AMT OCT/NOV 2021

OCT NOV 2021

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CONTENTS

Volume 21 Number 05 OCT/NOV 2021 ISSN 1832-6080

FEATURES TRANSPORT & LOGISTICS TRANSPORT: Driving the economy, delivering jobs Bombardier: On track for efficient production Locally manufactured hybrid school buses Trucking industry begins to turn electric AM Hub case study: Cobalt Design

44 48 50 52 54

CUTTING TOOLS Iscar: Beneficial modularity Mecaprec: Flying high with Seco Why manufacturers should embrace new tooling

56 59 60

ADDITIVE MANUFACTURING Medical applications expand limits of 3D printing Next-gen 3D-printed catalysts propel hypersonic flight Postive signs for Addeva

62 63 66

FORMING & FABRICATION Frontline Manufacturing –New Deratech press brake OMAX: The recipe for faster cutting

68 71

STATE SPOTLIGHT QLD Samin Sheet Metal –New Amada Ensis laser All types of solutions for Alltype Engineers Manufacturing in QLD? That’s surely worth a gold medal!

76 78 80

WELDING Laserline: Welding copper with a diode laser A gas-led recovery will not work

84 86

QUALITY & INSPECTION Tool presetters: the key to boosting quality & productivity ZYGO Nexview 650 – Large-format inspection/metrology

90 91

SOFTWARE The new cybersecurity imperative in manufacturing Manufacturing insights for all New technology in a skills shortage Major time savings with ESPRIT CAM

92 94 95 96

MATERIAL REMOVAL Adarsh expands with Okuma machining centre Eilbeck: Smooth commissioning with Applied’s support

97 98

BUSINESS MANAGEMENT What makes a great Operations Manager?

Aussie manufacturing resurgent, but needs help Australia manufacturers: Apathetic, too busy or just fed up?

Modern manufacturing trends in supply chains

100 102 104 106

REGULARS From the Editor From the CEO From the Industry From the Union

8 10 12 14

INDUSTRY NEWS: Current news from the Industry

16

44 TRANSPORT: Driving the economy, delivering jobs The transport sector is creating big opportunities for manufacturers across Australia. Alstom is bringing rail manufacturing back to WA, while in Brisbane, HC-ATM is assisting truck companies through innovative design.

68 Frontline Manufacturing – Reinforcing capability Frontline Manufacturing aims to establish Australia as a hub for military-grade armour-plate products.

In a massive project, CMTS helped Frontline procure a Deratech Ultima press brake amid the “minefield” of COVID.

72 One-on-One: Cori Stewart Associate Professor Cori Stewart, Chief Executive Officer of the ARM (Advanced Robotics for Manufacturing) Hub in Queensland, spoke to AMT.

82

VOICEBOX: Opinions from across the manufacturing industry 30 PRODUCT NEWS: Selection of new and interesting products 36 ONE ON ONE: Cori Stewart

72

COMPANY FOCUS: Marsh Alliance – Springing into action

82

AMTIL FORUMS

108

AMTIL INSIDE: The latest news from AMTIL

112

MANUFACTURING HISTORY: A look back in time

118

AMT OCT/NOV 2021

Marsh Alliance – Springing into action Many companies looking to bring production home have been surprised by what capacity still exists here in spring and pressed parts manufacturing. Marsh Alliance – a leading manufacturer of this underappreciated, yet vital, component - plans to grow what it has here.

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008

FROM THE EDITOR WILLIAM POOLE

Turning the boat around There’s been lots of news since the last AMT: Christian Porter’s resignation; COVID lockdowns, riots, and the debate over workplace vaccine mandates; the Victorian earthquake… plus there’s the business with the submarines.

For anyone who missed it, in September the Federal Government announced plans to shelve its troubled $90bn submarine contract with French company Naval Group, instead building a fleet of nuclear-powered subs in partnership with the US and the UK. Prime Minister Scott Morrison announced the switch as part of AUKUS, a new trilateral pact under which the three countries would collaborate on security initiatives in the Indo-Pacific.

The move was widely interpreted as a bid to counter China’s growing influence in the region. Very few people saw the announcement coming, and it raised a lot of questions.

From a strategic perspective, there were questions about the cost of the new plan, which is set to exceed that of the French program, which had already gone substantially overbudget, and which would also entail a substantial fee to break the contract. The new plan would also deliver fewer boats – eight, down from 12. With the first vessel not expected to enter service till the 2040s, it would entail a prolonged gap in our military capability, extending our dependence on the aging Collins Class fleet.

Some questioned the wisdom of equipping ourselves with long-range submarines for a US-led confrontation with China – arguing that for the same cost we could assemble a much larger fleet of cheaper vessels designed primarily to defend Australia and our neighbours. There were questions over how our strategic priorities might change by 2040, and whether China would still be seen as our prime rival. There was even speculation that ongoing advances in sensor technology might render submarines obsolete by the middle of the century anyway.

Military issues aside, the move had an impact on international relations. China, unsurprisingly, interpreted it as a provocation, while France voiced outrage over the cancellation of the Naval Group contract. This in turn will have trade implications. China is Australia’s number one export market, and our relation there was already tense. Now the French are threatening to scupper negotiations for a free-trade agreement between Australia and the EU. And obviously, trade implications mean implications for the Australian economy, and for Australian manufacturing.

And there are inevitably huge questions for Australian manufacturers. Morrison has insisted the new submarines will still be built in Adelaide – as with the French program. But first there must be an 18-month investigatory period to determine a “pathway” for the build – yet another delay in what has already been a stop-start process. Numerous Australian manufacturing companies who have made significant investments in preparation to supply the French program have been left in limbo – as have the hundreds of employees at Naval Group’s Adelaide facility.

Complicating matters further, Australia’s capability and expertise around nuclear technology are limited, and much of the IP on the new subs – specifically their propulsion systems – is likely to be zealously guarded by our AUKUS partners. The French program was already plagued by disputes with Naval Group over local content requirements, and it seems the new plan will see even greater curbs on supply chain opportunities for Australian manufacturers. Moreover, it will lock us into a long-term dependence on the US and the UK for maintenance support.

Ever since the carmakers left Australia, defence has frequently been touted as a replacement for automotive as the bedrock on which to build our sovereign manufacturing capability. It’s hard to see how this deal supports that. It’s hard to see how it supports our sovereign defence capability either.

Editor William Poole wpoole@amtil.com.au Contributors Carole Goldsmith Sales Manager Nicholas Raftopoulos nraftopoulos@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia using PEFC™ Programme for the Endorsement of Forestry Certification Chain of Custody certified from sustainable forests Contact Details AMT Magazine AMTIL Suite 10, 5 Corporate Boulevard Bayswater VIC 3153 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.

1570AMTOCTNOV2021

AMT OCT/NOV 2021

010

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

The people have backed manufacturing; what about the politicians?

The Australian people have become increasingly conscious of the need for this country to have a robust local manufacturing base. We just need politicians to give it the support it deserves.

Since the very start, the COVID-19 pandemic has been a wakeup call for Australia regarding our attitudes to manufacturing. From supermarket shelves stripped of toilet paper to the mad rush to establish local production of medical ventilators, we all got a clear lesson about the vulnerability of modern supply chains and the need for strong sovereign manufacturing capability, so that we have continued access to all the things we rely on as a society.

According to the AMGC data, manufacturing contributes more than $100bn to the local economy each year, amounting to 10% of gross domestic product (GDP). That’s significantly higher than the figure we often hear quoted – of 6%. The data also finds that manufacturing directly employs 1.27m Australians, 30% higher than official figures; in addition it creates 3.6 indirect roles elsewhere in the economy for every direct manufacturing role.

As the pandemic has dragged on, one of the few positives to come out of the crisis was the sense that there was at last widespread public recognition that manufacturing really matters.

The AMGC report is a vital piece of research. It highlights the crucial role played by manufacturing in the Australian economy.

In fact, it reveals that our industry delivers even more value to the nation than we had previously believed. But most importantly, it shows that ordinary Australians realise more clearly than ever that manufacturing is a sector that Australia needs, and that we need to invest in making it stronger.

Now new research has corroborated this, putting real numbers on how far the popular mood has swung in support of our industry.

The report from the Advanced Manufacturing Growth Centre (AMGC) reveals the general public’s current perception of Australian manufacturing and its understanding of this critical industry.

Comparing data from early 2019 – before the pandemic – to today, the AMGC examined the contrasting levels of public awareness and the changing attitudes toward local manufacturing. It found that support today is significantly higher compared to pre-pandemic times. The study shows that manufacturing is held in high regard by the public, is seen as vital to our nation’s economy, and is critical to maintaining our high standards of living.

The question now is: are our politicians getting the message? Are they doing enough to support the industry?

Key findings from the report include:

To be fair, there are a lot of very good initiatives coming out of government at the moment. The Federal Government’s Modern Manufacturing Strategy contains a whole raft of measures that will deliver genuine benefits for manufacturing businesses. There are plenty of other worthwhile federal initiatives as well – the AMGC being one of them. And state governments also have lots of good policies in place to support the industry.

• 72% (+7% from 2019) of Australians believe manufacturing is important or very important to the economy.

But there endures a lingering sense that manufacturing remains a “second-order” priority among political circles.

• The number of respondents who believe manufacturing will get stronger in the coming years has doubled compared to responses in 2019.

Last month, Christian Porter’s resignation marked the departure of a seventh person to hold ministerial responsibility for industry in eight years of this Coalition Government. Porter followed Ian Macfarlane, Christopher Pyne, Greg Hunt, Arthur Sinodinos, Michaelia Cash and Karen Andrews, and spent a mere five months in the role.

Obviously his departure could not be avoided, but the fact is the controversy that drove Porter from office had dogged him from the start. Moreover when he arrived in the job there was the distinct sense that he had been in some way “demoted”, handed a “less important” portfolio to allow him to deal with his personal issues.

• 79% of Australians perceive the trade and export of manufactured goods are important to the economy.

• Tasmania, Northern Territory, South Australia, and Western Australia rate manufacturing more highly than the Eastern States.

• The importance of manufacturing is rated more highly in regional areas, compared to metropolitan areas.

• 69% (+6% from 2019) of Australians believe manufacturing is important to maintain our standard of living.

• Manufacturing is perceived as the seventh-most important industry to the Australian economy relative to other industries.

• The appreciation of manufacturing and its importance increases with age – for example, approximately 85% of Australians over 65 agree manufacturing is important to the local economy.

• 80% of Australians believe it is important to purchase local products where possible.

• 63% believe these products are of higher quality and 58% noted that locally made products were worth paying a premium for.

• Almost half of the respondents view Australian manufacturing as high-tech and globally competitive.

AMT OCT/NOV 2021

At time of writing, Angus Taylor has been made Acting Minister for Industry, Science and Technology, while continuing to serve in the equally important role of Minister for Energy and Emissions Reduction. By the time you read this, Prime Minister Scott Morrison may have announced a longer-term replacement. But as things stand, it’s hard to escape the sense that our industry has essentially been left to fend for itself, at a time of when the sector is facing sigificant uncertainty on several fronts – from the recent dramatic overhaul of our submarines program, to the ongoing COVID-19 crisis. And all this with only a moonlighting resources minister watching over us from Canberra.

Manufacturing deserves better – ask the Australian public.

The full report from the AMGC can be downloaded here: www.amgc.org.au/wp-content/uploads/2021/09/AMGC-PublicPerceptions-Report-2021.pdf

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FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Beginning of the end of the COVID crisis?

Hopefully, and especially given the changing attitudes towards living with COVID-19 seen in our two largest states, the beginning of the end of this crisis may be in sight.

Ai Group has been relentless in arguing on behalf of our members and business generally for governments to take a more targeted approach to COVID-19 restrictions and move towards living with the virus – as they now appear to be doing. Every day I hear from members about how they are dealing with COVID-19.

Frustrations around closed national and state borders tops the list of barriers to business. The effective closure of our international borders is having a serious impact on many businesses, especially as they see the rest of the world opening up and their competitors travelling freely.

We saw some welcome announcements from the Federal Government in September on preparations for our international border opening, but free movement will be strongly dependent on vaccination rates and the states coming on board. The Prime Minister has spoken of beginning to open up when vaccination rates hit 70% and 80%, and home quarantine will then become the norm pending successful state trials.

Until this happens, challenges remain – including the need for exit approvals, and flights prone to cancellation – and few businesspeople to date have been prepared to endure two weeks hotel quarantine.

We are consulting governments on how the reopening will be achieved and stressing the importance of business travel to our economic recovery.

In discussions with governments on borders we have urged them to: • Allow fully vaccinated business travellers the automatic right to depart and return to Australia.

• Allow fully vaccinated Australian business travellers, business visa holders and returning Australians who pass a COVID-19 rapid test on arrival, and at regular intervals after arrival, to home quarantine in all states and territories – as is being trialled in South Australia.

• Remove the travel arrival quota for fully vaccinated business travellers and business visa holders and returning Australians.

The current vaccination trajectory should see these ambitions achievable by Christmas.

On state borders, once New South Wales (NSW) and Victoria open up to each other and the world, inevitably the other states will follow suit, especially when the target vaccination rates are reached.

We are also arguing for national consistency for the Health Pass that will be used as proof of vaccination status, and which would, for example, provide access to workplaces where vaccines are mandated, for major events and for international travel. Consistency is important as we don’t want the complexity of the states and territories all having different requirements. We are urging governments to limit its use as much as possible. The passes should also have a limited shelf life. Once the highest levels of vaccination are reached they may not be necessary – as has been found with the UK dropping vaccine passport plans altogether.

We have been big supporters of the vaccine roll-out and the need for governments to help businesses who want to host workplace-based vaccinations. On this we had a win recently with the Government agreeing to set up a COVID-19 Vaccination Claim Scheme. This Scheme aims to provide a simple, streamlined process to reimburse/ compensate eligible people for “injuries” associated with COVID-19 vaccinations, including in the workplace, without the need for legal

AMT OCT/NOV 2021

proceedings. It will assist in protecting employers from claims by employees in such circumstances.

I have also been a strong supporter of Rapid Antigen Testing, highlighting that while such tests are a valuable workplace safety resource for businesses, when governments require employers to use such testing on workers in certain circumstances, then they should be provided free to businesses. The tests should be made available for home use and the restrictive requirement for supervision of these tests removed as soon as practically possible.

Whether or not to mandate the vaccine in workplaces is also another issue on which we have been leading the case for employers. The clarity around the circumstances in which mandating vaccination would be lawful and reasonable that has now been provided by the Fair Work Ombudsman is a valuable resource for members thinking of going down that track. We have been helping many members with advice on mandating, and one of our own surveys found that more than half of businesses are considering that approach in some form.

Ai Group members tell me that another of their biggest concerns is the need to rebuild confidence based on consultation, certainty and the consistent application of state-by-state restrictions and requirements. We are taking that message to government and seeking clearer communication on the timing and application of new requirements imposed on businesses.

Finally, we are talking to governments at all levels on the need for consultation and support for businesses to help us exit COVID successfully, with a focus on business recovery initiatives around investment, creating jobs, reskilling and productivity.

Based on what we saw after restrictions ended last year, if the current progress with vaccinations across the country continues, there is every reason to believe that the December quarter will see a strong economic rebound.

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014

FROM THE UNION STEVE MURPHY – National Secretary Australian Manufacturing Workers Union

It’s time to have our say on what the future of our industry looks like Recently, the Senate announced that it would be holding an inquiry into the future of manufacturing in Australia.

As everyone reading this will be aware, it is not the first time that this topic has been looked into by the Senate, but the time is right for some real action to support our industry.

While other nations around the world are moving Heaven and Earth to protect, grow and diversify their manufacturing sectors in response to the challenges highlighted by COVID, the Morrison Government has sat on its hands.

The Government’s response to the biggest peacetime disruption of global supply changes has been to do more of the same. Despite its pricetag, the $1.3bn Modern Manufacturing Initiative is little more than a rebranding of the approach that has seen Australia become one of the least self-sufficient developed countries in the world for manufactured items. At best, this program tinkers at the edges – but it is hard to know exactly because nearly a year after it was announced, less than $100m has actually been committed!

It’s just not good enough – we can’t keep doing the same thing over and over again and expect to get a different result.

The AMWU and business leaders joined with the Federal Government at the start of the COVID-19 crisis to help protect our industry. We engaged with the Government in good faith because even blind Freddy could see how important a domestic manufacturing was going to be with the world in crisis.

As is now well publicised, the manufacturing taskforce was overtaken by advocates for a gas-led recovery, not a manufacturingled recovery. It was a slap in the face for the manufacturing workers who kept the shelves in our supermarkets stocked with the items that families and businesses needed during COVID-19.

So, once again, we’re back at the drawing board, looking to chart a new, bold course to grow our industry, deliver jobs and ensure our country is never caught short in a crisis ever again.

It is important that our industry shares the same vision for the future, so I encourage everyone to get involved in the Senate inquiry. For our part, the AMWU’s contribution will be focused on our members’ stories and their vision for the future. Since becoming the national secretary I’ve spent a lot of time listening to our members around the country, and in my view they are the best advocates for our industry. They’re skilled, passionate, and – most importantly – they love the work they do.

I want our policymakers to see the manufacturing industry through their eyes, to understand what it means to the workers it employs and the communities that it supports. Too often, industry policy has been focused on the latest and greatest at the expense of improving what we already do.

There are currently more than 900,000 manufacturing workers in Australia, despite decades of policy neglect. If we were able to achieve a level of self-sufficiency – to make and export as much as we import (something achieved by counties like Spain, France and New Zealand) we would create 400,000 more direct manufacturing jobs and a further 265,000 in the supply chain. That can only be achieved by building our existing small and medium businesses into large, thriving exporters.

Our members want Australia to be at the top of the queue in emerging industries like lithium batteries, green hydrogen, green steel and a whole range of emerging Industry 4.0 technologies – but they don’t want us to forget about the important work they’re already doing.

AMT OCT/NOV 2021

We need every manufacturing business in Australia to be investing in new technologies, new ways of doing business and constantly improving the skills of their workers.

We need workers who are confident and secure in their jobs, working productively with the best capital equipment money can buy.

We need a Government with the vision and commitment to make that happen.

Our members tell us that they don’t think the current approach is working because it sees their taxes spent buying products offshore that could be purchased here. They tell us that we’re not doing enough to support skill development – from apprenticeships to upskilling experienced workers.

The AMWU is acutely aware of the potential impact of climate change on our industry now and into the future. From disruption to supply chains and competition for resources on one end of the scale, to the potential for carbon tariffs being at the other.

The lack of leadership from our Federal Government has increased the climate-change risk to our industry, when it could be a huge opportunity to create jobs. Australia has been a huge exporter of energy for generations and with the right support, we can continue doing just that in a carbon-free future.

We want to see Australia’s energy transition support growth in manufacturing. Domestically, our access to limitless, cheap, renewable energy should make us an ideal place to invest in energyintensive manufacturing. Combined with our natural advantages in energy production, we should be on track to be increasing our exports of energy and renewably manufactured materials, even as the world transitions to net-zero emissions.

Sadly, that hasn’t happened – but we believe it can.

There is so much potential for our industry, but we need the government’s support to unlock it. That is why we’re working with the Senate inquiry to share our vision of hope for the future, and we encourage you to as well.

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INDUSTRY NEWS

AMTIL announces changes to Australian Manufacturing Week 2022 exhibition AMTIL on 10 September announced changes to the schedule for next year’s Australian Manufacturing Week (AMW) exhibition, relocating and rescheduling the event from Melbourne in March to Sydney in June.

Amid uncertainty over the latest COVID-19 outbreak, the AMTIL Board decided in early September not to proceed with the AMW 2022 exhibition that had been scheduled to take place at the Melbourne Convention & Exhibition Centre (MCEC) from 8-11 March. With the Melbourne event not going ahead, AMTIL has instead confirmed that AMW 2022 will take place at the International Convention Centre Sydney (ICC Sydney), running from 7-10 June 2022.

AMW 2022 in Sydney has drawn an encouraging show of support from the industry. Bookings for the show have been very strong, with 85% of the floorspace already sold.

The decision not to proceed with the AMW exhibition in Melbourne in March was taken in response to the ongoing COVID-19 outbreak in Victoria and the resultant uncertainty over the viability of large public events so early in 2022.

“The AMTIL Board made the very difficult decision not to proceed with the show in its current March 2022 timeslot,” said Shane Infanti, Chief Executive Officer of AMTIL. “Despite the great support we have for the exhibition from all our exhibitors, recent developments relating to the COVID-19 Delta strain have created an unpredictable environment that we felt had the potential to seriously jeopardise the event given that it is so early in the New Year.”

Following the decision, AMTIL began moving forward in exploring plans for a rescheduled event to take place later in the year in a different location. The ICC Sydney was secured as a venue for AMW from 7-10 June. AMTIL is confident that by June the current

COVID-19 outbreak will have been contained, and high vaccination levels will allow the staging of large public events. Infanti explained: “The AMTIL Board felt that the return of exhibitions is an important step in our COVID recovery plan and that there remains a very strong appetite for a show at some stage in 2022. We explored a number of options in regard to shows over the coming two years.

“Running AMW in June at the ICC Darling Harbour would represent a return to Sydney since we last ran Austech there in 2012, and reflects strong local demand for a significant manufacturing event.

We are confident that the COVID-19 implications for an event mid next year will be minimal.”

Looking further ahead, AMW 2023 will also take place in its usual May timeslot in Melbourne, running from 9-12 May 2023 at the MCEC. Infanti added: “This is planned to be one of the largest exhibitions of its type in the Southern Hemisphere. We are truly excited to be bringing this to the Australian manufacturing sector.

For both of these events, the industry can be confident of receiving the same great support and service that manufacturers have come to expect from AMTIL over 20-plus years of running trade shows.”

Owned and operated by AMTIL, AMW is Australia’s premier manufacturing solutions event, an industry exhibition encompassing all aspects of manufacturing in Australia. Since 2000, AMTIL has operated Austech, Australia’s premier advanced manufacturing and machine tool exhibition, which going forward has now been incorporated into the AMW exhibition. www.australianmanufacturingweek.com.au

Boeing, RMIT partner on space manufacturing capability RMIT University and Boeing have entered a partnership at developing and growing Australia’s space manufacturing.

The partnership announced on 15 September involves projects on product design strategy, materials research and process innovation. These collaborations will harness global networks and expertise to develop local solutions for the manufacturing of space equipment.

RMIT’s Advanced Manufacturing Precinct is a leader in the advanced manufacturing techniques required.

RMIT Deputy Vice Chancellor for Research and Innovation, Professor Calum Drummond AO, said the research & development will be undertaken at RMIT’s Space Industry Hub. Launched this year, the Hub is a launch pad and industrial solutions incubator dedicated to growing Australia’s space sector.

“Our ultimate goal is to maximise opportunities for commercialisation of the products that we co-develop with Boeing,” Drummond said. “This is a pioneering project which provides a tangible pathway for Australian businesses to upskill, innovate and export globally as manufacturers of products for

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space applications. Leveraging Boeing and RMIT’s joint expertise and facilities, we believe we can unlock boundless future opportunities for Australian industry.”

Paul Watson, Director of Aerospace Engineering and Production at Boeing Defence Australia, said Australia’s burgeoning space sector required the production of complex, low volume, bespoke components not suited to conventional manufacturing techniques.

“This partnership will develop new knowledge in advanced manufacturing technologies which will not only stimulate the development of a local fabrication capability but will also expose Australian industry to space export markets as part of Boeing’s global supply chain,” he said.

Boeing’s longstanding relationship with RMIT has contributed significantly to Australia’s aerospace manufacturing capability through innovation in undergraduate education, postgraduate research and collaborative research projects.

INDUSTRY NEWS

UniSA to develop cutting-edge lasers for manufacturing, defence The University of South Australia (UniSA) has been awarded a $1.8m Federal Government contract to develop technology that underpins the next generation of high-powered lasers in Australia for the defence and manufacturing sectors.

UniSA Professor of Laser Engineering, David Lancaster, will lead the three-year project, funded by the Defence Science and Technology Group (DSTG), in collaboration with the University of Adelaide.

Lancaster, who heads one of the country’s leading laser and photonics manufacturing research laboratories at UniSA, will use the funding to help build sovereign manufacturing capability, bringing Australia up to speed with other developed nations.

A proud Australian manufacturer of diverse bespoke metal products for 68 years.

“High-powered lasers are increasingly being used in defence and manufacturing, but despite a long history of developing lasers in Australia, our technology is still relatively immature compared to other countries,” says Professor Lancaster. “There is a substantial gap between the research outputs and the needs of our defence industry, so Australia has had to buy this technology from other countries, which is quite restrictive because most nations severely limit their exports of lasers.”

Over the next three years, Professor Lancaster aims to build a new type of high-powered laser that combines multiple smaller lasers, finetuning the manufacturing process so it is cheaper and more efficient.

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“In the past, I have worked on lasers that take years to build and cost millions of dollars,” he adds. “I think it’s more important to put years of effort to develop the technology and manufacturing processes to build many miniature and safer lasers which cost hundreds of dollars each. That is our aim.”

UniSA’s Laser Physics and Photonics Devices Lab will manufacture the lasers and the University of Adelaide’s Institute for Photonics and Advanced Sensors will develop the specialist laser glass. Professor Lancaster says Australia’s universities and defence sector need to be more closely integrated to build sovereign independence in laser technology.

“The reason that UniSA and the University of Adelaide have been selected for this project is that our miniature laser technology and manufacturing processes are world-leading and will supercharge the DSTG’s laser system program,” he says.

High-powered lasers are also the preferred tools for the manufacturing sector as they can cut, shape and weld most industrial materials with high precision. Their ability to manipulate and transform materials makes them ideal for the automotive, computer and clothing industries as they can create extremely fine features that are near impossible to make using traditional machining equipment. www.unisa.edu.au www.adelaide.edu.au www.dst.defence.gov.au

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INDUSTRY NEWS

Northern Territory, AMGC launch Advanced Manufacturing Ecosystem Fund The Northern Territory (NT) Government has opened applications to the $7.5m Advanced Manufacturing Ecosystem Fund (AMEF) in partnership with the Advanced Manufacturing Growth Centre (AMGC).

The Fund delivers on the recommendations from the Territory Economic Reconstruction Report, and will leverage AMGC’s experience in successfully increasing Australia’s manufacturing capability. With a focus on expanding manufacturing in the NT, coinvestments will target local projects that seek to:

NT Chief Minister Michael Gunner with AMGC NT Director Charmaine Barrett at the launch of the Fund.

• Grow an advanced manufacturing ecosystem and capability in the NT across the Territory’s priority sectors.

• Increase investment in advanced manufacturing activity in NT, and secure a greater number of advanced manufacturing jobs located in the NT. • Commercialise new products and processes, including transitioning a new product or process from pilot/prototype stage to full commercial operations.

• Support early-stage small-scale and pilot research projects in advanced manufacturing, allowing them to more quickly move to larger-scale commercialisation.

Funding will range from $25,000 up to $500,000 (or more based on scale and impact), and must be matched by industry. Projects should include collaboration with a research partner and a minimum of one industry partner.

“We are Australia’s comeback capital, but we also want to be Australia’s innovation capital,” said Michael Gunner, Chief Minister of the Northern Territory. “Advanced manufacturing will be a major jobs driver of the future, and this new partnership will provide local manufacturers with the ability to turn their dreams into realities.

“By building up the Territory capabilities in advanced manufacturing, we are expanding industries and export opportunities, and creating new and exciting job opportunities for Territorians and investors.”

AMGC’s Northern Territory Director, Charmaine Barrett added: “The NT has a significant opportunity to leverage its vast natural resources, research talent, and manufacturing base to grow its impact both locally and abroad. The launch of the Advanced Manufacturing Ecosystem Fund arrives at a time when public sentiment is high and the NT Government focus on the critical

industry is strong, we look forward to getting to work and to helping build prosperity for Territorians.”

The launch of the Fund coincides with the latest AMGC research finding that appreciation of local manufacturing in the Northern Territory has risen the quickest of any Australian region. Comparing data collected in early 2019, before the COVID-19 pandemic, with today, AMGC contrasted the awareness and attitudes toward local manufacturing, revealing that pubic support is higher compared to pre-pandemic times. Territorians' support for, and knowledge of, manufacturing is the highest of anywhere in mainland Australia, rising by 33% to 83% over the pre-pandemic survey.

Dr Jens Goennemann, Managing Director for AMGC, said: “The Northern Territory is certainly ahead of other jurisdictions, both in public perception and policy direction when it comes to investing in the potential of manufacturing. AMGC’s partnership with the Territory Government to grow the NT’s manufacturing ecosystem is a sound investment that will deliver secure jobs and higher growth to the Territory, helping to transform the local economy from a lucky one into a smart one,” Further information regarding the Fund, the application process and grant guidelines are available at: www.amgc.org.au/projects

Lithoz, Objective3D deliver ceramics 3D printer to UoW Despite ongoing COVID-19 travel restrictions, Lithoz and Objective3D have successfully completed the remote installation of a Lithoz CeraFab 3D printer at the University of Wollongong (UoW).

A partnership between UoW, Lithoz and Objective3D allowed the remote installation of the high-resolution ceramic printer to occur, which will be used for a broad range of applications in the development of bioprinting hardware. The printer was purchased by the Australian National Fabrication Facility (ANFF) Materials Node, which is based at UoW, for use at the Translational Research Initiative for Cellular Engineering and Printing (TRICEP).

TRICEP works with research institutions and industry to develop innovative technologies using 3D bioprinting.

Dr Johannes Homa, CEO of Lithoz, said the project highlighted the importance of agile working: “We are world and industry technology providers for ceramic 3D printing systems and materials, and have been working in research and industry for more than 10 years. After the past year, it has become clear to us

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just how critical flexibility in the manufacturing world is, and we are very happy that this remote installation has been a success.”

The investment from ANFF will give TRICEP a highly flexible means of customising and producing devices to support material development research worldwide. Associate Professor Stephen Beirne, Associate Director at TRICEP, said the team was thrilled to have access to this exciting new technology.

“The CeraFab 3D printer provides us with access to new families of materials with properties and printing characteristics that greatly expand our service and research capabilities,” said Beirne. “The system will be immediately put to use in the development of next generation biofabrication hardware and implantable structures.” www.lithoz.com www.objective3d.com.au www.uow.edu.au

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INDUSTRY NEWS

High-growth businesses reveal new technology plans Technology use is a major determinant of business success and is set to become more influential, according to a survey by CPA Australia.

“High-growth businesses spend more time and resources on technology,” said Gavan Ord, Senior Manager – Business Policy at CPA Australia. “Their choice of technology puts them even further ahead of their competitors. Our survey results suggest other businesses may improve their growth prospects by investing in the technologies used by high growth businesses.”

One of the world’s largest professional accounting bodies, CPA Australia surveyed 725 professionals in different industries in Australia, mainland China, Hong Kong, Macau, Malaysia and Singapore. Respondents were asked about their businesses’ past and expected technology use and past and expected financial performance.

“COVID-19 accelerated technology adoption by businesses, but not all businesses were equally placed when the pandemic hit,” Ord added. “High-growth businesses had already embraced technology enthusiastically. This helped them manage the disruption caused by COVID-19.”

In 2020, high-growth businesses were significantly more likely to develop a long-term technology strategy, work with technology companies and increase their recruitment of technology staff than businesses whose growth was stagnant or shrank.

“High growth businesses have been focusing on technologies that deliver greater value to customers, such as data analytics and visualisation software, business intelligence software and artificial intelligence,” Ord said.

Differences in future technology plans also sets higher and lowergrowth businesses apart. High-growth businesses are much more likely to expect to increase their use of or investment in

data analytics and visualisation software, business intelligence software, customer relationship management software and artificial intelligence than their lower growing counterparts.

The top technologies Australian businesses are most likely to increase investment in over the next 12 months are cloud technology and data analytics and visualisation software. Highgrowth businesses in Australia are also planning to invest in business intelligence software.

The key drivers of technology adoption by Australian businesses are improving operational efficiency and the customer experience, while the main challenges are financial constraints and complex legacy systems.

“If you want to do well in business, look at what others are doing well,” Ord remarked. “The clear lesson from our survey is that technology adoption, and making the right choices, leads to better business performance.”

Over the next 12 months, large businesses (more than 1,000 employees) are planning to use or invest in data analytics and visualisation software, cloud technology, robotic process automation and artificial intelligence. Small businesses (fewer than 50 employees) are more likely to focus on cloud technology, video conferencing and group collaboration tools, and data analytics and visualisation software.

“When it comes to technology adoption, it’s not a level playing field, and many small businesses struggle,” Ord concluded.

“We support government programs to build small businesses’ digital capability. It’s a great way for governments to future-proof the economy.”

MHI Australia, Primetals Technologies join Heavy Industry Low-Carbon Transition CRC Mitsubishi Heavy Industries (MHI) Australia and Primetals Technologies have joined the Heavy Industry Low-Carbon Transition Cooperative Research Centre (HILT CRC) as key partners.

The HILT CRC aims to develop technologies to decarbonise Australia’s heavy industrial sector, leverage the country’s natural endowments in mineral and clean energy resources and seize the opportunity of growing export markets for certified low-carbon products. Over the next 10 years, MHI Australia and Primetals, a member of MHI Group, will contribute financially to the CRC as well as with their experience in iron and steel production to this effort.

The companies will focus on research & development of hydrogenbased direct reduction of iron ore. This includes the novel HYFOR (hydrogen-based fine-ore reduction) technology currently being piloted by Primetals in Europe.

Australia has the world’s largest iron ore deposits and is the leading exporter of iron ore. Since the iron and steel sector is responsible for 7%-10% of greenhouse gas emissions globally, Australia has a key role to play in the decarbonisation of the industry. Switching from traditional coal and coke-based ironmaking processes to hydrogen-based production methods is the only way for the industry to fully decarbonise.

Deploying these technologies at scale in Australia could move producers up the value chain and turn the country into a major exporter of low-carbon, direct-reduced iron. This would help

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Australia meet its obligations under the Paris Agreement and make it easier for the global iron and steel industry to reach net-zero by 2050.

MHI Australia is an active partner in Australia’s sustainable development efforts with a focus on energy and decarbonisation.

Primetals brings an extensive portfolio of iron ore beneficiation, pelletising, sintering and iron ore reduction technologies. Earlier this year, Primetals commissioned a pilot plant for its HYFOR technology at a site of Austrian steelmaker voestalpine. The next step — building an industrial-scale HYFOR prototype — will be decided by the end of the year.

Dr Alexander Fleischanderl, Technology Officer – Upstream and Head of Eco Technologies at Primetals, said: “Australia has large deposits of iron ore, great potential for green energy, and boasts a dynamic academic and business environment. This puts the country in a unique position in the quest for net-zero by 2050 as a supplier of clean metallics. The HILT-CRC, with its wide range of partners from across the energy, hydrogen, mining, and cement industries, will form a great ecosystem for innovation.” www.mhi.com

www.primetals.com

www.hiltcrc.com.au

AUSTRALIA’S PREMIER MANUFACTURING SOLUTIONS EVENT

W H E R E T E C H N O L O G Y M E E T S I N N O VAT I O N AUSTRALIAN MANUFACTURING WEEK is the industry exhibition encompassing all aspects of manufacturing in Australia. AMW will showcase the latest in manufacturing technologies and processes, with a strong focus on innovation and digital transformation. AMW will be a week-long celebration of manufacturing in Australia today.

To exhibit or visit Australian Manufacturing Week, go to WWW.AUSTRALIANMANUFACTURINGWEEK.COM.AU

AMW SYDNEY: 7-10 June, 2022 INTERNATIONAL CONVENTION CENTRE SYDNEY AMW MELBOURNE: 9-12 May, 2023 MELBOURNE CONVENTION & EXHIBITION CENTRE

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INDUSTRY NEWS

Research collaboration to strengthen welding wire composition New high-strength aluminium-scandium welding wire for Wire Additive Manufacturing (WAM) applications will be developed in a $600,000 research partnership between AML3D Limited and Deakin University, supported through the Innovative Manufacturing Cooperative Research Centre (IMCRC).

AML3D, a pioneer in Wire Arc Additive Manufacturing (WAAM), has teamed up with Deakin's Institute for Frontier Materials (IFM) to investigate scandium as a strengthening element for existing aluminium wire feedstock for 3D printing and welding, with the potential to commercialise. The 12-month collaboration will see IFM researchers create and road-test new alloy compositions that deliver high-strength, corrosion-resistant WAAM structures, using AML3D’s WAM technology. Dr Thomas Dorin, who leads the research at IFM, says most aluminium alloys obtain their strength via additional heat treatments, which can be costly and impractical when using WAM technology.

“When you add scandium to aluminium, it acts as an ‘excellent strengthener’,” says Dr Dorin. “Our preliminary research has shown that aluminium-scandium forms strengthening AI3Sc particles during WAM and create as-printed high-strength structures with limited need for subsequent heat treatment. Also, scandium is electrochemically neutral with aluminium. The new WAM structures are thus expected to be more corrosion resistant compared to the ones created with existing welding wires.”

AML3D is trialling aluminium-scandium compositions for various industry use cases. Successful trials will enable many new applications for WAM, with the automotive, resources and transport industries (such as shipbuilding) showing strong interest in highstrength aluminium products. Encouraged by the success of initial industry-scale welding trials, Andrew Sales, Managing Director of AML3D, describes the research progress as promising.

“The uniqueness of our WAM technology lies in its ability to 3D print large metallic structures,” says Sales. “The welding wire compositions created through this research project will enable us and our customers to manufacture components with stronger and better mechanical properties. This will help us to position high-strength aluminium products produced by WAM as a viable alternative to existing processes.”

With the potential of generating new Australian-owned intellectual property, the project also provides AML3D with new revenue prospects not only through high-strength aluminium WAM parts but also wire feedstock sales for 3D printing and welding applications.

Australia is one of the largest producers of aluminium, and with scandium being declared a critical commodity for Australia, the US and Europe. Dr Matthew Young, Manufacturing Innovation Manager at IMCRC, sees the collaboration also as a significant opportunity to value add to Australian resources.

“The project is a great example of creating new, higher value products using Australian resources,” says Dr Young. “By enhancing the properties of aluminium by adding scandium, and thus its value, the research demonstrates that Australia is capable of manufacturing and delivering high-quality products.”

Deakin University and AML3D are looking to expand their partnership to develop a range of purpose specific alloys for WAM applications and provide unique facilities and capabilities to assist in their growth.

Smart manufacturing, R&D commercialisation get $16.12m boost at Monash Smart manufacturing and research & development (R&D) commercialisation at Monash will be enhanced by a $16.12m investment through the Victorian Higher Education State Investment Fund (VHESIF).

The investment aims to enhance research commercialisation, support the creation of future industries and jobs, accelerate the attraction of international investment, and build access to global supply chains. The funding will support investment integration to maximise impact in three core areas across the Monash Technology Precinct by June 2022, including: • Medicines Manufacturing Innovation Centre (MMIC): Expansion of MMIC’s presence to a new node at Clayton, allowing the scale-up of medicine manufacturing capability, and support for clinical trials and growth of exports and jobs.

• UP-LINK university partner collaboration space: A platform at the heart of Clayton campus that will drive manufacturing innovation and modernisation. This will provide industry with early access to Monash research and talent pipelines. In addition, incubator and start-up facilities will support commercialisation and spinouts, enabling entrepreneurial activity across the precinct, and creating new businesses.

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• oNKo-innate Headquarters: A biotechnology research and development facility to accelerate the development of cancer therapies, enabling target identification, validation, and subsequent development, manufacturing and commercialisation of cancer treatments.

President and Vice-Chancellor Professor Margaret Gardner AC said: “Monash University is pleased to receive $16.12m through the VHESIF to drive commercial and entrepreneurial activity across the Monash Technology Precinct. This funding will enable the MMIC to greatly enhance process optimisation and product development, and advance medicine manufacturing and clinical trials through the establishment of a new node at Clayton campus.

UP-LINK is an excellent example of university, government and private-sector collaboration to realise the significant innovation towards Australia’s advanced manufacturing industry, and to enable job-ready graduates to secure a prosperous future for our communities.”

INDUSTRY NEWS

Bosch opens new Manufacturing Automation Centre Bosch has opened its new $17m Manufacturing Automation Centre in Clayton, Victoria, a purpose-built facility that houses Bosch Australia Manufacturing Solutions (BAMS) and the Rexroth Drives and Controls businesses.

The establishment of the new centre completes the consolidation of all Bosch’s businesses in Victoria at its Clayton campus, boosting strategic collaboration and innovation.

Gavin Smith, President of Bosch Oceania, said: “Manufacturing automation is now the fastest growing part of our business. We are leveraging our more than 50 years of manufacturing experience and factory automation know-how and drawing on the global expertise within the Bosch group, to help Australian manufacturers become fit for the future.”

BAMS has become one of the country’s leading factory automation companies, working with a diverse array of blue-chip, mid-tier and start-up manufacturers to automate their manufacturing. Most recently, BAMS was engaged by digital diagnostics company Ellume to automate the high-volume production of its rapid COVID-19 tests.

BAMS is highly regarded in the biotech sector, currently working with CSL to create a high-tech automatic materials handling line for their manufacturing facility in Broadmeadows. BAMS was also part of the industry consortium led by Grey Innovation that built ventilators in the fight against COVID-19.

Also occupying the new centre is the Victorian arm of Bosch Rexroth Australia. With significant investment in new equipment, the business has increased its support to customers in Victoria and offers advancements in repair and testing technologies, including industry 4.0 solutions.

Bosch Rexroth Australia is focused on meeting its customers’ needs into the future. Its team of expert hydraulics and application

engineers continually develop new technologies, working closely with local customers to develop state-of-the-art solutions. This support provides technical solutions to design challenges in a changing global market. With a complete portfolio of drive and control technologies, Bosch Rexroth represents a one-stop source for controls, electric drives, hydraulics, mechanics, and system solutions.

Martin Pakula, Victorian Minister for Industry Support and Recovery, said: “Victoria is the place for innovators like Bosch Australia to grow and thrive, due to our skilled workforce, established supply chains, engineering expertise, education excellence, and research and development capability. We will continue to support businesses to capitalise on the opportunities and talent available in Victoria, ensuring we remain at the forefront of advanced manufacturing, innovation and technology.” www.bosch.com.au

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INDUSTRY NEWS

Advanced recycling: Turning plastic waste into resources Advanced recycling technologies could turn problematic plastic waste destined for landfill into valuable resources, according to a new report by CSIRO. The report, Advanced Recycling Technologies to Address Australia’s Plastic Waste, evaluates the ways to convert plastic waste that can’t be recycled with existing methods, into new resources to build Australia’s circular economy. It is estimated that 130,000 tonnes of plastic leaks into the Australian marine environment each year. Less than 12% of plastic waste is recycled and about 85% ends up in landfill.

Advanced recycling of plastic waste, also referred to as feedstock, molecular, or chemical recycling, converts plastic waste into its chemical building blocks and back into plastic, or other useful resources such as fuel. CSIRO researcher Sarah King said with new waste plastic export rules in place, new technologies were critical to support the increased recovery and recycling of plastics.

“Advanced recycling technologies could turn hard-to-recycle plastics, such as mixed, multi-layer, flexible or contaminated plastics back into food-grade recycled plastics or other products through chemical, thermal or biological processes,” King said. “It is suitable for flexible or soft ‘scrunchable’ plastics used for food packaging, such as food pouches and chocolate wrappers. When collected, these types of plastics may be contaminated with food, or mixed with other materials so currently can’t be recycled.

“Advanced recycling could process this plastic waste to increase opportunities for the polymer manufacturing and waste sectors by supporting new industries. The North American market is estimated at $120bn, demonstrating there is economic potential for adopting advanced recycling in Australia.”

Australia has set a national target of 70% of plastic packaging recycled or composted by 2025, and 80% average recovery rate from all waste streams by 2030. Chemistry Australia’s Director for Strategy, Energy and Research Peter Bury, who collaborated with CSIRO on the report, said advanced recycling is an important and complementary technology able to progress an Australian plastics circular economy.

“Mechanical recycling methods are our foundation technologies and very effective for a range of well-sorted plastics used for food and other packaging,” Bury said. “Advanced recycling can sit alongside these to further strengthen Australia’s recycling capabilities for plastics that can’t be processed through existing channels.

“Australia already has the critical industrial capability in polymer manufacturing, steam crackers, and refineries, to integrate advanced recycling outputs to produce new polymers. Importantly, we have the talented and skilled people in place to introduce and develop this additional technology.”

The report was produced in consultation with Chemistry Australia, LyondellBasell and Qenos. The report and opportunities to adopt advanced recycling technologies are key parts of CSIRO’s developing Ending Plastic Waste Mission to achieve an 80% reduction of plastic pollution entering the Australian environment by 2030.

“Our report aims to build awareness of advanced recycling technologies, how they apply to different plastic types, and the key factors to enable adoption and scale up of these technologies in Australia,” King added. “Plastic pollution and waste are challenges we need to solve. Advanced recycling will improve the recovery, recycling and reuse of materials, consistent with a circular economy.”

Call for local procurement on infrastructure projects like windfarms Weld Australia has called on the Federal Government to mandate local content in the construction of critical national infrastructure projects after it introduced legislation on 2 September that will pave the way for construction of Australia’s first offshore wind farms.

The Offshore Energy Infrastructure Bill could permit the construction of the 2.2-gigawatt Star of the South wind farm off the Gippsland coast in Victoria’s south-east. The Bill could also enable construction of the Marinus Link interconnector between Victoria and Tasmania, as well as windfarms in areas like Gladstone, Newcastle and Wollongong.

“The only way to ensure that these massive wind turbines meet Australian Standards for reliability, quality and safety is to award the fabrication contracts to local Australian companies,” said Geoff Crittenden, Chief Executive Officer of Weld Australia. “Local fabricators comply with internationally recognised Australian Standards and are certified by the relevant Australian authority.

The Star of the South and Marinus Link interconnector projects alone are worth $10bn combined and are expected to create

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10,000 jobs. According to Crittenden, a procurement policy that mandated local content would see that $10bn reinvested back into the Australian economy. It would also create thousands of jobs in regional areas like Gippsland, Gladstone and Newcastle, supporting Australia’s post-COVID-19 recovery.

“The importance of our local manufacturing industry cannot be underestimated when it comes to Australia’s post-COVID recovery,” said Crittenden. “Australia’s jobs-driven COVID-19 recovery must be manufacturing-led. Now is the time to make manufacturing a national priority. Government, at all levels, must support and invest in the manufacturing sector to aid its growth.

“Mandating local content in national infrastructure projects is the only way to ensure product quality and public safety, create new jobs, and strengthen Australia’s economy.”

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To exhibit at AUSTRALIAN MANUFACTURING WEEK, contact Anne Samuelsson, Head of Sales at AMTIL on 0400 115 525 or email asamuelsson@amtil.com.au WWW.AUSTRALIANMANUFACTURINGWEEK.COM.AU AMW SYDNEY: 7-10 June, 2022 INTERNATIONAL CONVENTION CENTRE SYDNEY

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INDUSTRY NEWS

Beep Cricket – Enabling active, inclusive lifestyles for the blind and vision impaired At a time when sport has been curtailed and confined to restricted environments, a team of innovators including GoProto have been working on developing a new improved cricket ball for blind and visually impaired players.

Blind cricket has been played as a competitive sport in Australia since 1922. It uses a ball slightly larger than a standard cricket ball that is traditionally filled with ball bearings or bells to provide audible cues. Listening to the sound of the ball is how the players can bowl and catch. The biggest challenge is when the ball stops moving and no longer makes a sound.

Supported by legendary wicketkeeper Ian Healy, non-profit organisation Blind Bats Inc and its newest venture in Beep Cricket promote increased sporting accessibility for the blind and vision impaired. Paul Szep, president of Blind Bats Inc, is an avid supporter of blind cricket. After becoming aware of the Kookaburra Smartball and its technology, he came up with the idea of a continuous beeping cricket ball controlled remotely by a phone app. For the beeping ball, the design has to withstand the punishment of a cricket bat without damaging the internal electronics, while keeping the ball at a reasonable weight and size. With the assistance of local community and government grants, Szep presented his idea to Kookaburra Sport and Sportcor, the developers of the Kookaburra SmartBall, which features an embedded micro-chip to provide cricketers with real-time feedback.

Using this same technology and with the support of Kookaburra, development moved forward in designing a new audible ball that would meet the game’s regulatory requirements. To test and validate the design, 3D printing has long been a popular medium for producing presentation and functional prototypes, and more recently for volume manufacturing.

With a long-standing history in 3D printing and contract manufacturing, GoProto helped Kookaburra achieve the desired

results using a combination of stereolithography (SLA) and traditional moulding technologies. James Sanders, General Manager for GoProto, has worked with Kookaburra Sport on a number of projects over the years.

“Professional 3D printing and moulding technologies have enabled sporting goods manufacturers, like Kookaburra, to develop sports equipment that’s lighter and better suited to the needs of the athlete,” says Sanders. “The technology and materials used in creating the beeping cricket ball has the ability to cement social cohesion and greater participation”. www.goproto.com.au

www.blindbats.org

Supporting sport with 3D scanning tech The Australian Institute of Sport (AIS) made innovative use of the latest 3D scanning technology from Hi-Tech Metrology in its work supporting Australian sporting development.

The AIS was established under the Australian Sports Commission Act 1989, to build sustainable winning systems for Australian athletes that are measured through consistently producing podium success over multiple cycles, inspiring the next generation. The AIS’ investment philosophy is to target multiple medallists over multiple cycles, and support their partners through their resources, research and facilities. They know that success will be driven by innovation, athlete wellbeing, targeted investment and a commitment to being “ahead of the game internationally”.

These core values instigated an exhaustive search into the latest 3D scanning technology capable of meeting the stringent guidelines that the AIS is renowned for. As a result, Hi-Tech Metrology were approached to present the extensive range of Creaform Scanners, and after much research and investigation AIS acquired the HandySCAN BLACK|Elite.

Essential to the decision was the availability of professional, nationwide training and support personnel both initially and ongoing for the project. Hi-Tech Metrology has a number of engineers located throughout Australia, which provided the reassurance that AIS needed to proceed with the purchase.

Since acquiring the BLACK|Elite, AIS mechanical and manufacturing engineer Callum McNamara says: “We can

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undertake tasks such as reverse engineering in field measurement and data referencing for complex CAD modelling, which in the past were either done manually or not at all. The ability to capture high-resolution data at a rapid rate including highly reflective surfaces translates to delivering projects on time in a high-performance environment.”

The investment in this leading-edge, dynamic scanning technology ensures the AIS maintains its commitment to providing innovative solutions and giving Australian athletes their best chance at achieving international sporting success. www.hitechmetrology.com.au www.sportaus.gov.au

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GOVERNMENT NEWS

$47m in grants to boost research collaboration in manufacturing A bionic “eye” that could restore visual and spatial perception for the blind is one of 22 industry-led collaborative research & development projects to share in $47.1m in funding from the Morrison Government.

Successful projects under round 11 of the Cooperative Research Centre Projects (CRC-P) initiative will deliver a range of innovative technologies and create job opportunities in key manufacturing sectors, including in regional Australia. These projects will leverage a further $86m of cash and in-kind contributions from 95 project partners.

Aria Research Pty Ltd will partner with the University of Sydney and World Access for the Blind to undertake clinical trials of its bionic prosthesis, which could provide new levels of independence and autonomy for Australia’s 600,000 vision impaired citizens.

The successful projects this round include: • SunPork Pty Ltd (QLD) with a grant of $2,892,374 to eliminate the removal of pig’s tails, improving pig welfare and the sustainability of the pork industry.

• Rux Energy Pty Ltd (NSW) with a grant of $2,770,000 to develop an efficient hydrogen storage system, a key barrier to the uptake as a new zero-carbon fuel.

• iOrthotics Pty Ltd (QLD) with a grant of $2,044, 034 to advance the manufacturing of smart orthotics to reduce diabetes-related amputations.

• Seer Medical Pty Ltd (VIC) with a grant of $465,183 to develop its long-term brain monitoring electrodes for an improved patient experience in the diagnosis of epilepsy.

The two regional projects are: • DefendTex Research Labs Pty Ltd (VIC) with a grant of $3,000,000 will establish a research centre in Gippsland for additive manufacturing of energetic materials to advance manufacturing capability for its rocket fuel additive for space launch.

• Nourish Ingredients Pty Ltd (NSW) with a grant of $2,829,073 will establish a commercial pilot-scale fermentation facility in Goulburn to develop lipid fermentation for the local manufacture of future foods.

Since the first round of CRC Projects in 2016, the Government has awarded over $376m in funding under the CRC-P Program to support 176 projects. These projects include over 900 collaborating partners from industry, research, government and community organisations, and are leveraging $853m in partner contributions.

CRC-Ps can run for up to three years and must have at least two Australian industry partners, including one small or medium-sized business, and one Australian research organisation partner. www.business.gov.au/grants-and-programs

Siemens backs Victoria’s Digital Jobs program Siemens will support the Victorian Government’s $64m Digital Jobs program, a first of its kind in Australia that will help 5,000 mid-career Victorians reskill and upskill on much-needed digital skills.

Joining other companies committed to the program, Siemens will train an intake of mid-career workers on key digital technologies used by some of the most well-known companies worldwide, making them more digital job-ready. The program follows the success of Siemens’ previous award-winning Industry 4.0 Apprentice program that was launched along with Swinburne University and Australian Industry Group (Ai Group), as well as the significant grants of the company’s hi-tech industrial software to a national network of universities.

Speaking on the announcement, Jeff Connolly, CEO and Chairman of Siemens Australia said that digital readiness plays a critical role in Australia’s ability to innovate and create new pathways for growth.

“Digital preparedness is a constant process and happens throughout a person’s career,” said Connolly. “Gone are the days when you get a qualification early in your career and that sets you up for life. Society expectations and technology developments are driving constant change, which means everyone needs to continually learn and adapt to stay relevant.”

Connolly is an advocate of on-the-job training being an important part of the learning mix: “A mix of academic learning and on the job application and training is a powerful combination and digital skills are critical. This not only makes you more employable, but it also opens up possibilities for business and society to look at ways to accelerate improved outcomes. We’re delighted to support and participate in the Victorian Government Digital Jobs program.”

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Siemens will host a selection from the first cohort of 450 participants scheduled to start industry placements in October.

Jaala Pulford, Minister for Innovation, said the Victorian Government was committed to growing the state’s pipeline of tech talent: “We know the demand for Jeff Connolly, CEO and digital talent is increasing Chairman of rapidly, and the Digital Jobs Siemens Australia. program has been designed to build our tech workforce and create new opportunities for Victorians. It’s fantastic to see Siemens jumping on board. Not only will the participants benefit from learning in such a fantastic environment, but Siemens will get access to passionate and driven workers who could become long-term assets to the business.”

Participants will complete 12 weeks of skills training at a leading Victorian training provider in fields such as data analytics, web development, digital marketing, cloud computing and cyber security. Following the training, participants will undertake a 12week paid internship with organisations such as Siemens to further develop their new skills. www.vic.gov.au/digitaljobs

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Underpayments and prosecution, are employers vulnerable?

As an employer, you would be aware of your legal and fiscal obligations when employing workers – specifically, the obligation of ensuring correct payment of wages and entitlements in accordance with the Fair Work Act 2009 (Cth) (FW Act). By Stephanie Shahine and Simone Caylock of AMTIL corporate partner Rigby Cooke.

The Fair Work Ombudsman (FWO) is tasked with enforcing compliance with the FW Act, including ensuring employees receive their lawful entitlements. The FWO can investigate employers if a complaint has been made regarding a failure to comply with workplace laws, including wage underpayments. If a breach has been identified, the FWO has a range of compliance powers, including issuing a compliance notice requiring that the breach is rectified within a certain period of time, entering into an Enforceable Undertaking and/or issuing prosecution proceedings against the employer and persons knowingly involved in the alleged breach, including directors.

Sapphire Freighters: a case study The consequences of not paying the correct wages to employees and failing to rectify the issue were demonstrated recently in a Federal Circuit Court case against Sapphire Freighters Pty Ltd, a long-haul trucking business based in Melbourne. The FWO successfully secured a financial penalty of $21,500 against Sapphire Freighters for failing to comply with a compliance notice requiring back-payments of entitlements to a former truck driver, as well as orders that Sapphire Freighters calculate and backpay approximately $6,000 in outstanding entitlements owed to the driver, plus superannuation.

In July 2018, the FWO received a request for assistance from a truck driver who had worked at Sapphire Freighters between December 2016 and January 2018. Following an investigation, the Fair Work Inspector formed a belief that throughout the driver’s employment, the company had failed to pay him a rate of pay that was in accordance with the Road Transport (Long Distance Operations) Award 2010, which included certain allowances.

As a result, the FWO issued the company with a compliance notice in December 2019. The compliance notice also alleged that Sapphire Freighters breached the FW Act by failing to pay out accrued annual leave on the driver’s termination.

Sapphire Freighters failed to co-operate with the FWO and ignored the compliance notice. In situations where an employer fails to comply with a compliance notice issued by a Fair Work Inspector, the FWO can commence proceedings seeking remedies and penalties for any contravention of an entitlement provision, as well as penalties for failing to comply with a compliance notice.

When the matter came before the Court, Justice Mercuri found that there was no evidence of any contrition, corrective action or cooperation with the authorities by Sapphire Freighters, who did not appear at the penalty hearing.

Justice Mercuri said: “There is also a strong need for general deterrence, particularly in the road freight transport industry, which has significant rates of non-compliance with workplace laws.”

The evidence given by the FWO during the proceeding highlighted that the road freight industry currently generates the second-highest number of disputes dealt with by the FWO, identifying road freight operators in Victoria as the worst offenders.

The Fair Work Ombudsman, Sandra Parker, said: “When compliance notices are not followed, we are prepared to take legal action to ensure hard-working employees receive their lawful entitlements.”

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This case demonstrates that if an underpayment has been identified, the risk of being prosecuted is high if the employer does not cooperate with the FWO and comply with any compliance notice which has been issued.

Other recent developments – Award Increases and Wage Theft Laws For all employers, it is important to note that on 16 June 2021, the Fair Work Commission handed down its 2021 Annual Wage Review Decision, increasing full-time minimum wage rates in modern awards by 2.5%. The effective date for the increases varies between awards.

In addition to this update, if you are in Victoria, wage theft became a crime from 1 July 2021 under the Wage Theft Bill 2020. Therefore, any employer in Victoria who dishonestly or recklessly underpays employees, withholds employee entitlements, or falsifies or fails to keep employment records to obtain a financial advantage faces a fine of up to $218,088 or up to 10 years in jail for individuals, and a fine of up to $1,090,440 for companies.

What does this mean?

Businesses should conduct regular reviews of modern awards and agreements to ensure continued compliance.

Should it be brought to your attention that you may not have met your legal obligations, we recommend that you seek immediate advice regarding corrective action you should take, including to minimise your exposure to penalties and other consequences.

All employers need to properly understand their legal obligations to avoid any possible claims by employees, the imposition of civil penalties or prosecution. An audit of compliance can not only identify problems but also reduce the risk of being prosecuted if errors recklessly go uncorrected.

Rigby Cooke Lawyers has extensive experience working with clients to ensure their employment contracts are up to date and employee wages are paid in accordance with the Fair Work Act 2009 (Cth).

Stephanie Shahine is an Associate in Rigby Cooke’s Workplace Relations team. Simone Caylock is a Partner in the Workplace Relations team. www.rigbycooke.com.au

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

We need qualified VET and Technologies school teachers – so where are they?

Australia is staking much of its post-pandemic recovery on our manufacturing and engineering sectors. However, a lack of suitably qualified VET in Schools and Technologies teachers raises doubts over the supply of skilled workers that this recovery will need. By Karen O’Reilly-Briggs.

Late last year, the only undergraduate course in Australia purposefully designed to recruit and ‘upskill’ industry experienced tradespeople and technology experts to become qualified Vocational Education and Training (VET) and Technologies secondary school teachers was closed. What makes the closure of this program of particular concern to industry is that it has come at a time when the nation is gearing itself – more so than any other time in Australia’s history – for an economic recovery that is dependent on young people wanting to pursue trade and technologies-based vocations.

The Federal Government has promised a “pipeline of skilled workers to support sustained economic recovery”, but in order to generate this pipeline, we need appropriately skilled and qualified teachers with industry expertise and a deep knowledge of pedagogy (the science of teaching and learning) to nurture young people’s curiosity and their desire to enter trade and technical career paths after completing their schooling. The closure of this teaching course has left a vacuum in the secondary school sector, with many stakeholders wondering how exactly governments intend to achieve this “pipeline” to recovery, without the quality or quantity of specialised teachers needed for the job. Compounding the gravity of this situation is the already-existing skill-shortage of graduate VET and Technologies teachers. In 2019, the Design and Technologies Teachers’ Association (DATTA) conducted a nation-wide survey of schools to find that the overwhelming majority of schools surveyed had difficulty finding qualified Technologies teachers, and that 84% of these schools were using unqualified teachers (teachers from other learning areas, such as geography) because they were unable to find the teachers with the expertise that they really needed.

The Victorian Teacher Supply and Demand Report 2018 supports these findings, revealing that Digital Technologies teachers and Product Design and Technologies teachers are some of the most difficult teachers for schools to find. Curiously (with one cursory exception), VET teachers did not even rate a mention in this report, which is arguably indicative of the Victorian Government’s lack of concern for quality VET provision in schools. Although no official data appears to exist to quantify the actual shortage of VET in Schools teachers, there is plenty of anecdotal evidence to support this claim. Reminiscent of the proverbial ostrich with its head in the sand, omitting or censoring data concerning the demand for VET in Schools teachers will not make the problem go away.

The Organisation for Economic Co-operation and Development (OECD), the Australian Institute for Teaching and School Leadership (AITSL) and the 2018 Gonski Review of Australian schools all acknowledge the importance of having appropriately qualified VET teachers with relevant industry experience and accreditation to help prepare the next generation of workers. However, the nation now finds itself in a situation where the existing pool of qualified VET and Technologies teachers is depleting with each passing day, and secondary schools are increasingly desperate to find suitable teachers to stand in front of these classrooms. Somewhere between the skill-shortage of VET and Technologies teachers, and the nation’s reluctance to develop suitable courses to generate the quality of teachers needed, some highly questionable practices have been taking place.

Without access to appropriately qualified teachers, it is now not uncommon for principals to place ‘out-of-field’ teachers in front of Technology and VET classes, or use trade or technically-qualified (but not teacher-qualified) trainers to teach on a special (but temporary) authority called Permission To Teach (PTT). Both of these ‘solutions’ are unsuitable for quality school teaching, and in some cases cause safety risks. DATTA’s 2019 survey found that 70% of respondents harbour concerns for the health and safety of Technologies students as a result of the practice of using unqualified teachers to teach these subjects – and with good reason.

What is needed is a solution that includes a practical and accessible way for expert tradespeople and technologists to become professionally qualified teachers.

While VET and Technology professionals continue to be denied the opportunity to achieve a professional teaching qualification, schools, and the students who would otherwise be benefiting from their industry expertise, will be disadvantaged. Meanwhile, the industries that depend on schools to produce a vocationally ‘ready’ workforce should brace for disappointment.

Karen O’Reilly-Briggs (PhD) is a trade-qualified metal fabricator, welder, trade teacher, researcher, academic course writer for Box Hill Institute, and former coordinator of the Bachelor of Technology Education program at La Trobe University. A version of this article was published in Education Review.

E: k.oreilly-briggs@boxhill.edu.au.

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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

The pandemic has been the ultimate test of supply chain resilience Events brought on by the COVID-19 pandemic, such as movement restrictions, supply shortages, panic-buying, closure of major international ports and skyrocketing shipping container prices, have put significant pressure on global and local supply chains, writes George Harb.

These disruptions have presented a whole set of new challenges for organisations in terms of how they can meet the needs of consumers. Even as we journey toward what appears to be the latter stages of the pandemic, Australia’s supply chain continues to face significant challenges; in early September 2021, Australia Post announced a temporary pause on parcel collections from ecommerce retailers due to a shortage of staff, with 500 employees having to isolate, while many retailers are already worried about stock availability and their ability to meet the upcoming Christmas demand peak.

Over the past 12 months, the Federal Government has already taken several positive steps to help introduce more resilience into the supply chains supporting its economy. Alongside the governments of Japan and India, and in recognition that local and global supply chains have been left vulnerable due to a range of factors, the three nations formally launched in April 2021 the Supply Chain Resilience Initiative (SCRI) to build resilient supply chains in the Indo-Pacific region.

Highlighting at the time the importance of risk management and continuity plans to avoid supply chain disruptions, the trio said that possible policy measures may include, in addition to trade and investment diversification, supporting the enhanced utilisation of digital technology. The tripartite agreement builds on a local SCRI launched by the Australian government in October 2020, when it announced an investment of $107.2m committed towards addressing supply chain vulnerabilities.

Moving forward, how can organisations ensure their supply chain ecosystems are resilient? Digital technology is clearly a major part of the answer.

Digital technology is imperative to building a strong supply chain network that can withstand disruptions however it’s important to invest in the right technology. Every organisation should invest in systems and solutions that integrate with the broader ecosystem; operating in isolation is no longer a viable route for long-term success. Information must flow smoothly and securely between employees, business departments, and extended business networks. Without the right technology at the core, organisations increase the likelihood of negatively impacting collaboration among employees, transparency with partners, and ultimately the smooth operation of the entire supply chain.

Characteristics of the modern supply chain As the modern supply chain incorporates more organisations across a broader geographic footprint than ever before, it becomes increasingly complex. For this reason, it’s vital for supply chain participants to collaborate. Failure to do so can prove costly and disruptive, seeing materials go to waste, longer order-to-delivery cycle times, inaccurate shipments, impacts on quality of service and so on. This is where the need for a connected and resilient supply chain comes in.

The pandemic and its effects have tested supply chains across the globe, perhaps more than at any other time in history, and the ones

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that have proved strongest and most resilient are those that have been able to pivot at a moment’s notice. This feat is achieved by collaborating effectively through technology. Modern technologies such as the cloud, the Internet of Things (IoT), big data and so on must be embraced and connected at all levels to make this a reality.

The next level: accelerate digital transformation To take it to the next level and build true resilience, organisations need to accelerate their digital transformation initiatives so their supply chain ecosystems can integrate data analytics, transactional content and cybersecurity, while providing robust activity reporting, content creation and receiving capabilities and dashboards.

Additionally, the use of artificial intelligence (AI) and analytics is now a key enabler for Australian manufacturers as they seek to better align operations that will meet the needs of customers. These innovations also give them the flexibility they need to respond to unforeseen events, quickly change their business model and adapt to new demands.

Emerging technologies are at the heart of the fourth industrial revolution. AI and data analytics are transforming the speed at which manufacturers are creating products by using past data to recognise which methods work most efficiently. Hence, it is unsurprising the Advanced Manufacturing Growth Centre has revealed many Australian organisations are embracing these emerging technologies in order to drive growth.

The importance of the consumer While technology facilitates collaboration and transparency in the supply chain, it also increases transparency, which is increasingly important for today’s environmentally conscious and socially responsible consumers. In fact, 84% of Australian consumers prioritise buying from companies that make it clear they have ethical sourcing strategies in place.

To meet these needs, Australian manufacturers need to invest in technology that allows them to share data in real-time and gives them clear visibility into partner performance, practices, and certifications – making it easier to establish and operate an ethical supply chain and appealing to the demands of today’s consumer.

While some manufacturers are still plodding along with their digital transformation efforts, it is evident that many others are recognising this opportunity and using emerging technologies to accelerate progress. The combination of IoT, AI and data analytics will provide organisations with access to intelligent supply chain data that will measure and analyse activities within the organisation and with downstream partners. Not only will this ensure an efficient and resilient supply chain, but it will also deliver maximum transparency into the working practices of supply chain partners and give organisations the opportunity to earn customer loyalty by demonstrating their entire supply chain operates ethically.

George Harb is Regional Vice President | Business Ecosystems, APAC at OpenText. www.opentext.com

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TECH NEWS

USA: Robot arm stretches, bends and twists without a motor

USA: NASA unveils first glimpse of supersonic jet

A team at the Ohio State University and the Georgia Institute of Technology has developed a robot arm that moves like an octopus arm without the need for a motor (ie moving in response to changes in a magnetic field around it). Most robot arms are heavy because of the need for motors and control units. This one requires neither.

Individual segments made of hexagonal-shaped, soft dual silicon plates are embedded with magnetic particles. The plates are connected using tilted plastic panels and the arm placed into a controllable magnetic field. Because each segment had its own magnetic particles, each could be controlled individually by changing the parameters of the magnetic field. This gives the robot arm 360 deg. of movement. It also allowed the robot arm to change its length.

The design allows for customisation and is suitable for applications that require more finesse than strength (ie medical applications).

NASA has released the first glimpse of its experimental supersonic aircraft being developed in conjunction with Lockheed Martin. The aircraft - a 30m demonstrator prototype named X-59 QueSST - is unique because it has no cockpit or front-facing window. It differs from conventional planes due to its dart-like shape that stops the shockwaves forming on the surface from joining together – thereby eliminating the sonic boom. It is designed to fly at supersonic speeds – approximately 660 mph at sea level. NASA will work with US communities to understand their response to the aircraft’s sound and provide that data to regulators, which could change the rules that currently ban supersonic flight over land, cutting travel time in half. It is hoped the larger aircraft will fly over several US cities in 2022 to validate the results.

Space Connect online

Tech Xplore Artist illustration of the X-59 Quiet SuperSonic Technology aircraft, NASA’s first purpose-built, supersonic experimental plane in decades. Lockheed Martin

Switzerland: Lightweight composite material inspects itself USA: Smart laser cutter system detects different materials “SensiCut,” a smart material-sensing platform for laser cutters, can differentiate between 30 materials. In contrast to conventional, camera-based approaches that can easily misidentify materials, SensiCut uses a more nuanced fusion. It identifies materials using deep learning and an optical method called “speckle sensing,” a technique that uses a laser to sense a surface’s microstructure, enabled by just one image-sensing add-on, suggesting subtle cutting adjustment, and even engraving items. This is done by leveraging a material’s unique micron-level surface structure. The team trained SensiCut’s deep neural network on images of 30 different material types of over 38,000 images, where it could then differentiate between things like acrylic, foamboard, and styrene, and even provide further guidance on power and speed settings.

Beyond laser cutters, the team envisions SensiCut’s sensing technology could eventually be integrated into other fabrication tools like 3-D printers.

MIT

Japan: Quantum entanglement of three spin qubits in silicon For those of you into quantum physics: A three-qubit entangled state has been realized in a fully controllable array of spin qubits in silicon. Silicon quantum dots have properties that make them highly attractive. To usefully connect silicon-based spin qubits, it is crucial to be able to entangle more than two qubits, an achievement that had evaded physicists until now.

RIKEN Center for Emergent Matter Science.

Researchers have developed a “proof of concept” laminate that changes colour when the material is deformed. Composed of individual layers, the laminate is translucent, break- resistant and yet very lightweight. It is composed of alternating layers of a plastic polymer and artificial nacre. It consists of countless glass platelets arranged in parallel, which are compacted, sintered and solidified using a polymeric resin. The second layer consists of a polymer to which the researchers added an indicator molecule which is activated as soon as the polymer experiences stretching forces, and this changes its fluorescence. The more the material stretches and the more of these molecules are activated, the more intense the fluorescence becomes. The researchers can now identify overstressed areas within the composite material even before fractures form.

ETH Zurich

Australia: Sugar opens a path to longer-lasting lithium sulfur batteries Simply by adding sugar, researchers have created a longerlasting, lighter, more sustainable rival to lithium-ion batteries.

Using a glucose-based additive on the positive electrode they have stabilised lithium-sulfur battery technology. “In less than a decade, this technology could lead to vehicles that can travel from Melbourne to Sydney without recharging. It could also enable light weight drones” says Prof. Mainak Majumder. In theory, lithium-sulfur batteries could store two to five times more energy than lithiumion batteries of the same weight. The problem has been that the electrodes deteriorated rapidly, and the batteries broke down. Last year the team demonstrated they could open the structure of the sulfur electrode to accommodate expansion and make it more accessible to lithium. Now, by incorporating sugar into the web-like architecture of the electrode they have stabilised the sulfur.

Monash University

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TECH HEADING NEWS

China: Launch of the world’s largest wind turbine

Australia: WA-made robot ‘spider’ unveiled

MingYang Smart Energy has reached a milestone with the world’s largest hybrid drive wind turbine. The MySE 16.0-242 will have a capacity of 16MW, a 242m diameter rotor, 118m-long blades and a 46,000m2 swept area. Designed for high winds including typhoons, a single turbine will generate 80,000MWh of electricity every year.

The nacelle weight is lower: the modest head mass allows for more efficient use of the tower and foundation construction. All the power electronics and MV-transformer have been relocated up the tower into the nacelle, simplifying cabling and enhancing system maintenance. And an air-tight design protects the nacelle from harsh salt spray corrosion while allowing for internal natural air cooling.

Commercial production is expected in the first half of 2024.

Nexxis, an WA company that is exporting robotic parts to help with the clean-up of Japan’s Fukushima nuclear plant unveiled MagnetoEX: a small spider-like robot with electromagnetic feet, “cutting-edge” AI and advanced localisation and object detection features for use in hazardous area inspections in confined spaces. It can place its feet in small gaps and on narrow beams, adapting its body configuration to navigate complex geometry and through narrow apertures. A novel magnetic foot quadruped platform was developed which provides enough limb workspace and limb manipulability while enabling the traversing of complex 3-D structures and achieving a wide range of body configurations. It has been developed with the support of the CSIRO’s Data61, SixDe and National Energy Resources Australia. The company is seeking partners for viability testing and a commercial release.

MingYang Smart Energy

China: Firefighting drones and flying taxis Chinese company EHang is a pioneer in “flying taxis”. While other companies are struggling to launch, EHang has been routinely carrying passengers on multiple test flights for the last few years and is considering Japan as early as 2023 as a potential market for commercial drone-based transport and delivery services. It also has several eco-tourism projects underway in Europe and Southeast Asia. The company has released a behind-the-scenes video that shows off the company’s fully-operational flying taxi production facility. More recently, the company ventured into firefighting, with a firefighting drone capable of breaking high-rise windows via projectiles and then extinguishing flames. It recently passed a technical evaluation of its EH216F AAV (Autonomous Aerial Vehicle) via 52 different types of tests. A number of companies have been testing prototypes, but they’re generally smaller machines with limited payload capacity.

DroneDJ and mixed

InnovationAus/Nexxis Magneto-EX robot

USA: Lightning no match for wind turbine blade protection system Lightning protection systems currently exist for wind turbine blades.

But protection was needed for blades made from a new type of material - thermoplastic resin composites - and manufactured using an innovative thermal welding process which allows for the replacement of adhesives (which add weight and cracking potential).

Because thermal welding requires adding a metal heating element which can attract lightning, a protection was invented to keep the novel thermoplastic materials safe. The team infused an expanded aluminium foil into the blade skin to divert lightning current away from the metal heating elements. Tests demonstrated that about 80% of the electric current went into the expanded aluminium foil layer and not into the blade skin.

National Renewable Energy Laboratory

Singapore/USA: Chain mail fabric stiffens on demand Scientists have developed a new ‘chain mail’ lightweight fabric that is flexible but can stiffen on demand. It is 3D-printed from nylon plastic polymers and comprises interlocking, hollow octahedrons.

When the soft fabric is wrapped within a flexible plastic envelope and vacuum-packed, it turns into a rigid structure that is 25 times stiffer/harder to bend than when relaxed. This could pave the way for nextgen smart fabrics that can harden to protect a user against an impact or for additional load-bearing capacity. Typical solid particles are usually too heavy and do not provide enough tensile resistance for wearable applications. But here, each particle is made of hollow frames in different shapes that are then interlocked. The team is working on fabrics made from various metals, which could be used for larger-scale industrial applications.

NTU University

“Until now, robotic inspections haven’t been possible in confined spaces due to the risk of ignition, but Magneto-EX changes that” – Jason De Silveira of WA-based Nexxis, a company which has developed a novel robot (Magneto-EX) for hazardous, confinedspace inspections. The Magneto-EX has had its design approved and EX-certified – working safely and reliably in the most extreme conditions. WA’s Innovation and ICT Minister said that Magneto-EX was a prime example of how the state’s robotics sector was thriving and competing globally. “Innovation has an important role to play in growing and diversifying the state’s economy, and the Western Australian Government is committed to nurturing local innovators” he added.

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PRODUCT NEWS

Walter: Tools for titanium with twice the expertise Walter has launched its MD377 Supreme and MC377 Advance solid carbide milling cutters, designed for the effective machining of titanium.

Incorporating a corner radius and central through coolant supply, the new MD377 utilises Walter’s proven HPC Ti40 titanium geometry and new WTZ coating that makes it perfect for full slotting up to 1XD, ramping, shoulder milling and plunging. Also, the MD377 Supreme is suitable for dynamic milling processes. In comparison, the MC377 has a centre-cutting geometry without the through-coolant supply.

The MD377 Supreme has been developed for the aviation and aerospace industry and is therefore precisely matched to its requirements. The titanium specialist with a central coolant supply represents a benchmark when it comes to machining engine and structural components. It allows for tight tolerance machining and it stands out thanks to its extremely high metal removal rates. This high material removal rate is a credit to the optimised cutting geometry and the five cutting edges that can improve productivity levels and reduce vibration credit to its differential pitch design.

The MD377 Supreme is available with a range of corner radii in diameters of 6mm, 8mm, 10mm, 12mm, 16mm, 20m and 25mm with a flute length of 13mm on the 6mm diameter tool ranging up to 45mm on the 25mm tool with each tool designed with a back radius into a necked diameter for clearance when machining deep cavities.

In contrast, the MC377 is a four-flute titanium end mill that is also suitable for ISO P and M material designations. This diversity is credit to a tough AlCrN coating that works with Walter’s WK40EA substrate that makes the MC377 suitable for steel, stainless as well as titanium alloys. With regard to the MD377, the tool life and performance is assured with the latest Walter-exclusive AlTiN+ZrN (WTZ) coating with HIPIMS technology.

The impressive new MC377 end mill without corner radii is available in diameters of 2mm, 3mm, 4mm, 5mm, 6mm, 8mm, 10mm and 12mm, whilst the MC377 with corner radii is offered with a 2mm, 3mm, 4mm, 5mm, 6mm, 8mm, 10mm, 12mm, 16mm, 20mm and 25mm diameter, with the 2mm tool having a three-flute geometry and all other diameters having four flutes.

Depending upon the tool diameter, each MC377 tool is available with a choice of corner radii from 0.2mm to 4mm. The series has a flute length that ranges from 6mm on the 2mm diameter tool through to 45mm on the 25mm diameter tool. The MC377 cutter range is also designed with the back radius into a necked diameter feature for clearance.

Both tools are the perfect partners for the machining of small parts, engine components or structural components as well as additively manufactured components in the aerospace, motor sport and medical technology sectors. From a process security perspective, both the MC377 and MD377 are available with plain cylindrical shank across all diameters, but from 16mm to 25mm diameter there is also the option of a cylindrical shank with clamping flat to DIN6535 HB to prevent tool pull out and increase stability. In addition to the standard ranges with cutting lengths up to 2XD, Walter also offers custom-designed tools via the Xpress service with short delivery times. www.walter-tools.com

ADDE brings OTTO Motors autonomous mobile robots to Australia Melbourne-based automation system builder Andrew Donald Design Engineering (ADDE) has partnered with OTTO Motors to bring the OTTO range of autonomous mobile robots (AMRs) to the Australian market.

OTTO Motors, a division of Clearpath Robotics, develops market-leading AMRs that enhance the logistical operations of facilities in order to reallocate valuable manpower to more specialised tasks. These mobile robot platforms are designed to withstand the day-to-day rigors of industrial environments while maintaining the safety of the human operators around them. OTTO AMRs are being used by Fortune 500 manufacturing companies to deliver cost reductions and operational efficiencies.

ADDE has extensive experience developing automation solutions for the Australian industry with robotics and custom engineered solutions.

“We see enormous opportunity to improve efficiency and safety in manufacturing and distribution operations with autonomous vehicles,” said Barry Hendy, ADDE Managing Director. “Like traditional robots, AMRs require a complete solution design

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and tight integration with existing equipment, workflows and data systems. The OTTO range of vehicles and the supervising Fleet Manager system give us a powerful capability to offer turnkey solutions to our clients.”

John Stikes, Director – Strategic Alliances at OTTO Motors, added: “As we have deployed our systems around the world we have always looked to partner with experienced local integrators to ensure every deployment can be seamlessly and fully integrated into the client’s facility. We are excited to now be able to offer our vehicles to the Australian market through ADDE.” The OTTO motors range spans from the 100kg-capacity, smallfootprint OTTO 100, to the heavy-duty 1,500kg-capable, palletsized OTTO 1500. For multi-vehicle application the OTTO Fleet Manager provides the integration, overview control, traffic flow and vehicle management to allocate missions to appropriate vehicles. www.adde.com.au

PRODUCT NEWS

MAQ – Self-tuning boring bars reduce vibration Minimising vibration during machining operations has a number of advantages, including improved surface finish, reduction of scrap parts, increased cutting insert life and improved production costs.

Vibration issues are often present in machining operations where there is a high length-to-diameter ratio or if the machine tool itself is aging.

The challenge for “mass-dampened tools” is the change of the vibration frequency on machining tools due to change in the cutting conditions such as tool wear, condition of the machines moving parts, and the variation of work piece materials. For these reasons traditional mass-dampened tools require the tuning of the mass damper to optimise performance. An out-of-tune condition can make the vibration problem worse in the form of tool chatter, which is often solved by reducing cutting speed or depth of cut, or increasing feed per revolution.

The team at MAQ in Sweden studied the effects of vibration on the machining process and in 2015 developed a method of measuring a polymer’s frequency-dependent stiffness. They found that some polymers exhibited an increase in stiffness where there was an increased frequency, and it is the results of this study that were incorporated into the development of MAG’s STMD series of toolholders.

The STMD (Self Tuning Mass Dampener) series boring bars from MAQ use a different approach where the mass dampener in the toolholder body will automatically adjust its stiffness as in relation to the vibration frequency of the machine tool. Inside the tool is a tungsten mass that is completely dry; this is supported by polymer discs that react to changes in vibration and change the stiffness of the tool; this response maximises the dampening effect. STMD toolholders are designed to be “plug and play” – no tuning is required, and one holder can be used for more than one application. As the tool is self-tuning it adjusts to the vibrations that are causing tool chatter, allowing an increase in speed and feed with improved surface finish.

All MAQ vibration damped turning tools have the self-tuning mass damper technology inside and cover lengths from 3xD to 15xD. Starting from 10mm in diameter up to 60mm in diameter. Some of the boring bars in the range have an interchangeable cutter, the user can choose the cutter head to suit different insert shapes.

MAQ is also developing a range of adaptors that incorporate the same self-tuning dampening technology to reduce vibration during milling operations. www.whitelawtooling.com.au

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PRODUCT NEWS

LinX tubular linear motors: Superior alternative to pneumatics, ball screw and flatbed Modular, flexible and highly dynamic, the LinX range of tubular linear motors from ANCA Motion delivers improved performance even in harsh environments.

Applications such as packaging, labelling, sorting, and pick and place require robust and efficient actuation methods. Significant compromises are made by machine makers on linear actuation mechanisms used under harsh conditions.

This is where the LinX M-Series Linear Motor from ANCA Motion stands out as a lucrative solution offering better outcomes. LinX with its fully potted body and cylindrical design achieves higher IP ratings than conventional flatbed linear motors and rotary motors, and enables system integrators and original equipment manufacturers to target applications that were previously not on their radar.

The ability to achieve high speed and acceleration, the flexibility offered by its modular structure, and its higher IP rating make LinX an ideal choice for material handling applications within factory automation such as warehousing.

Thanks to its cylindrical design and direct drive nature, LinX motors do not wear on railings, significantly improving machine lifetime and drastically reducing maintenance costs. Larger spacing between the magnets and the machine base ensures that safety of operators

is never compromised. The LinX range is designed to allow easy replacement of ball screw and pneumatic cylinders in existing machine designs.

Elan Anbanandam, Automation Product Manager at ANCA Motion, said: “Our cylindrical motors are highly dynamic with integrated position feedback giving absolute accuracy to ±0.5mm and resolution of 10μm. Their pneumatic retrofit-friendly mounting, direct drive nature, higher IP rating and the ability to achieve velocities of up to 10m per second make LinX M-Series motors suitable for a multitude of applications.”

ANCA Motion is an Australian developer and manufacturer of motion control systems, hardware, and software including for its sister company ANCA CNC Machines. ANCA has used LinX tubular linear motors for its globally renowned tool and cutter grinders since 2014. As experts in motion control, ANCA Motion’s local team provide bespoke solutions for custom needs. A world-leading supplier of flexible motion controls, ANCA Motion also offers a range of other automation products such as human machine interfaces, servo motors and servo drives. www.ancamotion.com

Kaeser Mobilair M450: Heavy-duty portable compressor The heavy-duty M450 portable compressor from Kaeser has been especially developed to deliver unwavering performance under extreme environmental conditions.

The largest portable compressor in the Mobilair series, it assures a dependable supply of quality compressed air no matter whether in the desert or in the cold. This versatile portable compressor offers a maximum available flow rate of 48.1 cubic metres per minute and adjustable pressure between 6 and 14 bar. In addition, it also provides exceptional power and versatility.

Beneath the hood is an electronically-controlled MTU engine with an output of 2,360kW. In combination with a premium efficiency compressor block – featuring the flow-optimised Sigma Profile rotors – and the energy-saving fan installed as standard, it ensures exceptionally economical diesel consumption. Thanks to the innovative pV control, the operator only has to choose between two pressure levels. The set pressure 'p' directly influences the maximum flow rate 'V'. One and the same system can therefore deliver pressures between 6 and 14 bar.

For applications requiring 7 bar, a version delivering up to 8.6 bar is available, for example, with a powerful flow rate of 48.1 cubic metres per minute.

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Operation could not be simpler, as the M450 uses the proven Sigma Control Smart controller, which also indicates when the next scheduled maintenance is due. Following the push-button start, the system runs in unloaded state to ensure a safe cold start in all situations. The display shows the end of the warmup phase and the system can then be switched to load operation to generate compressed air. Pressure adjustment is also straightforward.

Depending on the application, the system can be equipped with a compressed air aftercooler, or with a microfilter combination for technically oil-free compressed air. With environmental protection in mind, accumulating condensate does not drip out of the system, but is evaporated via the hot exhaust gases.

The M450 is optionally available on a construction site chassis with a steering axle and parking brake, or as a stationary version with skids. The system is equipped as standard with an integrated forklift guide and lifting eyes for ease of transport, which can be safely accessed using climbing aids. www.kaeser.com.au

CoroPlus® Machining Insights

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To learn more about our data analytics application, visit: coroplus.sandvikcoromant

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PRODUCT NEWS

Konica Minolta announces availability of MiR250 mobile industrial robots Konica Minolta Australia has announced the availability of the MiR250 through its partner Mobile Industrial Robots (MiR), a leading manufacturer of collaborative mobile robots that increase efficiency and drive productivity.

The MiR250 is a more flexible autonomous mobile robot (AMR) that can work around the clock and is simple to set up for improved productivity. With a smaller footprint and increased adaptability, it can help optimise internal logistics without changing layout in industries such as manufacturing, fastmoving consumer goods (FMCGs), and defence.

The MiR250 has a footprint of 580mm by 800mm and is only 30cm high. It can move up to 250kg at speeds of 2m per second. The MiR250 is more agile than any other AMR on the market and highly adaptable for challenging environments.

According to the SafeWork Australia website, forklift and cranes accounted for 15% of fatalities in 2019, above the average of 11% over the past five years.

Martin Keetels, National Manager – Robotics & Innovation at Konica Minolta, said: “The MiR250 eliminates risk around forklift operations and is one of the safest autonomous mobile robots on the market designed according to current applicable safety standards. The latest scanning technology with a 360-degree view means there are no blind spots so it can navigate safely around other objects and humans.” The MiR250 has a fast charge of zero to 80% in one hour with an operating time of 13 hours

at full charge. As a critical piece of infrastructure, it has the ability for a fast battery swap to support 24/7 operation.

This means production flow remains uninterrupted with no downtime. Top modules can also be mounted on the MiR250 for a complete solution to tow carts and shelves and lift and transport shelves. The MiR250 signals with light and sounds to demonstrate its status.

The LED light band indicates its current operational state such as emergency stop, mission paused, path blocked, or mapping. The MiR250 also has signal lights that work similarly to lights used on cars; white at the front, red at the back, and indicating a left or right turn by blinking. Signal lights suggest the immediate motion plans by signalling forwards, backwards, braking, and left and right turns.

Keetels added: “Konica Minolta is excited to bring innovation to highly dynamic manufacturing and logistics environments by safely and cost-effectively automating the movement of materials.

Humans move thousands of carts manually around the factory floor, a highly repetitive and time-consuming task. This solution frees up workers for other critical tasks and significantly improves safety.” www.konicaminolta.com.au

Guhring: New drills deepen productivity gains The productivity of deep hole drilling has taken a step forward according to Guhring, with the arrival of its new fourfluted series of gun drills.

The new VB 80 four-fluted deep hole drills with a solid carbide head and the solid carbide VB 100 Series are ideal productivity partners for cast iron drilling. The straight flute deep hole drills are extremely robust with a geometry that ensures the drill core is more than 50% of the overall diameter, demonstrating maximum rigidity, strength and performance.

Guhring has also developed an innovative geometry that consists of two core cutting edges that are supported by four outer flutes that are axially displaced to split the chips, improve centring and precision while reducing cutting forces. This means the bottom of the hole will be two-stepped, as the drill has a 141-degree angle on the primary cutting edge, which is followed by a 145-degree cutting angle on the outer cutting edges. The chip clearance is further improved by four cooling channels that allow high-pressure coolant to be directed to each of the four cutting edges – prolonging tool life by preventing swarf re-cutting and creating an efficient chip removal sequence.

The new VB 80 and VB 100 deep hole drills also consist of four round margins with a 90-degree division that further enhances precision, concentricity and surface finishes down to IT6. With the abrasive wear divided through four flutes as opposed to two, as in most ranges, the new VB 80 and VB 100 have proven to improve tool life and performance significantly. In fact, the new deep hole

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drills have reduced cycle times by more than 30% during field tests whilst also extending tool life, hole quality and overall performance far beyond the realms of two-flute gun drill variants.

At present, the new VB 80 and VB 100 Series is available in diameters from 13.5mm to 28mm diameter with flute lengths up to 500mm. Additional diameters and lengths can be specified upon request. The new drills can be reground from five to ten times depending upon the axial wear on the drills. This regrinding facility drastically reduces cutting tool costs for the end-user with the drills being returned in a perfect ‘as-new’ condition. At present, the VB 80 and VB 100 are new product lines and Guhring is working tirelessly to develop an extended range of drill diameter and length options whilst trialling the exciting new drills on a host of additional materials, an exercise that will undoubtedly create huge productivity enhancements for manufacturers. www.guhring.com.au

PRODUCT NEWS

Hyster UT Series: Raising comfort, lowering cost A new range of the Hyster UT Series is being introduced to Australia to provide enhanced driver comfort and a low total cost of ownership for the forklift operator.

The new H4.0-5.0UT internal combustion counterbalance pneumatic tyre forklifts, with lift capacities from 4,000-5,000kg, complement the broader range of Hyster UT Series forklifts in providing costeffective performance for everyday materials handling tasks.

“The H4.0-5.0UT range features the toughness and backup Hyster is known for globally, but without any advanced functionalities that aren’t required for less frequently used forklifts, meaning total cost of ownership is kept low,” says Mark Chaffey, Area Business Director, Pacific at Hyster. “Industries that may sometimes require less frequent use forklifts – such as food & beverage, frozen produce, manufacturing, distribution and truck & transport – do need a quality forklift with outstanding sales and service backup. The Hyster H4.05.0UT range delivers an ideal solution to less frequent materials handling needs, without compromising on performance.”

The new H4.0-5.0UT forklifts – in 4,000kg, 4,500kg or 5,000kg models – have a number of features to further enhance driver comfort, visibility and ease of operation, including: • A small diameter steering wheel with adjustable steer column.

The 300mm steering wheel is easy to manipulate, responsive, with optimum manoeuvrability when working confined spaces.

The ideally positioned steering wheel allows eight degrees of tilt adjustment, to suit a variety of different operators.

• A high-strength profiled steel overhead guard to provide enhanced reliability and operator protection.

• Excellent through-mast visibility of the load and the operator’s forward field of view, optimising comfort, safety and productivity.

• A large access area for service and repairs, including large access space to the engine compartment to minimise downtime when servicing the forklift.

• A suspension seat for excellent comfort.

• Exchangeable components, including overlaps with other forklifts in the same range, which further optimises maintenance and spare parts inventories.

• Improved lift speed, which enables higher productivity.

The new machines’ value proposition – “Meets the Need. Makes the Move” – relates to customers who don’t need advanced functionality features, but prefer proven materials handling solutions. The use of high-quality, robust components, efficient filtration and excellent cooling helps contribute to reliable operations and lower wear and tear. This, together with fast availability of cost-effective replacement parts, reduces maintenance requirements and costs. www.hyster-yale.com

DISCOVER WHAT AN OMAX ABRASIVE WATERJET CAN DO! OMAX Waterjets streamline operations by reducing your need for multiple machines, secondary processes and extensive employee training. OMAX Waterjets are the perfect complement to your shop. The flexible tool cuts like a saw, machines like a lathe, contours like a mill and shapes like a wire EDM. Learn more today.

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PRODUCT NEWS

Enerpac HMT 13000: Rugged, safe and fast low-profile torque wrench Enerpac has introduced its new lightweight, low-profile HMT 13000 interchangeable torque wrench, offering faster operation, fewer moving parts, with rugged alloys that give it a significantly longer lifespan.

The HMT 13000 – an extension to the previously introduced HMT product line – is designed especially for low-profile applications only and suits hex sizes from 62mm to 115mm AF. The HMT 13000 delivers output torques from 1,829 to 18,289 Nm in applications including those requiring powerful tool access to confined spaces in tasks in mining and aggregates, oil and gas, infrastructure and construction, manufacturing, maritime and power generation and distribution.

“The HMT 13000 shares the same low cost of ownership as the broader range, and is also costeffective and reliable because the cassettes have up to 25% fewer internal components than other manufacturers, reducing the risk of failure and cost of repair,” says Tony Cooper, Marketing Manager at Enerpac Asia-Pacific.

“The HMT 13000 distinguishes itself through speed, durability, and efficiency. It is designed to be interchangeable with different tools in the market. When it comes to speed, it offers a best-in-class outputto-weight ratio and is up to 25% faster than leading competitors.

As for durability, superior alloys make this tool lightweight and gives

it a 2.5 times longer life expectancy than comparable tools.”

With regard to operator efficiency, the modular parts allow for interchangeability, but at the same time guarantee a higher productivity.

Its 30-degree angle of rotation saves time and money and is 25% more efficient. Other features that improve operator efficiency are a 360-degree swivel hose attachment, lightweight design that results in less fatigue, and a standard ergonomic safety handle.

The HMT series is complemented by Enerpac’s broader range of non-impact professional bolting technologies – including market-leading S and W torque wrenches – and by one of the world’s most comprehensive ranges of pump technologies.

These include system-matched electric, air and petrol-powered types as well as the XC Series cordless torque wrench pumps, which are ideal for remote locations, sites that do not have access to power or where having electric cords could cause trip hazards, such as in maintenance workshops. www.enerpac.com

Algra Tooling: Going from strength to strength Started up in 2019, Algra Tooling has pulled out all the stops in its two years of trading to help industrial companies throughout Australia access cutting tools. Now Algra has announced the launch of its brand new eCommerce website.

The sole importer of Dormer Pramet products into Australia, the new company has enjoyed rapid growth. To date Algra stocks more than 2,500 product lines, with a wide range of round and indexable tools provided to industrial distributors across the country.

Dormer Pramet is a global manufacturer and supplier of tools for the metal cutting industry. Its comprehensive product program encompasses both rotary and indexable tools, covering drilling, milling, threading and turning applications for a variety of production environments. Andrew Sherry heads up Algra, assisted by fellow director Sandra Sherry and their competent team from the company’s premises in Hallam, Victoria.

Sherry said: “Since launching Algra we have recruited additional staff, increased stock holding of more product lines, opened more accounts, created additional storage and now launched a brand new eCommerce website. The first two years have been a whirlwind, as with starting any new business. However, we have been really pleased with the reaction and support we have received from the marketplace.

Algra can offer next-day delivery for most items right across Australia, meaning customers have easy access to high-quality tools whenever they need them. Even during COVID-19 times, the company has been receiving deliveries twice weekly from Dormer Pramet’s global warehouse in Europe. Therefore if it doesn’t have the relevant product available, it knows it can be here within four days.

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Andrew Sherry of Algra Tooling.

“The launch of our new website allows our customers to find products and place orders at the touch of a button, as well as read key features and benefits of the assortment available,” Sherry added. “The search functionality is an added time saver and the machining tips offer bite-sized learning. Dormer Pramet’s 2021 catalogues are featured on our website showing the complete and up-to-date ranges. And of course, we are still only a phone call away.” www.algratooling.com.au

DERATECH specialize in designing and manufacturing sheet metal working machines, headquarters for research and design are based in Belgium.

The DERATECH vision is to bring high-quality machines on the market at an acceptable price, without sacrificing the quality of the parts and components. The success of DERATECH products lies in an excellent price-quality ratio.

DERATECH offer a complete range of products and solutions: • • • • • •

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“Probably the best price / quality ratio in the world”

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TRANSPORT & LOGISTICS

TRANSPORT:

DRIVING THE ECONOMY AND DELIVERING JOBS The transport sector is creating big opportunities for manufacturers across Australia. In Perth, Alstom is bringing rail manufacturing back to WA, supported by suppliers such as Hofmann Engineering, while in Brisbane, HC-ATM is assisting Australian and international truck companies through innovative design and know-how. By Carole Goldsmith.

Rail manufacturing has returned to the Midland area in Western Australia, 27 years after the old Midland Railway Workshops closed.

World-class railcar manufacturer Alstom is building a fleet of 43 trains for the Public Transport Authority of Western Australia (PTA) at its new METRONET train manufacturing facility in Bellevue, east of Perth. This is part of the $1.3bn, 10-year contract that the WA State Government signed with Alstom in December 2019 to supply 246 new METRONET railcars.

Alstom commenced operations at the PTA’s new facility this May. The site’s official opening in June was attended by WA’s Premier Mark McGowan and the Minister for Transport Rita Saffioti. This is an exciting time for new rail manufacturing in WA, and the first of the new trains will be delivered to the PTA next year, much to the delight of all the passengers who will ride these super-smart, innovative new trains.

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The project will create around 200 new jobs in WA, including for apprentices and Indigenous Australians, to manufacture, test, commission and maintain 41 six-car electrical multiple unit (EMU) trains and two three-car diesel multiple unit (DMU) trains. It also includes 20 years maintenance of the EMU trains and maintenance support services for the DMU trains.

Alstom’s Project Director for the METRONET railcar procurement project, Fabrice Ponti explains that Alstom moved into the Bellevue facility in May, and the fit-out will be completed by early October.

“The fleet of 43 trains will be built with local suppliers, contractors and equipment vendors,” advises Ponti. “Alstom has committed to 50% local content for the railcars, bringing additional flow-on benefits beyond the delivery of the trains to the WA economy.”

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After graduating as a mechanical engineer in France and the US, Ponti’s career has spanned 18 years at Alstom. He has managed a wide range of global roles for Alstom in France, Argentina, Russia and China, before coming to Australia and settling in Perth with his family in 2019, specifically to work on the METRONET rail project.

As Alstom did not have its own manufacturing site in WA, Ponti says: “We are in the process of hiring a significant number of employees for the project. We have already sourced 80 local people to work on the site, mainly for production.”

As of late August the Alstom team was happy with progress on the fit-out of the new facility, as Ponti explains: “So far, the PTA has provided a manufacturing workshop for the fitting area, which is where we will assemble the railcar and install its components, plus a bogie workshop. The bogie is the rolling undercarriage, essentially composed of a steel frame, axles and suspension systems.”

Local supplier Hofmann Engineering will be manufacturing the bogie frames at its Perth manufacturing site from early 2022. Ponti remarks: “Hofmann is a significant supplier as the bogie frames are important parts of the railcar.”

He adds: “Soon the PTA will provide a 25,000-volt facility on this same site to enable us to test the train before delivery. The first train is scheduled for completion in the first half of next year. All the 43 trains will be completed by the end of 2029.”

From left: Mark Coxon, Managing Director of Alstom Australia; WA Premier Mark McGowan; and Fabrice Ponti, Alstom Project Director, at the opening of the new METRONET train manufacturing facility in Bellevue, Western Australia.

Alstom’s new team of production employees attend a two-to-fourweek internal training program depending on their proposed job.

They learn about the company and then are trained on the products and manufacturing processes specific to the project. Trainers use company videos on manufacturing systems and procedures to assist new employee’s learning and skill development. Also, trainees can use virtual reality 3D display technologies to visualise assembling components inside the railcars.

“Production employees have iPads, which they use on the job for production processes and to access documentation,” Ponti explains.

“As part of our local employment initiative, we are also working with the North Metropolitan TAFE, East Perth, on an apprentice program for Indigenous people. They will serve their apprenticeship on the METRONET project. This will enable them to learn valuable skills on the job, with the view to continue their career with Alstom after they complete their apprenticeship.”

Ponti is proud of how the METRONET railcar project is progressing and is very enthusiastic about its future operations: “It’s the return of railway manufacturing to WA after the Midlands railways’ workshops closed in the 90s. Alstom is proud to contribute to this important project for WA.” Contined next page

The fitting line being set up at the Bellevue facility.

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TRANSPORT & LOGISTICS

A visual of the electrical multiple unit (EMU) train that is being manufactured in Bellevue Continued from previous page

Hofmann Engineering – Gearing up for bogie production As Product Specialist and Operations Engineer at Hofmann Engineering, Karl Hofmann manages the company’s rail portfolio, and he’s looking forward to working on the Alstom METRONET project with his rail team. Hofmann Engineering will commence manufacture of bogie frames for the project’s railcars at its Bassendean manufacturing site in east Perth early next year.

“The Transfer of Technology process between Alstom and Hofmann is now being undertaken,” says Karl. “This includes detailed manufacturing plans that needs to be prepared before the bogie production commences. That’s what’s being undertaken at the moment and we have a team of six people working on this phase of the project.”

As a global business headquartered in Perth, Hofmann Engineering is well equipped to handle large railcar bogie frame orders. It also manufactures bogies at its Bendigo factory for Public Transport Victoria’s High-Capacity Metro Trains. The first of these passenger trains entered service in Melbourne’s train network in December 2020, and will be rolling stock for the METRO Tunnel when it opens in 2025. Among its other rail projects, Hofmann Engineering also manufactures bogie frames for Downer’s Yarra Trams, in addition to locomotive bogie machining and heat treatment for freight locomotive manufacturer UGL. Explaining about the bogie and its production process, Karl says: “The bogie, which is the steel chassis of the railcar, measures approximately 4m x 3m and is half a metre tall. It’s a fabricated bogie design made primarily from plate material, cut into shapes using a plate cutting machine before being welded using a state-of-the-art welding robot. Following this, a five-axis gantry milling machine will be used for final machining and inspection of the bogie frame. “The manufacturing process is fully integrated in our enterprise resource planning (ERP) system that implements all of the necessary manufacturing controls to ensure that the bogie has been manufactured correctly. From start to finish, it will take the rail production team approximately three months to make a batch of 12 bogies (one trainset).”

Today John’s son, also named Erich, is at the helm as Managing Director, and the company has close to 600 employees, including 350 at its Perth headquarters. The rest of the workforce are located across four manufacturing sites across Australia, its three international manufacturing sites in Chile, Peru and Canada, and at its offices in USA, India and China.

Engineering certainly runs in the Hofmann family. Soon after graduating as a mechanical engineer in 2016, Karl spent six months as an engineering intern at five different companies in Germany.

He says that the knowledge and experience of German advanced manufacturing he gained was invaluable for his subsequent career at Hofmann Engineering, which he commenced after returning to Australia.

A gantry milling machine at the Bendigo facility, where it manufactures bogies for Public Transport Victoria’s High-Capacity Metro Trains.

Hofmann Engineering is one of Australia’s greatest business success stories. Two brothers from Germany, John (Karl’s grandfather) and Erich set up a small toolmaking shop in a Perth backyard in 1969, thinking that there would be a future in gears. It’s come a long way since then, and is now one of the largest gear-making operations in the Southern Hemisphere.

Hofmann Engineering’s head office and manufacturing site in Bassendean, Western Australia.

Karl Hofmann, Product Specialist and Operations Engineer at Hofmann Engineering, and Erich Hoffman, the company’s Managing Director.

Regarding the future plans for the family-owned company, Karl says: “We are doing a lot more work in the mineral processing, defence, aerospace, rail and renewable energy sectors. We want to continue growing the business, and are currently extending the Perth factory to cope with the current and anticipated demands. All the company’s profits are put back into the business, with many of the family members working here. In the next 10 years, the target is to work hard to increase the current $170m business value to become a half-a-billion-dollar company.”

The way the company is going, it will achieve that successful outcome quickly.

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TRANSPORT & LOGISTICS HC-ATM manufactures high-quality truck, trailer and tooling aftermarket parts such as this manifold for the heavy transport industry.

The HC-ATM Group team at its Brisbane facility.

HC-ATM – Competing with imports on price and quality Brisbane-based manufacturer HC-ATM Group prides itself on manufacturing high-quality truck, trailer and tooling aftermarket parts for the heavy transport industry. Trading under the name of Australian Truck & Trailer Parts, it is regarded as an essential supplier to Australian distributors and major transport brands, and has experienced an increase in demand for its products during COVID lockdowns.

Directors Peter Henderson and Greg Hudson first acquired the business’ assets in 2010 from a Brisbane manufacturer that was closing. Both Henderson and Hudson had worked together in IT, before creating Australian Tool Manufacturers, as the business was known then. Henderson and Hudson are still the majority investors in the business, and together with Murray Curti running daily operations, they form a team that has been able to implement advanced manufacturing concepts with their key staff. The wide range of products made in their factory can compete with imports both on price and quality.

Henderson says that when Curti came onboard, it was to help them develop and streamline the manufacturing design and operations side of the business: “Murray, who’s our Operations Director, is a trade-qualified boiler-maker and certified welder, and he’s very talented in finding alternative, cost-saving solutions to manufacture and solve existing problems with OEM parts.”

Curti adds: “My previous working history required me to go into companies to problem-solve and implement solutions to existing problems. When I came onboard at HC-ATM, we invested in advanced manufacturing technology and machinery, which we continue to do today and for the foreseeable future.”

“We are a problem-solving manufacturing company, number one,” says Henderson. “Murray is contacted daily by transport operators, so he goes out to help them with suspensions and other components. He offers a solution to their problems, then comes back to redesign it in-house, and then manufactures a prototype for trial. We sell worldwide and are very competitive in price, against the imported variants coming in from Europe, China and elsewhere, as many of parts don’t stand up to the Australian conditions and roads.”

HC-ATM Director Peter Henderson (right) with Machine Operator Daniel Zamora.

Speaking on one issue that they solved recently for an international truck manufacturer, Curti explains: “When their V8 trucks were pulling heavy loads up the hills, they had a lot of problems with the manifold cracking. The manifold is an important keg in the truck’s exhaust system. Every six months they had a costly manifold replacement, plus the trucks were off the road, being repaired.

“The manifold was cracking because of casting limitations, so we redesigned and machined a new manifold that takes away any limitations that manufacturing previously had, by making it from a billet of steel on our Okuma five-axis machine. The transport company is very happy, as the manifold we have made for their trucks will last for many years to come. There is now a high interest in this manifold and the potential to make other manifolds for different brands and purposes in other industries.”

HC-ATM has conducted a lot of R&D and one area of focus is in the redesign of rubber engine mount suspension systems for its customers.

“We were contacted by a large cleaning and rubbish removal contractor that had started buying their trucks from an international truck manufacturer,” says Curti. “The two original rubber engine mounts that were supplied in those trucks became faulty quickly.

The cleaning contractor sent the truck manufacturer to us to solve the problem. They were using a rubber engine mount on the engine, which is not suitable for Australia’s climate. I redesigned it using a strong polyurethane polymer instead of rubber – it’s been a great success for all concerned. Business is good HC-ATM at the moment. Currently the company is struggling to keep up with the demand for its products and services. It will be increasing employee numbers from its existing team of 16 people in the near future.

“Our biggest problem is securing our raw advanced material, most of which comes from Europe, so there are delays on the docks, because of COVID restrictions,” adds Henderson. “However, COVID has been very good for our business as a lot more clients are now buying our Australian-made components, because of the delays in getting imported parts into this country. So that’s a positive for our company and for Australian-made.” www.alstom.com www.hofmannengineering.com www.aussietruckparts.com.au

HC-ATM Director Greg Hudson (right) with Machine Operator Ian Melville.

Murray Curti, Operations Director at HC-ATM.

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Bombardier: On track for efficient production Bombardier Transportation used additive manufacturing technology from Stratasys to speed up the development process for components on new trains.

Bombardier Transportation is a global mobility solutions provider.

Its lead engineering site for Central and Eastern Europe and Israel is located in Hennigsdorf, Germany. This location is responsible for pre and small-series production of mainline and metro projects, as well as design validation to enable the large-scale manufacture of passenger vehicles at other Bombardier Transportation sites around the world.

Maintaining, servicing and manufacturing these vehicles while upholding Bombardier’s standard of excellence requires fast, effective and cost-efficient processes across many teams. A key factor in achieving these objectives is the versatility to work efficiently across different projects.With specific goals to support digital inventory and produce large certified interior train components, Bombardier Transportation’s Hennigsdorf site invested in industrialgrade 3D printing.

Using 3D printing to produce train parts like this connector with the F900 saves nearly 77% in production time.

“Our customers choose Bombardier Transportation because we deliver innovative design concepts,” André Bialoscek, Head of the Vehicle Physical Integration department at Bombardier Transportation, explains. “Each of these customers has different yet demanding manufacturing requirements, so it’s vital we deploy the most advanced technologies available to ensure we effectively fulfill their needs. That is why we decided to invest in additive manufacturing technology, and specifically the Stratasys F900 3D printer – it enables fast production of large-size productiongrade parts.”

The Vehicle Physical Integration department is part of the Hennigsdorf site’s new vehicle construction. It is of central importance for the design validation to provide a multitude of customised parts.

Bialoscek says the integration of additive manufacturing has been transformational in achieving these objectives.

The F900’s print capacity lets Bombardier Transportation produce larger 3D printed vehicle components, such as this air vent system part.

“Our goal during the development process for new trains is to speed up the production of project-specific parts that take a while to design,” said Bialoscek. “While speeding up production, we still need to ensure that total functionality, safety, and repeatability are upheld. With our F900 3D printer, we are able to do all those things – it has been a game-changer for our department.”

The department recently produced a complex custom air vent system for a battery-powered prototype train. The large part was 3D printed in ULTEM 9085 resin material, which significantly reduced the component’s weight and optimised overall material use. ULTEM 9085 resin also meets EN45545-2 rail certification guidelines for smoke, toxicity, and fire - a requirement for all train components produced at Bombardier Transportation.

“With regard to the battery train’s air duct, we were able to reduce production time from four months to roughly four weeks,” explained Bialoscek. “That’s a resulting time saving of nearly 77%. That is an incredible outcome for our department and demonstrates our ability to now produce certain parts on-demand to our exacting needs without enduring lengthy production times or compromising on material quality. Also, parts can now be replaced much quicker in the servicing of older trains.”

The F900’s build capacity is big enough for Bombardier Transportation to produce large vehicle components or print several different parts on the same build tray. This gives flexibility to on-demand production and delivers an increased scope for large-size parts like the air duct.

Building a digital inventory For Bombardier Transportation, the F900 also marks a shift in service, as Bialoscek pointed out. The company is now building a digital inventory, ensuring spare part needs are fulfilled on-demand

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The final custom air vent system, 3D printed in ULTEM 9085 resin.

regardless of the particular train model or its age. By simply storing 3D scans of parts, Bombardier Transportation bypasses the physical storage of parts. When a part is needed, Bombardier Transportation uses the F900 to build it from the digital CAD file. Indeed, a significant benefit of the F900 is the way it enables the team to quickly recreate one of its “digital” parts as a certified train-ready part, leading to fast and direct service for its customers.

“We are now also exploring Stratasys’ PolyJet 3D printing technology for our design validation process, and the results we have witnessed so far have been convincing,” Bialoscek commented. “Indeed, in engineering, the use of 3D printing to produce prototypes has seen us reduce our design process time by a massive 30%-40%, while also increasing the quality of our overall designs.” www.objective3d.com.au www.stratasys.com www.bombardier.com

TRANSPORT & LOGISTICS

Symons Clark Logistics: Getting there with MaxiTRANS It was 75 years ago that the first Freighter trailer rolled onto Australian roads. Today supplied by Australian manufacturer MaxiTRANS, the Freighter’s success is built on the loyalty of customers such as South Australia-based Symons Clark Logistics, managed by brothers David and Ricky Clark.

“Freighter has never given me any grief in 25 years,” says David.

“They have always accommodated in helping me achieve what I wish to achieve with my business needs. The quality that Freighter makes and the durability of these trailers is very good.”

Symons Clark is one of the oldest transport and logistics businesses in South Australia, with its roots dating all the way back to 1875.

With a fleet of over 90 trucks and 176 trailers, the business provides transport, bulk haulage, container services, warehousing and distribution and equipment hire across the South Australian market, along with transport services to major cities along the east coast.

“The majority of our trailers are from MaxiTRANS, made up of Freighter, Hamelex White and Lusty EMS units,” David says. “Our first trailer was a 40-foot tri-axle Freighter trailer and we continued to buy the same model for some years to cart shipping containers.

Once B-Doubles came in the market, we started buying those sets and now we buy Road Trains and AB-triples. We have ordered three new Stag sets of B-doubles from MaxiTRANS that are coming later this year.

Most of Symons Clark’s trailers and equipment are standard models, but it does have some custom-built Freighters with features such as longer tipper bodies on the A-trailers, tri-axle tipper racks, and a custom-built Sliding Tipping Skel bought around seven years ago and still in use. “The design of Freighter trailers is 100% productive,” David adds. “Our trailers are in use every day, they do a lot of work but they don’t wear out. They are very robust and a very good

product. Since the initial days of our link with Freighter, we have not had any problem with their sales or customer service.

“I go with quality, experience and service and how people look after my business so I’m not one to change. I’m a bit of a creature of habit and when I know I’m being looked after, I’m totally committed.

That’s what draws me to Freighter. They look after me.” www.symonsclark.com.au www.maxitrans.com

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E: sales@integrasystems.com.au P: (03) 9359 3133 www.integratransform.com.au/k40 197 Northcorp Boulevard, Broadmeadows, Vic 3047

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Locally manufactured hybrid school buses drive SA transition to cleaner transport Australian bus manufacturer BusTech (SA) has begun delivery of 20 new school buses, including 17 hybrid-electric vehicles, to meet increased demands on South Australian school bus routes.

With a hybrid chassis provided by Scania and the body manufactured

by BusTech (SA) at its facility in the northern suburbs of Adelaide, the 20 new school buses will support the South Australian State Government’s commitment to providing school students with a safe, effective and reliable bus service.

The milestone was celebrated on 20 August at Unley High School, with the State Minister for Transport and Infrastructure, Corey Wingard, congratulating BusTech (SA) and Scania for delivering the first tranche of locally built school buses for South Australian students.

“We want to provide the next generation of school students with a cleaner and greener public transport experience, especially as Year 7 transitions into public high schools from next year,” said Minister Wingard. “As an added bonus, our adoption of the Scania Hybrid for the Adelaide Metro fleet is also creating jobs for South Australians as it has led to an increase in the number of employees at BusTech (SA) dedicated to bus body-building.”

The partnership with BusTech (SA) and Scania to build the additional hybrid models for use on school routes is part of a shared goal to deliver commercially sustainable transport solutions for customers across Australia.

“BusTech Group continues to work closely with State Governments and operators to transition diesel fleets to lower-emission solutions and ultimately zero-emission solutions, which will significantly benefit the local environment and public health,” said Christian Reynolds, Executive Chairman of BusTech Group. “These new hybrid-battery buses built in Adelaide for Adelaide are an important step in achieving cleaner and more sustainable public transport options for South Australians.”

The first three of the new hybrid buses have already rolled off the production line with the remainder, including three articulated

buses, to be delivered by the end of 2021. These new buses will help to meet demand as a significant number of extra students start attending secondary schools due to the transition of Year 7 into high school in Term 1 of 2022.

A cleaner, quieter journey Late last year, BusTech (SA) delivered two hybrid-electric buses, built in partnership with Scania, to service the South Australian O-Bahn network. These hybrid buses were the first of their kind in South Australia and have proven to significantly reduce carbon emissions along the O-Bahn bus route.

BusTech onboard for Gold Coast e-bus rollout The Queensland Government has announced a plan to build 16 new electric buses on the Gold Coast as part of its commitment to rollout more zero emissions vehicles on the state’s roads.

The $15.6m deal with Keolis Downer, Australia’s largest private provider of public transport, will also create the state’s first 100% electric bus depot in North Lakes. Keolis Downer CEO David Franks said: “With this project, we are also encouraging local manufacturing through our partnership with BusTech Group. BusTech Queensland will manufacture the 16 Australiandesigned and engineered electric buses in their facility in the Gold Coast, bringing more than $17m of estimated value into the economy for local suppliers, contractors and local job creation.”

Transport and Main Roads Minister Mark Bailey said the deal would play an important part in Queensland’s COVID-19 economic recovery plan: “This deal will see the largest rollout of electric buses in Queensland to date. These buses will be built right here in Queensland, at BusTech on the Gold Coast.”

Deputy Premier Steven Miles said the agreement was not only a win for local commuters and the environment, but for the Queensland manufacturing sector too: “The investment to make the North Lakes depot fully electric and build these buses on the

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Gold Coast is expected to support 150 jobs over the next two years. It’s also expected to bring more than $17m of estimated value into the economy for local suppliers, contractors, which is the kind of investment we need right now.”

BusTech Group Executive Chairman Christian Reynolds said the company was excited to be involved in the project: “BusTech Group is delighted to partner with Keolis Downer to deliver Australian designed, engineered and manufactured zeroemission buses with the most energy dense battery solution.

Manufactured in Queensland, BusTech’s all-electric ZDi is built with the highest local content of any electric bus available on the Australian market.

“These 16 new electric buses will provide Queensland with cleaner, quieter transport whilst also supporting employment opportunities, the local supply chain, the renewables industry and generating lasting economic benefits.”

The new buses, which will use 100% renewable energy and be zero emission, will be built on the Gold Coast by Queensland bus manufacturer BusTech. The first bus is due to arrive at the North Lakes depot in September 2022, ahead of all 16 being ready for service by late 2023.

TRANSPORT & LOGISTICS

Professional Measuring Instruments

The hybrid buses can switch to electric drive when idled at bus stops or in school zones. When these buses are in electric mode, they do not produce any tailpipe emissions and make very little noise, giving schoolchildren a much more pleasant commute to school.

“The batteries recharge whilst driving, allowing buses to automatically alternate between electric and diesel modes which means they are more fuel-efficient and have lower exhaust fumes than traditional school buses.” explains Gregg Dinning, Chief Technical Officer of BusTech Group. “The Scania drivetrain technology for these hybridelectric buses has been proven to cut diesel consumption and emissions by up to 25% per vehicle. The buses can operate without harmful emissions and noise, particularly in areas with a high level of pedestrian traffic, such as schools.”

Locally built with the highest Australian content The production of these 20 new buses at BusTech Group’s Adelaide facility is a testament to the advanced technical, engineering and manufacturing expertise within South Australia.

“It’s vital that we demonstrate to our school children that we can manufacture vehicles in Australia, and we don’t need to be net importers of technology,” says Reynolds. “Making as many school buses as we can in Australia is a great way to do that.”

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

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

Being 100% Australian-owned and employing over 250 staff Australia-wide, BusTech Group is passionate about sourcing and harnessing local manufacturing and engineering capabilities to design and build its products.

“Through engaging a local supply chain and building these buses in Adelaide, rather than importing buses from overseas, we significantly decrease our carbon footprint while also generating compounded employment and economic benefits through the supply chain far greater than the manufacture of these 20 buses,” Reynolds adds.

Zero-emission school buses BusTech Group wants to see all school buses one day mirror the transition happening in public transport more broadly. Electric school buses can lead to long-term savings for schools and companies that provide school transportation services. Electricity is less expensive than diesel fuel and when combined with the reduction in maintenance costs, the total cost of ownership of electric school buses can be reduced over their useful life.

“We see the hybrid-electric buses as part of the transition roadmap to zero-emissions transport solutions,” Reynolds says. “Ultimately, we want to see all students travelling to school on zero-emission transport, and we are keen to partner with operators and governments to help them with the technology that best fits their needs.” www.bustechgroup.com.au

Available now at:

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The trucking industry has begun to turn electric; cars will take longer Australia’s trucking industry is making moves to go electric. The latest development — a system for using swappable batteries instead of time-consuming recharge stations for long-haul trucks between Sydney and Brisbane — shows how this transition is gathering momentum. By Gail Broadbent and Graciela Metternicht.

There will be clear socio-economic, environmental and healthrelated benefits from the switch to electric trucks — for the broader community as well as for the trucking industry and truckies themselves. As electric vehicle researchers, we think swappable batteries could work well for trucking, but are perhaps less suitable for everyday electric cars.

Electric trucking There are many benefits from electrifying truck transport. Companies such as Woolworths and Ikea have already started to transition to electric delivery vans for the environmental benefits (and a possible boost for their brands). Many leading truck manufacturers such as Scania, Mercedes Benz and Volvo are proceeding apace with trials and plans to make their trucks electric.

Trucks make up 20% of the vehicles in Australia, and Australia’s transport emissions are still growing. Australia’s motor vehicles consume more than 33 billion litres of fuel each year. The transport sector was responsible for about 100 million tonnes of carbon dioxide emissions in 2019.

Australia spent some $31bn in 2019 to import oil, with half used for road transport. This not only affects Australia’s balance of trade, but poses a risk to our freight industry (including supermarket deliveries) if geopolitical instability affects fuel imports (which mainly come from just a few countries).

The trucking company Linfox appears to have understood the advantages that transition to electric trucks can bring to its business, and is one of the early adopters trialling them here in Australia.

Not just trucking companies Many big companies are making commitments to cut their carbon emissions, such as Fortescue Metals’ target of net zero operational emissions by 2040. Its mining fleet operations account for half of its operational emissions. Procurement of electric trucks by government and mining fleets could not only help reduce transport emissions but signal to the community that the transition away from more polluting vehicles can be done.

Modernising the fleet is an imperative that we need to prioritise.

The business sector can play a key role in the success of the latest Australia Government Technology Investment roadmap. Innovative solutions such as the truck battery swap system mean that not only big companies but also sole operators can make the change, by converting existing trucks and leasing batteries.

A typical articulated truck uses 53.1 litres of diesel per 100km. A trip from Brisbane to Sydney could cost more than $600 in fuel (which you, the consumer, helps pay for when you purchase transported goods). Going electric would not only at least halve that cost but reduce maintenance costs and reduce emissions, even if batteries are recharged from the grid.

Swap and go?

Swapping out depleted batteries, rather than stopping to recharge, is a great solution for trucks: they make regular trips along major routes with regulated rest stops for drivers, which means you only need battery-swapping stations at key points along the routes.

However, battery swapping for ordinary passenger vehicles may be a different story. It has been tried before, but didn’t take off.

US company Better Place, founded in 2007, got as far as setting

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up trial stations (with one even planned for Canberra). But the company collapsed in 2013.

One problem was that car manufacturers would have had to agree to use a common battery platform to enable swapping, and only Renault came on board. Another was that the cost of installing enough battery swap stations to satisfy the wider community was enormous.

Trucks travelling on major transport routes won’t face this problem, so battery-swapping has a better chance of success.

Our ongoing research on policies to foster electric vehicle adoption has found that electric passenger cars are mostly recharged at home. This means we need solutions to help those without offstreet parking get access to convenient local rechargers. This will help Australia reduce its balance of trade problems, reduce our health costs, and help the environment.

We just have to hope our Government comes on board with suitable regulatory action to help us all go electric. One step might be to follow the US Government’s recent announcement that it will electrify its entire fleet of vehicles. This will help car manufacturers, help bring down carbon emissions, help reduce the nation’s health budget and also help everyday people reduce their transport costs, which would be fairer and more sustainable.

Gail Broadbent is a PhD candidate in the Faculty of Science at UNSW. Graciela Metternicht is a Professor of Environmental Geography in the School of Biological Earth and Environmental Sciences at UNSW. This article was originally published by The Conversation. www.theconversation.com www.unsw.edu.au

TRANSPORT & LOGISTICS

Green hydrogen boost for NSW transport industry Buses, trucks and cars powered by green hydrogen could soon be a reality in New South Wales thanks to a new agreement between energy infrastructure company Jemena and gas supply company Coregas.

Under the new agreement, Jemena will produce and supply green hydrogen from its Western Sydney plant for use by transport and industrial customers from early 2022. This is the first time the New South Wales transport industry will have access to green hydrogen.

Gabrielle Sycamore, Jemena’s General Manager for Renewable Gas, said the agreement further demonstrates the potential of green hydrogen to store renewable energy and integrate future gas, electricity and transport refuelling networks.

“We know that green hydrogen has the immediate potential to become a viable zero emission alternative to many petroleumbased fossil fuels currently used by industries such as transport and remote power generation,” said Sycamore. “Hydrogen fuel cells are particularly well suited to long-distance heavy haulage trucking requirements based on their comparatively light weight and fast refuelling times which can be just a matter of minutes.”

Hydrogen is used to power fuel cell buses and cars in countries around the world. In Japan 500 fuel cell vehicles are being used to transport competitors and staff at the Tokyo Olympics (hydrogen is also being used to power the Olympic flame), while in London hydrogen fuel cell busses are being used for public transport across the city. The green hydrogen will be produced at Jemena’s $15m Western Sydney Green Gas Project. Co-funded by the Australian Renewable Energy Agency (ARENA), the Power-to-Gas project is converting renewable electricity to hydrogen gas which can be blended and stored in Jemena’s gas distribution network to supply New South Wales homes and businesses.

“Together with the Western Sydney Green Gas Project, Jemena is bringing renewable gas to homes and businesses across New South Wales, it’s also offering the transport industry the opportunity to create their own path to a low carbon future,” Sycamore said.

“Our partnership with Coregas is an exciting extension to the Western Sydney Green Gas Project and will allow the New South Wales transport industry to innovate by offering cleaner energy solutions to their customers.”

Coregas Executive General Manager Alan Watkins commented that Coregas is working hard to apply their expertise in hydrogen distribution, compression and storage as part of Australia’s transition to a hydrogen economy.

“Transforming the transport sector is a critical piece of the puzzle,” Watkins said. “And we are delighted to partner with Jemena to make renewably generated green hydrogen available to the transport industry in New South Wales.

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Additive Manufacturing Hub case study: Cobalt Design Cobalt Design made use of 3D printing to create small-scale models for the refurbishment of a railway carriage’s servery café, with support and assistance from AMTIL’s Additive Manufacturing Hub. Regional rolling stock across Australia and New Zealand is experiencing a surge in refurbishment programs aimed at extending the usable life of the interior spaces and amenities. Vehicle structure (as well as propulsion, braking and so on) are retained, while rejuvenating and refreshing the interior spaces as a means to upgrading the rolling stock or repurposing it for emerging markets, growing needs or new destinations.

The challenge The traditional method of refurbishing a carriage is to produce 2D CAD drawings and imagery to convey the approach, and to then rely on the experience of manufacturing personnel to implement the designs directly into the carriage at full scale. The process is timeconsuming due to a range of issues: • Components and brackets are often custom-made due to specific designs and low quantities.

• Solutions often have to be compromised to be suitable for production requirements.

• Feedback from stakeholders and management is only possible on a full-scale mock-up or an actual first-iteration 1:1 build.

• Construction of structures in situ on rolling stock requires optimisation of subassemblies – minimising the number of subassemblies has advantages, but this must be balanced against the weight and size of the subassembly. Currently, this is typically managed ‘on the run’ during reviews of the first build or when a full-scale mock-up is built. Either approach is inefficient, and modifying full-scale structures and components extends development timelines.

• Rolling stock depots that facilitate the build work often do not have the experience to move quickly through this process as it can be their first exposure to the vehicles being refurbished or to the refurbishment of interior spaces such as serveries (or both).

Project Servo aimed to utilise additive manufacturing to create small-scale models of carriage interior spaces, components and equipment. This would enable stakeholders to communicate and evaluate different equipment alternatives within the space, as well as to test production methodologies and assembly sequences.

The solution Cobalt Design had been designing a servery café to be installed into a number of refurbished carriages. After the design concept was in development, Cobalt Design needed an effective method to communicate the design to the various project stakeholders, including production, maintenance, café staff and management.

Cobalt Design engaged GoProto (ANZ) Pty Ltd to create 1:15 scale models of the interior space, major sub-assemblies and important components such as: • Bench workspaces.

• Serving areas.

• Storage cupboards and drawers.

• Refrigerators.

• Food display and warmer units.

• Walls, door and structure.

• Food cart and food cart storage options.

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The Multi Jet Fusion (MJF) process was chosen as a reliable method to produce accurate models, with high durability, which would enable the servery to be disassembled and reassembled many times. This would be necessary to simulate the different configurations and assembly order options, and gain input by different stakeholders.

Quick 3D CAD models were created for the main sub-assemblies, and components of the servery were simplified to approximately 15 robust units able to be pieced together in a Lego-esque manner.

3D CAD images were sent to GoProto for production of the MJF parts. Within three days, parts were completed for Cobalt Design to verify the scale models, before air-freight to a New Zealand-based customer. Therefore, within a fortnight of initiation, the servery concept and various options were being simulated for use and evaluated by team stakeholders.

How the Additive Manufacturing Hub helped Scale models proved an important tool in achieving approval of the servery design by different stakeholders, offering various advantages: • Scale models enabled physical evaluation of the space – not just virtual evaluation via computer.

• Physical model parts allowed production staff to physically test the assembly order and methodology • Robust MJF parts allowed repeated assembly and disassembly, while evaluating and discussing alternatives

TRANSPORT & LOGISTICS

• The servery model was designed to be able to be quickly modified if desired; new iterations of parts could be prototyped and fitted to the model quickly. However, such iterations were not required as stakeholders were satisfied with one of the original versions of the assembly.

• Quicker sign-off was made possible as stakeholders could quickly evaluate the servery and physically test alternatives.

In addition to the benefits of the scale models, using 3D printing opened up discussions about additive manufacturing methods for production. Since many refurbishment programs require smallscale production, additive manufacturing opens up greater design possibilities and engineering materials – such as 3D printing using metals and fire-retardant polymers. Several parts were investigated and quoted using additive manufacturing for production.

It was assumed that the project would make use of a significant amount of a $20,000 Build It Better (BIB) voucher co-contribution from the Victorian Government via the Additive Manufacturing Hub. However, a only a small amount of the BIB voucher was spent, with GoProto. This was largely due to the successful design solution reached with the first concept, with no further iterations of the model required to be built.

While this may appear a truncated use of the RSP budget, it was far from ineffective. Cobalt Design contributed substantial in-house hours of engineering and costing of the other DFAM (Design for Additive Manufacture) proposals in an attempt to progress to additive manufactured samples that would demonstrate the effectiveness of additive manufacturing for rolling stock production parts. Other rolling stock projects have since commenced (with others forecast) that are planned to employ the use of scale models and additive manufactured parts for production.

The outcome The servery space was able to be built as a small-scale model – enabling stakeholders to evaluate and have input on the design, which would usually not be possible without the construction of a full-size mock-up. The scale model enabled the design to quickly move from concept stage to approval stage. With the model soon approved by stakeholders, the project was then able to proceed into final development and production. This saved weeks of work that would have been required to construct a full-scale mock-up, and then evaluate it, make possible modifications to full-scale parts, and so on. Cobalt Design has been able to showcase additive manufacturing to an industry where traditional methods such as full-scale mock-ups and techniques like hand-fabrication are the standard. With further projects on the horizon with the same customer, 3D-printed scale models will probably be used again to speed the project’s development and enable wider stakeholder engagement earlier in the design phase.

In addition, Cobalt Design has been able to highlight benefits of additive manufacturing for production parts. It is anticipated that metal 3D printing will be used in a refurbishment program in the near future, particularly as cost of this service reduces over time. www.amhub.net.au

www.cobaltdesign.co

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CUTTING TOOLS

Iscar: Beneficial modularity Modular systems have succeeded in finding their way into the lives of many people, from LEGO construction toys to IKEA’s modular furniture.

In metalworking, typical examples of these systems are unit-built machines and modular fixtures. As for cutting tools, modular structures have proven their efficiency in this area as well, and various tool manufacturers have developed their own modular products that are popular with their customers.

The FlexFit family for various assembled milling tools.

The main benefits of modularity are versatility and time-savings.

A modular concept facilitates the quick and easy building of an optimally customised cutting tool using an assembly of standardised elements. Hence, customers don’t have to order a costly, specialised tool and wait for months for it to be delivered. If a tool is urgently needed for immediate production, a suitable solution is close at hand. This concept contributes to reducing warehouse stock and diminishing inventory lists that cut manufacturing costs.

However, the modular tool concept is not free of disadvantages.

The main disadvantage is the decrease of rigidity; an assembly of several elements will not be as stiff as an integral product, and the assembled structure may lose accuracy when compared to a onepiece design.

When deciding on a particular tool, both the advantages and the disadvantages of the modular concept need to be considered.

The customer is the only one who can decide which tool would be the most suitable choice for their needs, based on the particular production strategy, current production demands, or an immediate need of a particular tool. The cutting tool manufacturer should provide the customer with the means to make the correct choice and at the same time continue to develop modular products that achieve greater adaptability, rigidity, and accuracy. A glance at Iscar’s modular cutting tools makes it possible to showcase the design features of a product.

Iscar’s FlexFit family of tools is the company’s oldest line. The FlexFit adaptation principle is based on using a cylindrical connection for centering and a general-purpose standard metric thread (M8…

M16) for securing. Simplicity and maintainability have made this rotating tool system a highly popular choice in the market. Today, FlexFit has a wide variety of shanks, adapters, and heads with indexable inserts, which are mostly used in milling operations such as machining complex 3D surfaces, slot, and grooves. The shanks are made from steel and cemented carbide. The carbide shanks increase rigidity, which substantially reduces vibrations especially in long overhang applications.

Iscar’s Multi-Master is a family of rotating tools with exchangeable heads; it comprises various modular assemblies. The Multi-Master concept features centering by a short precise taper, face contact and a thread with a unique profile. In turn, this enables a highly accurate and rigid connection that provides significant possibilities for modular tooling. The various elements include a wide range of shanks, extensions, adapters, and reducers, transforming MultiMaster tools into powerful and reliable cutters.

The shanks are made of steel; cemented carbide, which offers considerable stiffness; and heavy metal, which characterises good vibration-proof properties. The original Multi-Master design focused only on solid carbide heads. However, within a very short time the family has been replenished with various heads carrying indexable inserts. It is not a coincidence that the recently introduced NeoLogIQ and LogIQ campaigns include Multi-Master heads with inserts. Specially designed Multi-Master adapters and FlexFit mutual connections substantially expand the application range for both families.

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For turning operations, Iscar developed a modular system that comprises round bars and exchangeable heads with indexable inserts. The bars and heads are assembled with the use of a serrated-face connection. The system was initially intended for boring, though when selecting a boring bar, the ratio of a required bar overhang to the bar diameter strongly influenced the choice of the right tool.

There are three types of bars to cover the complete range of boring applications for overhang-to-diameter ratios up to 10:1. Steel bars enable machining with ratios up to 4:1. Cemented carbide bars facilitate boring with ratios up to 7:1. However, when machining where a higher overhang is required, the use of a stiffen carbide shank can be somewhat limited. Consquently, for ratios 7:1 to 10:1, Iscar has developed an anti-vibration bar that significantly reduces and eliminates vibrations during cutting operations. The key component of these bars is the damping mechanism, comprising a heavy mass supported by spring elements.

The success of the bars with exchangeable heads in the boring line led to the introduction of Iscar’s design concept in various turning, grooving, and threading applications. In addition, the newly developed bars with a serrated-face connection and a polygonal taper shank increase the application field of the system.

Modularity provides a valuable opportunity for the customer to configure a tool in an optimal manner. In today’s modern digital world, a great way to achieve this effectively is with a virtual assembly in a CAM software environment. The digital twin representation of a cutting tool based on ISO 13399 standard becomes an integral part of the tool as a product, and leading tool manufacturers have already expanded their portfolios with appropriate virtual counterparts and instrumentation to work alongside.

Iscar’s tool assembly options, which are incorporated in the company’s electronic catalogue, offer a good example of these emerging trends. These tool options represent a highly valuable instrument for preliminary processes in selecting tools at the design and planning stages of machining. In modular tooling,

CUTTING TOOLS

Multiple Multi-Master product combinations for finding optimally configured tools for various operations.

An anti-vibration bar with an exchangeable head and serrated-face connection. Significantly expands the application range in boring and threading

they significantly improve the way of finding the most optimal tool configuration, prevent the risk of errors being made on the shop floor, and deliver savings in terms of time and costs.

A flexible modular concept ensures the ability to quickly find effective tool solutions when a product program is constantly changing. This impact of diminishing tool inventory attracts large manufacturers.

Consequently, new developments focusing on reliable, accurate, and digital modular tools to meet industrial needs will remwain relevant and important in the market.

Modular cutting tools are more common in the metalworking sector and feature a wide range of products for the success of small-tomedium production runs and in die and mould making.

www.iscar.com.au

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Keeping me up to date with our industry As a member of AMTIL since its inception, Lovitt Technologies has appreciated the information we obtain from AMT Magazine, from the editor to CEO reports through to manufacturing trends and processes.

Also comments from various government personnel regarding our industry and general advertising of new machinery and tooling is of great interest to our organisation.

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CUTTING TOOLS

Mecaprec: Flying high with Seco Aeronautics is a demanding sector, with no room for error. French precision machining company Mecaprec found that working closely with Seco helped it to grow tenfold in a decade while supplying parts for the world’s biggest aerospace companies. By Anna McQueen.

Nestled in the foothills of the Pyrenees in south-western France is the small town of Lavelanet. The town is home to Mecaprec, a precision machining company with clients that include some of the world’s biggest aeronautics businesses. It’s also the hometown of the company’s CEO Jean-Marc Gomez.

Mecaprec mainly works with the milling of titanium, inconel and stainless steel.

“I acquired the company in 2008,” Gomez says. “At the time, it employed 12 people and had annual sales of some €780,000. I was very keen to invest in my hometown and provide employment for local people, so it was a natural fit. Around that time, I also met Christian Gil. He told me that if I took the company over, he’d come in as my workshop manager, and he’s been there ever since. He’s passionate about machine tooling, too, and together we have built an amazing team of people – we love what we do!”

Mecaprec was a company with genuine expertise in terms of hard metal machine tooling. Gomez soon realised that with new aircraft coming to market, such as the Airbus A350, there was going to be increased demand for hard metal parts and that could be a profitable area to explore. But there were a few challenges.

“Back then, Mecaprec wasn’t certified for the aeronautics industry,” Gomez explains. “So our primary focus was to obtain EN9100 certification, which we achieved in 13 months.”

Then the recession hit, and sales dropped by 40%. “But we came through thanks to some loyal customers and by expanding our production to include some finished products.”

This led Mecaprec to invest in a series of Makino machines, which then brought Seco Tools to the company’s attention. Gomez recalls: “They had the tools we needed for a big contract that we landed in 2011 for Aubert & Duval, a world leader in upscale metallurgy. The distributor was too expensive, so we were happy to work directly with Seco, and the rest is history.”

Since then, the two companies have worked together closely, adopting new tools as they have been developed, which has helped Mecaprec to further expand its product range while reducing unit costs. Since then Seco has been the company’s biggest supplier of cutting tools.

Today Mecaprec employs 75 people and has annual sales of €10.5m, supplying parts for such customers as Airbus, Boeing, Dassault, Embraer and Airbus Helicopter, along with tier-one suppliers such as Figeac Aero, Aubert & Duval, PCC France, Artus and Mecachrome. Some 98% of Mecaprec’s work is in the aeronautics industry, mainly working in titanium, inconel and stainless steel. The company mills parts in dimensions ranging from 10mm x 10mm up to 1,500mm x 1,500mm, turning out some 80,000 units each year.

“Our biggest challenge is optimising our prices while ensuring irreproachable quality,” Gomez says. “The aeronautics industry is a zero-fault sector, so we need to adopt all the Industry 4.0 automation and data exchange tools we can to compete with lowcost countries, and that is what we are doing.”

While there are many suppliers out there, what Mecaprec is looking for are true partners.

“We want suppliers who will bring us their new technologies, supply us seamlessly, train our people, listen to our needs and keep us at the cutting edge – in Seco’s case, literally!” says Gomez. “We have a great relationship with Seco, and we look forward to that relationship continuing long into the future as we grow.”

Mecaprec has just expanded its site, adding 2,000sqm of space (bringing the total up to 6,500sqm) and invested around €24m in 35 new machines. With these moves, the company is looking to diversify over the next few years.

“I’d like to see Mecaprec’s expertise extending into different industries such as automotive and oil & gas,” says Gomez. “It’s never good to keep all your eggs in one basket, so diversification will be our focus in the short-to-medium term. I’m looking forward to seeing what exciting new projects the future has in store.” www.secotools.com www.mecaprec.fr

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Fixing what isn’t broken: Why manufacturers should embrace new tooling solutions The father of modern political philosophy, Machiavelli, said: “Whosoever desires constant success must change his conduct with the times.” We are living in unprecedented times with the ongoing effects of COVID-19 on industry. Rolf Olofsson of Sandvik Coromant explains why now is the time for machine shops to embrace a new generation of tooling solutions to tackle steel ISO P turning challenges and make their production more efficient and productive.

For manufacturers, stepping away from the established way of doing things – whether it’s a production process, method of communication, or a trusted machine or tool – invites risk. No wonder it so tempting to fall back on the old adage of “if it ain’t broke, don’t fix it”. Could a new tool or digitalised process create more disruptions than it’s worth?

Yet, there is more onus than ever on manufacturers to change with the times – whether they are dealing with mass or batch production scenarios. Research by Pinsent Masons, the German law firm, has identified three main drivers for change.

First, its survey of 100 German manufacturers and German students found that disruptive Industry 4.0 technologies, like artificial intelligence (AI) and intelligent automation, are “sparking a fresh industrial revolution”. Second, the green agenda is driving manufacturers more quickly towards low-carbon business models.

Third, Pinsent Masons found “that macroeconomic pressures such as Brexit, and now COVID-19, will cause global supply chains to fragment”.

Sandvik Coromant added two high performing carbide insert grades to its existing range, GC4415 and GC4425.

The GC4425 insert delivers improved wear resistance, heat resistance and toughness.

How can manufacturers overcome this trio of obstacles without losing sight of the two main challenges: increasing output and reducing costs? And, how can they do so while machining one of most common and complex ISO P (steel) workpiece materials? The answer lies is next-generation tools – even if the last generation of tools ain’t broke.

The right stuff First, let’s look at the two ultimate goals for manufacturers to achieve profitable steel turning, increasing output and reducing costs.

Manufacturers should drive down the appropriate production costs for their specific situation. The situation will depend on whether they are dealing with mass or batch production, and is more unpredictable in the COVID-19 era where manufacturers are facing changeable high- or low-demand scenarios, and must adapt accordingly.

Manufacturers must always strive towards maximising their machining output; according to Sandvik Coromant’s findings, this can reduce the overall cost per component by 15%. To properly maintain a higher machine output, it’s also necessary to increase metal removal rates, and to reduce scrap and component rejections to manufacture more steel components in a shorter time.

Central to all of this is the manufacturer’s choice of tool, specifically their choice of insert. That’s why Sandvik Coromant recommends choosing steel turning insert grades that can deliver most predictable and consistent performance.

Stay in shape Sandvik Coromant added two high performing carbide insert grades to its existing range, GC4415 and GC4425. The inserts’ designations refer to P15 and P25, the demands that different working conditions impose on machining parameters – cutting data, surface finish, depth of cut, machined or rough surfaces, continuous or interrupted cuts. The two new carbide inserts from Sandvik Coromant can meet these parameters. While GC4425 delivers improved wear resistance, heat resistance and toughness, GC4415 is designed to complement GC4425 where enhanced performance and better heat resistance is needed.

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Both contain the second-generation Inveio coating technology.

What makes Inveio unique can be examined at the microscopic level: the material’s surface has a uni-directional crystal orientation.

Each crystal lines-up towards the cutting edge, creating a strong barrier that improves crater and flank wear resistance. Heat is also lead away from the cutting zone more quickly, which keeps the cutting edge in shape for longer time in cut.

So, GC4415 and GC4425 can machine a larger number of pieces within a mass and batch-production set-up. Each insert contributes towards extended tool life, eliminating sudden breakages and reducing reworking and scrap. With the ability to machine more components in one set-up, the new insert grades can reduce the production interruptions caused due to frequent insert changes and time spent in finding the right insert for each application or material – both factors are considered to be the biggest time killers in modern production.

Coolant can further improve the insert performance, deliver even better performance in all aspects, and play a crucial role in reducing overall production cost. Using under coolant controls the heat in the cutting zone, which leads to improved tool life and predictable machining. This makes it possible for operators to increase the cutting speed or feed, which allows for a greater productivity increase and maximised output.

CUTTING TOOLS Inveio coating technology has a uni-directional crystal orientation at the microscopic level, which enhances its wear-resistant properties.

In particular, if turning is a bottleneck operation, then companies suffer a restriction on the number of components produced per run.

Therefore, manufacturers need to reconsider their turning process in order to get maximum output from their modern machine tools, which are currently being underutilised.

This is where the PrimeTurning can provide support, offering flexibility to do turning in all-directions. With it, machine shops can realise a multi-fold productivity increase without compromising process security and tool life. This way of turning is found to be much more efficient and productive compared to conventional turning.

Positive change

In addition, precision coolant with pre-directed nozzles focused directly at the cutting zone, which is a good way to achieve chip control. That is why, if correctly applied, coolant will maximise output, increase process security and improve cutting tool performance and component quality. These are all important cornerstones in successful machining.

We’ve examined how factors like choice of tool and the use of coolant can yield tangible machining benefits – but what could manufacturing gain by applying a new methodology to their steel turning operations?

Sandvik Coromant’s specialists asked themselves this question, and the result was a new ethos that we call PrimeTurning, designed as a good choice for mass production or components needing frequent set-ups and tool changes.

GC4415 and GC4425 have already proven advantageous since they were launched to market, earlier this year. In one case, a manufacturer in general engineering, pitted the GC4415 insert against a competing insert, and put to work in machining an AISI/SAE CMC 02.1 steel workpiece with a Brinell hardness of 220 HB. As the workpiece was subjected to axial external turning and light roughing, the customer was able to run the GC4415 at a higher cutting speed (vc) of 300 metres/min and feed rate (fn) of 0.33 mm/rev compared with a competitor’s insert, which ran at a vc of 250 metres/min and fn of 0.25 mm/rev. The competitor’s insert machined 200 pieces per edge before breaking down, whereas GC4415 machined 256 pieces before only showing signs of risk of breaking down.

By switching to GC4415 and increasing the cutting data, the customer was able to achieve a productivity of 210% and reduce costs by 53%. As this example shows, manufacturers can indeed prove Machiavelli’s assertion that “whosoever desires constant success must change his conduct with the times.”

Rolf Olofsson is a Product Manager at Sandvik Coromant. www.sandvik.coromant.com

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Medical applications extend the limits of 3D printing It’s a safe bet that as time passes, the number of things you can additively manufacture and the ways in which you can do so will keep growing. One increasingly promising area is in the field of biofabrication.

After graduating as a materials engineer in the early 2000s and spending a decade working with newer production technologies such as 3D printing in the manufacturing industry, David Forrestal sought a career change and headed back to university for a PhD in tissue engineering. He graduated with a doctorate in 2019, developing new systems and methods for seeding living cells in 3D-printed bioresorbable polymer scaffolds – culturing cells and keeping them alive so a patient’s body can use them to restore tissue.

David Forrestal, Advanced Biomedical Engineer at Herston Biofabrication Institute.

Nowadays, Forrestal is an Advanced Biomedical Engineer at Herston Biofabrication Institute, a multidisciplinary institute at Royal Brisbane and Women’s Hospital (RBWH) which officially opened in February. It focuses on 3D scanning, 3D modelling and 3D printing of medical devices, bone, cartilage and human tissue. It has programs based around orthopaedics; burns, skin & wounds; vascular & endovascular surgery; urology; cancer care; craniofacial; and anaesthesia & intensive care.

“We’re an institute, but we’re directly in the health system, with Queensland Health,” explains Forrestal, who says the work is about clinical impact rather than blue sky scientific projects. “We have an affiliation with the University of Queensland, but are focused on bringing new developments in biofabrication to benefit patients directly.”

Among its facilities, Herston has a tissue culture lab, mechanical workshop, scanning and visualisation equipment, and a bank of various kinds of 3D printers. Current projects range from “lowrisk, ready-to-go now work”, such as anatomic models for surgical preparation on complicated fractures, to “more futuristic regenerative medicine techniques” involving organoids (lab-grown tissue grown from stem cells that is able to perform some of the functions of a full organ, which is therefore interesting for drug development and testing.)

“From 3D printed surgical models to custom surgical guides to place drill-holes,” adds Forrestal. “And custom 3D-printed devices to change the shape of a radiation beam to dose a tumour more effectively, in a more focussed way, with fewer side effects. A workflow is currently set up for that.”

As with most facilities with a collection of printers, each of Herston’s machines plays a different role. While not appropriate for biocompatible devices, their continuous fibre composite printer, for example, has great potential with external devices, such as splints and prosthetics, where a patient’s body has to be held in a certain way to help restore mechanical function.

“The reason it’s so good is you’ve got other techniques, but none of them really match up to the stiffness and strength you get with the Markforged, especially when you’ve got the reinforcing fibre,” Forrestal explains. “It can bridge a gap between making a much more complex, assembled device with lots of metal reinforcement or even having to go and CNC something. That’s really the niche I see for that within our organisation.”

The ‘horses for courses’ nature of 3D printing –an umbrella term for an array of technology families that are each themselves quite broad – can get missed by non-users. Throughout his work, Forrestal has used 3D printing for everything from tissue regeneration research to prototyping as a product design engineer at a major plumbing company. In a quirk of his academic career, his most-cited paper is on melt extrusion 3D printing with chocolate, based on a group project for a science expo. He and a student designed a heated jacket that could accommodate large-diameter syringes, with opensource slicing software, control software and an XYZ stage.

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“It was just a controlled way of pushing material out of a syringe in a robotically controlled pattern and then keeping it at the right temperature,” he recalls. “You could actually use that same printer as a bioprinter. You can mix in a hydrogel with live cells and you could do your bioprinting.”

Since its beginnings in the 1980s, 3D printing has burgeoned, and both the number of solutions it offers and its overall market size have expanded handsomely. Even during 2020, the global industry grew 7.5% to be worth US$12.8bn. Average growth for the decade has been 27.4% annually.

As for emerging additive manufacturing technologies, Forrestal says he sees great promise for volumetric 3D printing to impact his work as a bioengineer. Volumetric methods use a rotating vat of photopolymer resin, cured at many different angles by a light source. The engineering challenges are multi-faceted – including in chemistry, software and mechatronics – but the potential for highspeed jobs is vast.

“That’s a really exciting development in bioprinting, because it means you can print these structures with living cells in them, and you don’t have a problem where you’re printing a whole day, while you’ve got to keep all the cells viable and fed with nutrients,” says Forrestal. “I think you’ll be seeing that 3D printing method in all sorts of different areas over the next 10 years or so.” www.markforged.com metronorth.health.qld.gov.au/herston-biofabrication-institute

ADDITIVE MANUFACTURING

Next-gen 3D-printed catalysts to propel hypersonic flight Ultra-efficient 3D-printed catalysts could help solve the challenge of overheating in hypersonic aircraft and offer a revolutionary solution to thermal management across countless industries.

Developed by researchers at RMIT University, the highly versatile catalysts are cost-effective to make and simple to scale. Lab demonstrations show the 3D-printed catalysts could be used to power hypersonic flight while simultaneously cooling the system.

Lead researcher Dr Selvakannan Periasamy said the work tackled one of the biggest challenges in hypersonic aircraft development: controlling heat build-up.

“Our lab tests show the 3D-printed catalysts we’ve developed have great promise for the future of hypersonic flight,” Periasamy said.

“They offer a potential solution for thermal management in aviation – and beyond. With further development, we hope this new generation of ultra-efficient 3D-printed catalysts could be used to transform any industrial process where overheating is an ever-present challenge.”

Only a few experimental planes have reached hypersonic speed (defined as above Mach 5 – 6,100km/hour). In theory, a hypersonic aircraft could travel from London to Sydney in four hours, but many challenges remain in the development of hypersonic air travel, such as the extreme heat levels. First author and PhD researcher Roxanne Hubesch said using fuel as a coolant was one of the most promising experimental approaches to the overheating problem.

“Fuels that can absorb heat while powering an aircraft are a key focus for scientists, but this idea relies on heat-consuming chemical reactions that need highly efficient catalysts,” Hubesch said.

“Additionally, the heat exchangers where the fuel comes in contact

with the catalysts must be as small as possible, because of the tight volume and weight constraints in hypersonic aircraft.”

To make the catalysts, the team 3D-printed tiny heat exchangers made of metal alloys and coated them with synthetic minerals known as zeolites. The researchers replicated at lab scale the extreme temperatures and pressures experienced by the fuel at hypersonic speeds, to test their design’s functionality. When the 3D-printed structures heat up, some of the metal moves into the zeolite framework – a process crucial to the unprecedented efficiency of the new catalysts.

The next steps for the team from RMIT’s Centre for Advanced Materials and Industrial Chemistry (CAMIC) include optimising the 3D-printed catalysts by studying them with X-ray synchrotron techniques and other analysis methods. The researchers also hope to extend the potential applications of the work into pollution control for vehicles and miniature devices to improve indoor air quality.

Distinguished Professor Suresh Bhargava, Director of CAMIC, said the trillion-dollar chemical industry was largely based on old catalytic technology: “This third generation of catalysis can be linked with 3D-printing to create new complex designs that were previously not possible. Our new 3D-printed catalysts represent a radical new approach that has real potential to revolutionise the future of catalysis around the world.” www.rmit.edu.au

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Additive manufacturing and the ‘zero-mile’ supply chain The production of parts using additive manufacturing (AM) offers the possibility of a ‘zero-mile’ supply chain, ith significant potential benefits for manufacturing operations.

Manufacturers must often respond fast regarding the repair and turnaround of faulty equipment, minimising production disruption and downtime. Using 3D printing, parts can be produced rapidly in common materials such as steel, titanium, aluminium, or more exotic materials.

Moreover, new materials designed specifically for AM offer improved performance. Given the large inventories found within typical manufacturing operations, a major question is: which parts are technically and commercially viable for AM? A recent audit for a US operation included a total inventory of 4,500 individual parts. Of these, some 450 were identified as technically feasible for printing, and 200 offered significant commercial benefits to the company compared with historic sourcing.

Given the speed of production possible using AM in prototyping and serial production, manufacturers may consider investing in their own in-house 3D printing operation. The advantages include a ‘zero-mile’ parts supply chain, avoidance of high inventory levels, better process control, and risk mitigation against costly downtime. The alternative option is to source from a supplier offering printing services, with their specific lead times and supply chain risks. However, given the focus on productivity among mainstream manufacturing operations , it may be hard to justify the investment of time, technology and resources associated with an in-house AM facility.

A more viable, proven option offers the ‘best of both worlds’, with quality parts are manufactured rapidly ondemand, with a zero-mile supply chain. This results in low operational risk, supporting onsite manufacturing or maintenance operations, but without the need for high capital investment or increased fixed manufacturing costs.

In this scenario, an end-to-end provider of AM services, working under a parts supply contract, establishes a production facility, requiring minimal physical space, on or near the customer’s premises. A dedicated, secure digital parts library is established following a full audit of the client’s inventory. Relevant printing technology is established onsite and print parameters developed for the materials concerned.

The supplier manages the AM production and internal parts order system on the customer’s behalf, delivering virtual on-demand parts production with a zero-mile supply chain. Operational risk is mitigated against the lack of availability of components, and inventories can be managed at lower cost. 3D Metalforge has developed this model at the Port of Singapore, undertaking a full audit of AM-suitable parts, digitalising them into a dedicated parts library ready for production, and manufacturing them on demand for the Port using a Hybrid Wire Arc printer. www.3dmetalforge.com

CSIRO develops low-cost titanium wire for additive manufacturing The CSIRO has developed a novel and innovative process for turning inexpensive alloy waste into a high-value wire product suitable for the additive manufacturing market.

CSIRO Team Leader Dr Robert Wilson said researchers used low-cost titanium alloy particulates like machining swarf to produce a wire that can be used to make 3D-printed parts such as aerospace components.

“The result is a product that is significantly cheaper than titanium wire made by conventional processes,“ Dr Wilson said.

The wire is being fine-tuned for use in large format additive manufacturing such as Sciaky electron beam manufacturing and Wire Arc Additive Manufacturing (WAAM) – processes that melt the wire to form beads that stick together to create a layer of metal material that is then built up to form the 3D-printed part.

Richard Newbigin, Director of the Australasian Wire Industry Association, said Australia is well represented in various types of wire manufacturing, but until now has lacked sovereign capability in wire production for additive manufacturing: “Currently, Australian additive manufacturers have to source their titanium wire offshore, but this new capability will change that.”

Barrie Finnin, CEO of additive manufacturing company Amaero International, agrees that locally produced titanium alloy wire and powders offer a valuable local capability for Australia’s growing additive manufacturing sector.

“This technology has the potential to put Australia on the map as a competitive supplier of aerospace grade titanium alloy wire for additive manufacturing and will greatly impact on our CSIRO’s wire production process has been demonstrated at pilot global competitiveness,” Finnin said. “Even plant scale. © Nick Pitsas better, the end product will be comparable to what is currently available overseas, but much cheaper because it is using waste product.”

The patented wire extrusion process, which is optimised using The wire can be used to make large complex parts for markets computational modelling, is being demonstrated to produce 50kg such as aerospace, biomedical, defence, marine, automotive, of titanium wire at pilot scale. The team is working to scale this up to construction and consumer goods. www.csiro.au 100kg-300kg pre-commercial volumes over coming months.

The global market for titanium wire is worth over $200m. There is a lucrative market for 2.5mm to 3mm titanium wire as feed for this type of wireadditive manufacturing, and the cheaper wire generated from recycled sources can also be used to produce metal powders for 3D printing.

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UNSW MMFI delivers AM solutions with help from Konica Minolta Konica Minolta Australia is assisting the Materials & Manufacturing Futures Institute (MMFI) at the University of New South Wales (UNSW) with 3D printing technology for rapid prototyping and the manufacture of products.

The MMFI is an interdisciplinary research hub delivering tangible solutions to emerging global problems by studying, building, and transforming the future of materials innovation and advanced manufacturing. Through the MMFI, Australian manufacturers have access to state-of-the-art advanced manufacturing research and problem-solving skills coupled with the technology to address the barriers and opportunities in material sciences and advanced manufacturing, with diverse applications in printed electronics, transport, energy, information technology, and health.

Professor Sean Li, the Institute’s director, said: “MMFI has the research expertise and infrastructure to support local industry. It also has access to other skills within UNSW such as science, chemistry, electrical engineering, and medical science, providing an even broader skillset that can be tapped. Not only can MMFI come up with a theory, we can use the in-house resources to test it, make changes, and in a short timeframe, produce a practical, real-world solution.”

Matthew Hunter, Innovation Product Marketing Manager at Konica Minolta, said: “There is a renewed focus on onshore manufacturing and a massive opportunity for manufacturers in sectors such as aerospace, defence, automotive, and food and beverage. Therefore, it’s critical to have access to resources and skills such as those available through the MMFI to assist with this without requiring massive investment. MMFI has a unique capability to help local industry produce specialised parts that they may previously have had to source offshore.”

The MMFI houses a 3D Systems ProJet HDMax 3500 and a Markforged ProX DMP 300, provided and supported by Konica Minolta. These were both recently used to ensure smooth transfer of graphite powder along the length of a helical screw in a manufacturing line. From prototyping to the end-use part, the finished tool was delivered successfully and is now being used to manufacture quality composite materials. From the prompt to the prototype to the product, this whole process was completed within two weeks using the expertise and facilities at the MMFI. Professor Sean Li said, “MMFI is keen to continue working with diverse industries to provide simple and elegant solutions that meet specific, complex requirements. MMFI has the capability to assist with any step of the process, whether it’s just a concept or ready for the production line. MMFI is committed to helping the industry with the creation of real and useful products, with a balance between commercial viability, performance, usability and sustainability.” www.unsw.edu.au www.konicaminolta.com.au

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Positive signs for +addeva Victorian start-up +addeva is developing an online, end-to-end platform that allows customers to have design input and purchase signage on the same platform. +addeva then supplies the tailored signage, printed locally, inclusive of user-friendly mounting options.

The idea behind +addeva came about several years ago. Whilst running prototyping and manufacturing facilities, Leon Gairns, now director at +addeva, was regularly approached to quote and supply custom signage, vehicle badges and to remedy parts ordered offshore. Often, these projects were well suited to local additive manufacturing but lacked the appropriate CAD files and design input.

In the early stages, the team at +addeva approached several software developers that could offer part of the solution but ultimately did not proceed, instead deciding to provide an end-to-end solution themselves. The Build It Better (BIB) voucher programme, provided through AMTIL’s Additive Manufacturing Hub, offered a pathway to design, optimise and validate the part geometry intellectual property (IP) in parallel with developing the online platform. The intent was to maximise the adoption of localised additive manufacturing.

The challenge • To allow the geometry and process validation of a customisable signage system with design freedom.

• To remove the burden of CAD expertise, production lead times and often minimum order charges.

• The inclusion of an alignment and mounting system as integral to the final product.

The adoption of additive manufacturing allowed +addeva to quickly scale from a single letter, a combination of letters or even 2,000 letters without the commitment of tooling or having to machine from solid workpieces. The signage is printed in a robust polymer, with further post-finishing offered as optional.

The solution In undertaking the project, the Additive Manufacturing Hub engaged the assistance of registered service providers (RSPs) X-FORM Pty Ltd and GoProto (ANZ) Pty Ltd. +addeva’s familiarity with Multi Jet Fusion (MJF) as an additive production solution, along with robust material properties, presented MJF as the ideal candidate process against other legacy production processes.

The project followed the following stages: a) Additive part geometry and appearance validation trials. b) System volume and online customer additive production trials. c) Printed and post finished marketing samples.

Rapid design iteration and flexibility in geometry allowed +addeva to arrive at validated parameters, ensuring mass customisation and repeatability. The trials allowed the team to optimise the geometry, packing density, mounting system design, and post-finishing options to ensure consistent production throughput. The final geometry saw a 40% reduction of the original material requirement and allowed for a 15% increase in packing density.

How the Additive Manufacturing Hub helped It was predicted the project would make full use of the $20,000 BIB voucher co-contribution. The estimated breakdown was: • $20,000 to X-FORM ($10,000 via BIB voucher).

• $20,000 to GoProto ($10,000 via BIB voucher).

Ultimately, a total of $30,250 (ex GST) was spent with the two RSPs. Of this amount, $15,125 was contributed by the BIB voucher and the remaining $15,125 was paid by +addeva.

The breakdown per RSP was as follows: • X-FORM: $19,750 (ex GST).

• GoProto: $10,500 (ex GST).

Funds spent with GoProto were less than planned, largely because +addeva could reduce the final parts’ density, allowing more parts in each combined prototype build. MJF’s versatility in combining builds also reduced the quantity of printing required before +addeva was sure it had a commercial-ready production option. (Please note the software element was outside the BIB voucher scope). +addeva’s online platform is focused on signage, but it allows for the addition of other customer-defined products with set customisable geometry to be added in the future. +addeva’s adoption of additive manufacturing allows for a relatively risk-free ramp-up stage to supplying thousands of parts per week, and allows for manageable peaks and troughs that invariably come with early production. The IP developed in this project allows for easy transition to existing user groups but with added flexibility in design and supply. As volume increases, additional sales and production resources will see increased employment at +addeva.

The outcome The project outcome has allowed +addeva to develop:

Once the validation and production parts trials were complete, +addeva had confidence that the outcome was repeatable, so CAD automation and print trials were then undertaken. These then increased to production volumes. Marketing reference samples followed, paired with volume trials for select customers.

• A lean, fast, end-to-end local supply chain.

The MJF process enabled +addeva to trial and re-trial in quick succession and to ultimately supply quality end-use production parts, quickly and sourced locally. Additive manufacturing provided the flexibility to quickly scale without the upfront expense of CAD, tooling or shipping. It eliminated the significant lead-times experienced with legacy production such as subtractive and moulding processes.

Over the project, part geometry could easily be modified, printed, and trialled in real-world conditions. +addeva was able to optimise the parts to further increase production capacity.

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• An online, self-serve customer-customisable signage.

• The ability to scale from one part to thousands.

• Several, flexible mounting systems.

To find out more about +addeva, please contact Leon Gairns on 0477 352 549 or email: leon.gairns@addeva.com.au. www.amhub.net.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. + 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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FORMING & FABRICATION

Frontline Manufacturing – Reinforcing capability with new Deratech press brake Having overcome some big challenges in its 25-year history, Frontline Manufacturing is now a thriving manufacturing business operating from its plant in Meadowbrook, in Brisbane’s southern suburbs. The company recently invested in upgrading its specialist technical capability with the purchase of a state-of-the-art Deratech press brake, supplied by CMTS Sheetmetal Machines.

Matthew Ellis is a true inspiration to the Australian manufacturing industry. He established Frontline Manufacturing in 1996 when he was just 26 years old . In 2010 he lost it all when the Queensland floods destroyed his business and the insurance did not cover the loss. However, he successfully rebuilt the company and subsequently sold it to a larger company that shares his belief in Australian manufacturing. This financial support has seen Frontline grow into a 40-staff operation.

With investment in news machines such as the recently acquired Deratech Ultima 1500/6100 press brake, the company’s future looks ever brighter. Ellis spoke to us about the company and the new machine.

AMT: Tell us about Frontline Engineering?

Matthew Ellis: I started Frontline in Queensland in 1996 with the aim of manufacturing pressed components.

We started making componentry for the Australian manufacturing industry, and over the years we have grown to have a substantial manufacturing service that is highly respected.

Lately we have been trying to establish Australia as a hub for military-grade armourplate products. These are the metal plates that are placed in military vehicles to protect soldiers from the danger of IEDs (Improvised Explosive Devices). The sheetmetal material used in this industry is very expensive and needs specialised expertise, equipment and technical ability to work with. There is folding tolerance that must be met. Because of the flexibility of the steel, it needs a lot of tonnage to fold. Get it wrong and the sheet is wasted at great cost.

We needed to update our technology if we were to establish Frontline in the armoury plate industry.

AMT: What brought you to CMTS Sheetmetal Machines?

ME: One of our engineers went to a manufacturing exhibition in Melbourne where he came across the CMTS stand.

They were displaying a range of machinery including the Deratech range. It was while striking up a conversation with Michael Schneider (Director Sales and Service at CMTS) and Bjorn Rabiot (Managing Director of Deratech Industries) that we decided to look further into Deratech’s

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The new Deratech Ultima 1500/6100 press brake, in Frontline Manufacturing’s workshop in Meadowbrook, Queensland.

technology. We found them knowledgeable, and they seemed willing to help us out in our endeavour to establish Frontline in the armour plate industry.

AMT: Tell us about the machine you ended up purchasing.

ME: We decided to buy the Deratech Ultima 1,500-ton, 6,100mm machine.

The Deratech Ultima is a CNC-controlled synchronised press-brake equipped with a multi-axis CNC-controller with angle programming possibilities. It has a CNCcontrolled mechanical crowning system and a fast and accurate backgauge on ball screws. This machine has the capacity and intelligence to work with the armoury plate steel. It has a laser angle measuring device that measures and controls the angle as it is folding. As mentioned, any mistake when folding this material will be costly. This laser technology manages the fold accuracy; therefore, there is no material loss and reduced costs.

AMT: How did the installation go?

ME: It was a massive project just to get the machine into Australia. With COVID-19 everything coming in from China had stopped. Everything required exemptions

from the Australian Government. This was like a minefield because of all the restrictions in place.

The staff at CMTS did so much work for us on this. They even had to bring in an engineer from Belgium to help with the install. They were outstanding; I can’t praise them enough. It took at least a year with everyone working together to get the job done. There were times where the CMTS team were in tears trying to get things done, but they did, and we really appreciate their efforts.

AMT: It sounds like it’s been a significant commitment on your part.

ME: Frontline Manufacturing is taking a leap of faith by investing in this machinery.

We need to build a capacity that we believe will pay off. Our aim is to build the “Australian-Made” sector, and to do this we need to gear ourselves, ready for what we believe will be a growth in this sector. This installation was a major project for us, and it was good to have the CMTS team getting us there.

AMT: Why is investment in technology like this so important for the Australian manufacturing industry?

FORMING & FABRICATION

ME: It is using this technology that allows Australian manufacturers to save on costs and therefore become more competitive globally. It’s amazing what Australian manufacturers can produce, and if we can be competitive there is no reason why things can’t be made here in Australia. So, we went to look for what machines are out there to make this happen. We had assistance from the Australian Government, so it is also important to the Australian economy to make this work.

It is important for manufacturers to invest in their business with capacity, machinery, technical knowledge, and people. Frontline Manufacturing’s new owners believe in the business and have put their efforts and

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Michael Schneider, Director Sales and Service at CMTS Sheetmetal Machines, with the new machine.

capital in so that they can grow and lead new industries such as the armoury plate technology. We need to promote the idea that “Australian-Made” is worth it for all of us. In doing this, our government must also take the leap of faith in Australian manufacturing. Australian manufacturing is some of the best in the world and we

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now have the opportunity to do so with our lessening reliance on China. We all need to look internally to see what we can do.

Australia is in a perfect storm right now, and as a country we should start looking at what we can manufacture here. www.cmts.net.au www.frontlinemanufacturing.com.au

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FORMING & FABRICATION

Metalmaster: An all-applications garage press The hydraulic press is an essential tool for metal forming or separating rusted parts. Presses also make the job easy when removing and installing bushing, ball-joints and bearings. Garage presses really show their value when straightening or flattening components.

Metalmaster garage presses range from 10 tonnes up to 50 tonnes in terms of capacity. They are ideal for home workshops or mechanical repair shops, and are well suited to the needs of engineering and light manufacturing applications.

The popular Metalmaster 20-tonne HP-20PP Workshop hydraulic press has a robust design and is constructed from industrial-grade C channel. The press has an adjustable sliding cylinder ram, a pressure gauge calibrated in both metric and imperial, and bending vee plates. The 20-tonne hydraulic ram and pump unit are also easily removed for use on other pressing jobs outside a workshop, such as straightening or bending.

The HP-20PP hydraulic press features an adjustable sliding head, allowing up to 320mm of travel between the centre of the vertical posts. To accommodate offset pressing jobs, the user simply loosens the clamping plate bolts and the head of the press can be moved sideways.

The Metalmaster HPF-50 trade press includes a convenient hand or foot operated pump that allows you to have both hands on your job when operating the foot pump. A unique feature of this 50-tonne press is its two-speed hydraulic system. This feature gives the benefit of rapid speed approach to get close to your work piece for increase productivity. The operator simply flicks over the dial switch into the slower working speed for increasing the pressure.

As with the HP-20PP, the HPF-50 press has an adjustable sliding head, providing up to 240mm travel between the vertical post, a table height adjusting winch, metric/imperial pressure gauge. Also included are two heavy-duty multipurpose vee block/pressing plates, making this press ideal for professional mechanics or industrial workshops.

According to Metalmaster distributor Hare & Forbes/Machinery House, this 50-tonne press exceeds the construction quality of today’s standard market versions, as this model features a fully robotic welded frame for the highest quality, accuracy and extra rigidity. To make the most out of your Metalmaster garage press

productivity, a range of accessories are available including a 17-piece push driver set, a bearing race and seal driver set and an 11-piece steel press pin driver set. www.machineryhouse.com.au

Hafco Metalmaster EB-330FAS Band Saw The Hafco Metalmaster EB-330FAS is a fully automatic hitch feed, single mitre band saw designed for repetitive cutting of small-to-medium-sized sections in single or pack forms.

The EB-330FAS NC Swivel Head Metal Cutting Band Saw features an automatic hitch feed and is equipped with a 178mm touch screen controller that stores 20 programs, while an inverter infinitely variable blade speed control over the range of 25-85mpm.

The band saw cuts from 0 degrees to 45 degrees right in its automatic cycle, and from 0 degrees to 60 degrees right in the semi-automatic cycle. It also features hydraulic vice clamping with a manual hand wheel adjustment. Featuring a 500mm stroke hitch feed vice with ball screws and servo driven motor, the band saw is able to

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cut infinite lengths. Ball bearing blade guides ensure minimal blade clearance wear, which increases blade life due to less friction. A mechanical position sensor allows the saw frame to lower quickly toward the material and automatically detect the start-cut point. Blade wear is minimised by the bi-metal blade function that retracts the vice after cut, preventing the blade from rubbing on return. Other features include a quick action lock/ release lever for the swivel head, a heavy-duty gear drive system and a blade cleaning brush.

Operation of the Metalmaster EB330FAS bandsaw is vibration free, with low noise and designed to produce clean, high precision cuts. www.machineryhouse.com.au

FORMING & FABRICATION

OMAX: The recipe for faster cutting Faster cutting is an important factor to take into account when buying new machinery, but there are other criteria that should also be assessed, writes Patrick Turpin.

The Austrian educator and management consultant Peter Drucker once wrote: “Time is the scarcest resource and unless it is managed nothing else can be managed.”

There are two types of machine tool manufacturers: those who offer machines that cut faster; and those who say cutting faster is unimportant. When looking to buy new equipment, the ability to process parts faster IS an important consideration because it affects the bottom line. It seems obvious that when a machine can process parts 30% faster, it will reduce the cost of labour, consumables, and utilities. On the other hand, when a machine tool is not fully utilised, there can be a tendency to dismiss faster cutting as irrelevant: when in fact it is relevant. If a machine tool cuts 30% faster than the competitor, and the cost of operation is $38.00 per hour for consumables, then over the course of 1,000 hours machining time, faster cutting will save $11,400.00 in consumables alone!

Faster cutting is one consideration when buying a machine tool and it is important to prove cutting speed claims before plunking down the big bucks. To these ends, time studies and test cuts that prove or debunk the manufacturer’s claims need to be a priority in the purchasing cycle. For example, when looking for a machine tool to cut Bisalloy, do not accept time studies or test cuts that show how fast aluminum is machined!

freight shipments from the US can take up to seven days longer than they did 18 months ago. With more companies competing for limited space, shipping delays can translate into critical downtime for a machine tool, which makes having a local source for consumables an important factor to consider when making a capital investment.

One final thing to note is that having a “technician” to support a machine is not the same as having a factory-certified technician.

When it comes to maintaining machine tools, the adage that “parts are parts” does not apply. Every new machine tool has learning curves for its applications and its maintenance. Local service should mean that factory-certified technicians are available incountry to support that learning curve – which will translate into better machine uptime. In the final analysis, you need to research both performance and local support, as you make your capital investment decision.

Patrick Turpin is Asia Sales Manager at OMAX Corporation.

Headland is OMAX’s exclusive supplier in Australia www.omax.com www.headland.com.au

However, faster cutting should not be the only criteria used to purchase a machine: the availability of factory-certified local support is critical to machine uptime and the bottom line. During the ongoing pandemic, the criticality of local support has been amplified, and not just between countries, but across state borders as well. Having consumables and technical support in state to support a machine tool has been the harbinger for a company’s on-time deliveries: the fastest cutting machine in the industry is worthless when consumables are stuck over the border. Today’s reality is that air

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ONE-ON-ONE

Associate Professor Cori Stewart is the Chief Executive Officer of the ARM (Advanced Robotics for Manufacturing) Hub in Queensland. She spoke to William Poole.

AMT: Firstly, what is the ARM Hub and why was it established?

Cori Stewart: The ARM Hub is now a year and a half old, and it was established around a couple of drivers. Firstly, to see Australia drive the commercial value of robotics and come out big in the way robotics are applied to industry. One of our founding partners, Queensland University of Technology (QUT), is the nation’s leading robotics centre, and they got behind it. Along with its national partner network, QUT has been conducting amazing fundamental research in robotics. That technology is now coming down and being used on the factory floor – things like computer vision, AI, machine learning ... all the things that make robots smart and integrate into wider manufacturing capability. So, ARM Hub came about to offer this agile translation capability, and also knowhow, for new technology.

The other part was as the country drives towards a manufacturing future – and this was happening before COVID – we had major manufacturing strategies in place across the country, knowing manufacturing will be the future of high-value jobs, regional development, of Australia keeping its living standards. When COVID hit, it really brought to bear exactly why it’s essential to have manufacturing, and also the challenges facing manufacturing.

The ARM Hub opened the day the first COVID lockdown was announced, and our journey has been a COVID response journey.

The ARM Hub was always there to drive advanced manufacturing capability in collaboration with industry, but COVID-19 escalated the urgency for this type of support.

For the ARM Hub, manufacturing companies, particularly SMEs, are our focus. They can come to us and we’ll work with them on the technology roadmap in their companies, we figure out what Industry 4.0 or Industry 5.0 capabilities they need, and then build the expert teams around those needs. We solve the adoption and implementation problems that are essential to future growth. We draw on researchers; we have partnerships with over 12 research institutions, and we draw down that capability. We also partner with smart tech companies, and we also have our own in-house mechatronics and data science team that move around on projects and augment what needs to be done. So in a nutshell, we have an agile teambuilding capability that fills the skills gap that industry has around Industry 4.0 and Industry 5.0.

AMT: Can you give examples of the projects you’re working on?

CS: We do two kinds of projects: We do projects that are about modernising manufacturing capability, moving companies that aren’t advanced manufacturers into advanced capability. And we work with deep-tech companies where our technology development and capability goes into industry and making that technology commercially available.

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As a leading example of modernising manufacturing, we colocated with a company called UAP – in their niche production of high-end public art - they’re the biggest in the world. They were a manual foundry and steel production house; they brought in robotics and AR/VR (augmented reality/virtual reality); and we ran an $8m program to modernise them. That really catalysed a lot of our collaboration, because if a company steeped in tradition, that’s not a tech or science company can undergo dramatic digital transformation, almost any company can. We also work with companies like Sun Metals and other large resource companies that are innovating and modernising their manufacturing processes – these are established facilities that are modernising to maintain their competitive position.

The other kind of project, probably the more common case, is tech companies trying either to make something or to disrupt the manufacturing sector and provide new solutions. We find ourselves doing AI with these companies, building smarts into their products.

An example is Verton Technologies Australia. They came to us with a new product for the heavy-lifting industry, eliminating the need for taglines. Their innovative system is now being used with cranes on large-scale wind turbine installation and maintenance in Europe.

Being able to adjust, through applied physics and AI, how to get those blades on and off was a gamechanger. Verton’s product makes cranes themselves work like robots, and keeps humans safe on risky jobs.

They put a lot of data science into the system that tells them all sorts of things – project timing, workers’ capability, and even risk factors – so they actually become a data supplier to other industries.

Sectors from the shipping industry to the construction industry can use the data. What the ARM Hub is finding is we’re working with companies who are making a new product that they’re going to sell, but they can also sell a data service, and become a platform company.

Verton is a great example because they were a start-up, then they got major joint ventures in Europe that set them off, and they’ve just moved out after being co-located with us for a year because they’ve expanded to have their own very large warehouse. And off they go. There’s a few companies like that – really small SMEs or start-ups that are going to scale up, and they use our technical capability to get to certain Technical Readiness Levels (TRLs), or for proof of concept, or to get their product to a certain standard so it can get the market interest it needs. We don’t do accelerator programs, but we definitely provide the capability to make sure they’re getting their product developed.

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AMT: Tell us about your professional background and your role here.

CS: I’ve got a background as an innovation policy expert. I worked in an urban and regional development context, then I was in and out of universities as a researcher in innovation policy, and in government. Before starting the ARM Hub, I was actually doing business development in the design school at QUT, because I have a history of using design for product improvement and high-value asset management through policy. And then I brought together the robotics and the design capability to roll out the ARM Hub. We’ve got a small team here; there’s 10 of us that do the bulk of the day-to-day activity, and then about 35 researchers and key leaders that come in on projects. The everyday job for me is really building the ecosystem and making sure that all the policies and stakeholders are connected, and the ARM Hub is working well with all our peers. We have this complex networked environment, where we work in collaborations with universities, industry, CRCs and so on. So I’m always trying to make sure those relationships are exactly as they need to be.

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

CS: What’s most exciting, because we’re out in a physical industrial facility co-located with companies inventing and innovating, is when they have great successes. When a company you’re working with has actually solved a technical challenge or brought a new product to market and they are thriving – they go from having an embryonic idea into a successful high-value product or service, taking their start-up or scale-up to the world. That’s why we’re here.

AMT: What would your advice be for manufacturing SMEs about how to engage with the ARM Hub and benefit from what it can offer?

AMT: And what is the Maker Space?

CS: The Maker Space is a physical area here in the Hub filled with collaborative robotics, which means we can use our own engineers and researchers, and work with industry partners who want to come in and trial how something’s going to work with a robot. Find out if it requires a robotics solution or other tech. It’s essentially a safe space in which to experiment with robotics, AR/VR technology and IoT (Internet of Things) integration tools. People can come and work with our expertise to trial and solve problems. We find that’s really important for companies who have their own technical team but want to collaborate with our technical team, and need a space in which they can basically bring their minds together and try to solve challenges. It’s really a practical space.

CS: The ARM Hub is supported by many levels of government and industry, and we’re here to support SMEs. We are that trusted independent advisor that will give you information and work with you on projects, in a timeline and at a cost point matched to your business. We are totally independent, so we’re not selling anything.

We also have independent experts that can work with you on your projects: aerospace engineers, mechatronics engineers, data scientists.

The whole point is to accelerate your ability to take your business forward. The ARM Hub has that expertise, but we also help with you with the direction: finding resources, leveraging money, connecting you to the wider ecosystem and supply chain opportunities. We’re here to make that network accessible to companies as well.

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ONE-ON-ONE Continued from previous page

AMT: We often hear about the need for collaboration in Australian manufacturing. How important is it that manufacturers find ways to work with each other and with organisations such as yours?

CS: Yeah, it always seems like old news, but it’s the most important news: everyone says collaborate. The way I like to describe it is, the ARM Hub has been able to bring some of the best robotics and data science people in the world, to be available on your projects as advisors as required. If you collaborate, you can get access to those people – you can’t buy those people in each and every organisation. So there are resources out there to help you accelerate your innovation; it’s de-risked financially; there is huge backing from government to make sure companies get the success they’re looking for. So use it. That’s what we’re here for.

If you have a skills gap or a knowledge gap, or you need to innovate in your supply chain, come and talk to us, and we’ll meet your problem, or we’ll connect you to the wider ecosystem if needed.

So collaboration is important. You cannot build diverse technical capabilities in every single business to be successful. To go faster, you have to collaborate.

AMT: We have a special feature on Queensland in this issue.

What are some of the most exciting things going on in Queensland manufacturing right now?

CS: Queensland is interesting because it doesn’t have that traditional process manufacturing depth in its industry compared to other states. What we have is smart tech manufacturing built off resource industry capability. We have a prominent METS (mining equipment, technology and services) industry, which allows us to manufacture equipment that’s deeply smart and integrated into large production capability. Mackay, one of our most remote regional cities, is one of the highest patent areas in the country, because they’re continually innovating to drive capability for the resources industry. We have a very important industry built off our natural advantages, and it has this regional flavour because of the prominence of mining and resource production.

That’s important also with global supply chains around critical minerals now. Queensland is a big provider of critical minerals, and that global supply chain is getting smart. That emergent industry tends to be small companies at this stage, but Queensland’s featuring quite highly in that just because of our natural competitive advantage. The other area that Queensland has always excelled in is robotics. And that’s doubled down in things like large-scale industrial manufacturing, where we’re supplying things to the mining sector, and also field robotics – whether that’s asset inspection, drones or autonomous vehicles that go underground, and similarly for defence. Our robotics capability is incredibly strong; we provide robotics across the country and we export to the world. What we’ve got is high-end research & develeopment (R&D) that’s putting the smarts onto our natural advantages.

AMT: More broadly, what are the key trends for manufacturing over the coming years?

CS: I think we’re going to experience supply chain innovation.

There is already an intense global race to be part of the advanced manufacturing network of the future. Companies are positioning themselves, and we want to make sure Australia is taking advantage, so we are able to be part of the positive disruption of those supply chains for the benefit of Australian companies. We’re definitely seeing a race to be part of what is a reordering of supply chains across our industry sectors. I think that’s a great opportunity for us.

There’s a lot of companies looking to onshore or set up new establishments, including here in Queensland. We are seeing a lot more interest in Australia as being the home for manufacturing.

We’re benefiting from that investment attraction trend, and that goes across all industries.

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The other trend is that manufacturing really is the next big tech industry. It’s getting smarter, and it’s going to have AI really unleash its potential, and we’ve got to keep up with that. We’ve got to be at the front of it. Certainly in Queensland, because we’re not a traditional manufacturing base, we need to do the really smart things, that we can compete on globally. It’s about using AI to expose the potential of existing assets and capabilities. It really is the service where most manufacturing companies are looking for ARM Hub support, to understand how to use data, machine learning, computer vision, asset management. That’s a big trend.

AMT: And what are the big challenges and opportunities for Australian manufacturing?

CS: I think the big opportunity is to use the smarts Australia has. We are 13th in the world in our R&D, but we fall short on commercialisation. We’re 31st in the world, among other countries that you would probably assume don’t have as big an industry capability as we do. We create the IP, we drive the innovation, but we don’t commercialise our talents, our R&D or our IP anywhere near the rate of the success we have in terms of R&D and innovation capability. There’s a whole range of reasons for that; partly it’s that there’s been a hollowing out of our middle-tier companies. We’ve either got small companies or very large companies. We need to grow our SMEs into larger, stronger companies, and be able to commercialise and realise the value in our own industry.

Australia has a big skills challenge. We’re really bright, we’ve got a lot of talent in this country. What currently happens is our talent goes overseas. Australians working in manufacturing innovating overseas are doing incredibly well. We need to bring that talent home, we need to hold onto our talent, rather than people seeing it as ‘if you want to work in high-end manufacturing, the only thing to do is go elsewhere’. We need to figure out how to keep our talent, and of course we’re up against the race of STEM skills, and keeping up those skill sets for the future.

There’s been a lot of discussion about how Australia’s industrial transformation needs to go forward. We need to look at models like the UK Catapult Centres or the Manufacturing USA institutes, where there is a higher level of investment co-ordinated across the country to build deep capability. We’re trying to create that now; it’s part of our model going forward, to build this network. Across Queensland we have deep AI and robotics capability. Swinburne’s got digital production, digital factory capability. Tonsley is really driving materials and space. And UTS is doing a lot of the start-up, scale-up business innovation capability. We need this connected ecosystem of capability where we’re not trying to just recreate small-scale operations at a level which is debilitating for the country.

We need consistent strong investment.

And when it comes to innovating in manufacturing, there’s no second-mover advantage. You can’t wait for someone else to do it and ride their coattails. You’ve got to build skillsets in your company; you’ve got to build and be integrated into supply chains; and you’ve got to be doing all of that now. So my message to businesses is: you’ve got to start now, start with a problem and look to solve it. Get a plan for growth, get a technology roadmap, and start that journey. Don’t delay. Because every delay you have, you’re deskilling your workforce, you’re moving further away from digital supply chains, you’re making the challenge more and more difficult for your company.

There’s never been a time like now for Australia to do something significant in manufacturing. And the risk if we don’t is that we won’t be able to drive high-value jobs, we won’t be able to replace a regional economy with high-value jobs. It’s very tangible in Queensland, and probably elsewhere as well, but if mining is on the downturn, which it is, who’s going to employ those people, those families in the regions, at a wage and at a skill level where they’re going to be able to thrive. The only strategy is advancing manufacturing. www.armhub.com.au

Real Business Real People Real Members I have been associated with AMITL as a member since its inception and have known most of the AMTIL staff for considerable years therefore I feel that I can say the organisation is of the quality the members should be very proud of. AMTIL conducts its activities with the enthusiasm and direction needed to promote Australia’s manufacturing industry across all appropriate sectors of government and industry alike. Their methods are generally of a consultative nature as they seek out inputs from all concerned and then having done so their feedback is informative. Most certainly confidentiality of matters discussed is paramount for the competitive industry we are in and there is never a concern with regards to such matters where AMTIL is involved. Anyone who has ever attended or participated in a AUSTECH exhibition could only attest to the quality of the exhibition and this is as a direct result of AMTIL’s overall co-ordination of the event and their methods of working closely with all involved.

Dean McCarroll, OKUMA Australia Pty Ltd

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/DM

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Samin Sheet Metal – Productivity boost with new Amada Ensis laser Joining his parents’ business in 1989, toolmaker Wade Samin soon began to reshape Samin Sheet Metal, which until then had been involved in cutting and folding simple sheet metal components. The company has come a long way since then, with an Ensis 6kw laser cutter becoming the latest in its line-up of machines from Amada.

Wade recalls how the business has evolved since he joined: “With my background as a toolmaker and understanding precision engineering, we started to develop a customer base that needed high-precision sheet metal. This move was the key driver for sourcing machinery that would give us the accuracy for precision cutting, folding and punching. “Targeting the electronics industry set our business on a solid growth path. We quickly discovered the unmet demands of that industry, and by satisfying its needs, built great customer relationships that boosted our growth.

“Visiting a Brisbane machinery show, we were introduced to Amada equipment and invested in our first Amada press brake. The success of our first high-precision machine encouraged further machinery investment that included Amada turret punches, laser cutters and additional folding machines.

“A bonus of our new precision capability was the ability to offer our existing customers additional services beyond cutting and folding. We soon discovered we could help our customers improve their designs or enable them to produce better designed products. For example, our precision manufacturing technology was highly suited for work such as PC board mounting chassis, racks and enclosures for electronic equipment.”

Collaboration is taken seriously “We collaborate closely with our customers on their designs,” Wade explains.

“Understanding the end use of the product gives us great insight in satisfying their needs. Working closely with customers at the design stage is a big benefit for them in terms of receiving an optimised product.

We believe this close working relationship with our customers is something that few others offer, and has helped us establish valuable goodwill and trust over the years.

“Many sheet metal businesses expect a customer to come to them with specifications and drawings and will only produce exactly what they have been asked to deliver. The difference with Samin Sheet Metal is that we engage with customers at the earliest stages of design and we are happy to respond accordingly.”

Driven by productivity “Since those early days, we have purchased many Amada machines,” says

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Wade Samin, owner of Samin Sheet Metal, with the Amada Ensis fibre laser machine.

consumption; an important consideration as energy costs were rising. The Amada EM2510 replaced both machines as well as giving us the extra capacity of a third machine. “The performance of the Amada machines cannot be faulted. The whole Amada package in sourcing, supply, installation and after-sales service has also been totally positive. This experience influenced our latest investment in the Amada 6kW Ensis laser cutter, which includes a load/unload system.”

Exceeding expectations

Wade. “When we look at purchasing a new piece of equipment we always look at what automation is available, and particularly what automation would suit our job and our manufacturing processes. Our core objective throughout the many years of purchasing equipment is to produce more with the same staff levels – it’s all about productivity.

“As an example, prior to purchasing our current Amada EM2510 turret punch equipped with its MP load/unload system, we had two turret punches with an operator at each machine. These machines were being run continuously throughout eighthour days and often at weekends. When we needed more punching capacity, we invested in a new Amada EM2510 servodriven turret punch, which allowed us to run with lights out unmanned operation.

“The machine requires little maintenance and gives us a huge reduction in power

“The Ensis laser has exceeded all our expectations in terms of performance and reliability,” Wade reports. “It is an outstanding machine. It is so fast we no longer needed to run our older automated laser cell, as the new Amada Ensis 6kw laser cutter with its MPL load/unload system was more productive than three machines combined.

“The next step was to run the Ensis laser at night, lights off, doing the work of three machines – with a single operator. This has enabled us to keep tight lead times, often on a very short cycle. We can now cut faster, cut thicker material, with lights-out unmanned operation. Its capacity to turn out three times the amount of work in the same timeframe has absolutely proven its worth.

“Whether simply cutting and bending material such as a simple flat intercom fascia for an electronic component, or a complete build of a cabin for a piece of earthmoving equipment, Samin Sheet Metal has the capability to deliver a total solution.” www.amada.com.au www.samin.com.au

Production Manager Hans Kummerehl checking the MPL loading system ready to feed the Ensis laser machine.

QUEENSLAND

STATE SPOTLIGHT

Gessner Industries increases output by 50% with Okuma Toowoomba-based company Gessner Industries recently commissioned the latest Okuma CNC vertical machining centre, model MB56VA with OSPP300MA Control, dramatically increasing output from its machining shop.

A market leader in the manufacture of agriculture and earthmoving machinery, Gessner Industries was founded in 1975 and is now owned by brothers Jim and Michael O’Connor. With more than 45 years of proven service to the agriculture, construction and mining industries in Australia, the company has built up an enviable name for both quality and reliability. Today the company occupies a modern manufacturing facility and boasts a full-time specialist engineering and design department capable of customising equipment to meet the needs of its customers.

After establishing a need for additional machining capacity, the Okuma machining centre was selected following a careful analysis of the specifications required for business both now and into the future.

This included the importance of four-axis capability, a full review of the service level available, plus strong positive feedback from other Okuma machine users. A critical factor in the selection process was the service provided by Okuma for customers in Far North Queensland and the exceptional level of technical expertise that was available for customers in the more remote areas of Australia.

“Like many industries, we are constantly under threat from imports but our customers want to support local business wherever possible and it’s important for us to remain highly competitive with robust quality products,” says Director Jim O’Connor. “Okuma was a good fit for us as both Okuma and Gessner Industries take quality and customer service extremely seriously, and the new machining centre is already providing us with the highest quality output and reducing our costs.”

Gessner Industries currently employs some 50 personnel. However, with a 50% increase in output from the machining shop as a result of the introduction of the new Okuma machine, it is allowing more fabricators to be employed to cope with an increase in fabrication work and a reduction in lead times overall for equipment.

The company’s product range includes broad acre and row crop equipment, sugarcane machinery, earthmoving attachments and an extensive range of spare parts servicing the market both directly and through an expanding dealer network throughout Australia. The range continues to develop with ongoing R&D and design development into new products, with an eye to export potential, particularly throughout South-East Asia.

“Gessner Industries is taking full advantage of the extensive training offered by Okuma,” says Jim. “The experienced staff within the machining department see this major investment in advanced precision engineering as an exciting positive step, opening up new opportunities, skill levels and enhanced job security.”

John Baker, Sales & Applications Engineer – Queensland for Okuma, congratulated Gessner Industries on the purchase of its first Okuma CNC machining centre: “We look forward to a long and productive relationship with Gessner Industries. The future looks bright for this business as they reap the benefits of fast production of high-quality precision parts culminating in the further enhancement of competitive Australian manufacturing.” www.okumaaustralia.com.au www.gessner.com.au

Components manufactured on the new Okuma CNC vertical machining centre.

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All types of solutions for Alltype Engineers Family-owned business Alltype Engineers has been in operation since 1973, providing hiqh-quality fabrication, site installation, construction and maintenance services to its customers locally in Brendale, Queensland, and across Australia.

Since Darren Aldridge took over the business from his father Mike, the company has been expanding its services, originally starting in material handling and diversifying into general fabrication. With up to 12 workers on the floor and out on site on any given day, a top priority is to ensure premium product quality and production efficiency by using high-quality welding equipment and gas.

Paul Broughton, Area Manager – North Brisbane at BOC, and Darren Aldridge, Director at Alltype Engineers.

Alltype Engineers faced a challenge when it won its largest ever order to weld aluminium trench shoring boxes. Trench shoring boxes are made from aluminium and placed in the ground on excavation sites to provide stability in trenches and keep workers safe.

To meet the requirement of this order, it was essential that the company had the best equipment and gases on hand to increase staff productivity and save time.

Meeting demand Working in a busy workshop with large projects and tight deadlines meant time was of the essence. With customer demands increasing, Alltype Engineers took a holistic view of its services and equipment. The team decided to start shopping around for high-quality gases, welding equipment, aluminium wires and day-to-day consumables. The workshop is welding every day, with anywhere between four and six cylinders used each week.

“We were ordering cylinders every second day,” says Darren. “This is hugely timeconsuming when you consider we have at least four people welding at all times and the work involved in connecting regulators and transporting them around the workshop.”

When staff detached a regulator from a cylinder, there was always a risk that they would drop it on the ground, break it, or crack the valve open too fast and blow the diaphragm. This creates a safety risk and would occasionally result in damage to the regulators.

running at 380 AMPs. We were so happy with the EWM that we now have six of them in our workshop.”

Time and cost savings “We immediately noticed time-saving benefits with BOC’s EWM machine,” Darren explains. “With previous welding machines, it would take us three days to weld a 6m panel. Now it only takes us about 16 hours in total, saving us four to six hours of work per day.

“The EWM machines have massively increased our productivity. We love the simplicity and versatility of the machine, that allows each welder to programme the machine to suit their task. Our oldest EWM has been working flat out for four years and we have never had a breakdown – that demonstrates just how robust they are.

Alltype Engineers was seeking value for money, and after a survey of the market it found that BOC’s F3 VIPR cylinders exceeded expectations. It decided to upgrade all of its G-size cylinders to the F3 VIPR cylinders.

“We were ordering gas every second day and now with the F3 VIPR bottles, we only order once per week. It has relieved me and my staff as we aren’t moving around huge gas bottles, and it saves me money as there is less downtime. In essence, it improves the profitability of our own products.”

“Not only did we switch over our cylinders but after an initial trial of BOC’s EWM MIG welding machine, we quickly realised this was the premium product on the market with an amazing price point,” Darren adds. “Our staff got the EWM Phoenix 405 and 355s with push-pull torches to cycle

The innovative F3 VIPR cylinder not only provides value for money by eliminating the need to replace or service regulators and gauges thanks to the in-built regulator, but they are also filled to a pressure of 300 bar and contain up to 15% more gas than the G-size. Consequently, Alltype Engineers

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Alltype Engineers has achieved significant productivity gains with BOC’s EWM MIG welding machine.

can get an extra day and a half out of a cylinder. It also has improved safety features including a handle, protective casing for the regulator, and a shorter height for easier transportation, manual handling and installation on the back of the welders.

Australian made Alltype Engineers didn’t stop there. The aluminium trench shoring box project required 25mm-thick aluminium to be able

QUEENSLAND

STATE SPOTLIGHT Welding operations in progress at Alltype Engineers workshop in Brendale.

by wearing the parts too quickly, but BOC’s SAFRA wire is triple shaved, so the welding spares like liners do not wear, unlike with other aluminium wires on the market. I can confidently say we have never had a faulty roll from BOC. “Our client used to purchase aluminium panels in the US and transport them to Australia, but now we cut and weld the panels together to make an Australian product.”

Darren concludes: “We wouldn’t have been able to do the aluminium trench box project five years ago, but thanks to our gas and welding solutions, we are the only aluminium panel maker in Australia, with panels that are 35% stronger than our US competitors. That is something we are very proud of.

to withstand intense heat. “This was our largest order ever,” says Darren. “It required 115 tonnes of aluminium and 18mm-wide fillets welding at 400 AMPS. We tried 15 products on the market to see what type

of aluminium wire best suited our needs and yet again, we found BOC’s aluminium wire to be the highest quality. With previous suppliers, one in ten was a faulty roll. Faulty rolls can damage the welding equipment

“We were getting our gas off BOC and now we get everything – gas, welding machines and all of our day-to-day consumables – because we know they are reliable and BOC experts are always on hand.” www.boc.com.au www.alltypeengineering.com.au

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STATE SPOTLIGHT

QUEENSLAND

Manufacturing in QLD? That’s worth a gold medal!

Five years ago, the Queensland Government announced the 10-year roadmap and action plan for advanced manufacturing. Since then it has continued to invest heavily in the sector. By Craig Barry of AMTIL corporate partner William Buck Chartered Accountants and Advisors.

With manufacturing contributing over $20bn pa to the Queensland economy and employing more than 170,000 people, the Queensland Government is committed to helping foster new growth and transition existing businesses into sustainable and successful advanced manufacturers to ensure the continued growth of the industry.

Our abundance of natural resources, comprehensive transport and infrastructure networks, world-class universities and training institutes, unrivalled proximity to the high-growth markets of the Asia-Pacific, competitive business and living costs, and enviable lifestyle make Queensland an attractive place to operate.”

In the words of the Queensland Government itself, its vision for the Queensland manufacturing sector is for it to be “… international market leaders in the delivery of advanced manufacturing technologies, systems, products and services that are innovative, sustainable, and embedded in local and global supply chains” by 2026.

Add to that the State’s handling of the COVID-19 pandemic, compared with other states where many businesses are struggling to operate due to the continued lockdowns.

Queensland businesses can operate comparatively freely with minimal COVID-19 restrictions in place, allowing them to continue to grow and thrive during this period.

This vision drives its strategy of supporting advanced manufacturing, which in Queensland, includes sectors such as:

Apart from the enviable lifestyle we have up here in Queensland, there are several key factors to consider when looking to establish or expand your operations:

• Aerospace • Biofutures • Biomedical • Defence industries • Food, beverage, and beef processing • Mining equipment, technology, and services • Precision agriculture • Rail manufacturing • Renewables and hydrogen • Resource recovery

High value sectors While there are many areas in the manufacturing industry, four sectors have stood out as high-value emerging areas to watch in Queensland. These are : • Aerospace. Potential for manufacturing opportunities in areas such as large-scale alloy casting, heat treatment for avionics, along with new opportunities for advanced materials.

• Biofutures. A fast-growing sector with an emphasis on manufacturing products from sustainable organic or waste resources. This is considered a sector with a high level of potential, given the future focus of renewables and sustainability in the general business environment.

• Biomedical. Growing demand for medical devices and assistive technologies for the state’s growing and aging population. In addition, Queensland is well placed for export opportunities of pharmaceutical products, including the manufacture of vaccines.

• Defence industries. Ongoing investment in the defence sector is creating opportunities for advanced manufacturing of heavy vehicles and new types of composites for structures and components.

Why establish your business in Queensland?

Queensland Premier Annastacia Palaszczuk stated in the foreword to the advanced manufacturing roadmap: “Queensland offers a unique home for manufacturing businesses to grow and evolve into manufacturers of the future, poised for further success.

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• Government grants. Queensland is committed to funding the manufacturing industry and has continued to deliver on grants to the industry, with a focus on partnering with those businesses looking to grow their Queensland operations. Successful grants include the Made in Queensland grant, which has delivered $77m to small and medium manufacturers.

• Manufacturing hubs. The Government has invested over $30m into regional hubs to support the growth of regional manufacturers in locations such as Townsville, Cairns and Rockhampton. These hubs provide a place for local manufacturing businesses to receive expert advice and support to transition to advanced manufacturing. The latest hub to open was located on the Gold Coast in July 2021.

• Housing affordability. With capital city prices increasing significantly over the past 12 months, the mean price of residential dwellings for Queensland is still only $586,000, compared with $1,011,000 in New South Wales, and $834,000 in Victoria. With affordability of property being a key issue for staff, Queensland represents significant value compared to other states, while still showing signs of long-term growth.

• Migration to Queensland. Since the COVID-19 pandemic started, there has been a significant change in the way people live their lives and where they are choosing to live. Coupled with housing affordability, this has led the latest statistics to show a net migration to Queensland of more than 7,000 people, compared to a loss of 4,900 in Victoria and 4,500 in New South Wales. With more people moving up to the Sunshine State, there will be greater opportunities to attract and retain staff.

• Olympics 2032. Brisbane has recently been named host of the 2032 Olympics and Paralympic Games, which will be the largest event ever staged in Queensland. The Brisbane 2032 Games are forecasted to generate $8.1bn in total benefits for Queensland.

Craig Barry is Director, Tax Services at William Buck. www.williambuck.com

QUEENSLAND

STATE SPOTLIGHT

Elexon Electronics takes quality management and development to next level Having passed the external ISO 9001 audit for the past 15 years, Brandale-based electronics manufacturer Elexon Electronics is set to build on that success by completing the ISO 14001 and AS 9100D certifications.

This is an exciting time for Elexon, according to CEO Frank Faller: “We’re extremely proud that for the past 15 years, Elexon has been successful in every Quality Assessment undertaken. Quality management and continuous improvement is in our DNA. It is not just a tick box, quality is what we live and breathe. “By achieving ISO 14001 and AS 9100D certifications later this year, we’ll continue to build on our reputation and deliver even greater quality to our customers from the defence, mining and other niche industries.”

To help achieve this significant milestone, Elexon recently recruited Kylie Warren to the role of Quality Manager and Jordan Metlikovec as an NPI & Process Engineering Manager to oversee the development of the quality system and manufacturing process quality respectively.

“The ISO 14001 and AS 9100D certifications are integral certifications for companies working in the defence sector and I’m looking forward to being a part of the Elexon team who achieves this,” said Warren.

“My plan is to actively connect engineering, manufacturing and quality departments and with a hands-on approach, actively contribute towards the continuous improvement of Elexon’s processes, products and services,” added Metlikovec Elexon has set a goal to complete the next level of certification AS 9100D by the end of 2021. AS 9100D works in conjunction with ISO 9001, and represents industry standards with added requirements specific to the aerospace industry. Elexon also plans to become compliant with the Environmental Management System under ISO

14001 within the same time frame. The Quality Management System (QMS) is fundamental to Elexon’s successful reputation as a highly professional manufacturing and engineering partner. The QMS has been successfully maintained since its introduction as the company has met the three-yearly ISO 9001 audits. Implementation of such management systems has allowed Elexon to embed resilience and agility into its strategies, elevated operational efficiency, and enhanced technical analysis and document control.

ISO 9001 standards were introduced as soon as the company was established in 2006. The two owners of Elexon: Pieter Kuiper and Leigh Bateman, immediately implemented an effective QMS into the company’s processes. The following year, Elexon successfully passed its first external audit, before becoming certified in 2007. www.elexonelectronics.com

John Hart delivers major manufacturing power for Rheinmetall NIOA Munitions plant John Hart is currently in the process of installing a full turnkey manufacturing line comprising 15 Mazak machine tools and robotic automation equipment for the Rheinmetall NIOA Munitions artillery shell forging plant in Maryborough, Queensland.

Nicholas Rehfisch, John Hart’s Managing Director commented: “As a 100% Australian-owned family business, John Hart is proud to be supporting Australia’s sovereign defence manufacturing capability by providing the world’s most innovative and advanced machine tool and automation technologies.”

Rheinmetall NIOA Munitions, a joint-venture between Rheinmetall Waffe Munition GmbH and NIOA, is committed to the development of Australian sovereign capability. The Maryborough facility will produce 155mm artillery shells, as well as other munitions-related products. When in full operation, it will create up to 100 jobs in the Maryborough and Fraser Coast region. www.johnhart.com.au

BRING THE WORLD TO YOU BACKED BY BOQ With support managing foreign currency and exchange rates, as well as providing a deeper understanding of international and domestic trade.

Chat to one of our experts: 1800 343 939 financial.markets@boq.com.au

These products are issued by Bank of Queensland Limited ABN 32 009 656 740 AFSL 244616 (BOQ). The current Product Disclosure Statements or terms and conditions for these products are available on request. Before making a decision, you should consider whether or not these products are appropriate for you. Terms and conditions and eligibility criteria applies.

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COMPANY FOCUS

QUEENSLAND

Marsh Alliance – Springing into action The modern world could not function without a lot of things we routinely take for granted, and this is certainly true of springs. Queensland-based Marsh Alliance is Australia’s leading manufacturer of this underappreciated, yet vital, component of our everyday lives.

Marsh Alliance operates from a 7,000sqm site at Carole Park, south-west of Brisbane, and employs just over 100 dedicated personnel.

Springs are everywhere but invisible, at least if you’re not looking.

And nobody looks for springs.

in Marsh Pressed Parts, Marsh Wire Forms and Marsh Specialty Coatings.”

But your house, for example, is full of them.

Marsh Wire Forms covers simple-to-complex wire clips and shapes manufactured in low- to high-volume runs to suit customers’ needs.

“In construction there’s a number of products that we manufacture, and garage door springs are one of our larger production lines,” explains Chris Watt, Sales & Marketing Manager at Marsh Alliance, of some of their uses by the company’s construction customer base. “Most garage doors and industrial roller shutters would have a spring appropriate to the size of the door to allow for balancing and easy lifting of the door.

“We also promote a number of products in the HVAC industry, from both our springs and pressed componentry divisions, for various subassemblies that installers would utilise within the larger construct of HVAC. Additionally suspension ceiling systems are a consistent part of our business, producing componentry that goes into suspended ceiling board systems.”

Watt’s company was known as Marsh Springs and Metal Products until earlier this year. It remains the country’s biggest spring maker, and employs just over 100 dedicated personnel. The company’s history goes back to 1953 when it was founded by Thomas Marsh.

Today it is still a family business, owned by Thomas’ son Greg Marsh, who has successfully run the business since 1979.

As of June 2021 the business was officially rebranded as Marsh Alliance, organising a company grown through a series of recent acquisitions into four unique business units, each reflecting a set of complementary strengths built up over the years as the business grew. All four units operate out of a 7,000sqm site at Carole Park, south-west of Brisbane, which the company has operated out of since 2007.

To allow customers an easy way to identify Marsh Alliance’s manufacturing capabilities and to easily communicate its business proposition, the company has been organised according to its four main production divisions.

“Marsh Springs, as the staple of the business still holds first place in our group,” Watt explains. “However, it is backed up with capacities

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Marsh Pressed Parts can make everything from small spring clips to pressed components over 2m long, and typically operates highervolume production. The press division offers presses suitable for a variety of customer requirements, with a press capacity of up to 110 tonnes. It is supported by a fully-equipped, inhouse tool room to keep it all running.

Finally, Marsh Coatings is a registered applicator of products made by anti-corrosion specialist Magni, with Australia’s biggest dipand-spin coating plant. The company coats with Magni 565 “on a daily basis”. This is a high-corrosive-resistent two-coat system, consisting of an organic aluminium-rich top coat of five microns, on an inorganic zinc-rich base coat of eight microns. Magni paint is applied utilising a dip-and-spin technology applying controlled layers of coating.

Magni 565 routinely achieves neutral salt spray resistance of 1,000 hours and is often specified in the automotive industry, with corrosion protection exceeding all automotive standards and requirements and protecting against hydrogen embrittlement. Automotive is one of the markets Marsh Alliance serves with technology, along with the construction and agricultural segments.

“It became a focus of ours to differentiate, firstly, these services within our business, so we can actively promote each section to the companies that are looking for that type of contract manufacturing,” says Watt. “And we were able to approach many of our existing customers with the offer of taking on some of their production, and even part of the retooling of their production, as we’re able to offer in-house tool design, manufacture and then manufacturing of the componentry.

“By displaying the four capability businesses that we have is to better position ourselves in the marketplace for companies looking for Australian contract manufacturers.”

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The company manufactures springs for a wide range of applications, across sectors such as automotive, construction and agriculture.

Marsh Alliance invests significantly in research & development (R&D) and design consultation.

A key supplier

Not your typical skillset

Marsh Alliance’s business is almost entirely contract manufacturing.

Its customer list includes Bluescope Steel, Schneider Electric, Assa Abloy, and Trajan Scientific and Medical.

Australia has a small collection of spring manufacturers according to Watt, numbering only a few significant companies. International competition is strong, he believes. The much-publicised desire for manufacturing to reshore has been difficult for a lot of companies to act on, despite a lot of good intentions about going local.

“I would say that construction, mining, automotive and certainly manufacturing would be the largest sub-sectors of our business,” adds Watt.

Some of its acquisitions – the company made seven between 2010 and 2020 – had an automotive heritage, and this lives on at Marsh Alliance. A “fair amount” of auto industry client orders find their way into locally demanded products, mostly aftermarket spares and accessories.

“And we do continue to support local automotive manufacturers because we can manufacture componentry used in their finished goods,” says Watt. “There is still a small sector of automotive suppliers in Australia manufacturing parts, which we continue to support, but the bulk of manufacturing would be exported at the present time.”

In general, he adds, the overall focus of the business has been serving Australian customers, but over the last four or five years it has actively ventured into export.

“It’s certainly a growing part of our business, that Marsh Alliance will continue developing.” He explains. “There’s a fundamental need to be able to serve existing business partners internationally, particularly when we find local Australian companies with multiple manufacturing points around the world. It became a natural way for us to approach global partners as we’re an existing key supplier, with a confirmed high-quality standard, capable of manufacturing and supplying parts globally to the standards required.”

As part of the service that Marsh Alliance offers, it maintains a sales force on the eastern seaboard with a presence in each state to ensure a hands-on, personalised customer experience. Being close to its customers has proved important in Marsh Alliance’s businessto-business sales context, allowing the company to understand its customers better and offer improved service, and meaning that customers can access design support and other assistance.

This year, Marsh Alliance has turned to digital marketing to drive new business, making use of Google tools, SEO, and revamping their website. Watt explains: “It’s part of the rebranding activity, which is an exciting opportunity for us to start showcasing what we have.”

“I think the retooling costs faced by many other producers in the country are a bit too high, and they’ve gone back to importing what they can, and if they have to, doing some sort of subassemblies locally,” Watt comments. “Recently we’ve managed to attract some good business and I think there’s still opportunity for us to grow within the local market. But it’s more on the back of other manufacturers being able to successfully reshore their manufacturing in Australia, and creating the opportunity for Marsh Alliance to work with them on their component needs.”

Happily, he says a lot of companies looking to bring production home have been surprised by what capacity still exists here in spring and pressed parts manufacturing. Marsh Alliance plans to grow what it has here, though Watt declines to give specifics about investments in machinery or meeting new quality management standards.

Marsh Alliance’s sustainability plan includes a 100kW solar system installed in 2018, and the business will continue to review other ways it can cut its energy consumption and operate more sustainably.

As for training for future needs, this is particularly challenging at one of the country’s few remaining spring makers, operating in the relative obscurity of contract manufacturing. Fortunately staff retention is high, and retaining skills for ongoing in-house training of new team members is paramount to ongoing growth. According to the Marsh Alliance website, some of its employees have been at the company for over 40 years.

“We’ve had a high retention of skills with an organisation, which has worked well for us, through our growth and some of the expansion that has happened over the last two years,” Watt says. “What I would suggest is the skill requirement in our industry specifically doesn’t really exist as a trained skill in the marketplace, so we actively train internally. We recruit for technical and mechanical aptitude and we train internally.

“Because spring-making is not a typical skill that you would find in the market.” www.marshalliance.com.au

They have also begun using print media. Watt adds that fingers are crossed for next year’s Australian Manufacturing Week exhibition and the resumption of trade shows.

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Laserline: Welding copper with a diode laser Research & development of diode laser systems has led pioneering German manufacturer Laserline to introduce a Hybrid system that notably can be used for welding thick copper parts.

Laserline laser systems is well known worldwide, with many installations in a range of industries including on the production line of various Audi models for welding tailgates, doors and roof joints.

The systems are favoured due to the high-quality finished product and their use in conjunction with a robot for automated process controls.

Welding of aluminium often requires a filler material but can be used on visible surfaces without further processing – a result that has been tested and used by Audi in Germany. In Australia Laserline lasers are used extensively for cladding, repair and refurbishment of worn or damaged parts. A 3D process is also possible to print new parts or add functionality.

Recently Laserline has focused on developing a system suitable for welding copper, a key component in many modern technological devices. Copper is one of the most important raw materials for electrical power and signal transmission, and with the growing use of small devices, the demand for good quality welding that provides suitable results was an area where Laserline focused its research & development (R&D). Found in battery cells of mobile devices, in induction coils and in accumulators of electric cars, copper can be found almost everywhere. Building a laser system that would be suitable for welding copper in devices led to the introduction of Blue Diode Lasers.

The Hybrid concept from Laserline, combining a blue diode laser with a traditional infrared laser.

Welding copper with the Hybrid concept, utilising LDMblue and infrared lasers.

Faced with the challenge of copper welding, Laserline analysed the range of copper components, identifying differences from waferthin wires to sheets millimetres thick. For example, to effectively join thin foils required a welding tool that has low impact depths and moderate energy inputs but high intensity to actually fuse the copper.

The decision was made to move from an infrared laser to test Laserline’s new LDMblue, designed for industrial purposes with a multi-kilowatt range and a wavelength in the blue spectrum. Its higher absorbtion in most non-ferrous metals leads to spatter free copper welding. However, the LDMblue did not provide a complete solution on its own to also weld thick copper components.

Having realised very early that diode lasers offer an economical and compact heat source that can be adapted to many laser material processing applications, Laserline pursued product development to meet the thick copper welding challenge. Clearly, further consideration was required to find a product that would be suitable for all types of copper, from wafer-thin wires to thick sheets.

To attain deeper welding seams, a Hybrid concept has been developed that combines the blue diode laser with the traditional infrared laser. The laser beam from each is merged using a special focusing optic. To fuse the workpiece surface, the high absorption rate of the blue diode laser begins the process, with the infrared laser performing the actual deeper keyhole welding process.

The advantages of the blue laser guarantees a calm and stable melt pool, significantly reducing spatters. In a welding process that requires a depth up to 3mm, the molten pool provides a finish without visible spatters or pores in the seam. Where lap welding of two copper sheets is required, smooth joining seams can be attained with no impurities observable.

While Laserline’s new Hybrid system has already shown it is reliable and suitable for customer usage, the company continues to develop and improve the usability of this new Hybrid system. Its goal is to make welding depths to more than 3mm using this Hybrid approach.

This is an exciting field given the move towards battery production and small technological devices that require copper components.

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The Laserline copper welding process.

Laserline aims to become a prominent solution provider as the demand for these products grows. Any Australian company intending to grow their market in this new sector with a Laserline blue and/ or Hybrid system can find assistance with Raymax Applications, offering training, advice and ongoing support. www.raymax.com.au

COMPETITIVE FINANCE SOLUTIONS SINCE 1973 interlease.com.au

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A gas-led recovery will not work The Federal Government has identified increased investment in the gas industry as the key to Australia’s post-COVID revival. Geoff Crittenden argues that building our economic future on the resources sector will not work, and that we instead need to build a manufacturing-led recovery.

“We need to get the gas from under our feet.”

So said Prime Minister Scott Morrison during a speech in late January, emphasising his plans for a ‘gas-led recovery’ following the COVID-19 pandemic. Morrison has committed a whopping $6bn to the development of gas in Australia, in an economic strategy that is entirely contrary to the interests of the country.

Meanwhile, Australian manufacturing is in decline, despite the significant contribution that the industry can – and already does – make towards the economy and the national interest. Our economic recovery should be led by manufacturing. It should take advantage of, and build on, the substantial innovation, skills and technology that are readily available.

Government, at all levels, must invest in the manufacturing sector to support its growth. Australia’s COVID-19 recovery cannot be resource-led. It must be manufacturing-led.

Now is the time to rejuvenate our manufacturing industry – to make manufacturing a national priority.

A resources-led recovery just won’t work The Federal Government’s plan to invest in gas would significantly expand the industry and tie our economic fortunes to the resource for decades to come. The strategy is based on the idea that manufacturing relies on gas in a way that cannot be replaced by alternative energy solutions. But as we know – and as Ai Group pointed out to the Government – manufacturing’s reliance on gas has been completely overstated. We do not need investment in gas to become a more successful industry. We need investment in manufacturing itself, including technology, equipment and education.

Furthermore, Australia’s major export markets for LNG, such as Japan, South Korea and China, have committed to reaching net zero emissions in the next 30 years. Globally, countries are turning away from gas and coal and investing in renewables. It simply doesn’t make sense to base our economic recovery on a resource that has a clear expiry date.

In fact, the gas industry has been preparing for this transition for years, cancelling major projects and laying off workers. Since 2011, Australian gas companies have lost between 50% and 70% of their value. To think that this loss-making industry is going to lead Australia out of economic trouble is absurd. Our Government needs to stop pursuing industries that will be almost redundant in 30 years’ time, and begin to invest in future-proofing our local manufacturing sector.

The future lies in advanced manufacturing Advanced manufacturing is the way forward. Overseas, investment in advanced manufacturing is prioritised by governments, and local populations support the industry by buying locally-made goods.

Advanced manufacturing employs millions of people in overseas markets, contributing billions of dollars to their economies.

In Germany, advanced manufacturing has been identified as one of the highest-priority manufacturing technology areas in need of government investment. Over 15m people are directly and indirectly employed in the advanced manufacturing industries in Germany.

By 2025, 84% of German manufacturers plan to invest €10bn per year into smart manufacturing technologies, including in engineering and construction, electronics, metalworking, and the automotive industry. Some 20,000 industrial robots are utilised in Germany each year, making it one of the largest markets for robots in the world.

Similarly, Sweden has invested heavily in research & development (R&D) and innovation to continually grow and improve their

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manufacturing sector.

Today, the manufacturing and industrial engineering sector accounts for 20% of Sweden’s GDP, or US$110bn. The sector accounts for 75% of Swedish exports, and employs more than one million people. The Swedish Government has long supported its local manufacturing industry, focusing on digitalisation, innovation, and promoting talent. It is no surprise that the industry attracts significant investment, with current annual R&D investment of around US$11bn.

Geoff Crittenden

Advanced manufacturing has been shown to boost profitability in countries around the world. Labour cost savings through automation and robotics have resulted in a 33% cost savings for manufacturing industries in South Korea, and a 25% saving in Japan. Money invested in upgrades and new technology has been shown to be quickly recouped: in the US, a Toyota plant spent $1.2m on a smart factory modernisation and saved $1m in the first nine months through maintenance savings alone.

And while there has been some scare-mongering around robots replacing humans in manufacturing industries, in reality the opposite is true. Higher profits that result from smart manufacturing technologies give companies more capital to finance improvements and expansions, which require hiring more workers. Dangerous and mundane jobs are completed by robots, while humans are retrained to take on more challenging tasks. According to one research company estimate, 15 million new jobs will be created in the US over the next decade as a direct result of automation and artificial intelligence.

The possibilities of local innovation Despite having a fraction of the support and investment that has contributed to other countries’ success in advanced manufacturing and technology, Australia has made astounding advancements.

The QUT Centre for Robotics is at the forefront of innovation in intelligent robotics. Some of their amazing projects include the

WELDING development of the: RangerBot AUV, an underwater robotic vehicle with advanced real-time image processing; the ‘Kelpie’, an autonomous robot for use in large-scale agriculture and weed management; and a robot manipulator designed to perform maintenance on mining machines to avoid the risk of human intervention.

Innovation in advanced manufacturing is in no way limited to Australian universities. Many of our local SMEs are at the cutting edge of R&D. For instance, the artificial intelligence (AI) and Industry 4.0 methodologies and technologies developed by Queenslandbased IR4 are setting global benchmarks in efficiency. It is for this reason that IR4 (in partnership with Weld Australia and QUT) is in a position to engage with global prime contractor BAE Systems on using ots technology to improve welding cobot capabilities for the Hunter Class Frigate Program.

Strength through technology transfer A key ingredient in a post-COVID recovery driven by advanced manufacturing is technology transfer. By sharing skills, knowledge, insights and technology, the Australian manufacturing industry can speed up commercialisation, reduce overheads, streamline internal processes and enter export markets more quickly.

Weld Australia recognises the importance of technology transfer, which is why we host and administer Technology Networks.

Comprised of industry-leading companies, state road authorities, major power stations and a range of prime contractors, our Technology Networks provide a forum for sharing insights and R&D, and link members with industry and research organisations.

We are not the only body helping to support technology transfer in the manufacturing industry; some state governments have also stepped up. For instance, the Queensland State Government recently allocated $30m to fund a series of Regional Manufacturing Hubs. These Hubs are assisting local manufacturing businesses

to take advantage of new technologies and build strong links with universities, TAFEs and schools, developing a future workforce ready to take on the challenges of becoming a world leader in advanced manufacturing.

Manufacturing contributes around $20bn to the Queensland economy each year and creates a significant amount of direct and indirect employment. Clearly, the Queensland State Government has made a smart investment in the Hubs, demonstrating a growth mindset that is sadly lacking in other parts of the country.

A manufacturing-led recovery Economic recovery in a post-COVID world must be based on investment in the Australian manufacturing industry. The boost to the national economy provided by a globally competitive manufacturing sector would put us in a strong position to repay the $230bn pandemic stimulus package debt – something that simply won’t be achieved through federal investment in gas.

It will take strong leadership, investment in technology and education, and the support of Government at all levels. Only then can Australian manufacturing return to its former prosperity and make a vital contribution to Australia’s economy, workforce, and future.

Geoff Crittenden is the CEO of Weld Australia. www.weldaustralia.com.au

surfaceCONTROL: New Generation 3D Sensor High Precision Inline Measurement for Detection of Defects and Shape Deviation This new 3D sensor use fringe projection to generate a 3D point cloud on diffusive, reflecting surface. Ideally suited for automated, inline 3D measurement for geometry, shape and surface inspections of components for machine buildings, electronics production, amongst all other industrial sectors.

• • • •

Large x-y-z Measurement area up to 120x120x206 mm Measuring resolution from 1 μm in z-axis Up to 2.2 millions 3D points/ seconds Easy-to-integrate, comprehensive SDK based on GigE Vision and GenICam

Contact us below or visit www.bestech.com.au for more info

Email: enquiry@bestech.com.au

Phone: (03) 9540 5100

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Demmeler Cobot WeldSpace: New welding cell from Leussink Leussink has expanded its range with the new Demmeler WeldSpace system, a fully equipped welding cell with a built-in welding cobot.

Leussink’s Managing Director Jason Leussink says the new Demmeler WeldSpace system is ideal for small and medium-sized companies with moderate production volume: “Like other cobot (collaborative robot) systems, the WeldSpace can significantly increase productivity levels. The cobot works alongside humans, taking on dull, repetitive tasks, reducing human error, and allowing humans to be more productive with other, more valuable tasks.

Being a modular system, it can be set up and used in many ways.

For example, while the robot welds on one side, an employee can set up and reclamp on the other side in parallel. Utilising a partition wall, this can be divided even further, thus creating a third workstation. There are four different options for extraction. The optional manipulator can move a workpiece independently by up to 360 degrees so that there are no blind spots when machining it.

“By using cobots, manufacturers lower their cost of production while increasing profitability. Humans can utilise cobots as a tool to ensure accuracy and consistency in their work, while minimising downtime in a manufacturing plant.”

As well as the new WeldSpace, the Demmeler welding table is an ideal partner product for a cobot. Versatile and durable, the Demmeler 3D workbench and welding table is suitable for all types of welding and fabrication work and can be set up easily and precisely for a cobot. Cobots can be anchored and fixed to a Demmeler table system to ensure accuracy and versatility, with the cobot able to return to the same position every single time.

The intuitive user interface of the Demmeler WeldSpace programming and operating concept (DWSP) for operating the cobots makes it straightforward for employees without programming knowledge to easily learn to control the robot. Developed by Demmeler’s welding experts the software is adapted to the robot and welding process.

The cobot can be moved by hand to the place where welding is to be started and stopped. Intermediate waypoints and sections are also programmed. This allows the operator to create professional welding programs with the touch of a button. The welder has full access to the relevant functions of the system with only one control panel.

The Demmeler WeldSpace cell has two very large and easily accessible working areas – Space A and Space B – with a length of approximately 2,400mm in the standard version, and requires very little floor space. It even has indentations for the forklift’s tines. The enclosure opens on both sides (roll-up doors) and automatically moves from the front to the rear work area.

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“Working in partnership with robotic experts, we develop cobotbased systems for clients in a range of industries, enabling them to meet many different requirements,” concluded Jason Leussink.

“One of our customers – a smart automation and robotic solutions business – packages its cobots with the Demmeler modular fixturing tables from Leussink as a collaboration system for its customers.

“At Leussink we don’t just sell a welding table and walk away. We work with our clients to make sure the Demmeler welding and fabrication system works for them by tailoring a solution to their needs, and providing onsite visits, training sessions, and a wide range of accessories. Through our knowledge and decades of experience, Leussink can create welding and fixturing solutions for the Australian market that stand the test of time. We work with our customers to capitalise on efficiencies and productivity, without compromising quality and accuracy.” www.leussink.com.au

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Elevating automated colour measurement in injection moulding plants Inline colour measurement systems are a widely used sensor for injection moulding applications, where highly accurate colour nuance detection is crucial.

The Global Standard for Wireless Connection

For example, colour measurements are performed at the step where the moulded pieces are extracted from the mould. During this step, the product may undergo changes in its colour as it cools, which in turn, affects colour compliance. Using inline colour measurement, early identification of these defects is possible and the rejects can be removed from the production line.

Depending on the angle of measurement and the lighting conditions, colour may appear similar but are actually different when assessed through their co-ordinates in the colour space. This is particularly integral in those plastic injection moulding applications where colour deviation is not tolerated. To support this measurement task, there needs to be a non-contact dynamic measurement system that can reliably measure the colour quantitatively and compare it with the colour space co-ordinates to generate a “PASS/FAIL” result.

Partnering with Micro-Epsilon, Bestech Australia supplies a wide range of sensors and measuring systems for industrial testing and measurement applications. Bestech has recently announced the ACS7000 inline colour spectrometer. This state-of-the-art measuring system offers highly precise non-contact detection of colour at high speed. The ACS7000 illuminates the product with a homogeneous white LED light to ascertain the co-ordinates in the CIE-XYZ colour system for all wavelengths of visible light (390nm to 780nm) and display them in the desired colour space.

Bluetooth

®

Manage Measurement Data Centrally and Wirelessly on a Smartphone, Tablet or PC The new U-Wave Bluetooth transmitter utilizes the popular Bluetooth 4.2 Low Energy Wireless Technology and allows a simple connection to smartphones, tablets and Bluetooth enabled Laptops and PC’s.

• A buzzer type and IP67 type with dustproof and waterproof specifications are available.

• Up to 7 units can be connected to 1 Bluetooth enabled PC without a receiver.

• New U-WavePak BLE for Android, iOS and Windows available at no cost.

The ACS7000 high-speed colour spectrometer enables the dynamic measurement at speeds of up to 2kHz, suitable for production line or manufacturing applications. The controller captures different observation conditions such as the illuminant and standard observer. To carry out light/ dark correction, the buttons on the controller or the user interface are used.

With the spectral measuring range of 390nm-780nm, trend analysis can be carried out for quality inspection purposes. The ACS7000 also has Ethernet/ EtherCAT, RS422, and digital I/Os for data output. Enabling direct feedback to the production process, this colourControl sensor is the most accurate device for online colour measurement. Minimisation of waste and lower production costs are additional benefits of deploying this system in continuous process measurement. Its optimised sensor models offer precise measurement on different surfaces including reflecting, transparent, curved surfaces. www.bestech.com.au

Available exclusively from Mitutoyo’s authorised national distributors

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QUALITY & INSPECTION

Tool presetters: the key to boosting quality and productivity.

Tool presetters improve quality and boost productivity by precisely measuring any tool off-line with micron accuracy.

This enables a CNC machine to keep cutting so that machine uptime is optimised and tool life is maximised.

Tool presetters provide three key features in the one machine: measuring, presetting, and inspecting tools. They save on set-up time, improve accuracy and produce better quality parts, while minimising scrap. A state-of-the-art image processing system measures the cutting edges of tools in seconds, then saves and documents the measurement results. As a result, the time-consuming process of making fine adjustments are a thing of the past.

Adjustable boring bars can be easily set with micron precision in less than a minute, which in turn eradicates frustrating “trial and error” cutting. Tool run-out can also be checked and cutting inserts inspected using the on-board inspection camera.

“Presetting and measuring allows for shorter fitting times and greater productivity – while your machine works you can get the next tool ready,” explains Paul Fowler, Managing Director of Dimac Tooling. “Thanks to correctly preset tools, the very first part will be of the highest quality. You can also be confident the tool will perform perfectly until the end of the tool life, thereby minimising the chance of rejects.

Dimac is the sole distributor for Zoller; acknowledged as the premium manufacturer of tool presetters. Zoller is a German brand founded by Alfred Zoller; the company today is still run by the Zoller family, which is now in its third generation.

Since 1968 more than 28,000 presetting and measuring machines have been sold, as well as tool measuring machines and globally unrivalled software solutions .

Zoller also markets the range of EZset tool presetters.

Dimac has had a long, successful association with the company, which started when Fowler met Christoph Zoller at the Austech manufacturing technology exhibition in Melbourne in 2007. Following a series of discussions, Christoph Zoller became confident of Dimac’s ability to successfully market his company’s brand in Australia and New Zealand, and Dimac was duly appointed sole distributor for the EZset range.

EZset presetters are assembled from high-quality brand-name parts, such as Bosch pneumatic components, THK guides and Heidenhain glass scales, to ensure a long, maintenance-free lifetime.

Equipped with image processing based on the newest technology available, a precise

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tool mounting spindle and numerous measurement functions, EZset sets the benchmark in cost-effective tool presetting outside of a CNC machine tool.

“Right from the start, the working dedication, eagerness to learn the product and focus on our brand gave me a very good impression of Mr Fowler and his business,” says Christoph Zoller. “Over the years we have met numerous times at trade shows where our relationship has strengthened. Having successfully marketed our EZset brand it made perfect sense to award distribution of our premium Zoller band to Dimac for both the Australia and New Zealand markets.”

Regardless of the model chosen, all Zoller presetters feature the highest-quality components, including a high-precision, freely accessible toolholder spindle, stateof-the-art optics, leading image processing technology and comfortable and easy to use ergonomic control units.

“We’ve been distributing Germanmanufactured tool presetters for a number of years and these have enabled many CNC

operators to improve their productivity and quality,” Fowler adds. “Offering the choice of both the EZset and Zoller range ensures we can cater to all market segments. No matter what your requirements or budget, we are confident we will now have a presetter to suit your needs perfectly.”

In addition to offering an extensive range of models, both EZset and Zoller offer extensive hardware and software options to suit individual operators’ production needs. Both brands have a range of optional features that includes a direct link via ethernet to various CNC machines. This facilitates the direct transfer of a measured tool’s library of results, thus eliminating the potential of damaging data entry errors.

“Precisely measured cutting tools deliver at least a 15% increase in productivity in your manufacturing processes,” Fowler concludes. “The initial investment in a tool presetting device is quickly returned through the increased productivity, higher quality and less waste. They are easy to operate and will save a company time and money.” www.dimac.com.au

QUALITY & INSPECTION

ZYGO Nexview 650 – Large-format inspection and metrology system The Nexview 650 from ZYGO is a large-format metrology system designed as an inspection tool for the automated measurement of injection moulding tooling, PCBs, glass panels, and other samples requiring an extended work volume up to 650mm by 650mm.

The Nexview 650 provides 2D and 3D measurements of a variety of surface features with sub-nanometer vertical precision and sub-micron lateral precision. The system is the latest addition to the Nexview range of 3D optical profilers from ZYGO, which are all characterised by the ability to provide precise, quantitative, ISO-compliant, non-contact surface measurement and characterisation of micro- and nano-scale surface features, capturing millions of data points in just seconds.

At the heart of the Nexview 650 is ZYGO’s coherence scanning interferometry (CSI), a technology that uses specialised optical microscope objectives that not only provide the imaging and magnification of a surface, but also measure its 3D topography. CSI profiling is completely non-contact, which eliminates any chance of the sample being damaged.

Also, in contrast with other microscopebased 3D topography techniques, CSI has the distinct advantage that the height resolution of the measurement is consistent across all magnifications, whether the field of view is 20μm, 20mm or much larger. CSI offers high-precision, highvalue surface metrology benefits, including measurements of all types of surfaces, subnanometer measurements, gage capable performance, and SureScan vibration tolerance technology.

“The Nexview 650 is a production-oriented tool that can accommodate large parts at the point of need within the factory,” said Eric Felkel, Product Manager at ZYGO. “The system combines ZYGO’s industry-leading Nexview NX2 3D microscope head with a robust production platform. This delivers 2D and 3D measurements with sub-nanometer vertical precision and sub-micron lateral precision – a level of performance that is critical to qualifying the components our customers in consumer electronics, manufacturing, optics, and semiconductor businesses need for success.

“The system’s large work volume accommodates both large and heavy parts.

With an integrated operator station and a split axis motion design, the system footprint is minimised. Integrated passive isolation is included to enable installation close to the manufacturing process to shorten the time to data.”

The Nexview 650 has been designed and built to ensure that it provides a return on investment for years to come. With a metrology area that accommodates lateral dimensions up to 650m x 650mm, a sample load of more than 100kg, a vertical range of 150mm, and options for a fully enclosed or partially enclosed system, the Nexview 650 provides maximum flexibility for large samples that require precision 3D optical profiling.

The system can accommodate any of today’s standard PCB substrate panel sizes; custom-defined sample holders for flexible sheets and so on; and large, highmass injection-moulding plates that benefit from precise non-contact inspection to minimise potential surface damage.

Customised chucks and sample holders can be designed or supplied by customers to adapt the Nexview for smaller panels or even singulated substrates, maximising application flexibility. In addition, the Nexview 650’s integrated recipe-driven automation software enables hands-free metrology of multiple features on each panel, all in a single workstation, reducing production time and increasing process knowledge. www.zygo.com

The portable, affordable solution to improve quality, reduce scrap, and increase the productivity of any workshop.

• Fast implementation • Reliable measurement results • For both inspection and reverse engineering • Low-cost entry for laser scanning

For full sales, support, installation and training of all your metrology needs contact Met Optix:

1300 363 409 info@metoptix.com.au www.metoptix.com.au

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SOFTWARE

The new cybersecurity imperative in manufacturing As an industry that contributes about 6% of Australia’s GDP, the manufacturing industry is still not safe from the ambitions of increasingly smart, organised and industrialised hacking groups. By Joel Camissar.

Globally, the volume of cyber attacks targeting the manufacturing sector increased 300% last year, and in Australia, 13% of all known cyber attacks are targeting manufacturers. What kind of threats is the industry facing? Why have manufacturers become key targets for cyber criminals? And most importantly, what can they do about this growing threat?

Joel Camissar.

The era of ransomware Ransomware is a type of threat that has grown dramatically in the past couple of years. The concept is to hold a company to ransom by threatening them to take down their systems or publish information, data or intellectual property (IP) they have managed to steal if the victims don’t pay.

The prospect of a downtime, and the associated financial cost and reputational damage are usually enough to convince many organisations to pay up. Some sources report US$350m in revenue was made from ransomwares in 2020. But with many attacks never reported, other estimates mention figures above US$1bn.

Malicious actors usually manage to implant their ransomware or malware leveraging company vulnerabilities, or taking it a step further by carrying out a Distributed Denial of Service (DDoS) attack against victims. There are also human-based attacks including spearphishing, stealing credentials, or paying disgruntled employees to implant the malware. And as manufacturers increasingly digitalise and modernise their operations, it also increases the opportunity for criminals.

Increased attack surface Many industries are reliant on new technologies and digital solutions to generate efficiencies, and the pandemic has only accelerated this trend, due to a stronger need for agility.

Manufacturing is no exception. Supply chains have often been dramatically disrupted to adjust to new and evolving industry and consumer needs. Other factors include the democratisation of connected devices and edge computing in recent years to monitor factory environments, security or machineries, which have led to a multiplication of new systems, and an acceleration of data exchange between them.

With new systems come new attack surfaces and vectors. There are more systems and devices, and more people who may not have received proper training on cybersecurity practices.

Especially if these systems were implemented in recent months to ensure business continuity or to quickly adjust to lockdowns and outbreaks. That is not to say that manufacturers should pause their digital transformation efforts, but they should do it including new risk management and cybersecurity considerations, because manufacturing will only become a larger target for malicious actors in the future.

Breaking the first link in the chain It would be a mistake to think cybercriminals are randomly and blindly targeting organisations. Hacking groups are becoming much smarter, strategic, and industrialised.

Their increased focus on manufacturers is the result of strategic thinking. Manufacturers are usually one of the first links in a supply chain, and disrupting their operations usually means disrupting the whole ecosystem. The potential damages are more significant than when attacking an organisation at the end of the chain, and is usually an additional incentive for victims to pay the ransoms.

In recent months, criminal organisations have publicly voiced their intentions to strike businesses that operate at the source.

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Unfortunately, that means manufacturing will also be a key focus.

In this context, is it essential that industry players look at improving their resilience to cyber threats.

Designing for security When designing new operational systems and infrastructure, manufacturers have to make sure they design with security in mind.

This starts with using a cyber risk framework to guide the security architecture development for production systems and measure maturity improvement over time. The Australian Cyber Security Centre has published its Essential Eight, acting as baseline cybersecurity recommendations to mitigate the risk of cyberattacks.

Other major economies have published cybersecurity standards, and it is worth looking at the NIST in the US, or the Cyber Essentials in the UK as well.

Adopting a Zero Trust approach is also part of designing with security. The idea with Zero Trust is to implement access rules across the organisation that grant company users, data applications and external partners or stakeholders, access to only the resources they need to operate, for only the time they need access to it. If any of them is compromised, hackers have very limited freedom to navigate an organisation’s network and systems. Zero Trust is particularly relevant in a flexible and remote workforce set-up, allowing organisations to properly protect remote employees and their devices.

Thirdly, take a ‘one enterprise’ approach to security and risk management. Many organisations still operate in silo. For instance, a chief information security officer (CISO) may be responsible for information technology (IT) only, yet not charged with securing operational technology (OT) environments. This needs to change.

Finally, manufacturers should explore the shared responsibility model. The idea behind this model is that the responsibility for security doesn’t fall solely on one party. All stakeholders across the supply chain, from cloud service providers to end-users, have a role to play.

The multiplication of headlines on major data breaches and cyberattacks, even on the largest organisations on the planet is a sign that malicious actors are undeniably making headways. As an essential industry for our society, manufacturers have a responsibility to make cybersecurity a priority in the years to come, and reduce the risk of potential major disruptions and associated losses.

Joel Camissar is Senior Director, Channels, Alliances and Cloud, APAC at McAfee Enterprise. www.mcafee.com/enterprise

SOFTWARE

Sandvik to acquire Mastercam creators CNC Software Global engineering group Sandvik has signed an agreement to acquire US-based CNC Software Inc., a leading provider of CAD/CAM software solutions for manufacturing industries and the company behind the Mastercam software suite. Gcode Engineering Solutions (Mastercam Australia) will continue to service the Mastercam brand in Australia.

By acquiring CNC Software, Sandvik gains Mastercam, the most widely used Computer Aided Manufacturing (CAM) brand in the industry with an installed base of around 270,000 licenses/users, as well as a strong market reseller network and well-established partnerships with leading machine makers and tooling companies.

The Mastercam brand and its reseller channel will remain intact.

Gcode has been supporting the Australian region as Mastercam’s reseller for nearly six years. Greg Williams, Director of Gcode, stressed that for Mastercam users in Australia, the customer experience will remain completely unchanged, with the same level of customer service and support that they have come to expect.

“Mastercam Software Australia is committed to support and training of all users,” said Williams. “I am very passionate about manufacturing in Australia and pride myself in partnering with progressive manufacturing companies to achieve better outcomes.

It’s an exciting time for manufacturing, and we look forward to moving the industry forward together.”

For Stefan Widing, President and CEO of Sandvik, the acquisition is in line with the company’s strategic focus to grow in the digital manufacturing space. “An acquisition of CNC Software and the Mastercam portfolio, in combination with our existing offerings and extensive manufacturing capabilities, will make Sandvik a leader in the overall CAM market measured in installed base. CAM plays a vital role in the digital manufacturing process, enabling new and innovative solutions in automated design for manufacturing.”

CNC Software has a strong market position in CAM, particularly for manufacturing SMEs, which supports Sandvik’s ambitions to develop solutions to automate the manufacturing value chain for SMEs – and deliver competitive point solutions for large OEMs. Combining the strengths of Mastercam with Sandvik’s offering and know-how within machining is expected to be an important enabler in automating the customers’ end-to-end manufacturing processes.

“Mastercam will be the cornerstone in Sandvik’s CAM portfolio, further improving machining productivity by combining our machining know-how with their CAM expertise to improve quality and reduce waste for our customers,” says Mathias Johansson, President of the Design & Planning Automation Division in Sandvik Manufacturing Solutions. “Specifically, we will leverage data capture and use to secure efficient tool selection and tool path optimisation for our customers.”

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www.ecisolutions.com/en-au | How business gets done.

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Manufacturing insights: beyond democratisation of data Imagine what could be accomplished if everyone has access to the data they need and knows what to do with it, writes Owen Keates.

The democratisation of manufacturing data won’t unlock the value of the Industry 4.0 era. Despite all the industry talk about it, democratisation of data isn’t enough. You need to focus on the democratisation of insights.

You need to get actionable insights based on real-time data into the hands of people who can use them, to achieve business objectives such as fewer shutdowns, improved health and safety outcomes, higher productivity, better throughput or increased profit margin.

But will your people actually trust these insights? Every business will experience this somewhat differently, but there are challenges we consistently observe, and tried and true tactics that work.

The amount of data isn’t the only issue There’s so much data to manage, and so many different types of data are required to paint the whole picture. Manufacturers need the infrastructure to support the seamless integration of data from a variety of disparate sources; data of different types and in different formats, structured differently or not at all.

To make the most of your data, you need to be able to ingest all that disparate data and make it useful and available to analytics, automation and machine learning solutions.

You also need to know what questions to answer, and what data sets to select.

This is a whole-of-business task Democratisation of data is all about making digital information accessible to everyone across the business that needs it, whether or not they have technical data skills.

Employees shouldn’t need to request help from the IT team, coding or new tools every time someone needs data access. It’s time to enabling the sharing of data across multiple parts of the business and put an end to gatekeeping.

Democratisation of insights takes that to a new level, involving the right mix of machine learning, analytics, automation, custom algorithms and more to draw useful insights out of the right data sets. It involves mixing data with suitable external data sets. And, crucially, it means feeding those insights to the people who need them, when they need them. You can’t make it IT’s responsibility to figure out how to sort all of that out.

They can’t read the minds of everyone who needs data. Include the people who will actually use the insights, so you know what questions you need the data to answer.

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Recognise that different roles may require different views of the same data in order to rapidly comprehend, contextualise and action the information and insights from this data.

It’s no good if people don’t trust the data Involving a cross section of your people early in this process is best practice. That includes people who have always based decisions on gut feel and experience. You need the machine learning to make the kinds of decisions these subject matter experts would make if they could combine that experience with all the data and processing power of advanced analytics solutions.

Invite your team members to participate in discussions with the data engineers and data scientists around how the analytics work, how machine learning algorithms are trained, or AI systems are developed, so that trust in the data and the process can be strengthened. The initial results of a predictive algorithm may not be very accurate, but models can be continually improved with support from the team. Then, when you start democratising insights, they will recognise those insights as having been developed with their input. That’s powerful.

The interface and user experience matter If your colleagues have been using the same tools and processes for a long time, they are likely to be resistent to new ones even if you promise them better information.

Invite team members to contribute to the design of the user interfaces. Consider solutions that work within your existing ecosystem, integrate with familiar tools, and even present the insights via existing dashboards or trusted interfaces. Most solution providers want to sell you on a

‘single pane of glass’ – while that’s the ideal outcome, that pane of glass can be your current system with new, modernised solutions in the background.

Ease of use goes a long way towards user adoption and return on investment.

Solve specific challenges To achieve true business value you need to quantify your technology investment against real business objectives. Here are two examples: • Tackle management of hygiene within manufacturing operations, by leveraging data gathered via industrial IoT devices and applying advanced analytics. Monitor this data in real time and feed predictive, actionable insights to your personnel.

• Reduce the impacts of supply chain disruption on your production flow. If your team members are fed insights based on a real-time assessment of production and assembly processes, they can dynamically reschedule processes or substitute components.

This kind of flexibility is mission critical when component supply can be suddenly interrupted by border closures or other shipping delays.

With the world still in a state of uncertainty, it’s more important than ever to be datadriven. To do so, you must be able to make your data available, reliable and presented as actionable insights. Quality insights lead to improved decision-making.

Democratisation of insights gives a business significant competitive advantage when all team members embrace the knowledge generated.

Owen Keates is Associate VicePresident, Asia-Pacific Manufacturing Practice at Hitachi Vantara. www.hitachivantara.com

SOFTWARE

How to “bundy on” with new technology in a skills shortage Manufacturing in Australia is set to undergo significant change during the next decades, and workforce issues are already beginning to bite. By Nick Bailey.

Right now, skills shortages and a lean cost environment means employee investments can suffer. These challenges come at a pivotal time for the sector. The Federal Government’s $1.3bn Modern Manufacturing Initiative calls for “bold changes that will create strong, resilient, thriving and internationally competitive manufacturing businesses”.

Manufacturing is one of the biggest employers of deskless workers, who rarely have adequate access to a computer to engage with the company.

The problem is, growth is challenging without the right skills. The global COVID-19 pandemic has enlivened the local manufacturing sector, which in turn has sparked an investment in technologies on the floor for process automation to boost productivity.

But what about investing in employees?

Finding, and keeping, skilled workers is an ongoing challenge, and the pressure won’t ease quickly.

There’s another issue. Manufacturing is one of the biggest employers of deskless workers, but they rarely, or never, have adequate access to a computer to engage with the company.

It’s a problem that has been reflected in studies that reveal deskless workers make up nearly 80% of today’s global workforce, yet a meagre 1% of total enterprise software spend is dedicated to supporting shift workers. Merely the ongoing presence of the low-tech, mechanical “bundy clock” illustrates the lack of commitment that companies have for deskless workers.

So what role can technology play to improve employee productivity and engagement in the manufacturing sector?

At Workforce Software we have identified two significant factors: forecasting and optimising schedules.

Modern solutions, such as those provided

by WorkForce Suite, help deliver the right staffing mix to meet demand, and provide an easy-to-use interface without sacrificing enterprise-grade capabilities. The key is to facilitate the interactions that matter most in the work life of an employee: accurate pay, pre-planned rosters, managing unplanned absences and leave approval, while still offering powerful predictive capabilities.

transparency over their shifts; they have the ability to fill unplanned absences with the next qualified worker in the queue; and they can see at a glance their leave entitlements for holiday planning, giving them agency over their working lives.

Taking advantage of these digital interactions through WorkForce Suite can drive more effective employee engagement, provide a safer, more compliant work environment, and boost employee retention for greater organisational resilience and agility.

Critically, all this can take place on mobile devices to support deskless workers who need two-way communications and realtime engagement with their employer. For employers, this dynamic transforms the way they engage staff, capture feedback and act on employee sentiment.

For the employer, artificial intelligence (AI) or machine learning overlaying the data enables leaders to drive momentum in their business. The WorkForce Suite is primed to supply data and recommendations to leaders for daily, even hourly, decisionmaking and actions, which can be used as a catalyst for growth. For example, it can be employed to predict optimum staffing levels based on demand, or where staff might need to retrain to ensure compliance.

WorkForce Software recently announced a key development within its WorkForce Suite solution as the first SaaS (software as a service)-based provider to fully integrate a set of employee experience (EX) capabilities that facilitate meaningful, in-the-moment interactions between managers and their hourly workers. Critical capabilities delivered in the newest release include a social media-style interface for accessing the system and enabling checkins by managers, who are able to gauge and respond to workers’ needs.

Making smart, fast decisions is crucial to building and maintaining momentum in the sector and ensuring that productivity is optimised – a much easier task when employees are engaged and connected into the process.

Nick Bailey is Senior Vice-President – APJ for Workforce Software. www.wfsaustralia.com WorkForce Suite facilitates a range of employee interactions across areas such as pay, rosters, unplanned absences and leave approval.

Accurate capture of time and attendance data (the new bundy clock) ensures that staff are paid accurately and compliantly because overtime and shift penalties are configured into the system and bridge across into payroll. Employees have

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SOFTWARE

Economy Spring makes major time savings with ESPRIT CAM US company Economy Spring & Stamping is a manufacturer of precision and custom wire forms, metal stampings, coil springs, tubular components, and product assemblies for the medical, pharmaceutical, aerospace, and industrial markets. To stay competitive, Economy recently invested in two Citizen seven-axis Swiss-type turning centres boasting 400W L2000 laser cutting systems.

Economy Spring is known for manufacturing a wealth of complex parts, such as two concentric tubes used in the medical industry for administering fluid to incisions. The outer tube requires a 4.4mm outer diameter and a 4mm inner diameter, while the inner tube requires a 3.9mm outer diameter and a 3.3mm inner diameter. The front end of the inner tube is marked by several intricate shapes, including two boot-shaped features precisely 180 degrees apart from each other. To make matters more complex, the inner tubes also require drilling of 22 injection holes in a helical pattern, each with a diameter of 0.18mm. There’s also a 30cm slot in the part that is longer than the total travel of the lathe.

Economy Spring programmers previously programmed this and other similar parts using the machine control. This entailed the entry of many manual commands, including laser commands and commands to co-ordinate the operations of the two spindles. After completing the program, programmers weren’t sure of accuracy or collisions until they ran the part for the first time.

Economy Spring’s use of ESPRIT CAM to program its Citizen machines has yielded major time savings

Balancing operations between the machine’s two spindles was also difficult. For example, programmers had no way to determine whether it was efficient to perform turning and drilling on the main spindle and perform a secondary operation on the sub-spindle at the same time. If time is money, then these decisions were doubly important. One spindle often sat idle until the other finished its operation.

“We decided to switch to ESPRIT CAM software because of its support for the latest machine tool features and its powerful simulation capabilities that enable us to optimise the program without taking up valuable machine time,” says Dale Akerley, advanced manufacturing department leader at Economy Spring.

Akerley began programming the tubes with ESPRIT by importing the SolidWorks CAD file that was provided by the customer.

Importing the part geometry saves time and minimises errors by ensuring that the program matches the customer’s original vision.

ESPRIT then analyses the imported geometry and automatically recognises all the features, such as the holes and boot-shaped features mentioned earlier.

Akerley selected each feature of the part and picked a tool to machine from a graphical representation of the Citizen Swiss lathe.

The knowledge base, included with the software, automatically generates typical machining parameters including cutting speed, feed rate, and depth of cut. Both the detailed features on the front end of the part and the holes were produced by the laser – which can produce nearly any geometric shape to an accuracy of 250nm.

When the company first began using the laser, it wasn’t supported by any CAM software, so it required time-consuming manual programming.

ESPRIT sent a technician to Economy Spring. The technician spent days working with Akerley to develop a post-processor that automatically generates the instructions needed to set up the laser and perform the machining operations. With the post-processor in place, Economy Spring programmers treat the laser as if it were an ordinary cutting tool. ESPRIT then automatically generates the G-code instructions for the laser and metalcutting operations needed to produce the part.

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Small holes cut on a part with the L2000 laser cutting system.

Akerley then tentatively assigned the operations to spindles and simulated the complete machining operation so he could visualise exactly how the operations are flowing and to determine if any time is being wasted.

“We can reorder operations, move operations from one spindle to another, and sync operations so they start at the same time with a few clicks of a mouse,” says Akerley.

He used a regrip operation to move the stock from the main spindle to the sub spindle so the 30cm slot could be fully machined.

“Switching to ESPRIT reduced the time required to program these parts from about three days to one day, and we have achieved proportional time savings on a wide range of other parts,” says Akerley. “This represents a major time saving and the time required to test the program of the machine is also greatly reduced because simulation helps us nearly always get the program right the first time. We have also achieved significant cycle-time reductions by identifying idle time during the simulation and modifying the program to make it more efficient. All in all, switching to ESPRIT has helped us significantly increase the efficiency of our machining options.” www.espritcam.com

MATERIAL REMOVAL

Adarsh Australia expands with additional Okuma machining centre Leading Western Australian manufacturing and engineering company Adarsh Australia has further expanded its manufacturing facility with the addition of the latest Okuma CNC vertical machining centre.

Adarsh is a private family business founded in 1995 and is part of a group of companies employing more than 80 personnel. The group offers CNC machining, casting and forging, fabrication, wire cutting and plastics manufacturing. Adarsh enjoys longstanding recognition in Western Australia for its production of high-quality components. Its sales are nationwide with a significant percentage of components going to export via the end clients.

Today the company services a diverse range of industries such as mining, defence, sub-sea projects, automotive and agriculture. It is expanding further into the health sector, having been involved in the production of high-quality face shields for WA’s frontline health workers during the COVID-19 pandemic, working with biomedical engineers from East Metropolitan Health Services Centre for Implant Technology and Retrieval Analysis.

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With reshoring of competitive component manufacturing to Australia, Adarsh is playing its part with the training of apprentices.

Two are currently in training, and Adarsh has a close working relationship with the local TAFE training colleges.

Adarsh has a longstanding relationship with Okuma Australia going back more than 25 years. Its new machine, an Okuma Model Genos M660-V-e S15 with OSP-P300MA-H Control, joins 17 other Okuma machines in Adarsh’s outstanding machining workshop.

“The performance of the Okuma machines has always been exceptional, and the service we receive from Okuma’s WA Branch Manager John Dale complements our business strategy of excellent performance, skilled training and quality technical support and advice,” says Adarsh Director Faz Pollard. “The new machine provides us with increased capacity and the ability to expand into larger component manufacturing and new business opportunities.”

Skilled operators in Adarsh’s machine shop are excited at the expanded functionality of the new machining centre, and the opportunities it brings for expansion and job security going forward.

“The future looks secure for this advanced manufacturing company as it looks to expand into additional high-quality medical products and with a development project underway into a recycling paper plant to process waste into finished products,” says John Dale. “A trusted and strong long-term relationship is so important. At Okuma, reliability, accuracy and fast turnaround times are something we strive for.” www.okumaaustralia.com.au www.adarsh.com.au

Adarsh Australia’s new Okuma M660V-e CNC vertical machining centre.

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• 90% of engineers using tablets on the workshop floor and the Empower Software App achieve a 20% to 40%+ reduction in time on jobs – therefore a 20% to 40%+ reduction in labour cost on jobs.

• An Engineer with 10 workshop staff is projected to increase production by 80 hours per week, therefore increase revenue by $6,000 per week and (80 hours by $75 per hour overhead cost), therefore increase revenue by $294,000 per year. This $294,000 per year is largely additional profit because overhead costs have been incured in existing production. Your 10 year investment $2.94m additional revenue, largely additional profit.

Sean O’Sullivan

B Com (Hons) Otago University

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

AMT Magazine 20/11/2020

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MATERIAL REMOVAL

Smooth commissioning of Eilbeck’s new vertical lathe with Applied’s support As it ramps up capability in its new heavy machining division, Eilbeck has completed a major acquisition with its investment in a new heavy-duty Hwacheon CNC vertical lathe, supplied by Applied Machinery.

If one was to nominate an Australian company that epitomises success in manufacturing, Eilbeck would have to be a lead contender. With close to 115 years of experience in the manufacturing sector, the family-owned company is currently managed by its owner/director Tom Eilbeck. Today the company’s staff numbers have increased to around 300.

Initially starting as a foundry on the Swan River in West Australia, the company evolved into a machine shop and eventually into designing and building overhead cranes. Today Eilbeck Cranes has around 65% of the local overhead crane market, supplying to a diverse range of industries including civil and industrial developers. In the bespoke crane market, the company’s market share has increased to around 75%.

The company is now into its fourth generation of the Eilbeck family and has grown through sheer hard work, an ability to capitalise on market opportunities, and an overarching commitment to producing the highest quality equipment. This high level of quality has been reflected in the repeat orders it receives from many clients – both from the public and private sector.

Eilbeck Cranes has now come full circle, building a state-of-the-art CNC machining workshop in 2015 to complement its existing engineering, fabrication and welding skills – gained from manufacturing components for the standard crane range. This bespoke new machining shop operates as a separate division under the banner of Eilbeck Heavy Machining, and is managed by Tom Eilbeck’s son Charlie.

Up until 2015 all the components for the company’s bespoke cranes had been contracted out to local machine shops. The new machine shop will enable this work to be brought back in-house; importantly it will also provide the opportunity to tender for large-scale machining work.

“One of the key attractions for customers is that we can offer a full turnkey solution given our capabilities extend to design and engineering, fabrication, painting, welding and the mechanical side of any job,” says Charlie. “This capacity makes us an attractive proposition to the contract engineering and manufacturing sector.

“We have purposely targeted large-scale work where there is less competition in the market; essentially big projects that

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Charlie Eilbeck with the new Hwacheon VT-2000 heavy-duty lathe in Eilbeck Heavy Machining’s factory.

were previously tendered out to overseas suppliers. We can handle work up to 200 tonnes and have some of the largest, most advanced CNC machines in Australia.

And we only ever purchase the very best brands.”

The mining industry, shiploader and railmounted machines, rail equipment and other major projects are just some of the sectors in which Eilbeck Heavy Machining’s expertise is utilised. Such has been the success of the CNC machine shop that the company has recently completed a second CNC heavy machining facility. This 6,000sqm block incorporates a 3,000sqm factory, which houses some of the newest, largest and most precise CNC machine tools in Australia. This is complemented by dual 160-tonne overhead travelling cranes.

Along with the existing facility, this has made Eilbeck Heavy Machining one of the largest machining shops in Australia.

A big investment for a big opportunity “We saw a big opportunity in the large vertical turning market and that’s where our hunt for a heavy-duty CNC vertical lathe started,” says Charlie. “Like many of our machine purchases we didn’t have work lined up – we bought it anticipating we would secure work. That’s the way we do things, and it always works out well for us.

“Applied Machinery had tendered for some other machines, and we found they always presented well so we gave them the opportunity to quote on this large new lathe with the Hwacheon brand they represented.

We already have a couple of conventional manual Hwacheon machines, so we knew the brand. They’re quite renowned for their vertical lathes and have a good reputation in the market which is why we ultimately ended up opting for the Hwacheon brand.”

MATERIAL REMOVAL The Hwacheon model selected is a heavyduty VT-2000 model – a ram-type vertical lathe with an 80-inch chuck that provides optimum machining conditions and performance for large-sized heavy-duty workpieces.

“I take my hat off to Applied Machinery,” adds Charlie. “They did a really good job throughout, from managing the whole purchase process from machine selection, agreement on specifications through to training and commissioning. Their staff were always available to answer any question or fix any issue.”

Charlie was also impressed with Hwacheon, who sent a team of engineers and technicians overseas from South Korea to undertake the entire installation and commissioning over a period of weeks.

This was made even more challenging given the COVID-19 situation and the need for 14 days quarantine.

“As an OEM they excel in their support,” comments Charlie. “I was very impressed with the fact that after the commissioning they kept one of the key engineers with us for three weeks to iron out any teething issues whilst we trialled different jobs through the machine. It’s actually been one of the smoothest commissioning of any machines we’ve had.”

The Hwacheon is being used to machine a variety of different parts including rope drums, mining equipment and brake discs for global OEMs. “We’re very happy with the performance of the machine so far,” says Charlie.

“It’s actually been one of the smoothest commissioning of any machine we’ve had. Given the quality of their advice and excellent service, I’ll certainly look at using Applied Machinery again for any future machine purchases.”

Investing in Australian manufacturing One of the outcomes of the COVID-19 pandemic is the recognition of the importance of nurturing and assisting local manufacturing. This is reflected in the significant support that the Federal Government is providing Australian manufacturers to encourage greater investment and the push to ensure major projects remain in the country – something that is benefitting Eilbeck.

A new block of land has been purchased in Wollongong that will house a factory that will be dedicated to heavy fabrication, painting and assembly. This will complement the company’s eight existing factories around Australia. With the extensive support the

The Hwacheon VT-2000 lathe will be used to machine a variety of different parts including rope drums, mining equipment and brake discs for global OEMs.

Government is providing to Australian manufacturers, ongoing investment in new factories and machines and a cando attitude to taking on all kinds of large projects, the future for Eilbeck Heavy Machining looks bright. www.appliedmachinery.com.au www.eilbeckmachining.com

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What makes a great Operations Manager?

What characteristics and behaviours indicate you have a good Operations Manager in your business?

Timothy McLean shares some thoughts.

The challenge in recognising the qualities of a good Operations Manager is that some of them seem counter-intuitive. You might not regard them as positive behaviours – or worse, you might see them as negatives.

So what are the signs that you have hired a really effective Operations Manager or General Manager ?

They prioritise safety first, then the customer Operations Managers have direct responsibility for the safety of people working in your business. This responsibility translates to you as the business owner, CEO or Director as well. Therefore, the first thing a new Operations Manager is likely to do is to identify, assess and address any immediate safety issues.

This also demonstrates their commitment to the team and provides them a chance to demonstrate their commitment to the standards they set – so production never comes before safety.

Next to safety, an Operations Manager should recognise that any business must always meet the needs of its customers.

This means the Operations Manager will address quality and delivery issues, before leaping into cost-cutting. It also means an Operations Manager will use positive language about the customer and be curious to learn what customers really need and value from the product or service the business provides.

They are humble and put the team first Often, we look for Operations Manager who are bold, tough and confident. These characteristics can be useful, but in my experience, the best Operations Manager constantly give the limelight to their team.

When talking about the projects and achievements of their area, they use “we” and “us” more than “I”. In presentations, they often let their team present and take a back seat . They will also stand up for their team and support them, even at some cost to themselves.

However, they will be decisive, fair and consistent in managing the performance of individuals on their team. They will value the experience around them and develop the people they have before turning over key roles. Nonetheless, they will also be prepared to challenge complacency and entrenched views, which may include challenging some long-serving subject matter experts. An Operations Manager who displays these traits will earn the

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respect of their team rather than expect it.

Earned respect is typically rewarded with the team confidently following the direction the Operations Manager sets, making the team more at ease with deviating from “the way we’ve always done it”.

Because they are humble, good leaders admit what they don’t know and ask for help when they need it. This should not be seen as a sign of weakness, but of strength.

It takes strength to reveal weaknesses and vulnerabilities and ask for help. Rather than criticising or rejecting such requests, you should welcome them and try and provide the help and resources needed.

They will also be respectful of others in the business. Behaviour like swearing, shouting or belittling staff have no place in the workplace under any circumstances, especially from leaders.

They will develop people and won’t feel threatened by peers and subordinates In fact, they will actively develop senior team members and provide them opportunities,

including allowing them to step up into the Operations Manager role during holidays and travel. They will be comfortable allowing their team to make decisions and take full responsibility for aspects of the business. They will support their team, even when decisions go wrong (they will never throw a team member “under the bus”).

However, they will ensure their team takes accountability for the decisions they make and the responsibilities they take on.

They will work hard to develop peer relationships and invite feedback and involvement of peers. They won’t gossip about peers or criticise peers (especially to their team). They also will not tolerate “them and us” attitudes in their team that can erode relationships between functions and impact customer service.

When things go wrong, they ask why, not who A good Operations Manager is not going to spend hours whining about subordinates or peers. Their focus will be on the process, not the individual. When things go wrong

BUSINESS MANAGEMENT they will ask why and seek to find and address the root cause of problems. This can be difficult and time-consuming at first, when there are many problems (it’s much quicker just to blame someone!), but in the medium term it is an investment of time you must make if your business to sustainably improve performance.

They set, maintain and improve standards Excellent performance is achieved by establishing well thought-out standard processes and then continually improving these processes. Early in their role, effective Operations Manager will focus on establishing standard processes and ways of doing things. This can include standardising the organisation of the workplace with 5S, standardising key tasks with standardised work, standardising business processes in the key business value streams, and establishing formal or informal service level agreements (SLAs) with the functions with which operations interact (e.g. sales and purchasing). In doing so, they highlight the importance and required level of respect between internal suppliers and customers.

Having set the standard, the effective Operations Manager will work to maintain the standard. They know that the “standard they walk by is the standard they accept”, so they will never “walk by” something that is not to standard without taking action.

They will also expect you to comply with these standards. Therefore, if you have got into the habit of walking into the workplace without personal protective equipment or not observing 5S standards, expect to be told to comply – and make sure you do!

Sometimes this focus on standards can seem like bureaucracy slowing things down, and you are allowed to ask “why” things are being done a certain way. The effective Operations Manager will be comfortable with having their processes challenged and be able to explain why the standard needs to be followed, or work with their team to improve the standard. However, they will always expect there is a standard that is followed.

They are well organised Operations Managers often have to juggle a broad range of responsibilities. Therefore it is important that the person in that role is well organised. You should see this in a well-organised desk and office that shows signs of some kind of a system to manage daily activities and projects. Ideally, the Operations Manager will have a system of regular routines or leader standard work.

These will be written down and tracked.

You should be able to get evidence of this being followed such as a tee card board or checklist.

Beyond themselves, they will expect their team to be well organised. They will get team members to develop their own plans and lists of daily routine tasks.

They have a plan with clear simple actions and goals When your new Operations Manager starts, one of their first priorities will be to understand the business strategy and the role of operations in delivering that strategy.

They will develop a plan for operations to support the strategy while seeking your input and the input of the team along the way. They will quickly identify the few critical metrics that drive operational performance and set challenging but realistic targets for these. These goals and the plan will be systematically communicated throughout the operations team so every member knows their individual or team objectives and how they can contribute to improved performance.

Importantly they will focus on the simple things first, getting the basics right before introducing more complex changes. They quickly identify one or two key metrics that drive operational performance in the business and focus on improving those rather than introducing a huge range of metrics.

Ideally, they will reinforce the plan and the objectives every day with a Lean Daily Leadership Process that provides feedback to their team and seeks their input on problems every day. This structure of short daily meetings will cascade up the organisation – they may encourage you to lead a regular stand-up meeting or conference call at senior management level to help set the overall business direction and address high-level problems.

They don’t substitute money for brains Many Operations Manager are engineers.

Engineers love technology (that’s often why they became engineers!) and get excited about robots and fancy data acquisition software. However, a good Operations Manager will not be constantly presenting you with shopping lists of capital investments and software tools. Instead, they will focus on trying to get the most out of the assets and tools they have. When they do come to you with a request for capital it will be supported by a strong business case, will be well thought out, and will align with the operations plan and business strategy.

You won’t often find them in their office The Operations Manager role is often the lynchpin of a manufacturing business.

They typically have the most staff reporting to them and the greatest number of interactions with peers. Therefore, a good Operations Manager will spend a lot of time

out and about. You might find them out on a workplace walk, interacting with their team and observing the process. They could be meeting with peers, running a daily standup meeting, or having an on-site meeting with suppliers or customers. They will generally be on site (beware the Operations Manager who always finds a reason to be out of the business), but even when they are in their office they will be rarely alone.

Despite this, they may allow themselves a bit of solitary reflection time during the day to catch up on issues and plan actions.

This is often at the start of the day, around lunchtime or at the end of the day. If you see this, avoid getting in the habit of “just dropping in for a chat” at these times, but instead schedule regular structured catchups in their office.

Another mistake to avoid is over-loading your Operations Manager with transactional work. They are the key leader in your business and the person who will drive improvement. They are also, typically, a fairly expensive resource. Therefore, tying them to their computer doing purchase orders, production schedules or stock adjustments is a waste of their resource and will prevent them doing their job effectively. Get a clerical staff member on half an Operations Manager’s salary to do the transactional work and focus the Operations Manager on leading their team and driving improvement.

They tell you the truth – not just what you want to hear It is nice to be told how great you are and how right you are. We all have an ego and are all susceptible to flattery. However, a good Operations Manager will be prepared to give you challenging, considered, constructive feedback, and you need to be prepared to take it. You also need to be prepared for the fact that not every idea you have will be regarded as a good one.

The Operations Manager should be comfortable with your presence in the business and on the shop floor, but it is best that these shop floor walks occur with the Operations Manager, at least at the start.

Avoid the temptation to establish a “back channel” of communication with long-term employees, as this will strongly undermine your Operations Manager and make these long-term employees believe they are “untouchable” because they have a “direct line to the boss”.

There are many other attributes of a good Operations Manager, but if your new person is demonstrating most or all of the qualities listed above, even if short-term performance is not where you would like it to be, it will pay to stick with them.

Tim McLean is the Managing Director of Lean manufacturing consulting TXM Lean Solutions. www.txm.com.au

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Aussie manufacturing is resurgent, but it needs help to build for the future The COVID-19 pandemic turned a much-needed spotlight on the decline of Australian manufacturing. Eighteen months on, there are positive signs of a resurgence for the industry, but more substantial support will be needed if we are to grasp its potential. By Jack Parr.

The signs are good for Australian manufacturing. The Australian Performance of Manufacturing Index (Australian PMI) has seen a long run of strong results. In addition, AMTIL has endorsed the optimism surrounding the metals manufacturing sector in its AMT magazine.

Articles have highlighted government grant funding to over 90 companies, buoyant sales for the Australian Manufacturing Week (AMW) exhibition, and rocketing student interest in manufacturing careers.

The nucleus of this resurgence was the Manufacturing Taskforce, led by Andrew Liveris, whose work has resulted in the Federal Government’s Modern Manufacturing Strategy. However, Liveris stressed the plan involved more than just current funding initiatives; it is a decade-long transformation plan involving all stakeholders: government, unions, industry bodies, the education sector, and industry itself.

To accelerate this transformation, various conditions must be met. That manufacturing remains ‘top of mind’ in the economy’s rebuilding and is not subsumed by political short-termism. That a climate of ‘bottom-up’ innovation is accentuated and funded. That the future skills required are supported and better funded, not just by the Government, but by the manufacturing industry itself.

In his column for the last edition of AMT (Aug 2021), the thenIndustry Minister Christian Porter spoke in buoyant terms about how the Modern Manufacturing Strategy is delivering for business with a range of grants. The Manufacturing Modernisation Fund (MMF) has delivered $55m in grants to 86 companies, and the Modern Manufacturing Initiative (MMI) is offering $800m for larger transformative industry projects. However the most pleasing aspect of MMF is not the $55m but the hidden fact that these 86 companies have invested $330m of their own funds into growth initiatives. Let's also put the $55m into context - an English soccer club just paid nearly $200m for one player!

Of course, the political imperative in these schemes is jobs, jobs, jobs. And it is necessary to boost the economy post-COVID. Plus of course, politicians will want to strengthen their re-election prospects.

However, there are some early signs that the strategic plan is more expedient than transformative, and lacks a real understanding of the amount of change required. First, Porter’s appointment as Industry Minister sees this key role occupied by someone with no manufacturing or engineering experience. Linked to this is the apparent loss of Liveris from the strategic execution of the Modern Manufacturing Strategy. His international pedigree and knowledge make him an ideal guide for the journey.

Another important issue is the strategic plan itself, with its four pillars of action. It looks more like a set of disparate ‘considerations’ rather than an integrated structure. Maybe it is just a foundation, but that remains to be seen. The really disturbing aspect, however, is that it does not mention the word ‘Innovation’ once! Surely, it is well accepted that, given its structural challenges – its high-cost economy, its large land mass, its small population – Australia must develop high-value innovative products to compete internationally.

Maybe the pillar ‘Making science and technology work for industry’ embraces this key area but ‘Innovation’ demands a pillar of its own!

In his column for the last edition of AMT, Steve Murphy, National Secretary of the Australian Manufacturing Workers’ Union (AMWU) claimed: “As we all know, manufacturing drives innovation.”

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Sorry, but it is the other way round – innovation drives manufacturing!

History is littered with atrophied companies who failed to recognise innovation and emerging technologies. Mature products are offshored for lower cost benefits, whereas new product manufacturing is kept close to its design base. It is Australian innovation that will drive tomorrow’s Australian manufacturing jobs!

Murphy’s article understandably emphasises protecting jobs and attacks the casualisation of the workforce. But casualisation is just one factor – automation, digitisation, offshoring, industrial relations and investment, all influence employment. There are shortages now in high-paying, permanent jobs for people with the right skills!

Hopefully ‘skills for jobs’ will become a greater focus.

Future engineers are the theme of two other AMT articles. Australian Industry Group CEO Innes Willox declared that: “Skills are key to continued manufacturing growth.”

Growth cannot be sustained without the right skills and attitudes.

Skill deficiencies are why ANCA created its own in-house apprentice training, why RMIT linked its training with Okuma, and why Sutton Tools and Swinburne are collaborating on real industry placements.

Willox endorses the point that technological and cultural influences are significantly affecting the industrial landscape now. He quite rightly concludes that “skills development needs a different approach moving forward, where learning is not separated from doing”. Again, skills development needs to be integral to the strategic plan!

Shane Infanti, CEO of AMTIL, cited two imaginative schemes in his column ‘Attracting the next generation of manufacturing talent’. He looks to address the current skills shortages by reskilling mature unemployed workers now, through intense short-term education programs. Meanwhile his Young Ambassador Program would endorse manufacturing career opportunities through a mix of integrated school and industry programs. Unfortunately, these schemes remain futuristic (the word ‘imagine’ is used eight times) because as Infanti concludes, “how do we fund these programs?”

Both Willox and Infanti’s articles embrace the funding actions required now, and reflect the need for the Modern Manufacturing Strategy to provide funding that provides both short and longer-term return results.

BUSINESS MANAGEMENT

HAVE YOU GOT AN HOUR TO SPEND ON YOUR BUSINESS? One of the major messages highlighted by Liveris in his promotion of manufacturing was ‘Advocacy’. And he clearly looked to the manufacturing sector itself to promote its appeal and value to the Australian economy. In other words, “Manufacturing must sell itself!”

In 2020, the AMGC released ‘Ten Ways to Succeed in Australian Manufacturing’, a report that outlined the ways businesses could promote their value to potential employees, their community and the wider public: things like factory tours for school students, open days for the local community, industry experts providing talks to schools and other groups. All these ideas could be implemented by the industry itself, at low cost, with two main purposes: to demonstrate to high school students that focusing on STEM (Science, Technology, Engineering, Mathematics) studies can lead to challenging and rewarding careers in manufacturing and engineering; and secondly, to dispell perceptions – among parents, school career officers, and the wider public – that manufacturing is an unappealing profession.

In 2016, in recognition of our international decline in STEM, the Government launched its STEM investment program. Judging by anecdotal evidence, this has been a success with schools setting up STEM initiatives. But again, this sector needs more investment.

Governments are both Federal and State levels invest in STEM, and it is hard to determine actual sums, but one credible recent report suggests that the 2020/1 Federal budget allocated $27.3m over five years. With over four million Year 6-12 students, this amounts to roughly $1.30 per student per year! Many local businesses make direct donations to schools, and industry-focused charities like the Vernier Foundation make grants for STEM learning tools, but more needs to be invested.

JFK once coined an epochal message: “Ask not what your country can do for you – ask what you can do for your country!” Today, it could easily be paraphrased as “… ask what you can do for your industry!”

Industry needs to look to be more innovative, but innovation really needs government backing. There are many SMEs looking to innovate who are not focused on the six industries identified under the Modern Manufacturing Strategy as Australia’s National Manufacturing Priorities, but they need financial help to drive their transitions forward. Grants as low as $10,000 could boost their productivity. The Government also need to look at innovation as a gamble. As Thomas Edison said: “I have not failed. I just found 10,000 ways that did not work.” Policymakers need to look at leading innovative nations like Israel, where investments are only paid back if they succeed!

Ultimately all members of the manufacturing community need to look at what part they can play in this decade-long, highly necessary transformation. We need to advocate for manufacturing!

Jack Parr is the Coordinator for the Vernier Foundation, a charity aimed at funding and supporting, STEM education in schools. The Foundation is the charitable arm of the Vernier Society, an organisation that for nearly 80 years has worked to support Victorian Manufacturing. www.vernier.org.au

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Australian manufacturers: Apathetic, too busy or just simply Fed Up? Despite constant public commentary regarding its importance to Australia and its economy, the manufacturing industry remains in a prolonged decline that has continued for decades. Moreover, this doesn’t seem to be of significant concern to the public – or indeed to many manufacturers. Linsey Siede explores the possible reasons why.

Like many of the readers of this magazine, I am a passionate manufacturing person who cares a little too much about things I can’t control, which subsequently results in me taking many things to heart that I really shouldn’t. This includes experiencing decisions about the manufacturing sector that I just don’t understand, which just seems to make me even more exasperated and upset than I would have been anyway.

I don’t mean to sound philosophical but I believe that people are either passionate about something or they’re not; and if they’re not, then they have most likely just given up on whatever it was that they did at one point care greatly about.

In my case this was the closing of the Australian automotive manufacturing industry. Then, after going through the Seven Stages of Grief – well, six of them – the seventh stage: “Acceptance & Hope”, was in my case really more thinking that there must be other things I could get interested in, and perhaps eventually even get passionate about. I was correct: there are; and I am again.

I wrote an article for the December 2019 edition of AMT entitled ‘Is “Manufacturing Value-Added” undervalued?’. It highlighted the fact that, despite all the public hype and rhetoric around advanced manufacturing and Industry 4.0 and how this would change, improve and save the industry, manufacturing in Australia was actually continuing to decline. At that time manufacturing was hovering around only 6% of Australia’s annual GDP, and yet somehow this fact seemed to be entirely lost on Australia as a nation, and in fact on most Australians. Maybe people didn’t understand the serious implications of this fall with regard to generating wealth for our country – or worse still, perhaps they just didn’t care. It’s amazing to me to realise that the manufacturing sector contributed almost 30% of Australia’s GDP in the 1950s before beginning its long and continuous decline. According to the World Bank, by 1999 this contribution had fallen to 12% with seemingly little concern, but by 2016 this had halved again to a miserly 6%. This figure is the second-lowest of all 32 OECD countries, and almost two and a half times less than the OECD average of 14%. To me at least, this would appear to be extremely concerning, and yet it continues to decline.

Again according to the World Bank,

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a survey to try and identify ways to help the manufacturing industry, and then pass this information onto government.

As one of only 253 people to complete the questionnaire, I was completely taken aback by the extremely low number of people who took the opportunity to provide feedback to AMTIL on questions regarding the help they needed and the government support programs that could support them.

I wondered about the reasons why people would not take 15 minutes to identify things that could help their business. As Professor Julius Sumner Miller used to ask: “Why is it so?”

Australia’s contribution to GDP from the manufacturing sector in 2019 had fallen to only 5.6%. While other countries have realised the contribution from this sector is far too low and have already halted the decline, in Australia the number is still falling.

This is confirmed by the Australian Bureau of Statistics, whose data shows that by December 2020 the percentage of GDP represented by the manufacturing sector had now fallen to 5.5%. Although the rate of decline is slowing, the level is still very low compared to almost all other countries.

Can this number be turned around?

What does it take before we as a Nation decide to get involved and do something about it? Why don’t we do something?

As a Country, do we actually understand what is happening? Do we care? Have we given up? Have we actually just lost the passion? Recently AMTIL undertook

AMTIL has a longstanding reputation that has been well earned from its excellent connections and relationships with government representatives and its nononsense manner of communicating with them. Based on that fact alone, I saw this as the perfect opportunity for people and companies to get their thoughts and messages directly back to government – whether it was positive or negative feedback they wanted known. This started me thinking (sometimes a dangerous thing) about why, from the 4,777 invitations sent out to people and companies, only 5.3% took the opportunity to complete this important survey.

Apathy?

Based on 10 years as the Director of the Automotive Supplier Excellence Australia (ASEA) program – that coincidently ended on the same date as the last of the OEM automotive manufacturers left Australia – I know that there are many companies that

Registered business breakdown by number of employees.

BUSINESS MANAGEMENT

simply cannot be bothered participating in programs run by organisations trying to help them become more efficient and effective. Despite the outstanding results achieved by the participants in the ASEA program, and the publicity this received, there were still companies we spoke to that just did not see any reason to take part.

In some cases it was a lack of trust; others could not see how we could possibly help them; and for others, they just didn’t want to change. For many, all they knew was the insular world they operated in, and that world was purely within OEM automotive manufacturing. The majority of suppliers didn’t even have any sales people, as they knew that if they did the right thing by their OEM customers (Ford, Holden and Toyota) on the current models, they would continue to get business on the new models.

However as that world evolved, changed, and finally disappeared, they were left stranded because they could not operate outside the very narrow, sheltered environment they had been operating within for so long. When those companies did eventually realise they needed outside help and support, and were willing to accept it, there was no time left to implement the changes needed before their decades-long revenue stream finally disappeared forever.

No matter how strong a company’s current revenue stream looks today, tomorrow’s changes can stop it in its tracks.

Too busy?

I am aware that most manufacturing SMEs (particularly after a year of COVID) are short of two things: time and money. I am also aware that 99.8% of the 2,375,753 registered Australian businesses in 2020 have fewer than 200 employees, and a whopping 2,314,647 have fewer than 19 employees.

Therefore time is definitely in short supply in smaller organisations. However, completing the AMTIL survey was an opportunity to provide important feedback to Government about the things they could do to support and help their company, so I can only assume that there were a lot of people that didn’t really give “completing the survey” a very high priority in their busy daily schedules.

Far too often, those things that can benefit us the most in the future are overridden by the many daily tasks and activities that must be completed, just in order to run the business. Time management is a critical part of any business, particularly for the leaders, and somehow time needs to be created or allocated throughout the day to focus on the future, and not just the now.

Fed Up? The third possibility of course is that people are just sick and tired of providing years and years of feedback to a variety of different governments (state and federal) that seem to come and go at regular intervals, but see nothing at all change in helping or supporting them in their endeavours.

One of the great strengths of the ASEA program was the incredible support that was received form the three government participants; federal, Victorian and South Australian. The representative from the SA Government had previously worked at Holden, and the Victorian representative had previously worked at both Holden and Ford, so their knowledge about what industry needed was relevant and up-to-date.

This industry knowledge within government, and the close working relationship between the government and industry people on the program were crucial to the huge success of the program. Unfortunately many of the former industry people in government are not there anymore, and I personally believe

the relationship between government and industry has suffered because of it.

Why is SME feedback important?

Based on the company breakdowns above, I believe that a very large percentage of AMTIL members would fall into the SME category. If that applies to your business, your specific feedback is very important. To understand why SME feedback is critical, let me refer to my earlier article from January 2019.

Typically, most of the small-to-mediumsized manufacturing companies are focused on “Operational Excellence”, and need different types and levels of support to their larger counterparts. SMEs typically need support and assistance to help them move through the “Operational Excellence” phase and into the “Business Excellence” phase, so they can successfully grow and become larger, and hence more successful.

There are currently many government programs, schemes, initiatives, CRCs, Innovation Labs and more to support innovation, advanced manufacturing, Industry 4.0, vollaboration, R&D and so on.

That is excellent news for those companies who are already at the “Business Excellence” stage of their journey. However, many SMEs are still in the “Operational Excellence” stage, and if you are one of those, you need a totally different type of support. If SMEs do not voice their opinion, the bulk of the help and support will be focused on advanced manufacturing and “Business Excellence”.

If Australia wants to halt the decline and begin to regrow its manufacturing industry, there needs to be a broader focus on the needs of the entire sector and a shift in both the thought processes and the funding mechanisms. The significant levels of support to help companies who are at the pointy end of their journey regarding “Business Excellence” should be broadened to also help those companies who are at the beginning of their journey with their “Operational Excellence”.

Without industry feedback and strong representation, your message cannot be heard.

If you are one of the people who did not complete the survey, which category are you in? I am sure AMTIL would like to know this information and get your feedback.

Linsey Siede is the Director of Likatibro Consulting Pty Ltd. Siede began his career in engineering with GM Holden, before becoming Managing Director of Delphi Australia in 1990. He was also General Manager of ANCA Machine Tools, prior to spending the last ten years as the Director of Automotive Supplier Excellence Australia (ASEA).

Email: likatibro@bigpond.com

Typical growth path of a new manufacturing business.

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Modern manufacturing trends in supply chains The disruption caused by COVID-19 is nothing new. Daniel Kohut looks at some of the ways manufacturers are futureproofing their supply chains against the next crisis.

The COVID-19 pandemic has been wrought with supply chain disruptions.

From the worldwide shortages of toilet paper at the start of the pandemic, to the ones that continue to occur as a result of situations such as the Suez Canal blockage or the Port of Yantian shutdown. Recent headlines have highlighted shortages of timber and of the semiconductor chips that are needed for cars and other electronics.

But supply chain disruptions are nothing new – they have just been exasperated by the pandemic. Organisations should have been readying their supply chains long ago to respond to disruptions and, now they are scrambling to do so to prevent future disruptions.

To prepare for the next disruption, manufacturers are looking at five key trends to future-proof their supply chain.

Automation is necessary The amount of data available these days can be overwhelming to manage, so that is why many companies are turning to machine learning (ML). ML can provide insights in near real-time, helping identify where delays may occur and rerouting deliveries that might otherwise not make it on time.

Solutions powered by ML can anticipate demand and stock levels and analyse typical production and delivery schedules to recommend changes that will avoid product shortfalls. With ML this type of analysis and decision-making takes a few hours, when it would normally take human workers days to gain an overview of the situation and make the right decision.

Human emotion and error are always a significant factor, but they are removed from the equation when ML is utilised because it ensures that decisions are based on data.

Cloud migration Migrating to the cloud allows for automation and the ability to use solutions powered

by ML. Manufacturers should look to migrate to cloud-based solutions, which can be integrated and customised with little effort thanks to advanced application programming interfaces (APIs). As more cloud services are employed, the level of automation will only further increase.

Seek data scientists Good, accurate and accessible data are the key to automation, ML and predictive analysis. Traditionally, data has been siloed across the company, which makes it challenging to gather, format and

AMT OCT/NOV 2021

harmonise this data. This is especially true in the manufacturing sector, where data has traditionally been spread across multiple departments. In order to enable the tools that support supply chain management, optimisation and real-time decision making, this data needs to be unified.

Daniel Kohut

This is where the need for data scientists comes in. While the data science field is growing, it is important to find the right people to help you successfully manage and optimise your supply chains.

Business apps with the user in mind Technology is constantly changing and the supply chain domain is not immune to this.

As the workforce changes, so too will the technology and how it is used. Millennials, and soon Gen Z, are entering the workforce, and they have grown up in an online world, interacting daily with applications of all kinds that have been designed with userfriendliness as a top priority. Old-fashioned apps, with text and table-based interfaces will be considered non-user-friendly and thus will be phased out. Those coming into supply chain management roles will increasingly demand graphical user interfaces that are intuitive and enable their staff to easily access and interpret the information they need to do their jobs.

The solutions that will be successful will have intuitive graphical user interfaces that use dashboards and diagrams to provide a quick overview of what is happening along the supply chain. This will be important as legacy, on-premise solutions are being replaced by new cloud solutions.

Single source of truth While supply chain management and supply chain execution have traditionally been siloed, bringing them together will be an important factor for a single source of truth. The other important factor will be

speed. Bringing planning and execution applications together is necessary, allowing you to quickly analyse data using automation and ML-enabled solutions. This results in more informed decision-making, less disruption and greater customer satisfaction.

Future supply chain disruptions are inevitabe, so manufacturing companies must invest in emerging technologies to enable greater visibility over their supply chains. Those who do will be able to catch and manage disruption quicker to remain competitive and meet customer expectations.

Daniel Kohut is Vice-President – ANZ at Blue Yonder. www.blueyonder.com

BUSINESS MANAGEMENT

Why technical specialists often feel “stuck” – and how to fix it Technical specialists keep your organisation functioning, but managing, motivating and retaining them can be challenging. By Alistair Gordon.

AMTIL PRODUCT E-BLASTS

Whatever field they’re in, technical experts are critical. They’re also hard to hire, expensive and hard to retain. Worse, they have an underserved reputation for being bad with business and soft skills – with negotiation, stakeholder engagement, commercial acumen and knowledge transfer. But what if the problem isn’t nature, but nurture? Most organisations frame their idea of a “high-potential employee” in a manner that excludes experts – yet these are the people you probably rely on most to change the way your organisation works or approaches difficult problems.

Organisations know what to do when they see a high-potential people leader – they roll out the red carpet. Emerging people leaders get coaching to polish business skills. They have well-developed career ladders and an appraisal process. People leaders enjoy all the encouragement of traditional leadership development. They’re seen as high potential because they can lead a team, and maybe even become CEO one day.

Experts, meanwhile, don’t want to manage teams or be CEO. So they aren’t offered the same “high-potential training” in business and people skills. (Or they’re sent on the same training as people leaders, which isn’t so relevant to the challenges they face.)

The problem then compounds. Without development, it’s assumed experts were “born that way” – that they were never capable of developing soft skills in the first place. And as a result, they don’t get promotion or movement. They stay in the same roles for a long time – far beyond the time where the role is rewarding or motivating. They’re stuck. They’re probably not happy, and eventually they leave. To get them unstuck, rethink your idea of potential.

Ask your head of data science or the head of policy to define “high-potential”. They’ll say that in a technical team, it’s not only about people leadership. Instead, they want experts to use domain knowledge to create competitive advantage, or solve problems that threaten your business. They’ll agree that talented experts need to master a broad range of enterprise skills – not just soft skills, but coaching to understand risk and reward, the creation and maintenance of business relationships, and your organisation’s commercials.

2. Frame enterprise skills as part of an expert’s day to day role. People leaders are told from day one that commercial acumen and soft skills are critical to their long-term career. Tell experts the same.

3. Create an expert capability framework. Do your experts understand which non-technical skills you want them to acquire? It helps to define what mastery looks like.

4. Consider where you need to shift focus to “expertship” rather than “leadership”. Expertship develops the skills needed to lead ideas, projects and innovation, where Leadership coaches the skills needed to lead teams. Experts welcome ideas to become better experts.

5. Ask leaders of technical teams to identify “stuck” experts, who have potential to add greater value than you may have realised.

Most employers look the same to experts. They’re not so aware of expert challenges, not so interested in expert ideas. Hiring is simplified and retention increased when experts understand you encourage their work and ideas.

You’re also improving expert happiness and creativity and effectiveness.

Alistair Gordon is the CEO of Expertunity, and an expert coach, speaker and author. www.expertunity.global

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Here are five ways experts can gain job satisfaction – while adding value to your marketing and organisational strategy.

1. Redefine “high-performing” to reflect the value added to your business, not just people leadership potential. Experts create competitive advantage, but only if you support and encourage their presence.

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FORUM LAW

Sexual Harassment: It’s time to get your house in order Time is running out to get your house in order... There are new sexual harassment laws proposed by the Federal Government. Employers need to determine where to draw the line between harmless banter and sexual harassment.

By Jonathan Mamaril.

Manufacturing and blue-collar businesses could find themselves embroiled in costly legal battles unless they overhaul their sexual harassment policies to align with the Federal Government’s new ‘Respect at Work’ laws.

On 1 September, the Federal Government acted on the recommendations of Australia’s Sex Discrimination Commissioner Kate Jenkins and passed the Sex Discrimination and Fair Work (Respect at Work) Amendment Bill 2021 – strengthening Australia’s stance on sexual harassment in the workplace.

The law change means employees can be fired if they are found to have sexually harassed a colleague.

It’s left employers in male-dominated industries, including transport, manufacturing and construction, where banter and sexual innuendo is often more common, urgently reviewing how they protect their staff, and themselves.

Sexual harassment is not always clear-cut, and what can seem like harmless workplace flirting or cheeky banter, may land employees, and potentially employers, in hot water.

So, what’s the solution? A Turnbull-style bonking ban? A banter ban?

The law change means employees can be fired if they are found to have sexually harassed a colleague A ‘stop sexual harassment order’, similar to the ‘stop workplace bullying order’ that has existed for some time now, has also been implemented.

Judges and politicians will be subject to the sexual harassment laws While not directly applicable to the manufacturing industry, it’s also interesting to note these sexual harassment laws will apply to government workplaces for the first time.

As a result, we may see even more claims of sexual harassment from staffers and public service.

It’s time to be proactive

The line is a difficult one to draw, but employers need to work out where to draw it now.

There are several initiatives employers can implement to ensure a safe workplace.

While the Federal Government’s new laws aren’t as heavy-handed as originally anticipated, the ‘me too’ movement has taught us even in the absence of strict laws, society will hold perpetrators and bystanders to account.

1. More specific sexual harassment training;

So, what is sexual harassment?

The Sex Discrimination Act 1984 (Cth) defines sexual harassment as: • an unwelcome sexual advance; • an unwelcome request for sexual favours; or • unwelcome conduct of a sexual nature in circumstances where a reasonable person, having regard to all the circumstances, would have anticipated the possibility that the person harassed would be offended, humiliated or intimidated.

Intention of the ‘harasser’ is completely irrelevant. Instead, the law focusses on how their actions or words are perceived.

An expanded definition of ‘Serious Misconduct’ under the Fair Work Act Some employment contracts already state that sexual harassment is ‘serious misconduct’. This gives an employer the ability to dismiss an employee who has been found to be a harasser.

In line with Kate Jenkins’ Respect@Work recommendations, ‘serious misconduct’ will be incorporated into the Fair Work Act. It will therefore apply to all employer-employee relationships, regardless of the contract.

This will make it easier for employers to defend an unfair dismissal claim where an employee’s contract has been terminated due to sexual harassment.

It also means the harasser will need to prove sexual harassment did not occur to avoid serious repercussions.

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2. Prescriptive sexual harassment policies; 3. A crackdown on sexual jokes, innuendo or other behaviours; and 4. Greater scrutiny and transparency in the investigation of sexual harassment complaints.

Proactive measures should also consider employees’ psychological health. This will no doubt require more management training on how to identify psychosocial risks, and what to do if they suspect an employee’s psychological health is impacted.

Some practical tips Prevention is always the best approach, but if you’re an employer and find yourself dealing with a sexual harassment complaint, there are two golden rules: 1. Complaints must be handled with care and empathy – trust is key; and 2. A thorough investigation should commence immediately after an allegation is made. This is not the time for a DIY approach.

A lawyer-run investigation, or at least obtaining legal advice, will ensure a fair process for all parties.

These new laws pave a clearer path for employees to file sexual harassment complaints.

It’s time to get your house in order.

Jonathan Mamaril is Director of NB Lawyers. For all Manufacturing Employers, NB Lawyers can offer an obligation-free consultation.

Tel: +61 (07) 3876 5111 Email: service@nb-lawyers.com.au www.lawyersforemployers.com.au

FORUM OHS

Foundation Ltd

Victoria's on-the-spot fines for OHS non-compliance now in force The issuing of on-the-spot fines last July by WorkSafe Victoria is an alternative to prosecution and to strengthen WorkSafe Victoria’s compliance and enforcement capability. Its primary goal is to act as an additional deterrent for employers, sending a clear and timely message to those who are still not taking their OHS obligations seriously.

On 31 July, the Victorian Government introduced on-the-spot fines for employers who put the health and safety of their workers at risk, to eliminate bad behaviour and help ensure every worker gets home safely. The introduction of on-the-spot fines provides an immediate alternative to prosecution, for those employers who do the wrong thing.

Further information and support

What is an infringement notice?

If you missed out on the day, you can catch-up by watching this informative, 16-minute WorkSafe video: “A new tool for a safer Victoria” at www.worksafe.vic.gov.au/infringement-notices-scheme

An infringement notice is basically a fine that is given by an inspector to a person who has committed an infringement offence, where the offending conduct is clear and doesn’t require an extensive investigation. The notice itself will contain information about the alleged offence, how much is owed, the date on which the fine must be paid (at least 21 days from when the notice is served) and also ways to resolve the infringement. This can include options for payment, requesting a review, or applying that it be heard and determined by a court.

The Penalties Inspectors from WorkSafe Victoria can now issue infringement notices with penalties of up to $1817.40 for certain offences, such as working without a required licence, registration, qualification or supervision, or the use of equipment or substances that are not licensed or registered. Infringements can also be applied to individuals or businesses failing to meet duties relating to the removal and storage of asbestos and failing to keep required records. Fines vary depending on the nature of the offence and range from $363.48 for an individual and between $1090.44 and $1817.40 for a corporation. All fines are processed through Fines Victoria with funds received from infringement notices to be allocated back to the WorkSafe Victoria scheme.

The infringement notice scheme is intended to strengthen WorkSafe Victoria’s compliance and enforcement capability and act as an additional deterrent for employers who do not take the safety of their workers seriously.

What are the changes?

WorkSafe Victoria and its inspectors and investigators will continue to provide guidance and information, issue improvement, nondisturbance and prohibition notices, and prosecute safety breaches where appropriate.

Under the infringement notice scheme, the obligations of employers do not change; duty holders must continue to do everything that is reasonably practicable to provide a workplace that is free from risks to health and safety. The ability to investigate and prosecute breaches of the OHS Act in the courts continues to be part of WorkSafe Victoria’s compliance and enforcement approach.

“Adding on-the-spot fines to the range of compliance tools available to WorkSafe will provide a clear message to employers that putting their workers at risk will not be tolerated. This is about making sure every worker gets home safely — and making sure those who are doing the wrong thing face the consequences” said Victorian Minister for Workplace Safety Ingrid Stitt.

To support the introduction of the infringement notices scheme on 31 July 2021, WorkSafe held an educational webinar to ensure key stakeholders, including employer and employee representatives and the Victorian community, are informed about the scheme, what it means for them and where to get more information.

What offences can an infringement notice be issued for?

An infringement notice can be issued for an infringement offence as an alternative to prosecution.

There are 54 offences under the OHS Act and Regulations that are prescribed as infringement offences.

In summary, the offences relate to: • undertaking work without a required licence, registration, qualification, experience or supervision • using plant that is not licensed or registered as required • failing to meet various duties relating to the removal and storage of asbestos • failure to keep various required records The prescribed infringement offences apply across all industries already regulated by the OHS Act, including construction, working with asbestos, major hazard facilities, hazardous substances, mining and quarries.

If you commit any of the offences under the OHS Act or OHS Regulations, WorkSafe inspectors can issue an infringement notice.

The offences may be accessed by visiting this website: www.worksafe.vic.gov.au/infringement-offences or phone 1800 136 089 These infringement notices add to the suite of tools that an inspector can use and serve as a reminder that there is no complacency with workplace safety. An employer or duty-holder should always be thinking of the risks that they are undertaking or their business poses to both employees and other persons and be thinking of ways to eliminate or reduce those risks.

The NSCA Foundation is a not-for-profit, member-based association focused on helping organisations protect their most important asset - their people. Since 1927, it has continued to inspire, educate, inform and engage the Australian work health and safety profession to create and sustain safe and healthy workplaces. It enables professional development through in-person events, webinars, updates on industry developments through the Safe-T-Bulletin and the National Safety magazine, networking opportunities, and online resources.

Tel: 02 8875 7820 Email: membership@nscafoundation.org.au www.nscafoundation.org.au

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FORUM FINANCE

What do the changes to the export market development grants mean for you?

Berrin Daricili explains what has changed with the Export Market Development Grant program.

The Export Market Development Grant (EMDG) program is a key financial assistance program designed to help businesses market and promote their goods and services internationally. It provides funding to assist over 4,000 small and medium enterprises (SMEs) per year cover export-related costs such as producing promotional material, travelling overseas, and providing free samples.

What’s changed?

Traditionally, the EMDG program operated under a reimbursement model, where eligible applicants were able to claim eligible expenses incurred during a particular financial year once that financial year had ended. Whilst the program still operates this way for any eligible export marketing expenses incurred up to 30 June 2021, significant changes came into effect on 1 July 2021 that changed the EMDG program from a reimbursement scheme (where an application is made in retrospect) to a traditional grant program. Importantly, applicants can now apply for the grant (for eligible export-related expenditure for each year over the next 2 or 3 years) and receive confirmation of funding before those expenses are incurred.

These changes are designed to: • Be more responsive to the needs of different types of exporting businesses, with different grant funding ‘tiers’ available based on an applicant’s export-maturity.

• Simplify the application process, allowing applicants to apply only once for a grant that will span 2 or 3 years (depending on funding tier).

• Provide applicants with more certainty regarding funding amounts they are entitled to before they incur export-related expenditure. Grant agreements will span two ort three years and will now specify the amount of funding that will be provided to a successful applicant for each of those years.

It is also important to note that the EMDG program remains ‘entitlement-based’ rather than competitive, which means all applicants that meet eligibility criteria will receive grant funding.

No comparison between applicants will be made. However not all applicants will necessarily receive the amount of funding they request as the total funding pool must be distributed among all eligible applicants. The grant also remains capped at 8 years – once an applicant has reached 8 years of grant funding (not necessarily consecutively), they will no longer be eligible to apply for the program.

Funding for exporters EMDG grants are available at three varying levels of support, called ‘tiers’. The funding amounts and lengths of these grant tiers reflect the different stages of an exporter’s journey: • Tier 1 – Ready to export: Tier 1 grants support first-time exporters with funding of up to $40,000 per financial year for two years.

• Tier 2 – Expanding: Tier 2 grants support those expanding their export promotion activities (i.e. they must already be exporting) with funding of up to $80,000 per financial year for three years.

• Tier 3 – Expanding and strategic shift: Tier 3 grants support those expanding their export promotion activities and making a strategic shift (e.g. targeting a new market or new type of customer) with funding of up to $150,000 per financial year for three years.

AMT OCT/NOV 2021

Applicants can apply for any tier level that suits their organisation, and do not need to progress through each tier consecutively.

Funding for representative bodies There are also grants for industry bodies and alliances to help their members to become export ready and export successfully, such as providing training to members who are new to export.

These representative bodies will be able to access up to $150,000 per financial year across three years to provide this training and undertake promotional activities on behalf of their members.

Eligibility criteria Applicants must be: • An Australian entity (e.g. sole trader, trust, partnership, company), hold an ABN, and have a turnover of less than $20m for the financial year previous to the claim year.

• Exporting or ready to export eligible goods, services, events, IP or know-how, and/or software that is of substantially Australian origin.

• Intending to incur eligible expenditure on activities undertaken for the purpose of marketing eligible products overseas (excluding NZ). All expenses must relate to promotional activities to market in foreign countries, or training activities to develop skills in such marketing.

• Able to match, at a minimum, the dollar value of the grant funding amount they receive (i.e. at least 50% of the total eligible expenses they plan to incur).

Application process EMDG applications must be submitted online, along with supporting documents that prove an applicant’s eligibility and describe its export marketing intentions. The specific attachments that will need to be collated and submitted along with an applicant’s EMDG application vary depending on: • The grant funding tier being applied for.

• Whether the applicant is exporting a ‘good’ or a ‘service’.

• Whether the applicant is an SME exporter or a representative body.

Applicants will also need to submit their 2020-21 Balance Sheet and Profit and Loss Statement as evidence that their turnover is less than $20m.

Once grant applications are assessed, eligible applicants will receive a grant agreement outlining the amount of funding they will receive and the length of the grant agreement. Grant funding is then provided via milestone payments (payments will be made within 14 days of submitting a milestone report), rather than in a lump sum.

EMDG applications for expenses incurred from 1 July 2021 are currently open and close at 5pm on Tuesday, 30 November 2021.

William Buck can offer assistance to businesses with determining their eligibility and preparing successful grant applications.

Berrin Daricili, Manager, R&D Grants & Incentives Tel: 03 8823 6846 Email: Berrin.darcili@williambuck.com Dr Rita Choueiri, Director Tel: 03 8823 6846 Email: rita.choueiri@williambuck.com www.williambuck.com

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FORUM IP

Australia’s Proposed New Patent Box: Update The Federal Government recently announced the proposed introduction of a patent box for Australian medical and biotechnology industries, as explained by Karen Heilbronn Lee. As part of the 2021-2022 Federal Budget handed down on 11 May 2021, The Federal Government announced the proposed introduction of a $206.4m patent box for Australian medical and biotechnology industries. The Government indicated that it would consult with industry on the design of the patent box, and to this end, Treasury released a discussion paper on 5 July 2021 advising further details of the proposed regime. Karen Heilbronn Lee Named quite literally after a tick box historically present on income tax forms, a patent box provides tax incentives designed to encourage companies to commercialise and manufacture patented technology locally. Australia’s proposed patent box is slated to tax income derived from eligible patents at a concessional corporate tax rate of 17%, rather than the standard corporate tax rate of 30%, or 25% for small and medium enterprises (SMEs), from 1 July 2022.

The measure is intended to incentivise Australian companies to invest in and perform their research and development (R&D), commercialisation and manufacturing of patented technologies onshore. The Discussion Paper states that the patent box is “a longterm tax measure to attract R&D activity and retain IP income in Australia”.

Which technologies will be eligible?

The Discussion Paper indicates the concessional tax rate would only apply to profits derived from inventions in the medical and biotechnology sectors, claimed in granted standard Australian patents having a priority date (first filing date) after 11 May 2021.

According to the Discussion Paper, determining whether profit is derived in the medical and biotechnology sectors, and is therefore eligible for the patent box regime, would be based on the “use or classification of individual patented inventions” rather than an overall industry classification of the company that owns the patented invention. This could be determined using either: • A patent-level test, where patented inventions only qualify for the regime if the invention defined in the patent claim is primarily used or classified in the medical and biotechnology sectors. The World Intellectual Property Organisation (WIPO) has suggested a breakdown of the International Patent Classification (IPC) system for medical and biotechnology inventions, which could assist in determining eligibility. All eligible profits would then receive the concessional rate, including eligible profits attributable to activity in other sectors.

• Income streaming test, where all patented inventions qualify for the regime, but only eligible profits attributable to activity in the medical and biotechnology sectors would receive the concessional rate. However, it is not clear how the determination as to whether profits are 'attributable' to activity in the relevant sectors would be made.

What about cleantech?

The Government is consulting on the potential expansion of the patent box regime to include low emissions technologies (i.e., “cleantech”). The Discussion Paper points to the Government’s commitment to the Paris Agreement, including its intention to meet and exceed Australia’s 2030 Paris target of reducing greenhouse gas emissions by 26 to 28% below 2005 levels by 2030, and achieving net zero emissions as soon as possible, preferably by 2050. While the Discussion Paper stops short of confirming whether low emissions inventions will be included in the patent box, it is

stated that it may provide an additional lever for the Government by encouraging further innovation in low emissions technologies.

Moreover, the Discussion Paper specifically asked for feedback on this issue. We are therefore hopeful that cleantech inventions will ultimately be included in the patent box.

What IP income would be eligible?

The Australian patent box would be consistent with Organisation for Economic Co-operation and Development (OECD) guidelines and standards, and on this basis will include a 'nexus approach', administered as part of the corporate tax system. To determine eligibility, a taxpayer will need to provide evidence of: • appropriate nexus between R&D activity and eligible patented invention, and • appropriate nexus between eligible patented invention and eligible profits.

Essentially, the concessional tax rate would only apply to profits from patented inventions in proportion to the amount of relevant R&D (i.e., R&D associated with that invention) that occurred in Australia. That is, the qualifying IP income would need to be adjusted by the R&D fraction, which represents qualifying Australian R&D expenditure as a proportion of overall R&D expenditure on the IP asset.

The types of IP revenue that will be eligible are currently under discussion, including: • royalties or licence fees derived from an eligible patented invention, • revenue embedded in the sale of patented good or services or the use of patented processes in production, • revenue from damages or an account of profits for infringement of an eligible patented invention, and • revenue by sale or assignment of an eligible patented invention.

Expenses that arise in developing, exploiting, generating and maintaining the relevant patented invention would need to be subtracted from eligible patent revenue, and accordingly, separated from non-eligible expenses that are unrelated to the patented invention.

What else do I need to know?

On a technical note, several years typically elapse between patent filing and patent grant, although patent grant can be brought forward by various means including requesting early national phase entry in Australia followed by expedited examination. Further, some patented inventions take several years to begin to return a profit.

Accordingly, it could be some time before the patent box regime begins to provide significant benefit. The Government has indicated it will issue and consult further on exposure draft legislation prior to introducing legislation into Parliament.

Karen Heilbronn Lee, PhD, is an Associate Patent Attorney at Shelston IP, a Tier 1 Intellectual Property Firm. Shelston IP has been providing the full spectrum of intellectual property services in Australia, New Zealand, Asia Pacific and beyond for over 160 years.

Tel: +61 2 9777 1111 Email: Karen.Lee@ShelstonIP.com www.ShelstonIP.com

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AMTIL INSIDE

Bringing our show back to Sydney Things are always pretty busy here at AMTIL, but these last few weeks have really been a special case.

Firstly, as I mentioned in my column in the last AMT, AMTIL has been preparing to move to a brand-new office. It’s been a big undertaking, but by the time you read this, we should be all settled in our new headquarters.

On top of that, the team at AMTIL has been working on a major project, the results of which will be unveiled at our AGM on 28 October. You’ll be able to read all about that in the next edition of AMT. It’s been a big job, and we’re all very excited about it.

Meanwhile on top of that, there have been the changes in our plans for next year’s Australian Manufacturing Week (AMW) exhibition. In early September, the AMTIL Board took the decision not to proceed with the plan to stage the inaugural edition of AMW in Melbourne in March. The decision was taken in response to the latest COVID-19 outbreak and amid widespread uncertainty over the viability of large public events so early in 2022.

With the Melbourne event not going ahead, work began on exploring options for a rescheduled event later in the year. The Board felt there was a very strong appetite for a show at some stage in 2022 and that the resumption of exhibitions is a vital part of our post-COVID recovery.

We were very fortunate to be able to secure a venue at a suitable date, and are moving forward with plans to run AMW 2022 at the International Convention Centre Sydney (ICC Sydney) from 7-10 June 2022. With this later date, we are confident that the current COVID-19 outbreak will have been suppressed and that the vaccination rollout will have advanced to the point where large public events can be staged with a strong degree of certainty.

Looking further ahead, AMW 2023 will take place from 9-12 May 2023 at the Melbourne Convention & Exhibition Centre (MCEC).

None of this has been easy. It has involved some very tough decisionmaking by the AMTIL Board, and a lot of very hard work from the team.

The Melbourne show we had planned for March had enjoyed great support from our exhibitors, and the AMTIL staff had put a lot of work into preparations for it. However, taking part in a show like AMW is a big investment for our exhibitors, and the COVID-19 Delta strain had created too much uncertainty regarding staging such a significant event so soon in the New Year.

So now we are pushing on with a June show in Sydney. This in itself is a big undertaking, with the logistics of relocating the event across from Victoria to NSW posing a whole new set of challenges, which the AMTIL team is working hard towards resolving. Nonetheless, I am very pleased to see the response we’ve received from the exhibitors, with floorspace for the new show already 85% sold out. And I’m excited that AMTIL will be bringing an exhibition back to Sydney again, for the first time since we last ran Austech there back in 2012. There remains strong local demand for a significant manufacturing event there, and we believe we will deliver a fantastic show www.australianmanufacturingweek.com.au

Shane Infanti, CEO AMTIL

AMT OCT/NOV 2021

AMTIL HEADING INSIDE

Julie Toth to give keynote presentation at AMTIL AGM AMTIL will hold its 2021 Annual General Meeting (AGM) on 28 October, with a special presentation by Julie Toth, Chief Economist at the Australian Industry Group (Ai Group).

The event will begin with Toth’s presentation, ‘The State of the Nation and the Future of Our Economy’. Toth joined the Ai Group in 2012, where she heads up the organisation’s economics team, producing economics research, reports, comment and policy advice. She is an active participant in Australia’s national business, industry and economic policy conversations and consultation processes. Toth has clocked up close to three decades of professional research in Australian economics, working across the public and private sector at the ANZ Bank, the Productivity Commission and other Federal Government agencies.

In addition to her work for Ai Group, Toth is currently an advisory board member at Swinburne University’s Centre for Transformative Innovation, a panel member of the Melbourne Economic Forum (hosted by the University of Melbourne and Victoria University) and a member for the Economic Society of Australia’s Economic Policy Panel.

Following Toth’s keynote presentation, the AGM will be an opportunity to hear about AMTIL’s latest plans and initiatives plus reports on the previous year’s activities. The event is free for AMTIL members, though registration is essential. This event is generously sponsored

by AMTIL’s corporate partners: Interlease; Rigby Cooke Lawyers; SternaGL; and William Buck.

This event will take place as a webinar via the Zoom teleconferencing platform. AMTIL had initially hoped to hold a physical gathering at the AGM's regular venue, at Riversdale Golf Course in Melbourne.

However, as a result of developments regarding the ongoing COVID-19 outbreak in Victoria, the decision has been taken to instead stage the event online.

Date: Thursday 28 October 2021 To register for Julie Toth’s presentation and AMTIL’s AGM, or for more information on AMTIL’s upcoming events program, please visit the Events page of the AMTIL website. www.amtil.com.au/events 1382V4AMTIL

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 INSIDE

New Members AMTIL would like to welcome the following companies who have signed up as new members of our association.

3D PRINTING SOLUTIONS

RICHMOND WHEEL AND CASTOR CO

1/1265 MAIN NORTH ROAD PARA HILLS WEST SA 5096

590 CLAYTON ROAD CLAYTON SOUTH VIC 3169

www.3dprintingsolutions.com.au

www.richmondau.com

ALLOYS (MAKERBOT 3D PRINTERS AUSTRALIA)

ROTACASTER WHEEL PTY LTD

40 KOORNANG ROAD SCORESBY VIC 3179

7 ENTERPRISE DRIVE BERESFIELD NSW 2322 www.rotacaster.com.au

www.alloysint.com.au

AW BELL AUSTRALIA PTY LTD

WAO CONNECT

145 ABBOTTS ROAD DANDENONG SOUTH VIC 3175

LEVEL 5, NEXUS BUILDING, 4 COLUMBIA CRT BAULKHAM HILLS NSW 2153

www.awbell.com.au

www.waoconnect.com

BNNT TECHNOLOGY LIMITED

MANUFUTURES BUILDING, DEAKIN UNI, 75 PIGDONS ROAD WAURN PONDS VIC 3216 www.bnnt.com.au

WHITELAW TOOLING SUPPLIES PTY LTD

UNIT 1/63 SECAM STREET MANSFIELD QLD 4122 www.whitelawtooling.com.au

QHDC BLICKLE AUSTRALIA PTY LTD

2/60 NEWHEATH DRIVE ARUNDEL QLD 4214 www.qhdc.com.au

REAP THE BENEFITS OF AMTIL MEMBERSHIP Contact us to learn more www.amtil.com.au AMT OCT/NOV 2021

A GRAND 'NEW' FLAG INDEED!

I come to you having witnessed a great AFL Grand Final (if you're a Dees supporter), after another year of distractions – I salute the all conquering Melbourne Demons on claiming the chocolates for season 2021. She was a tight one until early in the 3rd quarter and then WOOSHKA!!, an avalanche of goals to claim victory! Big Congrats to ESPNFAN872… ah bugger it, too long of a name, who also claimed the AMTIL Footy Tipping 2021 comp. Well done to BJCCNC and Gava66 who rounded off the placings – commiserations to LemmyK who missed out by a six point margin – a goal you might say and to those also who were tightly bunched up behind , better luck next year. Till then, stay safe…

Sanchez ROUND 23 1 ESPNFAN872729… 137 (637) 2 BJC-CNC 133 (638) 3 Gava66 133 (721) 4 LemmyK 133 (727) 5 Aust Mobile Tools 132 (526) 6 Eytan Epstein 132 (640) 7 BSTWJ 131 (636) 8 Shane Infanti 131 (688) 9 Mottdiggitydog 130 (552) 10 Lou AMTIL 130 (570)

Hotspots is proudly owned and managed

by AMTIL

Looking for the right support? HotSpots can help.

•

You need a specific component made, but don’t have the capabilities in house.

•

Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

•

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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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, with many countries’ borders still closed at time of going to print. 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/health-topics/novel-coronavirus-2019-ncov For more events, please visit www.amtil.com.au INTERNATIONAL MANUFACTURING TECHNOLOGY SERIES USA EASTEC: 19-21 October 2021, West Springfield, MA SOUTHTEC: 26-28 October 2021, Greenville, SC WESTEC: 16-18 November 2021, Long Beach, CA https://westeconline.com

METAL Poland 19-21 October 2021 www.targikielce.pl/en/metal

TOOL TECH South Korea, Goyang 19-22 October 2021 www.tooltechkorea.com

EASTEC USA, Springfield 19-21 October 2021 www.easteconline.com

SMART AUTOMATION AUSTRIA Austria, Linz 19-21 October 2021 www.smart-linz.at

SCHWEISSTEC/BLECHEXPO Germany, Stuttgart 26-29 October 2021 www.schweisstec-messe.de/en

AI EXPO Japan, Tokyo 27-29 October 2021 www.ai-expo-at.jp/en

PLASTEC/DESIGN & MANUFACTURING USA, Minneapolis 3-4 November 2021 Plastics Industry trade fair/conference http://plastecminn.com

ADVANCED DESIGN & MANUFACTURING EXPO Canada, Toronto 9-11 November 2021 www.admtoronto.com

TEKNOLOGIA Finland, Helsinki 9–11 November 2021 www.teknologia.messukeskus.com

WESTEC USA, California 16-18 November 2021 https://westeconline.com

FORMNEXT Germany, Frankfurt 16-19 November 2021 Additive Manufacturing exhibition https://formnext.mesago.com/events/en.html

AMT OCT/NOV 2021

METALEX Thailand, Bangkok 17-19 November 2021

ASIA MOULD China, Guangzhou 3-5 March 2022

www.metalex.co.th

www.asiamold-china.cn

XX INDUSTRIAL FORUM Ukraine, Kiev 19-22 November 2021

ALL ABOUT AUTOMATION Germany, Chemnitz 8-9 March 2022

www.iec-expo.com.ua/en/pfen-2021.html

www.automation-friedrichshafen.com

MTA VIETNAM Vietnam, Binh Duong 23-26 November, 2021

SIMODEC France, La Roche-sur-Foron 8-11 March 2022

www.mtavietnam.com

www.salon-simodec.com

BURSA TECH Turkey, Bursa 24-27 November 2021

MACH UK, Birmingham 4-8 April 2022

www.bursamakinefuari.com

www.machexhibition.com

TECH INDUSTRY Latvia 25-27 November 2021

HANNOVER MESSE Germany, Hannover 25-29 April 2022

www.techindustry.lv

www.hannovermesse.de/en

BLECH INDIA India, Bombay 26-28 November 2021

FABTECH Mexico, Monterrey 3-5 May 2022

www.blechindia.com/2021/english

https://mexico.fabtechexpo.com

MANUFACTURING INDONESIA Indonesia, Jakarta 1-4 December 2021

PLASTIC JAPAN Japan, Osaka 11-13 May 2022

www.manufacturingindonesia.com

www.plas.jp/en

MWCS China, Shanghai 1-5 December 2021

METAL SHOW & TIB Romania, Bucharest 11-14 May 2022

www.metalworkingchina.com

www.metalshow-tib.ro

ENGIMACH India, Gujarat 1-5 December 2021

SIMTOS South Korea, Seoul 23-27 May 2022

www.kdclglobal.com/engimach-2021.html

www.simtos.org

ATX USA, New York 7-9 December 2021

FABTECH CANADA Canada, Toronto 14–16 June 2022

www.advancedmanufacturingeast.com

www.canada.fabtechexpo.com

PLASTIC JAPAN Japan, Tokyo 8-10 December 2021

MANUFACTURING EXPO Thailand, Bangkok 22-25 June 2022

www.plas.jp/en

www.assemblytechexpo.com

LASER & PHOTONICS Taiwan, Taipei 15-18 December 2021

BI-MU Italy, Milan 12-15 October 2022

www.chanchao.com.tw/laserexpo/en

www.bimu.it

2022

EUROBLECH 2022 Germany, Hanover 25-28 October 2022

IMTEX India, Bangalore 20-26 January 2022 www.imtex.in

www.euroblech.com

TUBE INDIA India, Mumbai 23-25 November 2022 www.tube-india.com

INDUSTRY CALENDAR HEADING LOCAL AUSBIOTECH (ONLINE) 25-29 OCTOBER 2021 www.ausbiotechnc.org

CLEANTECH QLD. BRISBANE CONVENTION & EXHIBITION CENTRE 1-2 NOVEMBER 2021 How Cleantech will play in the economic recovery and achieving a net-zero future. https://nctce.com.au

IRON ORE CONFERENCE PERTH EXHIBITION CENTRE 8-10 NOVEMBER 2021 Developments in the iron ore industry and speakers at networking events. www.ausimm.com/conferences-and-events/ iron-ore

AUSRAIL PLUS BRISBANE 30 NOVEMBER-2 DECEMBER 2021 New opportunities and transformative rail projects underway in Australia and NZ. www.ausrail.com

2022 INTERNATIONAL MINING & RESOURCES CONFERENCE MELBOURNE, MECC 31 JANUARY–2 FEBRUARY 2022 Experts and educators from over 100 countries in Australia’s largest mining event.

DESIGNBUILD MELBOURNE, MCEC 10-12 MAY 2022 Shaping the architecture, building, construction and design sector. www.designbuildexpo.com.au

AUSPACK SYDNEY SHOWGROUND 17-20 MAY 2022 Food, beverage and pharmaceutical processing and packaging sector. www.auspack.com.au

CEMAT MELBOURNE, MCEC 19-21 JULY 2022 Trade fair for materials handling, intralogistics and supply chain management. www.cemat.com.au

AUSTRALASIAN WASTE & RECYCLING SYDNEY, ICC 24-25 AUGUST 2022 Innovative products and sustainable solutions to collect, process and recycle waste. www.awre.com.au

WASTE EXPO MELBOURNE, MECC 26-27 OCTOBER 2022 Co-located with All-Energy Australia, offers waste management, sustainability, clean energy and energy management information. www.wasteexpoaustralia.com.au

AMW INCORPORATING AUSTECH 7-10 JUNE 2022 SYDNEY ICC Encompassing all aspects of manufacturing in Australia. AMW will showcase the latest in manufacturing technologies and processes, with a strong focus on innovation and digital transformation.

www.imarcmelbourne.com

AUSTRALIAN AUTOMOTIVE AFTERMARKET MELBOURNE, MCEC 7-9 APRIL 2022 400 top Australian and international brands with the latest vehicle repair and servicing equipment, replacement parts, tools and accessories.

www.amtil.com.au/Austech

www.autoaftermarketexpo.com.au

YOUR INDUSTRY. YOUR MAGAZINE.

MAINTAIN MOMENTUM AND EMERGE STRONGER IN 2021.

DEC JAN 2021

OCT NOV 2021

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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 45

“I WOULDN’T LIKE TO BE IN YOUR SHOES”

WW2, May 1942: Laurence agrees to Gen. MacArthur’s secret, radio-silent and “hazardous” mission which involved flying from Australia to the US during the perilous days of WW2, along an unestablished route in a plane described as a “crate”. The plane was beset with mechanical problems and to top things off, was nearly the victim of friendly fire by the Americans after a forced detour. The mission’s objective was to change America’s negative perception about Australia’s ability to make war equipment.

I

was summoned to see Gen. MacArthur who was visiting Australia. He had an office directly across Collins Street from mine. Coming from behind his big desk, he said: "I have a feeling that the Australian point of view, particularly on machinetools, is not getting the right hearing. I have also had reports that you have been extremely helpful to the American Forces in equipment-modifications. I believe you know what you are doing. I think it might be wise if you were to state your case personally in Washington. We have a Liberator bomber going back very soon. It’s the first bomber to get through from Honolulu to Australia and it brought a couple of high-ranking officers. I want to be fair to you, Hartnett, the trip will be fairly hazardous”. This was because there were no established routes and the plane was not in a good condition. I said I'd do anything that was required. "Thanks a lot, Mr. Hartnett" MacArthur replied.

On the next day Essington Lewis (MD of BHP & DG of Munitions) noted: "This trip will give us the opportunity to have someone over there to put our story.

You know these Americans, and I'm sure you could do it where perhaps others have not been so successful. But we don't want any publicity."

It came to zero hour: We received word that the bomber would be at Laverton the following morning, ready to take off at the crack of dawn. Five o'clock on a dark, cold morning at Laverton, Melbourne was blacked out, and we almost got lost driving there. “What you're doing is a bit foolish” said the Officer in charge at Laverton. ”We've been looking this aircraft over. It's not what we'd call in A1 condition. Frankly I wouldn't like to be in your shoes." This didn't do much to cheer us up.

We soon found he was right. We plugged our ears while the engines revved up with a roar and scream. Suddenly, the engines stopped. An oil-pipe had broken. Then a battery had packed up; then there was electrical trouble. The Liberator wouldn't be flying that day. Next morning, however, we took off at about 8.30. But could we get those props into low pitch? No. They screamed like

The American P-40 Warhawk (painted with shark’s teeth) checking out the Liberator bomber, during what Laurence describes as a “scissoring” – manoeuvre an aerial dogfighting tactic, performed by the P-40.

something in pain - a phenomenon known as ''howling dog''. Round and round we flew over Laverton, with no altitude, and the pilot couldn't adjust the pitch.

He decided to land again, but just then the props picked up into low pitch and away we flew - three passengers: myself, Bill Wasserman and Arthur Wilson, an American General.

After a while, Noumea came up under our wing, and we put down on the rather small airfield. Next morning we took off - just made it, too, because our big aircraft ate up every inch of the runway, and we barely cleared the trees at the end of it. We flew on without incident to Nandi in Fiji. As we were coming down, there was a tropical deluge.

How we landed none of us will ever know.

Next stop: Canton Island in the Coral Sea. After a quick tour, our Liberator was ready for take-off. We wrapped ourselves in blankets and overcoats to keep warm, found a perch among the crates and equipment, plugged our ears against the scream of the engines, and held our breath as the bomber gathered speed along the strip. Flying as a passenger in one of those bombers was no picnic. There was no heating, sound insulation, seats or pressurization. After forty hours of travel in those conditions, you 're a non-compus heap.

Then we got the biggest fright of the trip: Because of a faulty drift-meter plus headwinds, we didn't have enough fuel to make it to Honolulu. The Pacific looked grey, endless and empty. Then Gen. Wilson said:

"To hell with it. Let's go somewhere else!"

Good idea. But where? Petrol was running out fast. "Well," said the pilot, "there's only one place. That's Palmyra”. Palmyra was a naval establishment and was bound to be jumpy after Pearl Harbour. “It's either that, or the drink, General!”.

The Liberator's starboard wing dipped, and we took a right-angle turn for Palmyra.

The next thing we knew was that we had company: Three American P-40 Warhawk fighters were scissoring around us. With our co-pilot and the boys up front waving violently and rocking the aircraft, we weren't sure we had been recognized, because ironically, there was a Japanese aircraft almost identical with the Liberator.

We couldn't blame the US fighter boys for being suspicious - we were not heralded; nobody knew who we were, and we couldn't break radio silence to identify ourselves.

Anyway, we came in with the P-40s right behind us. We had a day with the Navy while the crew refuelled, checked over the Liberator, got a new drift-meter, and away we went on our last, and uneventful hop to Honolulu.

"Fancy her holding together that long!" exclaimed a Sergeant who waited for as we taxied in at Hickham Field, Honolulu.

I said: "Why, what's the matter with her?"

He replied: "Look, she's so long over her hours she ought to be falling to bits. Sir, you're lucky! ... 'Gahddam crazy crate’” he pronounced, as we jumped down from the open bomb-bay doors.

To be continued…

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

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