?

RM: Challenges to deployment aren’t usually the technology or the actual PLM system, it’s usually the change in thinking that’s required within the business. Businesses either think they need to do everything at once as they see the value of PLM and the end result is what they want immediately; or

Reece Moore, Head of Digital Technologies at PhoenxPLM

BUSINESS MANAGEMENT

"PLM solutions can reduce operational costs and take the guesswork out of how to work more efficiently and effectively.

PLM allows you to standardise best practices across the business, identify issues early, leverage data that once you probably could not see or find before, help automate and centralise, support product growth, and so much more." opposite to that, some businesses or stakeholders don’t see how PLM will affect the business operations as a whole.

A lot of businesses see a lot of the functionality in the PLM and think ‘great, we want to do all this’, and they spend a lot of time defining requirements and processes, and just going around in circles. What we encourage is to just pick the most appropriate process that’s going to give you a better return on investment and that you have the most need for. Start with that first, and then gradually have a phased approach and bring in more capability in stages.

The other challenge we have is: when users get the PLM system, they may not see where what they’re doing fits into the overall business process. PLM exposes that what they’re doing in their silo actually has impacts on other stakeholders, and that could be quite a challenge because you’ve really got to explain that the reason you are doing this at this stage is to help someone at a later stage.

AMT: What are some benefits that you have personally witnessed a business gain from adopting a PLM strategy?

RM: An example that might resonate in the industry is: we recently had a customer that develops mechanical and electrical products.

Before they adopted the PLM strategy, their process really was that the mechanical engineers designed their hardware. When they were finished, they then passed that information over to electrical engineers, and electronic engineers would then design their wiring and harness around it. It was very much a sequential process, and the design time was a lot longer than it needed to be.

By adopting the PLM approach, as the mechanical engineers were designing their work, they could collaborate at the same time with electrical engineers, so those design teams began working in parallel. If a change was needed, it was much easier to have the electrical engineers update their information at the same time. That cut about three months out of their development lifecycle, and their typical development lifecycles were about one to one and a half years. They cut three months out of that cycle once they adopted the PLM approach.

A second example, in terms of other areas of improvements: another customer implemented PLM to improve their change process. So previously their change process was very much paper-based. The change went from one user’s desk to another; often changes got lost. And the other issue was during their manufacturing process, issues were uncovered, and the production team would make a change, but that change was never fed back to the designs. So, you would quite often have the same recurring issue again and again, because the issue was never fixed at the source. As you can imagine there were huge improvements in the quality of their production. www.phoenxplm.com.au

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Kaeser celebrates 30 years in Australia: Innovating and investing into the future Kaeser Compressors is celebrating 30 years in Australia this November. Peter Eckberg, Managing Director of Kaeser Compressors Australia, discussed how the company’s latest innovations can assist users in optimising the availability, reliability and efficiency of compressed air systems, through the current pandemic and beyond.

Kaeser Compressors has been present in the Australian market for 30 years, establishing its head office in Dandenong, Victoria, in 1990. Over the past three decades Kaeser has opened branch offices and developed a dedicated network of distributors that are strategically located to be able to deliver Australia-wide sales and service support.

Globally, Kaeser celebrated its 100-year anniversary in 2019. From humble beginnings in Germany, the company has grown to become one of the world’s largest compressed air system providers and compressor manufacturers, today employing in excess of 7,000 people worldwide and represented throughout the world through a network of branches, subsidiary companies and authorised partners.

The company remains owned and operated by the Kaeser family, now in their third generation, with all products proudly manufactured in Germany.

Kaeser Compressors Australia’s head office.

Construction of a new larger facility is due to start any day.

The SAM 4.0 compressed air management system binds individual components into a complete team, monitoring and controlling them so that the required volume of compressed air is available at all times, at the required quality.

An innovative spirit An innovative spirit continues to pervade all aspects of Kaeser, as Eckberg explains: “This has resulted in a steady stream of innovations in compressed air technology, and applying equally to hardware, software and services. From the refrigeration dryer to revolutionary controllers (Sigma Air Manager 4.0), from the portable compressor through to digitalisation and Industry 4.0, Kaeser still blazes a trail in the industry for the cost-effective, reliable, efficient generation and use of compressed air, thanks to its innovative, topquality products and services.”

The COVID-19 pandemic has led Kaeser to develop a number of initiatives, including contactless service, to ensure that compressed air users could continue to operate reliable and efficient compressed air systems. The company has remained open for business throughout the pandemic, ensuring that essential manufacturers have been able to continue to access high-quality, German-made compressed air equipment, local service support, and genuine essential spare parts.

One of the company’s most recent innovations brings many benefits to the end user in terms of complete lifecycle efficiency, and most importantly right now, the ability to view – remotely and in real time – key information and diagnostics, for maximum reliability.

Complete connectivity “Every part of a compressed air station, whether it be the compressors, compressed air treatment components or distribution system, should operate as efficiently as possible for its own sake,” says Eckberg. “Modern compressors and compressed air treatment components are therefore equipped with internal controllers based on industrial PC technology. But these components are not individual players – they must act together as a team, and a team works best when it is perfectly co-ordinated. A sophisticated compressed air management system is therefore required to perform this particular function.”

The Sigma Air Manager 4.0 (SAM 4.0) from Kaeser is an example of a progressive, Industry 4.0-ready compressed air management system that binds all individual components into a complete team, monitoring and controlling them so that the required volume of compressed air is available at all times, at the required quality.

Advanced management systems must successfully meet some highly demanding challenges. Not least, they must be capable

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of predictive compressor control, taking into account a range of contributing factors, such as switching losses, control losses, and so on. However, modern master controllers are now expected to do far more than optimise compressor operation according to current demand.

Efficiency is playing an ever-increasing role. Here, through the development of a patented, simulation-based optimisation process, the SAM 4.0 is meeting these requirements by predictively selecting the most efficient switching operations based on compressed air consumption profile analysis and equipment and system behaviour, in relation to the prevailing technical operating conditions. Decisions are no longer dictated by a narrow pressure range. Instead, the key is to achieve the lowest possible compressed air production costs through intelligent, energy-saving switching strategies.

Predicting service requirements The SAM 4.0 also allows for varying levels of involvement by external service providers. The end user can still perform all of the maintenance, evaluation and servicing of the system themselves (the SAM 4.0 will send notifications when service is required).

Alternatively, the end user can choose a predictive maintenance service model with remote diagnostics.

Here, the physical meets the virtual world within the framework of a structural model such as Kaeser’s Sigma Smart Air, in which the specific compressed air system – configured according to the operator’s requirements – is represented virtually by a digital twin. Operating data from the compressed air station is securely transmitted to the Kaeser Data Center, where it is analysed in real time. Such real-time availability of operating data makes it possible to monitor the ‘health’ of a compressed air station. This means maintenance is carried out precisely as needed and potential faults can be detected in advance and appropriate maintenance

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measures automatically initiated at the right time. Ultimately, the end user benefits from significantly reduced compressed air production and operating costs, as well as improved compressed air availability.

The combination of remote diagnostics and demand-oriented predictive maintenance ensures maximum compressed air supply availability and complete system effectiveness – preventing unplanned downtime, increasing energy efficiency, reducing service costs by up to 30% and delivering demand optimised compressed air system control throughout the system’s entire life cycle.

Remote and real-time monitoring Probably one of the greatest advantages of such advanced compressed air technology in the current pandemic – where many facilities still have staff working remotely, where the number of people in a facility may have been reduced, and where many facilities are still limiting access to suppliers – is the ability to remotely monitor a compressed air system in real-time.

From a PC, laptop, tablet or smartphone, the SAM 4.0’s integrated web server provides a visual display of all compressed air system data in the form of HTML pages. All operational and energy consumption

data, as well as cost information, can therefore be called up on any network-compatible device – anytime, anywhere. In addition, the end user can choose to configure the system so they receive alarm and maintenance messages for individual components, as well as timely warnings or service requirement notifications via email or text message.

When the end user integrates an advanced compressed air management system with a service model such as Kaeser Sigma Smart Air, they have the added peace of mind that a team of compressed air experts are also monitoring the real-time data and acting accordingly.

At the best of times a fully networked compressed air system offers the end user numerous benefits. However, many of these benefits – from remote monitoring and diagnostics, to achieving the lowest possible compressed air production costs through intelligent, energy-saving switching strategies – are even more advantageous in the current climate. After all as an essential utility to industry, many businesses rely on their compressed air system and will now more than ever demand maximum compressed air supply reliability.’

Investing in the future Construction is due to start any day at Kaeser’s Australian head office of a brand new factory. This will double the size of the existing facility – increasing the warehousing, workshop and office capacity.

While COVID-19 may have slowed down proceedings it has not stopped the company’s reinvestment plans.

“Kaeser Compressors has always reinvested heavily into the business,” says Eckberg. “The current pandemic has not halted those efforts. When we finally come out the other end, the company will be in an even stronger position to continue to support its customers.” www.kaeser.com.au

066BMS ACLR8

Peter Eckberg, Managing Director of Kaeser Compressors Australia.

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Where tubular linear motors blow away pneumatics For factory operators looking to save energy and costs, an obvious first place to look is compressed air. Highly useful in many industrial applications, some sites spend up to 30% of their electricity bill generating compressed air.

Pneumatic actuators, which run on compressed air, have been around since World War II. They are wellunderstood, cheap, and suited to harsh environments. However, they also come with their penalties.

Obviously, compressed air must be generated to power them.

Depending on the expansiveness of a factory, this can mean numerous compressors and/or a complicated reticulation system.

A reliable level of pressure must be maintained, or pneumatics will work poorly or not at all.

Air leaks can be expensive. According to a leading compressor technology company, one leak in one unit costing 15 cents/kW/hr to operate will represent well over $2,000 a year to a power bill. With a single point of failure – for example air leakage at one location – the air pressure of the whole plant will drop, and operations will be affected. Then there is the noise.

“If you are working in or visiting a factory, you will usually hear a lot of noise,” explains Heng Luo, Product Manager, ANCA Motion.

“And that’s one big advantage servo-controlled linear motors have against pneumatics.”

Linear motors – for example screw-driven and tubular linear kinds – are newer than pneumatic or hydraulic options, but are preferred for certain applications. Instead of a piston in a cylinder – driven by compressed air or an incompressible fluid – tubular linear motors use magnetic flux to create motion. They aren’t as cheap in upfront costs compared to pneumatics, but offer vast benefits in aspects including accuracy, cheaper operating costs, and flexibility.

Pneumatics can move quickly and forcefully from one point to

another (and hydraulics quicker and more forcefully still, for the same size) but with little positional control along the stroke.

ANCA Motion’s LinX M-Series offers 10 micrometre resolution, as well as velocity up to 10m per second and maximum acceleration over 30G. The M-Series comes with an integrated position sensor, with precise positional control.

It can also achieve a continuous force of 90-160 Newtons, and a peak force of 1,200 Newtons. An estimated payback period versus pneumatic cylinders – which with their form factor and mounting design, the M-Series is a neat substitute for – is only 18 months.

One area of obvious advantage over pneumatics is the ease of reprogramming between jobs. A recent application for a customer’s forming machine substituted LinX motors for pneumatics to move a cutting bed. Changes for different workpiece lengths could take six to eight hours for the painstaking recalibration of air pressure. Such adjustments now are a quick change in servo drive parameters – a matter of seconds. The improved positional control has boosted throughput by 50%, with the massively improved precision allowing the process to be confidently sped up.

ANCA Motion’s linear motors were originally developed for sister company ANCA CNC Machines’ FX Linear and MX Linear tool and cutter grinder machines. The LinX M-Series Tubular Linear Motor has a failure rate of less than 0.03%. Robust support is offered through an international network of 125 engineers in strategic locations. www.ancamotion.com

Sullair Australia launches Managed Air Power (MAP) Sullair Australia has launched new ‘Managed Air Power’ service, a comprehensive outsourced compressed air solution.

The MAP solution aims to assist companies to run their operations efficiently and reliably, regardless of their budget constraints and market volatility. It makes compressed air simple, and allows companies to outsource provision of compressed air to Sullair, allowing for total control over their compressed air without the significant upfront capital outlay. MAP allows companies to save time and money by relying on Sullair’s expertise. Sullair installs the appropriate solution and takes care of all maintenance and servicing over five years. Sullair Australia’s Managing Director, Fred Funnell, explains: “Outsourcing provides the customer with the essential equipment they need, along with a whole-of-life support package and the peace of mind to know the equipment is being closely monitored allowing them to focus on their core business.”

After the five-year period, companies have the flexibility to extend their contract, purchase the compressor outright, or end the contract. MAP gives clients the opportunity to buy compressed air on a consumption basis with a single monthly charge including usage, maintenance, and lease of the equipment. MAP is a flexible offering that can work for both large and small companies. Key benefits include: • Maximised reliability and uptime. Sullair’s equipment will be remotely monitored 24 hours a day, 365 days a year. Sullair

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will know if there’s a problem with your machinery before you do, and will act to minimise any downtime.

• Easy budget management. Customers will enjoy the convenience of one monthly invoice that covers all equipment parts, maintenance, monitoring and management.

• Expedite purchasing of new or replacement equipment. MAP allows clients to treat their compressed air as an operating expense rather than a Capex budget item.

• Improved productivity. Funnell says “People should be able to focus on their core business, not whether their compressor is optimised or if it’s missed its routine service”. By outsourcing to Sullair, clients can focus their time and resources entirely on their core business.

• Comprehensive monthly reporting. MAP comes with transparent monthly reports including usage, servicing and equipment performance, giving clients clarity and peace of mind.

Funnell adds: “Outsourcing options give the customer a chance to stop and reassess their actual air demand. Is it the same as it was 10 years ago when the old compressor was installed? Are we now paying for energy we don’t need?” www.sullair.com.au

Hotspots is proudly owned and managed

by AMTIL

Need help looking for the missing piece?

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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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WASTE & RECYCLING

Microrecycling science delivers new ‘material microsurgery’ technique A new technology that promises to enhance the advanced manufacturing sector in Australia has been developed by the pioneers of ‘microrecycling science’ at UNSW’s Centre for Sustainable Materials Research and Technology (SMaRT).

The novel ‘material microsurgery’ technique developed by Professor Veena Sahajwalla and her team at SMaRT can extract valuable materials and elements from complex waste items and reform them into strengthening layers for steel and other applications.

The technique is the latest breakthrough by Sahajwalla’s team as they seek to develop new ways to address society’s growing waste and recycling challenges with innovations that can boost manufacturing capability, creating jobs and prosperity while enhancing environmental and social outcomes.

The SMaRT Centre created the phrase ‘mircorecycling science’ to describe its novel approach to researching innovative approaches and technologies to reform various waste streams into value added materials and products.

“Australia’s governments have agreed to ban the exporting of glass, plastic, paper and rubber tyres from January 2021,” Sahajwalla explains. “Therefore we need to start treating these waste items as the ‘renewable resources’ they really area. Ever-increasing population, technological advancement, variable consumption trends, and lack of efficiency in using materials are forcing us near a crisis point in terms of waste management.

“And since COVID-19 has disrupted global supply chains, Australia’s manufacturing has come under sharp focus. The problem of countries now being affected by unreliable global supply chains for certain materials and goods has sparked questions around how to produce the goods they need.”

Sahajwalla’s team is developing new technologies that don’t just reform complex waste items into new, value-added materials to help address this ‘sovereign capability’ issue, but do so through decentralised manufacturing.

“A key challenge is that existing, centralised recycling and waste treatment methods at scale often just turn things like PET bottles back into PET bottles,” Sahajwalla adds. “What we need is a recycling and manufacturing system that can innovate to reform waste for more diverse and value-added end uses.

“Recyclers traditionally haven’t seen themselves as manufacturers and manufacturers haven’t seen themselves as recyclers, but we need them to. So, if we accept that we need plastic and want to keep it out of landfill, we need a system that treats it as a renewable resource.”

Green materials and products ‘Material microsurgery’ is the latest innovative technique from the SMaRT Centre, which has pioneered the technological concept of Microfactories to reform different waste streams that mostly end up in landfill or stockpiles by turning them into value added ‘green materials and products’, thus able to revolutionise the recycling and manufacturing sectors.

Material microsurgery uses the ‘foundational selective thermal transformation’ techniques developed in the microrecycling science by the SMaRT Centre to extract valuable core elements from electronic waste. This can be used in a novel way as a highperformance hybrid layer to improve performance of the surface of steel, meaning that regular steel can be enhanced to have a ‘super surface’ via the modification.

This method could be a suitable alternative to conventional surface coatings and reduce the burden on raw material feedstocks. In the material microsurgery study, glass and plastic from discarded

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Professor Veena Sahajwalla in a section of the Microfactorie at UNSW’s Centre for Sustainable Materials Research and Technology (SMaRT).

computer monitors and copper from printed circuit boards were used to produce a hybrid thin film layer on a steel substrate to provide a protective layer over the base material at the microscale to alter the overall performance of the material. This high-performance advanced material is a hybrid layer chemically bonded in situ on steel to produce a super surface with enhanced mechanical properties compared to the uncoated steel.

Material microsurgery “We use the term ‘material microsurgery’ because we were inspired by the processes medical surgeons use in microsurgery where they apply targeted and selective solutions to problems,” says Sahajwalla. “Existing waste and recycling technology doesn’t do this for our traditional waste treatments. We need to step up to do the things that were thought unimaginable for waste management so it can be cutting edge.”

Sahajwalla and her team’s Microfactorie technologies use various discrete modules to transform problematic waste materials, such as glass, textiles and plastics, into new value-added materials and products such as engineered green ceramics for the built environment, or plastic filament as a ‘renewable resource’ for 3D printing. This modular technology is capable of harnessing value from waste resources to deliver high-value materials and products.

The SMaRT Centre now houses various Microfactories and the material microsurgery technique is the latest innovation that holds promise to help treat waste as a ‘renewable resource’ to produce green materials and products that otherwise require virgin resources.

“COVID has unearthed the weaknesses in our current way forward to meet these challenges,” says Sahajwalla. “But we can start a whole new ‘green materials’ movement where we use waste as renewable resources for decentralised manufacturing to supercharge our economy.” www.unsw.edu.au

WASTE & RECYCLING

New research hub to tackle global waste crisis A major new Australian Research Council (ARC) Industrial Transformation Research Hub, led by RMIT University, will focus on reducing landfill waste and transforming reclaimed waste into new materials for use in construction and other manufacturing sectors.

Australia’s landfill space is expected to reach capacity by 2025, with roughly 67 million tonnes of waste generated every year, and 30% of that waste going to landfill. The ARC Industrial Transformation Research Hub for Transformation of Reclaimed Waste Resources to Engineered Materials and Solutions for a Circular Economy (TREMS) will address the urgent waste crisis in Australia. The new research hub will involve leading scientists, researchers and industrial experts from nine Australian universities and 36 state, industry and international partners.

Professor Sujeeva Setunge.

The TREMS hub will draw from expertise across multiple disciplines including civil, chemical, materials and construction engineering, artificial intelligence, behavioural sciences, environmental procurements and policies and standards.

RMIT Deputy Vice-Chancellor for Research and Innovation and Vice-President Professor Calum Drummond said the Hub would deliver novel solutions for reclaiming Australia’s waste resources and position Australia as a leader in research contributing to a circular economy. “At RMIT we work closely with industry and other partners to tackle complex environmental, economic and social issues,” said Drummond. “We are proud to be leading such a globally significant research hub that will help transformation towards a circular economy and contribute to the United Nation’s Sustainable Development Goals.”

Minister for Education, the Honourable Dan Tehan announced the $18m collaboration, saying the research hub will undertake research with applications in the real world.

“Our Government is investing in research that will foster strategic partnerships between universitybased researchers and industry organisations, to find practical solutions to challenges facing Australian industry,” Minister Tehan said.

TREMS research hub lead, RMIT Professor Sujeeva Setunge said the multi-sector collaboration would focus on holistic solutions to address the waste crisis, co-designed in partnership with stakeholders.

“Our investigations will include changing behaviours, smart designs to minimise waste, optimum processing of waste and converting waste to energy, developing novel materials using recycling and upcycling technologies, and metrics and tools to encourage uptake of new materials and solutions,” she said. “There is currently a material shortage for Australia’s $14bn heavy construction industry, so this research to reclaim waste and transform it into new materials will deliver benefits both economically and environmentally.”

Setunge added that she is looking forward to working with local, national and international partners and acknowledged existing long-term collaborations with the Cities of Brimbank, Kingston and Hobsons Bay, as well as the Municipal Association of Victoria. The new hub will focus on ten challenging waste streams: textile waste; biomass; tyres; glass; paper and cardboard; construction and demolition waste; fly ash; plastics; biochar and timber. www.rmit.edu.au

Boeing Australia awarded for carbon fibre recycling program Boeing Aerostructures Australia’s efforts to promote sustainable aerospace manufacturing have been awarded with the 2020 Sustainability Leadership Award from the United States National Association of Manufacturers.

The award was in recognition of Boeing Australia’s achievements in the recycling of more than 76 tons of aerospacegrade carbon fibre. The recycling endeavour, achieved in partnership with UK-based ELG Carbon Fibre, saw scrap materials from Boeing manufacturing sites collected and sent to ELG to be treated to remove binding agents. The result of this process is clean material that can then be sold to third parties to make products such as electronic accessories and automotive equipment.

“As Australia’s largest aerospace manufacturer, we have a responsibility to our employees and our community to continuously identify ways to minimise environmental impact while we produce state-of-the-art product parts for our commercial programs,” said Jose Garza, Managing Director of Boeing Aerostructures Australia.

“The Australian manufacturing environment has experienced some extraordinary challenges and now, more than ever, we need to look to sustainable practices to guide our future.”

The Sustainability Leadership Award recognises what Boeing has done to embrace global processes to achieve several environmental goals by 2025, including reducing greenhouse gas emissions by 25%; water use and solid waste to landfill by 20%; energy use by 10%; and hazardous waste at worksites by 5%.

“Boeing is demonstrating that you can be environmentally sustainable in a cost-effective way,” said Bryan Scott, Vice-President of Environment, Health and Safety at Boeing. “We are the largest consumer of aerospace-grade composite, and the only company able to recycle 100% of it.”

Boeing Australia designs, tests, certifies and manufactures advanced structures for commercial aeroplanes. As a Tier 1 partner to the Boeing 787 Dreamliner program, Boeing Australia is the sole source supplier of 787 moveable trailing edges, comprising an inboard flap, flaperon, outboard flap and aileron.

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FORUM COMPLIANCE

Ammonium nitrate in Australia The recent ammonium nitrate explosion in Beirut has generated questions and concerns.

What are the risks in Australia? Laura Whiteman explains.

There have been a number of ammonium nitrate (AN) explosions throughout the world, with four major incidents occurring within the last 10 years. These include a fertiliser company in the US, a rolled truck in Queensland, the Tianjin explosion in China, and the latest explosion at a port in Beirut. Some of the incidents linked to ammonium nitrate are accidents, while there have been others which are labelled as suspected terrorist attacks, such as the Oklahoma City bombing in 1995 and the Hyderabad blasts in India in 2013. The question is then asked – what is ammonium nitrate used for, can it be safely handled and stored and should we have it in Australia at all?

Ammonium nitrate is typically sold in pellets, also known as prills, and is a commonly used fertiliser in the agricultural industry and explosive in the mining industry. It is produced by neutralising nitric acid with ammonia, and was first discovered by a German chemist in 1659. The chemical itself is not an explosive but requires a combustible material to be present for it to explode.

More than 20 million tonnes of ammonium nitrate are produced and stored worldwide each year, with Australia importing close to 112,000 tonnes. It is estimated that of the close to 2 million tonnes each year that Australia produces and stores, over 90% is produced locally.

There are three main producers of ammonium nitrate in Australia, and their typical volumes as stated on their websites are: CSBP Wesfarmers Kwinana, WA (780,000 tonnes pa) Orica Kooragang Island, Newcastle (360,000 tonnes pa) and Yarwun, Gladstone (500,000 tonnes pa) Queensland Nitrates JV Moura, Qld (222,000 tonnes pa) Each of these producers indicate that they generate the majority of their ammonium nitrate for the manufacture of explosives in the mining and quarry industries. According to Primary Industries & Regions SA, mining use makes up approximately 90-95% of all ammonium nitrate use in Australia, with the rest used in fertilisers.

In accordance with national security objectives, in June of 2004, the COAG developed a national approach for Security Sensitive Ammonium Nitrate (SSAN). SSAN can be defined as ammonium nitrate, ammonium nitrate emulsions and ammonium nitrate mixtures containing greater than 45% ammonium nitrate by mass, excluding solutions and Class 1 Explosives. Each State and Territory in Australia has adopted their own relevant legislation for the restriction, use, manufacture, transport and storage of SSAN. Typically, this includes a legitimate reason for access to SSAN, the person being over 18 years of age, a license, agreeing to report any loss or theft of the product and a security clearance. It also prohibits the movement of SSAN into or out of any State or Territory without permission.

For transport throughout Australia by road and rail, ammonium nitrate can be listed under different UN numbers in the Australian Dangerous Goods (ADG) code, depending on the concentration and other impurities in the product. The ADG code sets out the conditions in which they must be transported, including restrictions on load sizes, and that they must not be transported with any sensitising or initiating agents. One of the main types of ammonium nitrate used in Australia is classified as a Class 5.1 Oxidizing

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agent, UN 1942 – Ammonium Nitrate with ≤ 0.2% combustibles.

Ammonium nitrate can be listed as a Class 1 Explosive (although any information in the ADG for explosives is advisory only, and should be read in conjunction with the SSAN legislation for each State and Territory). Where ammonium nitrate is used as a fertiliser, it is typically a Class 5.1.

Australia has been using ammonium nitrate for decades, with very few incidents. In SA, 170 locations store ammonium nitrate. In other states, much larger amounts are stored, sometimes close to residential areas, and resident groups are campaigning to have them moved. In a statement put out by Orica, they indicated their “team is trained to stringent accreditation standards associated to AN storage, and all AN storage areas at Kooragang Island are fire-resistant, built exclusively from non-flammable materials, and have designated exclusion zones around them”. With such stringent regulatory requirements and the conditions needed for an explosion to occur, the risk becomes minimised. The States and Territories are well aware of the potential issues and determined that it was better to regulate its transport, use and storage, rather than banning ammonium nitrate.

So what does all of this mean for ammonium nitrate in Australia? Are there any alternatives? For fertilisers, the University of Missouri has been researching suitable plant-friendly, nitrogen-rich alternatives to AN. They are investigating ammonium sulfate as well as Urea, with both offering a source of nitrate. There are also studies presented at the 43rd Annual Conference on Explosives and Blasting Techniques, into the development of ammonium nitrate-free mining explosives.

Some of the initial work conducted has identified three possible alternatives, although further research needs to be undertaken.

While suitable alternatives are being evaluated, strict regulatory control around ammonium nitrate has led to a relatively low number of incidents in Australia.

Laura Whiteman is a senior regulatory specialist at UL Materials & Supply Chain, which provides innovative material and regulatory data solutions for a transparent and sustainable product supply chain. With fully automated chemical compliance software platforms, industry-leading data resources and a global network of regulatory expertise, UL removes barriers and solves critical challenges to help companies stay one step ahead of global regulations. customerservice.anz@ul.com Ph: 03 9846 2751 msc.ul.com

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FORUM INSURANCE

Why using an insurance broker makes good business sense With millions of individual insurance policies offered through multiple brands, it can be difficult to find the one which works best for you. It is for this reason that insurance brokers are a valuable guide, as explained by BMS. As a business owner, it can be tempting to seek short cuts to find your best-fit insurance cover. The internet offers you an overwhelming range of options, but it can be tricky to work out the right cover to suit your business needs (and cheaper is not always the best).

You could have then taken out a policy because it was quick and ticked most of your boxes. Maybe the impact of COVID-19 has belatedly made you take to the fine print with a magnifying glass.

For example, did you have a chance to check the independence of the comparison website? Social proof might have weighed in on your decision-making too, rather than doing your usual due diligence.

Spoilt for choice With millions of individual insurance policies offered through multiple brands, and distribution channels across Australia, insurance brokers are a valuable guide to help businesses determine which policy offers the best fit for their needs.

It can be hard work finding the right one. A quarter of sole traders have no insurance, according to an Industry Council of Australia report. Meanwhile, one in 10 businesses underinsure their business assets, saying: • “I can’t afford to pay more for insurance.”

• “Premiums are too high”, or • “You can never be adequately insured.”

Maybe you’ve thought or said the same about your own business?

DIY insurance cover is not your best bet

• Costs of a diverse range of competing insurance policies, and • Validity of the insurance cover when there are changes in the business.

We’ll also advocate for you when making a claim, seeing that process through and allowing you to focus on running your business.

A licence to broker To become a broker, we’ve each undertaken training and must successfully apply to the Australian Securities & Investments Commission to secure an Australian Financial Services Licence. We can also do this work as a representative of a licence holder.

This licence compels insurance brokers to provide “efficient, honest and fair financial services” and to comply with the Corporations Act 2001. We must also follow the Insurance Brokers’ Code of Practice.

In short, businesses need to protect their assets, customers, employees, business owners, and earnings. There’s plenty more that companies might need to insure, including compulsory coverage.

Safety (and savings) in numbers

If you’ve gone for the Google ’quick-fix’ option, you could be paying higher insurance premiums after an initial honeymoon period.

Chances are you’ll need to renegotiate with an insurance company for a better rate or elect to take a higher excess to reduce your premiums. This will need to be repeated for each of your policies.

Once we’ve discussed your insurance needs and risk management issues with you, we could suggest bundling policies together to offer you savings. But, if you prefer to spread your policies among different insurers, you’ll still do well to use a broker.

Would it make better business sense to deal with the same person for all of your business insurance policies? Someone who’ll guide you when your policy needs reviewing, provide regular updates and take the stress out of insurance for you.

This is where we come in. Insurance brokers manage more than 90% of commercial insurance transactions in Australia.

What insurance brokers do As insurance brokers, it’s our business to navigate the information tsunami. We offer professional advice with expertise in insurance and risk management. Our aim is to scaffold business growth - and support you in selecting your best-fit insurance cover. Once you’ve purchased the policy, we keep tabs on it, your circumstances, and how it relates to you.

We drill down into insurance products and policies for insights into the finer details such as the: • Terms and conditions in the policy • Benefits (also known as optional inclusions) • Exclusions (these are critically important to ensure you don't have nasty surprises when you need to make a claim)

Licencing, laws, and the code of practice give a broker’s client great peace of mind.

In fact, that process helps pre-qualify you for a policy in the eyes of an insurance company. They see you as a lower risk because you’ve taken on board your broker’s expert advice. That’s why brokers can access better rates for their clients than if a business dealt directly with an insurance company.

Having a broker on your side helps make you more savvy about risk management in your business. It’s a proven way to ensure you have sufficient cover for your risk exposure, leaving you to get on with what you do best - running your business.

BMS is a dynamic global broker that provides specialist insurance, reinsurance and capital markets advisory services.

The company was established in 1980. Today, $2.6bn of premiums are placed each year and more than 450 people are employed worldwide. BMS is growing fast and has 19 offices around the world in key hubs including London, New York and Bermuda.

The BMS team is highly experienced and respected in the market. We value our strong personal relationships with clients and contacts which – together with our entrepreneurial flair – enable us to get the best solutions for our clients. ph: 1800 290 978 amtil@bmsgroup.com www.bmsgroup.com

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108

FORUM LOGISTICS

COVID-19 and its impact on manufacturing supply chains – force majeure?

Nathan Cecil looks at the force majeure framework likely to come into play as a result of the global supply chain disruption caused by COVID-19.

The COVID-19 outbreak signifies an unanticipated and overwhelming event, so far infecting approximately 27.6 million people worldwide and resulting in the death of at least 898,000 (these figures will tragically be materially out of date as soon as this article is published).

Naturally, the primary focus is on the human impact, with measures being taken by governments to limit the spread of the virus.

Actions by government authorities in quarantining areas and shutting down businesses and restricting movement have caused significant disruption to supply chains around the world. As a result, manufacturing and distribution have been significantly impacted.

The extent of supply chain disruption Supply chains the world over have been adversely impacted by the impacts of the COVID-19 crisis in two significant ways: • Workforces have been impacted by infection and workplaces have been impacted by mandatory worker limitations and shut-downs as a result of infection incidents and/or mandated closure.

• Procurement supply chains have been impacted as a result of the above impacts on the businesses of suppliers (impacting their ability to provide supply of input materials and components) and also through the interruption to logistics networks as a result of border closures, both hard and soft.

The situation and its impacts are mercurial, sometimes shifting beneath our feet on an hourly basis.

Faced with these circumstances, the immediate questions for manufacturing businesses include: • What remedies are available to me in respect of the delay or failure of my suppliers to supply me?

• What relief is available to me in respect of my delay or failure to meet my obligations to customers?

Unfortunately, most supply arrangements did not foresee anything like the COVID-19 situation arising and so do not contain any clear roadmap as to how businesses are to navigate their contracts in the current circumstances.

As a result, most businesses are looking to their contracts (e.g. supply agreements, distribution agreements, manufacturing agreements, transport and logistics agreements) to see whether ‘force majeure’ provisions may be used against or by them and whether there are any other ways to avoid the adverse impacts facing them.

Force majeure A force majeure (literally ‘superior force’) clause allows one or both contractual parties to cease or suspend performance of a contract following the occurrence of a pre-defined ‘force majeure event’.

If successful, the party will not be liable for failing to perform its obligations under the contract. It may also give rise to termination right, usually where the force majeure event continues for an extended period.

In most common law countries, such as Australia, there is no independent legal concept of ‘force majeure’. As such, it is a creature entirely of contract and the scope and effect of any such clause is dependent on its particular terms. In most cases, they contemplate acts of God, extreme weather events, riot, war or

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invasion, government or regulatory action including strikes, terrorism or the imposition of embargo as being ‘force majeure events’ in respect of which a party may be relieved of their liability for failure to perform. Many such clauses also extend to include pandemics or epidemics, which may apply in the current circumstances.

It is also important to consider whether the clause in question applies only to ‘direct’ impacts of a force majeure event or also extends to ‘indirect’ impacts.

Unfortunately, many manufacturing arrangements drafted from the ‘buyer’/‘customer’ perspective exclude failure to secure supply of materials or components from being a force majeure event.

If a business is seeking to invoke force majeure, it must consider carefully whether it is able to do so under the relevant contract. A party could be in breach of contract, risk termination and potentially damages claims if it fails to meet its obligations and cannot rely on force majeure, or if it invokes force majeure and ceases to perform when it is not entitled to do so.

To successfully invoke force majeure, a business will also need to ensure compliance with any other contractual obligations that may include providing prompt and correct notice and seeking to mitigate any loss that might otherwise be suffered (e.g. by seeking alternative sources of supply or alternative ways to perform the contract).

It is equally important to proactively consider whether your counterpart might be able to rely on a force majeure clause to delay or avoid its performance obligations, so that you can prepare for this possibility and assess in advance whether it will impact your arrangements further downstream.

If your suppliers are unable to rely on force majeure, it is more likely that they will be liable to compensate you for any delay or failure to perform the supply. If you are able to rely on force majeure, it is more likely that you will be able to claim relief from your delay or failure to perform.

Given the potentially significant impact on your legal rights and obligations, you should be looking into this issue now, so that you can navigate a course through this outbreak.

Nathan Cecil is a Partner in the national Transport, Shipping & Logistics group at Holding Redlich; a large national independent Australian law firm with offices along the East coast. Holding Redlich partners with many Australian manufacturers, importers and distributors in relation to their Australian and international operations, assisting them with their commercial issues, regulatory compliance and resolving disputes.

Nathan.cecil@holdingredlich.com Ph: 02 8083 0429 www.holdingredlich.com

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FORUM OHS

Lead exposure risks in the advanced manufacturing industry There are multiple opportunities to address lead exposure risks within the advanced manufacturing sector, as explained by Phoebe Gane.

Lead is an abundant heavy metal with diverse industry applications due to its low melting point, electrical conductivity, high density, malleability, and chemical stability. There are, however, numerous associated adverse health effects of exposure including impacts to the nervous, cardiovascular, skeletal, immune, gastrointestinal, reproductive, and urinary systems. Inorganic lead and organic lead compounds are also classified as a Group 2A - Probable Carcinogen to humans by the International Agency for Research on Cancer (IARC).

The use of lead has consequently been phased out of many of its former applications such as in fuels and paints. However, lead and lead alloys continue to be utilised in the production of leadacid batteries, alloys for solder and ammunition, some plastics, protective coatings and ceramics, and therefore remains a hazardous chemical of concern for industry.

Legislative duties Australian Model Workplace Health and Safety (WHS) legislation states Persons Conducting a Business or Undertaking (PCBUs) must ensure that workers are not exposed to hazardous chemicals, including lead, at concentrations higher than the relevant exposure standard. Model WHS Regulations also include specific additional requirements for work activities with potential for significant lead exposure - referred to as lead processes. Where lead processes are undertaken, PCBUs must identify whether ‘lead risk work’ is carried out in their workplace and, as part of wider risk controls, implement routine health surveillance to ensure the level of lead in workers’ blood does not exceed acceptable ‘blood lead levels’.

Lead processes in the manufacturing industry include production/ recycling of lead-acid batteries; melting or casting lead or alloys; handling lead compounds such as lead UV stabilisers and dry lead pigments; machining or foundry processes involving lead or lead alloys; and welding, cutting or cleaning leaded, or lead-paint coated steel.

Routes of exposure Lead is not readily absorbed through the skin and most human exposure occurs rather via inhalation of dusts and fumes contaminated with lead, or by ingesting lead-contaminated particles. Additional exposure routes also include dermal absorption; absorption from retained or embedded leaded foreign bodies; or even trans-placental (endogenous) routes.

IARC research (completed 2006) identified workers with the greatest potential exposure risk in the manufacturing industry to be those directly employed in production undertaking tasks such as machining, welding, and soldering. The production and recycling of lead-acid batteries also presents a high exposure risk, albeit to a relatively small group of workers within Australia.

Controlling exposure There are multiple opportunities to address lead exposure risks within the advanced manufacturing sector. Industry trends and technological innovations can, in the longer term, reduce the potential for workplace lead exposure, for example by elimination through replacement of lead-acid batteries with lithium-ion batteries, or via transitioning away from lead-tin solder.

The establishment of the Advanced Robotics for Manufacturing (ARM) Hub in Queensland supports accelerated industry uptake of process automation for activities such as welding and metalwork through the use of innovative technologies such as collaborative robots, augmented and virtual reality and robotic vision. Advances in offline robot programming, and its interaction with 3D modelling software, allows greater flexibility in the use of plasma cutting cells, welding cells and other automated processes, giving greater flexibility and opportunities for substitution of traditionally manual production processes.

Whilst these advancements will certainly play a role reducing exposure, there are also readily accessible control mechanisms immediately available to individual PCBUs including: • Engineering Controls including ventilation systems to control welding fumes; and dust suppression, extraction and filtration technologies to minimise lead inhalation risks.

• Administrative Controls including amended shift patterns and task rotation to reduce the exposure duration for individual workers.

• Use of PPE - the training, use and maintenance of appropriate PPE and Respiratory Protective Equipment (RPE) can provide an additional layer of protection to workers.

Ensuring effective risk control and compliance with legislative duties The development of an Occupational Health and Hygiene RiskBased Management Plan (OHHMP), followed by implementation of exposure monitoring and assessment programs, provides PCBUs with robust tools for WHS compliance. OHHMPs and associated monitoring help to identify potential occupational exposure risks for workers; document processes to manage these risks; define the controls; and monitor the process by which efficacy of these controls is confirmed.

When combined with operational and appropriately designed engineering and administrative control systems, the ongoing and future technological advances and innovations in production, assembly and manufacturing processes have the potential to transform the risk profile of lead exposure within the Australian manufacturing industry. Notwithstanding this, continued application of robust processes to identify, assess and mitigate lead risks are critical to ensure a safe and healthy work environment for workers, and drive best practice in accordance with WHS legislation.

Phoebe Gane is the National Practice Lead for Health & Safety at Greencap. Greencap has been leading the way in risk management and compliance in Australia since 1984 providing businesses with expert services, online solutions & training to manage risks for people, property & the environment. With over 300 professional, technical and engineering staff, Greencap services a wide range of industries including thousands of private and government clients in the infrastructure, education, property, resources, industrial, manufacturing, retail and services sectors. Greencap is part of the Wesfarmers Industrial and Safety Group as well as a Platinum Partner of NSCA Foundation.

Ph: (08) 9214 6100 Email: phoebe.gane@greencap.com.au www.greencap.com.au

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Focusing on the customer Having just installed a new Customer Relationship Management tool at AMTIL, part of the evaluation process involved looking at the advantages a powerful CRM would bring to us. The Customer Experience was a key area of focus, along with improved productivity and reduced costs.

There were six areas we looked at when evaluating different CRM programs.

The digital sales funnel The rise of digital and social media has made word-of-mouth marketing exceptionally powerful. Companies today rely on customers’ goodwill to spread the word about their businesses. We are no different. We are leveraging our digital and social media presence to cultivate member trust, and ensuring our members derive great benefits from the first point of contact. And we are trying to build a long-term relationship with our members to get solid word-ofmouth recommendations.

Better member engagement We want stronger communication mechanisms, with customer engagement encouraging more interactions and thus building strong web-based relationships. We are using emails and social media to engage with members and get more feedback. These real-time interactions create a forum where members can share their needs with us. In turn, we can provide improved products and services.

Increased customer conversions Any CRM seller will tell you a satisfied existing customer is more likely to engage than a new prospect. Our CRM will enable us to better track the value we provide through campaigns and interactions. It will identify where members are not engaging with us, allow us to enhance our member experience, and turn current members into life-long members.

Reduced cost of service and marketing The CRM will help us understand our members better. The idea is to take out the guesswork about what members want. Our approach will have built-in checkpoints helping us take a more member-centric approach to marketing.

We will collect data, create business analytics and understand the market dynamics. This will lower costs, while increasing customer satisfaction.

Improved customer service Trust is a pillar of great customer experience. When customers trust a business, they are more likely to communicate any complaints directly. Our CRM will allow us to improve the service we provide through more efficient methodologies and automated processes.

Increased customer loyalty and retention Exceptional customer experience builds a foundation of loyalty and improves customer retention. We will further improve the experience our members have with us and continue to strive for delivery of member benefits. The CRM will help us to evaluate “value for money” services and reward customer loyalty.

User experience has become more important than ever; efficiently managing AMTIL’s relationship with our members was a key consideration in our purchasing decision. For the record, we invested in HubSpot as our new CRM, and look forward to the benefits it will provide.

Shane Infanti, CEO AMTIL

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AMTIL HEADING INSIDE

AMTIL postpones AMW/Austech till 2022 AMTIL has announced the postponement of its Austech and Australian Manufacturing Week (AMW) exhibitions until 2022. Initially scheduled to take place in May 2021, Austech and AMW will now be held at the Melbourne Convention and Exhibition Centre (MCEC) from Tuesday 8 March to Friday 11 March 2022.

AMTIL made the decision to postpone the two exhibitions primarily in response to general public health concerns relating to the COVID-19 pandemic, with the ongoing prospect that social restrictions that may still be in place at the time, and the continued economic uncertainty over the coming months. In light of these concerns, the AMTIL Board concluded that it would be unwise to hold such signficant industry events at a time when the risk of disruption remains high, and that rescheduling the exhibitions would allow both the organisers and all participants to plan with greater confidence.

The decision was heavily influenced by sentiment among AMTIL members, many of whom had voiced reservations about moving forward with an exhibition in the current climate. Feedback from the industry had highlighted challenges in terms of planning overseas shipments of machinery to Australia for the event during a prolonged pandemic, and uncertainty over future overseas travel potentially limiting the capacity of technicians to attend to install and demonstrate machines.

“AMTIL has a proud history of running strong industry exhibitions, and to forge ahead with a reduced event in 2021 would not provide the strong outcomes that AMTIL desires for its members and the industry as a whole,”

AMTIL’s recent announcement of the launch of AMW had drawn an overwhelmingly positive response from across the manufacturing industry in Australia. However, it rapidly became clear that there were widespread reservations among potential exhibitors about making such a significant commitment in terms of participating in AMW or Austech in the current climate. Therefore, AMTIL decided that, by allowing the industry a longer timeframe to plan with confidence, the postponement would result in a much stronger event in 2022.

said Shane Infanti, Chief Executive Officer of AMTIL. “This decision has not been taken lightly, and the Board and all of the AMTIL team are disappointed that this decision has had to be made.” Austech is Australia’s premier advanced manufacturing & machine tool exhibition, owned and operated by AMTIL since 2000. In July, AMTIL had also announced the launch of AMW, Australia’s premier manufacturing solutions event, following the news that Reed Exhibitions has discontinued its National Manufacturing Week (NMW) exhibition. The inaugural edition of AMW had initially been planned for 11-14 May 2021, co-located side by side with Austech.

“From the feedback we’ve had since announcing AMW, we know that Australian manufacturing is keen to get back to work once this crisis is over and the recovery is underway, so there’s a lot of excitement about these shows,” Infanti added. “In these challenging times AMTIL is fortunate to have secured suitable space at MCEC for these new dates, and we’re looking forward to delivering a safe, robust event in March 2022.”

For more information about Australian Manufacturing Week, Austech and all of our upcoming events, please contact AMTIL’s Head of Events Kim Banks on kbanks@amtil.com.au. www.amtil.com.au/events

1382V3AMTIL

AMTIL gratefully acknowledges 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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AMTIL 2020 Member Census: Getting the measure of Australian manufacturing Recently, AMTIL has been contacting our members to gather feedback on their confidence in manufacturing in Australia. Member Liaison Alan Taylor outlines his findings on the current outlook across Australian manufacturing.

For this census I made calls to the membership which consisted of 275 members, both Manufacturing Technology Users (MTUs) and Manufacturing Technology Suppliers (MTSs). A total of 559 calls were made, and 178 of AMTIL’s 275 members listed were successfully contacted.

Of the 178 member contacts, I was required by 41 of those contacted to help them with follow-up activities or with connections to other AMTIL services or other members (23% of those contacted). These participation rates are slightly lower that those experienced in the past. From the raw data, the total turnover of the AMTIL members contacted was approximately $3.403bn. Based on this sample, the turnover of AMTIL’s entire membership can therefore be estimated to be as much as $5.25bn, of which $315m is generated by exports.

The members contacted also reported employing a total of 7,376 employees, indicating that overall AMTIL’s membership employs more than 11,000 employees.

per employee of around $356,000. The average MTS member generates about 28% of their total turnover through IP they own.

Exports account for approximately an average 11% of turnover.

The following two graphs show the distribution of MTS member companies in terms of their turnover and their headcount, with standard deviation applied.

As usual for the census we applied a standard deviation to the data, eliminating members who have a turnover of less than $1m and in excess of $200m, and also factoring out any business with more than 200 employees. This enabled us to find benchmarks that will be more applicable for the majority of AMTIL members to measure their performance against.

With our standard deviation applied, the census showed that an average MTU member of AMTIL has an approximate turnover of $9,170,000 and 30 employees. An average employee would therefore contribute approximately $305,000 in turnover.

The following two graphs show the distribution of MTU member companies in terms of their turnover and their headcount, with standard deviation applied.

Members were asked what parts of the supply chain they supply to the most. It was interesting to see that none of our members contacted said they supply to Tier 4. There does not seem to be any explanation readily apparent from this data alone that would give reason to this. In addition, 20.5% of respondents did not know which tiers they supplied to, or in many cases what traditional supply chain tiers were. This is up from the approximate 13% in previous years. This may be attributable to AMTIL’s recent influx of members through the Additive Manufacturing Hub, who do not follow traditional supply chain models and do many one-off projects.

Type Member supplying to:

The average MTU member generates about 29% of their total turnover through IP they own. Exports account for approximately an average 9% of turnover.

Applying this standard deviation to the responses from our MTS members, the average MTS member has a turnover of approximately $7,530,000 and 21 employees, indicating an approximate turnover

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OEM Tier 1 Tier 2 21

30

38

Tier 3 18

Tier 4 Don’t Know 0

17

Ancillary information gleaned from comments during the conversations offered no conclusive trends regarding expectations about business conditions. Most of the conversations centred on consternation around the uncertainty of future opportunities because of the events of 2020.

However, perhaps unsurprisingly, the percentage of members who reported a favourable situation shrank from about 60% last year to 42% this year, while those reporting unfavourable conditions increased from 11% to 27%. www.amtil.com.au

AMTIL INSIDE

Big 3D surprise for 10-year-old Tom Huisman Brisbane boy Tom Huisman got a big surprise on 4 September, when he was given a brand new desktop 3D printer.

Tom has become quite renowned over the last year for his remarkable sculptures, which he has entered in international exhibitions and which have developed a huge online following for his Facebook page: ‘Tom’s Welding Projects’. He first came to AMTIL’s attention when Events Manager Kim Banks saw him on TV being interviewed by Channel Seven about his amazing welding talents.

“At the end of the interview he mentioned that he wants to get into 3D printing next,” recalled Kim. “That’s when I sought out John Croft, the Manager of AMTIL’s Additive Manufacturing Hub, to see if we could do something to help Tom, given his talent and enthusiasm at such a young age.” John got in touch with Hub member Bilby 3D, who were delighted to help, agreeing to donate a printer and filament.

AMTIL member Autodesk also agreed to provide free training for Tom.

The printer was presented at Bilby 3D’s Brisbane branch. Tom arrived with his parents Heidi and Nigel, who had told him that they were only visiting to look at the printers. Tom didn’t know that he would actually be receiving one.

“I was so speechless I didn’t know what to say,” said Tom. “I would like to say a big thanks to AMTIL and Bilby 3D printing for donating a 3D printer as a surprise to me. I am definitely one lucky boy.”

“Tom is a passionate, articulate and talented 10-year-old,” Kim added. “I can’t wait to see what he creates as he hones his skills.”

Tom with the new 3D printer, along with AMTIL Events Manager Kim Banks and Emily Walmsley, Store Manager at Bilby 3D’s Brisbane branch. Bilby 3D’s Chief Operations Officer Lee Bilby also logged in on videolink (centre).

Graeme Sinclair marks 40 years as owner of Parish Engineering Congratulations to Graeme Sinclair and the team at AMTIL member Parish Engineering. In August Graeme celebrated 40 years since becoming Parish’s owner, and he marked the occasion with a message to colleagues in the industry.

On Saturday 15th August, I celebrated 40 years since taking over Parish Engineering. It has been an incredible and rewarding journey with the great changes, developments and tribulations that have occurred in our industry over these 40 years. During this period there has been many recessions, a global financial crisis (GFC) and now the COVID-19 virus.

Despite these difficulties Parish has prospered and survived. I have experienced the growth and the closure of the automotive industry, and a general reduction in manufacturing. However, the manufacturing industry of Australia has managed to improve and survive through all these trials and tribulations.

I know that Parish Engineering would not have prospered during these times without the support of many people and companies.

I have been privileged to have worked with some of the best staff anyone could wish for, and I highly value the wonderful people that have worked for our firm.

Parish has been blessed with the continual support and hard work of many great staff. The majority of our staff have been with us for over 20 years, particularly three staff that have been with us for more than 30 years. I thank them all for their great support and comfort during the good and the bad times.

One of my greatest thrills has been the training and mentoring of over 20 apprentices. I hope that I have had a positive contribution to their careers.

I would like to thank our many great customers and suppliers that have strongly supported us over the 40 years. In particular MTM, which was my first new customer in 1980 and which is still a customer today. Forty years as a customer is a great achievement and I thank the Albert family for their great support and encouragement over this period.

Graeme Sinclair and his daughter, now CEO of Parish Engineering, Nicole Sinclair.

I also wish to thank the many suppliers that have been very much part of the Parish story. Bill Parish, who started in business in 1932, once told me: “There are three things to look after to maintain a successful company: your staff, your customers, and your suppliers.

All are needed to survive.”

I would like to thank all that have been involved with Parish, in particular my first business partner and mentor for 27 years, Julian Lucas, who was a great mentor, and I could not have asked for a better business partner. I now have the greatest of pleasure in observing the development and growth of my daughter, Nicole, in her role as the CEO and my business partner for the last 13 years.

I guess I will not make another 40 years but I will try for as many more years as I can. www.parishengineering.com.au

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Enter a Different Zone: Mike Rolls on Personal Resilience There’s still time to register to hear Mike Rolls’ inspirational tale of personal resilience on 27 October, as the keynote address ahead of AMTIL’s Annual General Meeting.

Going online

In September 2001, aged just 18, Mike contracted one of the deadliest diseases on the planet, meningococcal septicaemia.

His chances of survival were as little as 5%, and the infection left him with horrific internal and external injuries, including the amputation of both his legs. Mike spent six months in hospital, where he was told it could take years to perform even such basic tasks as walking and driving.

This year AMTIL will be holding its AGM online – the first time it has been held as a virtual event. The decision to hold the AGM came in response to the COVID-19 pandemic, as the ongoing requirement for social distancing has made it difficult to organise physical gatherings safely.

The AGM is one of an ongoing series of online events that AMTIL has been running throughout the COVID-19 crisis.

His journey back to health was aided by a positive outlook, an adaptive mindset and a conscious decision to embrace challenge and change. Mike’s accomplishments as a double amputee include running again after many years, representing Australia in golf, climbing one of Australia’s tallest buildings, and supporting other amputees facing similar circumstances.

Mike’s method of building resilience is simple yet effective: what can we take away from our life in order to improve it?

He believes we are all far more powerful than we can ever imagine and must never underestimate our capabilities – a timely message for all of us as we face the continuing challenges posed by the COVID-19 crisis.

Mike’s presentation will take place via the Zoom video conferencing platform from 11.00am (Sydney/Melbourne/Canberra

Our Virtual Meeting webinar series have proved highly popular, covering a wide array of subjects, encompassing COVIDsafe workplaces to the government support options available, and from employee wellbeing to ways that manufacturers can help combat the pandemic. Our next Virtual Meeting event will be held on 15 October, in which AMTIL corporate partners William Buck and Interlease will explore the theme ‘Thriving in business, after the dust has settled’. time) on 27 October, with AMTIL’s AGM following directly afterwards. The event is free for AMTIL and AM Hub members, though registration is essential. This event is generously sponsored by AMTIL’s corporate partners: BMS Group; Interlease; Rigby Cooke Lawyers; SternaGL; and William Buck.

To register for Mike Rolls’ presentation and AMTIL’s AGM, or for more information on any of the webinars in our Virtual Meetings series, please visit the Events page of the AMTIL website. www.amtil.com.au/events

SternaGL – Speedy delivery for SPEE3D As an AMTIL corporate partner, Sterna Global Logistics (SternaGL) is on hand to offer our members a range of specialist freight services. One company that has recently taken advantage of this member benefit is SPEE3D. In the last edition of AMT, we covered a recent field exercise by the Australian Army to test out a WarpSPEE3D metal 3D printer in the Northern Territory (page 100, AMT Aug-Sep 2020). When it came to getting the printer to the Army in Darwin, SPEE3D turned to SternaGL for help – and SternaGL shared a few photos of the delivery in progress. www.spee3d.com www.sternagl.com

The printer on its way

AMT OCT/NOV 2020

Onsite in the Northern Territory

AMTIL INSIDE

New members AMTIL would like to welcome the following companies who have signed up as new members of our association.

A SEASON TO FORGET?

The 2020 season began without any crowds, postponed and then rebooted to all parts of Australia except at the home of football, Victoria – did it really matter?

It certainly did to the mighty Nick Sear who managed to convincingly come away with the coveted prize and bragging rights of AMTIL Footy Tipping Champion for 2020 – well done to you mate!

Congrats also go to the bridesmaids Tungaloy Australia and TWJ as they sit on the lower levels of the podium. Highlights, lowlights with everything in between was served up in a compromised season where many teams found it difficult to get any momentum. Most AFL Finals will be played in the Sunshine State where it will be good to see actual crowds contributing to the atmosphere. Who will stand on the 2020 top deck with Nick? For me it's the Tigers to lose, or maybe the Lions bag it at home, don't dismiss the Power leading from start to finish. One thing for sure, let's bank this season into the archives… over and out for 2020, Sanchez.

ROUND 18 1 Nick Sear MIIB Ins 2 Tungaloy Australia 3 TWJ 4 Brendan 5 Adrian C 6 Mottdiggitydog 7 Lem 8 Daniel Fisher 9 The 2 K's 10 DM

113 (427) 110 (410) 109 (412) 109 (421) 109 (463) 107 (463) 107 (465) 107 (501) 106 (459) 106 (492)

ADDITIVE ASSURANCE PTY LTD 22 Alliance Lane Clayton VIC 3800 www.additiveassurance.com

PINCHES INDUSTRIES PTY LTD 21 Malua Street Reservoir VIC 3073 www.pinches.com.au

COLUMBIA AUSTRALIA PTY LTD 2-4 Philip Street Cheltenham VIC 3192 www.columbia-aus.com.au

SIEMENS INDUSTRY SOFTWARE 885 Mountain Highway Bayswater VIC 3153 www.sw.siemens.com

CONRY TECH DEVELOPMENT PTY LTD 3/42 Ramset Drive Chirnside Park VIC 3116 www.conrytech.com

TEC FIT 20 Macquarrie Street Prahran VIC 3181 www.tec.fit

ELEXON ELECTRONICS 7/253 Leitchs Road Brendale QLD 4500 www.elexonelectronics.com

X-PRODUCT 35 Collins Street Melbourne VIC 3000 www.xproduct.com.au

Real Business.

Real People.

Real Benefits.

Call AMTIL’s Membership Manager David Mohorovicic on 03 9800 3666 to learn how your business can be part of the leading Advanced Manufacturing association in Australia. www.amtil.com.au

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INDUSTRY CALENDAR Due to the ongoing coronavirus pandemic, many industry events world-wide have been postponed, rescheduled or cancelled, while both domestic and international travel has been severely disrupted. Readers are advised to check direct with all event organisers for the latest information. For up-to-date advice on coronavirus, visit: www.health.gov.au/healthtopics/novel-coronavirus-2019-ncov. For more events, please visit www.amtil.com.au INTERNATIONAL MECSPE Italy, Parma 29-31 October 2020

RAJKOT MACHINE TOOLS SHOW India, Rajkot 1-4 December 2020

INDUSTRIE PARIS France, Paris 16-19 March 2021

www.mecspe.com/en

www.kdclglobal.com/events.html

www.industrie-expo.com/en

CEMAT ASIA China, Shanghai 3-6 November 2020

AUTOMATICA Germany , Munich 8-11 December 2020

AI EXPO Japan, Tokyo 7-9 April 2021

www.cemat-asia.com

www.automatica-munich.com/en

www.ai-expo.jp/en-gb.html

ITM INDUSTRY EUROPE Poland, Poznan 3-6 November 2020

VIMM -VIETNAM INTL METALWORKING Vietnam, Ho Chi Minh City 9-12 December 2020

HANNOVER MESSE Germany, Hannover 12-16 April 2021

www.itm-europe.pl

http://vimm-isme.vietfair.vn

www.hannovermesse.de/en

MTA VIETNAM Vietnam Ho Chi Minh City 4-7 November 2020

IMEX India, New Delhi 17-19 December 2020

www.mtavietnam.com/en-us

www.imexonline.com

INNOTRANS 2020 Germany, Berlin 27-30 April 2021 Intl. trade fair for transport technology.

METALTECH Malaysia, Kuala Lumpur 10-13 November 2020 www.metaltech.com.my

MOSCOW INTERNATIONAL TOOL EXPO Russia, Moscow 10-13 November 2020 www.mitexpo.com

FORMNEXT Germany, Frankfurt 10-13 November 2020 Additive manufacturing event www.formnext.de

SIAMS Switzerland, Moutier 10-13 November 2020 Microtechnology exhibition www.siams.ch/the-trade/presentation

ANNOFER Turkey, Istanbul 12-14 November 2020 www.annofer.com

GRINDTEC Germany, Augsburg 10-13 November 2020 www.grindtec.de/en

CHENGDU INTL INDUSTRY FAIR China, Chengdu 18-20 November 2020 www.cdiif.com

METALEX Thailand, Bangkok 18-21 November 2020 www.metalex.co.th

BIEMH Spain, Bilbao 24-26 November 2020 http://biemh.bilbaoexhibitioncentre.com

AMT OCT/NOV 2020

2021 STEELFAB Arab Emirates, Sharjah 11-14 January 2021 www.steelfabme.com

AMTEX India, New Delhi 20-23 January 2021 www.amtex-expo.com

SMART FACTORY EXPO Japan, Tokyo 20- 22 January 2021 www.sma-fac.jp/en

ALL ABOUT AUTOMATION HAMBURG Germany, Hamburg 20-21 January 2021 www.automation-hamburg.com/de

MACH UK, Birmingham 25-28 January 2021 www.machexhibition.com

ADVANCED MANUFACTURING/SUBCON UK, Birmingham 26-28 January 2021 www.advancedmanufacturingshow.co.uk

THAILAND INDUSTRIAL FAIR Thailand, Bangkok 27-30 January 2021 www.thailandindustrialfair.com

EXPO MANUFACTURA Mexico, Monterrey 2-4 February 2021 www.expomanufactura.com.mx

EUROBLECH 2020 Germany, Hanover 9-12 March 2021 www.euroblech.com

www.innotrans.com

FABTECH MEXICO Mexico, Monterrey 4-6 May 2021 Chicago: 13-16 September https://mexico.fabtechexpo.com

METALLOOBRABOTKA Russia, Moscow 24-28 May 2021 www.metobr-expo.ru/en ROSMOULD Russia, Moscow 15–17 June 2021 www.rosmould.com

IMTEX/TOOLTECH India, Bengaluru 17-23 June 2021 www.imtex.in

INTERPLAS UK, Birmingham 29 June-1 July 2021 www.interplasuk.com

VIETNAM MANUFACTURING EXPO Vietnam, Hanoi 11-13 August 2021 www.vietnammanufacturingexpo.com

EUROSURFAS Spain, Barcelona 14-17 September 2021 www.eurosurfas.com

TOOL TECH Korea, Goyang 19-22 October 2021 www.tooltechkorea.com

PLASTEC USA, Minneapolis 3-4 November 2021 Plastics Industry Trade Fair and Conference http://plastecminn.plasticstoday.com

INDUSTRY CALENDAR HEADING LOCAL DESIGNBUILD MELBOURNE, MCEC 11-13 MAY 2021 Trends and strategies shaping the architecture, building, construction and design sector.

WA MINING CONFERENCE & EXHIBITION PERTH CONVENTION & EXHIBITION CENTRE 11-12 NOVEMBER 2020 Theme: "Accelerating WA's Mining Future to 2030". The expansion of remote and deeper mines will have a direct impact on activity and productivity costs. Includes case studies, seminars and panel sessions.

www.designbuildexpo.com.au

LAND FORCES 2021 BRISBANE CONVENTION & EXHIBITION CENTRE 1-3 JUNE 2021 Showcasing equipment, technology and services for Australian and Indo-Asia-Pacific armies. Key decision-makers, enabling government representatives, defence officials, military procurement managers and senior army officers to network with defence materiel manufacturers, equipment suppliers and service providers.

www.waminingexpo.com.au

AUSTRALASIAN WASTE & RECYCLING EXPO Interactive online event 25-26 November 2020 Reimagined as an interactive online event. Premier event for the waste, r ecycling and resource recovery sector. www.awre.com.au

www.landforces.com.au

2021

www.expotradeglobal.com/events/ victransport

www.cospar2020.org

SAFETY IN ACTION (VIRTUAL) SYDNEY, ICC 23-24 MARCH 2021 Australia’s leading workplace OHS event.

Includes seminars, small-group consultations and three co-located conferences exploring safety, wellness and the return to work of injured employees.

Adfoam

69

Applied Machinery

25

Austral Wright

19

Automated Solutions

53

Bilby 3D

85

BJC Machine Tools

17

BMS Risk Solutions

101

Bystronic 120 Complete Machine Tools

21

DMG MORI

15

Elexon electronics

79

Empower Software

59

Export Finance Australia

FLAP

Hare & Forbes

4-5

IMTS

13, 87

Industrial Laser

9

Interlease

93

Intermach 51

VICTORIAN TRANSPORT INFRASTRUCTURE CONFERENCE 2021 MELBOURNE, MCEC 16-17 JUNE 2021 Discussing the prioritisation, planning and delivery of critical transport infrastructure across the state. Topics covered:Transport, Ports, Roads, Railways & Airports.

COSPAR: SCIENTIFIC ASSEMBLY OF THE COMMITTEE ON SPACE RESEARCH SYDNEY 28 JANUARY-4 FEBRUARY 2021 Combines the latest in space research findings with activities to enrich the global space research community,including helping equip our future leaders, and workshopping with space industry to inspire the next generation of scientists and engineers.

Advertiser Index

Iscar 2-3 John Hart

37

LaserThings 63 Linear Technik

57

M Gamer

71

Machinery Forum

119

MTI Qualos

35, 75

New Forge Engineering

47

New Touch Industries

41

Okuma 7

FOODPRO SYDNEY SHOWGROUND 25-28 JULY 2021 Includes the technology and innovations to shape the future of food processing and packaging and solutions for a more sustainable world. Six zones: Ingredients, Food Science & Technology, Processing Equipment, Plant Equipment, Packaging and the new Supply Chain Integrity Zone.

Phoenix PLM

65

Rigby Cooke

95

Ronson Gears

31

www.foodproexh.com

William Buck

www.safetyinaction.net.au

Sandvik 27 Sheetmetal Machinery

11

Sterna 99 Sutton Tools

91

Techni Waterjet

39

Thyssenkrupp 23 73

Air Liquide

Insert

Sheetmetal Machinery

Insert

YOUR INDUSTRY. YOUR MAGAZINE. AMT OCT/N OV20

SUPPORTING AUSTRALIAN MANUFACTURING

DEC JAN 2021

OCT NOV 2020

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SENSORS & PROCESS CONTROL PLASTICS MOTORS & DRIVES WELDING CUTTING TOOLS FORMING & FABRICATION MATERIAL REMOVAL

AMT OCT/NOV 2020

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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 39

MISSION X (Part 1)

It is January 1942, and the Japanese are racing towards Singapore, whose fall is imminent. A precious horde of precision machine tools, located in Singapore must not fall into the enemy’s hands. Sir Laurence volunteers to make the dangerous journey north to rescue them.

T

The letter in my wallet was quite explicit. It said I could spend £500,000 of Australian Government money how I liked, and if I wanted more, all I had to do was cable for it. I could make any commitments, enter into any deals, and no questions would be asked.

I had bags of gold and silver coins, thick bundles of U.S. dollars, Dutch guilders, Portuguese escudos.

No private citizen had ever left Australia armed with such complete authority over such a large amount of the nation's cash.

But then, to my knowledge, no private citizen had ever gone off on a mission for Australia that was quite so desperate – and quite such an obvious gamble – as this one.

It was late January 1942, and the Japanese were racing down the Malay Peninsula, sweeping everything before them. They were heading for Singapore, and so was I. I was flying north in a R.A.A.F. flyingboat, at a time when every other private citizen with any sense was heading away from Singapore. My mission was to get to Singapore before the Japanese, and beat them to the richest war-industry plum in South-East Asia: the magnificent collection of precision machine-tools, worth at least £5 million, in the Royal Navy workshops at Seletar, on Singapore Island. How I would get such a huge amount of machinery out of Singapore ahead of the Japanese, I had only a vague idea. But money can work miracles, and I had plenty of that. There was a half­ formed scheme in my mind to commandeer the huge floating dock, load the stuff on it, and, somehow or other, tow it south to Australia and safety.

What a crazy scheme it was! But, in those times, the maddest plans sometimes came off. This one simply had to be attempted.

had not yet started. And in Singapore was the answer to our most serious machinetool problems. No machine-tools means no munitions. From Australia's war production point of view, the loss of those machines to the enemy would be as great a disaster as the fall of Singapore itself.

I had felt for weeks that Singapore was doomed. I knew it first when I met AirMarshal Brooke-Popham, the tall, gaunt G.O.C. of British forces in Malaya, who paid us a flying visit just after the Japanese had invaded Malaya. The man was obviously depressed. He walked around my office, his manner distant and distraught. "Look, we're in a pretty poor plight," he said. "We must get more arms and equipment. What have you got that we could have?" I suggested the best thing we could send was a supply of two-inch and three­inch trench mortars.

But he didn't seem very interested. He didn't rate his chances high even then. We agreed to arrange the shipment of a supply of mortars, with ammunition, on top priority.

He left my office, still in his distant, worried state. The poor fellow was up against it and he knew it.

Then I began to get copies of cables sent urgently by General Gordon Bennett, commanding the Australian Eighth Division in Malaya. He was pleading for arms of any kind. As the situation in Malaya worsened, it seemed quite obvious that Singapore

could not be held. I began to think more and more seriously about the Royal Navy's beautiful workshops at Seletar in Singapore. Australia had been sending supplies there - items such as hexagon brass, steel plates and rods and one such consignment had been assembled and was even then awaiting transport. How utterly stupid it was! With the Japanese on the doorstep we were still sending raw materials to Singapore.

I suggested to my Minister Norman Makin that instead of us sending raw materials to Seletar, we should be trying to get the machinery out. I begged the Government to do everything possible to save the precious machine-tools. For a week I awaited an answer. The frustration was almost killing me. Daily the Japanese came closer and closer to Singapore; hourly, our chances of rescuing the equipment became slimmer.

Finally I was summoned to a meeting with the War Cabinet, in Victoria Barracks, St.Kilda Rd. Melbourne. I outlined my plan to load the machine-tools on to the Royal Navy floating dock and tow the lot home to Australia. "Would you do it?" I was asked.

"I'd like to have a go at it," I replied. "I used to live in Singapore. I speak Malay”. “All right" they said. "When would you go?"

"There's no time to lose" I said. "I could go right now”.

As Director of Ordnance Production, one of my biggest handicaps was the lack of precision machine tools. LendLease, upon which we were to rely heavily before the war ended,

Japan invaded and captured the British stronghold of Singapore on 15 February 1942. It was considered the largest British surrender in history.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT OCT/NOV 2020

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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